Developing Wood Pellet Production Centers in Indonesia

Vast land with a tropical climate with year-round sunshine and high rainfall is a gift from Allah SWT that makes Indonesia a world center of biomass. Biomass-based products such as energy and animal feed are very relevant in the bioeconomy era which is predicted to become a world trend in the near future. Potential optimization must be carried out especially since it is very much in line and relevant to world trends (decarbonization & sustainability) in general and Indonesia's specific national conditions in particular. On the other hand, we can see a number of countries whose majority of their economies depend on fossil energy, especially oil and gas, such as Saudi Arabia and Qatar or the Gulf countries in general, have to change their course to fight to reduce dependence on these natural resources. Efforts for realization/implementation and acceleration should be carried out immediately, even though it is actually a little late compared to other countries in Southeast Asia, especially Vietnam, for more details please read here, but given the potential and future direction of the world economy, of course, besides being urgent, it is also important to do this.  

As a reference for the development of the wood pellet industry in Indonesia, we can take the example of a country in North America, namely Canada, especially in the province of British Columbia. The province has the highest concentration or the most wood pellet factories, which are estimated to reach around 70% of the country's production. From the research conducted, it was found that 85% of the wood pellet raw material used was sawmill waste and the remaining 15% was forest waste. And the forest waste can be further broken down into 11% low quality logs and 4% bush plants. So all the raw materials used in the province use wood wastes produced from sawmills and remnants from the forest. The production of wood pellets basically has to use raw materials from wood wastes or wood which are worth the wood waste.

By utilizing these wastes, in addition to overcoming environmental pollution, even  sawmill operations become zero waste, it also provides additional income or economic benefits which are quite large in value. Forest wastes in Indonesia such as from acacia plantations have the potential to be used for the production of wood pellets. For example, with an acacia plantation, if every hectare produces 20 tons of acacia wood waste, then with an area of 20,000 hectares, 400,000 tons of acacia wood waste will already be produced. The area of 20,000 hectares of acacia plantations is not too big, this is because there are a number of HTI (industrial plantation forest) concession holders covering hundreds of thousands of hectares, so the volume of wood waste produced is also very large. Acacia forests or plantations in Indonesia are estimated to reach 2 million hectares and almost all of these acacia forests are used to supply pulp and paper mills. Every pulp and paper mill always has acacia forests with an area of thousands of hectares to fill the pulp and paper mill. Acacia wood with a minimum diameter of 8 cm is used as the raw material, while those with a diameter smaller than that are only used as waste. After the tree is felled, a new planting is carried out (replanting).

Wood products come from different parts of the tree, each tree has a unique potential, depending on a number of factors including the diameter and straightness of the trunk. In acacia trees trunk diameter is the main parameter.

Likewise in the sawmill industry, apart from waste in the form of sawdust, wood waste such as wood chips can also be used as raw material for the production of wood pellets. Each stage of the sawmill industrial process will produce wood waste, with varying shapes, sizes, quantities and uses. It is estimated that around 40% of wood waste produced from sawmills is around 40%. Factors such as worker skills, operator experience, equipment conditions and the shape of the wood affect the wood waste produced. Based on the above waste percentages, a sawmill that processes 1000 m3/month of logs will produce a total of around 400 m3/month of wood waste. More detail as in the table below:

Energy plantations are another option and are even an ideal option for wood pellet production. This is because the volume is large and its availability can be guaranteed, rather than collecting the wood wastes. With this energy plantation, raw materials in the form of wood will be obtained which costs as much as wood waste. Thousands to tens of thousands of hectares of energy plantations can be made for this purpose. In addition to wood, which is the main product of the energy plantation, by-products with significant value are leaves for animal feed and honey from beekeeping. Optimizing the utilization of all these trees will provide maximum added value from the use of the land. The regions of Kalimantan, Sumatra, Sulawesi, Maluku and Papua can become centers of wood pellet production such as the province of British Columbia in Canada.

The Importance of SRF (Slow Release Fertilizer) With Biochar in Palm Oil Plantations

Biochar is not a fertilizer so even the nutrient content in biochar can be ignored. Even though there are a number of biochars that contain certain nutrients, this is a special matter and really depends on the raw materials used. Biochar is a soil amendment that functions to improve soil properties such as soil structure including increasing soil porosity/soil friability so that roots can penetrate deeper, soil aeration, water availability, shortening the age of harvest, inhibiting the development of plant pests and retaining nutrients and reducing soil acidity. Compared to other soil amendments which have weaknesses, including the need for large and continuous amounts because they decompose quickly, have the potential to negatively affect the climate, and introduce disease-causing microbes/pests, biochar has many advantages, including the volume required is not large enough, not continuous and able to survive in the soil (helps conserve carbon in the soil) is not decomposed for hundreds or even thousands of years. The above makes biochar can function to improve soil fertility and climate solutions (carbon sequestration / carbon sink) or an action to increase organic matter on agricultural land or plantations and mitigate the effects of climate change. 

Even so, biochar can be used to make fertilizer, namely slow release fertilizer (SRF). SRF is a fertilizer whose release is regulated to provide maximum growth effect or SRF is designed or modified fertilizer for controlled fertilization according to plant needs so as to provide increased use efficiency and at the same time increase yield or harvest. This is motivated by the low efficiency of fertilization so that even more is wasted than is utilized or low NUE (nutrient use efficiency). The function of biochar in SRF is as a slow release agent in the fertilizer because it has a porous structure. In making SRF, several methods can be used, including increasing the size (granulation, pellets, etc.), smoothing the surface of the fertilizer, mixing it with other materials that are difficult to dissolve (slow-release agent) and covering the fertilizer with certain materials so that the release of the fertilizer becomes slow (coating). The use of SRF is becoming popular to save fertilizer consumption, increase yields and minimize environmental pollution. 

Soil fertility is a complex trait or condition that must be kept optimal, especially regarding this fertilization. The component of soil fertility itself includes a number of things, namely the depth of the soil solum, soil structure, nutrient content, storage capacity, humus content, number and activity of soil microorganisms, and the content of toxic elements. Productive soils with high soil fertility, both naturally and/or due to human actions, are mainly due to the following characteristics: nutrients in the soil are mobile and easy to obtain, the ability of the soil to convert fertilizer into easily available forms, the ability of the soil to store nutrients dissolved in groundwater from the leaching process, the ability of the soil to provide a natural balance of nutrient supplies for plants, the ability of the soil to store and provide water for plants, the ability to maintain good soil aeration to ensure the availability of oxygen for roots, and the ability of the soil to bind (fix) nutrients and convert them into forms available to plants. Soil fertility must guarantee high, consistent and sustainable production.  

An understanding of the nutrient composition of fertilizer and its release mechanism will help make strategic plans to slow down the release of the fertilizer at a certain level. Compared to conventional fertilizers slow release fertilizer (SRF) has a very slow release speed which can be tens of times slower so that fertilization efficiency increases significantly. It is estimated that more than 50% of fertilizer is wasted due to various reasons including evaporation, immobilization in the soil and leaching due to water, for example due to rain or irrigation. This inefficiency of fertilization is not only detrimental from an economic aspect as well as the environment, namely making the soil acidic, killing soil microbes, and water-soluble fertilizers that can poison water that may be consumed by humans and animals.

Currently, developing countries use more than 60 million tons of fertilizer per year, while according to the Food Agriculture Organization (FAO) world fertilizer consumption reached 190.4 million tons in 2015. With this low level of efficiency, can be imagined how much fertilizer is wasted useless and only pollute the environment. Regarding SRF, the dose of biochar use must also be measured properly because the use of biochar that exceeds the dose will be useless. This is due to the hydrophobic nature of biochar, so that the excess dose does not or only a little can release the fertilizer slowly.

A number of parameters to be observed for administering biochar as SRF are the amount of FFB (fresh fruit bunch) production and its quality (yield of CPO, and its FFA content), continuity of fruiting throughout the year, and the level of uniformity of fruit maturity in one bunch. And it turns out that the use of biochar gave significant positive results, namely FFB production increased by more than 20%, fruit maturity uniformity was almost 100%, CPO yield was more than 25%, and FFA was only 2-5%. With the high production of FFB and the yield of CPO, the intensification of palm oil plantations should have been carried out rather than the extensification that was suspected of being an attempt to convert forest functions or deforestation which tends to receive negative attention from various parties. For more details, read here. There are still many things that can be optimized so that the palm oil industry is efficient, environmentally friendly and sustainable.

Tens of millions of tons of empty fruit bunches (EFB) at the palm oil mills are potential raw material for biochar production as well as tens of millions of hectares of oil palm plantations that can be used for biochar applications. In addition to overcoming the problem of biomass waste, biochar production also produces energy that can be used for the palm oil mill itself, in more detail, please read here. Compared to the production of fuel pellets from empty fruit bunches (EFB pellets) and the production of electricity from empty fruit bunches, the production of biochar has many advantages and advantages both economically and environmentally. In the end, modifying the fertilizer according to the use of the biochar will significantly increase the nutrient use efficiency (NUE) in the fertilizer, ensuring the effective circulation of nutrients and mitigating climate change with carbon sequestration.
 

Green Economy in the Cement Industry Part 3

Fly ash is a byproduct or waste of coal power plants. Like slag, fly ash is also an additive or supplement (SCM/supplementary cementious material) in cement production. The difference is that fly ash is very fine so it doesn't need to be refined anymore and can be mixed directly with clinker and gypsum. Every ton of fly ash used prevents about 1 ton of carbon dioxide (CO2) from escaping into the atmosphere. This is in line with the green economy or decarbonization as a climate solution effort for the industry.

Unloading fly ash

As the same with slag, the chemical content of fly ash also influences the quality of the cement produced, for example certain regions or countries have requirements for grade 120 alumina in the slag. Cement with a certain quality can be designed with the use of these additives. In the current era, apart from technical factors such as mechanical strength or cement adhesion, microstructure, durability and so on, and economic factors, environmental friendly product factors are also a concern or have their own positive image. Circular economy in the form of utilizing waste from other industries to become raw materials for this industry, also occurs in the cement industry. And basically the cement industry besides being able to process waste is also a waste destroyer.

Biochar to Improve Soil Fertility, Fuel, Industrial Raw Materials or Climate Solutions?

Currently there are still a lot of agricultural wastes (corn stalks, soybean plants, soybean shells and so on) that have not been utilized so that they pollute the environment. Utilizing these wastes so that they become useful products that provide added value is the best solution. What kind of utilization or processing is the best solution for utilizing these wastes? This of course depends on a number of influencing factors such as market readiness, availability and continuity of supply of biomass waste, especially agricultural wastes, technological readiness including technology investment, profits and business continuity, infrastructure and human resources (HR). Production of biochar or charcoal from biomass waste could be the best option. But indeed biochar or charcoal is multifunctional or can be used for a number of uses. Then the question is the use of biochar for what field gives the best results or benefits?

The biochar production is carried out using slow pyrolysis technology. With this technology biochar production can be optimal both in quality and quantity. It is different when using fast pyrolysis technology which produces biooil product or liquid product as the main product, with much less biochar product. Or if you use gasification technology where the main product is gas, so that the proportion of biochar is smaller or it can be considered as a side product, then this will also be less than optimal. These things make choosing the right technology an important thing to be able to give optimal results.

The production of biochar for agriculture has also not become a trend among farmers in Indonesia, so that much of their agricultural waste is not utilized and even pollutes the environment. Another influencing factor is the condition of the agricultural land itself. Dominant and excessive use of chemical fertilizers has damaged agricultural lands so that agricultural productivity continues to decline. And efforts to improve the soil require effort that is not easy and quick so that the fertility of the soil can be restored (recovery) and continues to be maintained for the long term. The combination of using organic materials with certain techniques needs to be done to achieve this. Biochar can also be used to make the use of organic matter more efficient, such as reducing leaching and increasing soil microbial activity. With the increased efficiency of this technique due to the use of biochar, it also minimizes input so that production costs can be further reduced. The integration of agriculture and animal husbandry is a must in order to obtain an adequate supply of organic matter, the quality is maintained and sustainable. Whereas in acid and dry soils, the use of biochar will have a more significant effect.

The use of biochar as an ingredient, especially for bbq and cooking as well as other uses, namely as a reducing agent in steel making. There are not too many uses for BBQ, this is processing or cooking food on a BBQ basis only as a hobby or only for special community segments. And there isn't much biochar for cooking either, or this is more common in Africa, while in Indonesia the option of using firewood or LPG is more common. Likewise, the need for biochar as a reducing agent in steel making is also not much. Meanwhile, the use of biochar for industrial fuels such as boiler fuel and electricity generation is almost non-existent. This is because the production process takes longer (requires a carbonization process), the conversion from biomass to biochar is small (~25%), and the price of biochar is more expensive. Wood pellets and palm kernel shells (PKS) are more of an option for these industrial fuels.

Biochar can also be used as a raw material for various industrial goods for human needs or for the substitution of materials derived from fossils (such as oil and gas) into more environmentally friendly and renewable materials. Materials such as plastic can be replaced with biochar. Particle board, which usually still uses wood waste, can also be replaced with biochar. This trend has not yet occurred, but it is predicted that soon it will become a concern and even a new trend in the industry.

Biochar for climate solutions is likely to become a trend soon. CO2 from the atmosphere is converted into biomass by plants, converted into biochar and stored (sequestration), especially in the soil. The carbon stored in the biochar will not be released into the atmosphere because biochar does not decompose for hundreds or even thousands of years or can be stored permanently. In principle, this is like storing carbon (CO2) with a conservation forest so that it becomes a carbon sink. Trees or plants will absorb CO2 from the atmosphere and be maintained in such a way as to achieve the desired CO2 uptake target then compensated with carbon credits, as well as biochar, how much carbon can be stored (sequestration) then also compensated with these carbon credits. In practice, the use of biochar will be optimal with efforts to enrich the soil on damaged or problematic soils such as post-mining soil, acid soil and diseased soil due to an overdose of chemical fertilizers. Carbon sinks with biochar are easier and cheaper than the carbon capture and storage (CCS) method with CO2 stored beneath in the earth's layers.

To reduce the temperature of the earth by reducing the concentration of greenhouse gases. To reduce 1 ppm of CO2 concentration in the atmosphere is equivalent to absorbing about 15 gigatonnes of CO2. Meanwhile, the costs needed to mitigate major climate change disasters are estimated at USD 1.6 trillion to USD 3.8 trillion each year. To reach the concentration of CO2 in the atmosphere to 350 ppm, around 70,000 biochar the size of the Giza pyramids is needed, assuming that fossil fuels are discontinued. With a volume of the Giza pyramids of 2.6 million m3 and an average biochar density of 200 kg/m3, biochar the size of the Giza pyramids weighs 520 million kg or 520 thousand tons. Huge job of course. Biochar production must grow 5000 times from its current production capacity. With biochar the size of a unit of the pyramids of Giza we need to build 4 pyramids per day (about 2 million tonnes of biochar per day) for the next 100 years and starting now.