1.1 Palm Oil Mill

1.
0 Introduction
1.1 Palm Oil Mill
Palm oil - fresh fruit bunches (FFB)

Processing Steps including sterilization, stripping,
digestion and pressing, clarification, purification, drying

and storage
1.0 Introduction (Cont)

1.2 Waste Disposal from Palm Oil Mill Palm oil mill effluent (POME) Palm oil Mill Sludge (POMS) About 1800m3 waste is discharge from palm oil mill annually
2.0 Proposed Site for Effluent Treatment Plant

The proposed site to build a new effluent treatment plant is at RH Lundu Palm Oil Mill Sdn Bhd, Sibu
2.0 Proposed Site for Effluent Treatment Plant (Cont)
2.0 Proposed Site for Effluent Treatment Plant (Cont)

Reasons 1. In progress to design and build the palm oil mill. 2. Still looking for tenders, suppliers, vendors and contractors. 3. Good chance to propose the effluent treatment plant
3.0 Sludge Treatment and Disposal Process Step 1: Gravity Thickening

Advantages Least operation skill required Low operating costs Minimum power consumption Disadvantages Large space required Odour potential Erratic and poor solids concentration (2-3%) for WAS Floating solids
Step 2: Anaerobic Digestion

Advantages Good destruction of volatile solids and pathogens Use of methane gas can reduce net costs Widely applicable Reduces raw sludge volume Low energy requirement Disadvantages Requires skilled operators May give rise to foaming Scum and grit may be difficult to clean May generate odour High capital cost
Step 3: Chemical Coagulation

Advantages Usually filters well on mechanical filters Moisture content of filter cake is usually lower than the moisture content of filtered fresh or digested sludge Lower capital equipment Disadvantages Dry weight varies not digest satisfactorily Chemically precipitated sludge may produce objectionable odors when piled in a heap
Step 4: Belt filter press

Advantages Relatively low capital, operating, and power costs Easier to shut down the system Easier to maintain Disadvantages Very sensitive feed sludge characteristics Sensitive to polymer type and dosage rate Requires large quantity of belt wash water
Step 5: Gasification
Advantages Significant reduction of weight and volume of sludge. The use of less oxygen results in less emissions. Syngas produced have many uses Disadvantages Expensive initial set up. Complex multi-stage process Syngas must be cleaned/purified Energy input to start reactions.
Step 6: Landfill
Advantages volume can increase with little addition of people/equipment filled land can be reused for other community purposes Disadvantages completed landfill areas can settle and requires maintenance requires proper planning, design, and operation
5.0 Treatment Description
Flow Diagram of Sludge Treatment
Gravity Thickening
Anaerobic Digestion
Chemical Coagulation
Belt Filter Press
Gasification
Landfilling
6.0 Calculation
Table 6.0 (a): Specifications for Gravity Thickening

Sludge Production, Q Total solid mass, Ts Hydraulic loading of the sludge, HL Detention time, t Dimension 13.5 m3/day 9000 kg/day 3 m3/m2.day 4 hours 8 m Diameter and 3 m Depth
Equation used: A = Q/ HL (HL is hydraulic loading) Areq = Weight of solids/ ML (ML is mass loading) D=
4
Table 6.0 (b) : Specifications for Anaerobic Digestion

Incoming Flow Rate, Q Detention time, t Volume Area of the Pond, A Dimension 1800 m3/day 20 days 36000 m3 7200 m2 145 m x 50 m x 5 m (Depth)
Equation used: Volume = Qt Volume = L x W x D
Table 6.0 (c) :Specifications for Chemical Coagulation

Chemical Coagulant: Alum (Aladded3+) BOD3 loading rate BOD3reduced per day Sludge Conversion rate form BOD3 Dimension Sludge Production Rate Hydraulic Retention Time 7.674 mg/l 36000 kg/day 810 kg/day 405 kg/day 13 m x 13 m x 4 m (Depth) 13.5 m3/day 44 days
Equation used:
BOD3 loading rate = Flow rate x BOD concentration SAl = 21.34 + 2.77 (Pin Pout) + 3.07 Aladded3+ (Snurer, 1999) Slugde age =
Hydraulic Retention Time =
Table 6.0 (d) :Specifications for Belt Filter Press

Model 3DP- 0.75meter belt filter press 1. High Strength Tubular Steel Construction 2. Upflow High Solids Feedbox with Variable Speed Distribution Paddle 3. Independent Variable Speed Gravity Drainage Section 4. Vertical Pressure Section 5. Machined Bearing Pads 6. Double Flange Roll Construction 7. Self-Compensating Hydraulic Tensioning System 8. Hot-Dipped Galvanized and Painted Corrosion Protection System 2.0 % 10.8 m3/day 2.7 m3/day
Concentration of Solid Water Reduction Filter Cake Production
Equation used:
Concentration of Solid =

Water Reduction = Flow rate x (1-percentage of water residue) Filter Cake Production =Total flow rate Liquid Flow rate
Table 6.0 (e) :Specifications for Gasification

Thermal power consumption (full load) Heating value of biomass Biomass consumption gasifier Height h of the nozzle plane above the smallest cross-section of the throat, h Diameter of the fire box, dr Diameter of nozzle top ring, drl Nozzle diameter, dn 116.6 kW
17000 kJ/kg 0.0069 kg/s 10.7 cm
29 cm 21.4 cm 10.4 mm
Equation used:
Bg max = 0.9 m3 / cm2 h =
1. Height h of the nozzle plane above the smallest cross-section of the throat (dthroat = dt). h/dt = 1.15 2. Diameter (dr) of the fire box. dr/dt = 3.0 3. Diameter (drl) of nozzle top ring drl/dt = 2.3 4. Nozzle diameter (dn) Total nozzle area (An) =
2 5 4
Table 6.0 (f) :Specifications for Landfilling

Total feed to Landfill Dimension Hydraulic Retention Time 1.89 m3/day 25 m x 48 m x 4 m (Depth) 7 years
Equation used:
Volume = L x W x D Hydraulic Retention Time =

ECONOMY ANALYSIS
Plant Specifications:
Production rate : 231,921 tons/year Efficiency : 80% Operation : 365 days/year or 7,300 hours/year (20 hours/day) Maintenance duration : 1,460 hours/year Land Price (Size) : RM 254,166 (3 acres, approx. 12,140.569 m2)
Estimating plant equipment purchase cost

Equipment Gravity thickener Digestion tank 36250 m3 70,000 70,000 Size (S) 9760m3 Cost per Cost per Total Cost
Unit (MYR)
15,000
Unit (MYR)
15,000
(MYR)
15,000 70,000
Mechanical
mixing chamber Belt filter
676 m3
20,000
20,000
20,000
0.75 m
55,750 15,000
55,750
press
Gasifier Purchased Equipment Cost (PCE) 15,000
55,750
15,000 175,750
Estimation of Fixed capital:

Item f1 f2 f3 Major Equipment Equipment Erection Piping Instrumentation Factor Fluids 0.40 0.70 0.20
f4
f5 f6 f7 f8 Total
Electrical
Buildings, process Utilities Storages Site Development PCE
0.10
0.15 0.50 0.15 0.05 3.25
Total Physical plant cost (PPC) PPC= PCE (1+f1+f2++f8) =MYR 175,750 (3.25) =MYR 571,187.50
Total Fixed Capital Cost, CFC

Item f9 f10 f11 Major Equipment Design and Engineering Contractors Fee Contingency Factor Fluids 0.30 0.05 0.10
Total
Fixed Capital
1.45
Fixed Capital = PPC (1+ f9+ f10+ f11) = MYR 571,187.50 (1.45) = MYR 828,221.90 @ MYR 828,222
Estimation of Working Capital Working Capital = 0.15(MYR 828,222) = MYR 124,233.30

Total Investment = Fixed Capital + Working Capital + Land Purchase = MYR 1,206,621.30
Fixed cost
Cost Maintenance Operating Labour Laboratory costs Price (MYR) 82,822.20 584,000 116,800
Laboratory costs
Capital charges Insurance Local taxes
146,000
82,822.20 8,282.22 16,564.44
Total Fixed Cost = MYR 1,037,291.06 @ 1,037,291
Variable cost
Main Raw Material Chemical coagulation Price (MYR/t) 573.2 5.55765 Quantity (t/year) Total (MYR/year) 3,185.65
Miscellaneous Materials (10% of maintenance)= MYR 82,822.20

Utilities Electricity = MYR 2,850,935.10 Water = MYR 3,947,448.60 Total Variable Cost = Total Raw Material Cost + Miscellaneous materials + Water + electricity = MYR 6,884,391.55 @ MYR 6,884,392
Production Cost Direct Production Cost = Fixed Cost + Variable Cost = MYR 7,921,683 Production Cost (MYR/ton) = MYR 36.12/tons @ MYR 36.00/tons

1.1 Palm Oil Mill

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1.

Palm oil - fresh fruit bunches (FFB)

digestion and pressing, clarification, purification, drying

1.0 Introduction (Cont)

2.0 Proposed Site for Effluent Treatment Plant

2.0 Proposed Site for Effluent Treatment Plant (Cont)

2.0 Proposed Site for Effluent Treatment Plant (Cont)

3.0 Sludge Treatment and Disposal Process Step 1: Gravity Thickening

Step 2: Anaerobic Digestion

Step 3: Chemical Coagulation

Step 4: Belt filter press

5.0 Treatment Description

Flow Diagram of Sludge Treatment

Belt Filter Press

Table 6.0 (a): Specifications for Gravity Thickening

Table 6.0 (b) : Specifications for Anaerobic Digestion

Equation used: Volume = Qt Volume = L x W x D

Table 6.0 (c) :Specifications for Chemical Coagulation

Hydraulic Retention Time =

Table 6.0 (d) :Specifications for Belt Filter Press

Concentration of Solid Water Reduction Filter Cake Production

Table 6.0 (e) :Specifications for Gasification

Bg max = 0.9 m3 / cm2 h =

Table 6.0 (f) :Specifications for Landfilling

Estimating plant equipment purchase cost

Estimation of Fixed capital:

Total Fixed Capital Cost, CFC

Estimation of Working Capital Working Capital = 0.15(MYR 828,222) = MYR 124,233.30

Total Fixed Cost = MYR 1,037,291.06 @ 1,037,291

Miscellaneous Materials (10% of maintenance)= MYR 82,822.20

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