Biochar for Energy Plantations

The low productivity of wood from energy plantations is one of the obstacles to the development of energy plantations. Although energy plantation plants such as calliandra can grow on marginal or critical lands, the quality of the soil affects the productivity of the wood produced. This makes it important to improve the quality of the soil of these energy plantations so that they can produce optimal plant productivity. Biochar can be an effective solution for this. Biomass waste that pollutes the environment can be used for biochar production or wood products from these energy plantations can be partly used for biochar production.

Biochar and energy plantations are two positive things for climate solutions. Energy plantations for the production of carbon neutral biomass fuels such as wood pellets, while biochar is to improve soil quality, save fertilizer use and so on and as carbon sequestration / carbon sinks that are carbon negative. The biochar solution for energy plantations will maximize CO2 reduction and sustainability efforts. The vastness of energy plantations is because they are pursuing the target of producing biomass fuel quantities which are comparable to land use and also comparable to the use of biochar. This is so that industrial-scale biochar production is needed to support this, read more details here. The more damaged the land or critical lands are, the greater the need for biochar. And the production of large-capacity biochar has the opportunity to get carbon credit or BCR (Biochar Carbon Removal) credit which can be a driving force for the growth of biochar industries.

Taiwan, Asia's New Wood Pellet Market

After Japan and Korea have been the main markets for wood pellets in Asia for years, Taiwan is predicted to emerge as a new destination for the wood pellet market in Asia. This is because Taiwan's energy policy targets 20% renewable energy use by 2025. Namely by focusing on the energy transition from coal and other fossil fuels to renewable energy sources including biomass, solar and wind to increase renewable energy from 10% to 20% by 2025. The Greenhouse Gas Reduction and Management Act requires annual carbon emissions to be reduced by 20% by 2030 and 50% by 2050, below 2005 levels or a reduction of 53 million tons of CO2 equivalent by 2030 and 133 million tons by 2050. This is also part of Taiwan's nuclear-free vision and supports the national goal of achieving net-zero carbon emissions by 2050. Renewable energy development is the most important implementation to achieve this goal and wood pellets are a top priority. Taiwan will import wood pellets in large quantities to achieve its new green energy production targets.

The need for wood pellets in Taiwan reaches millions of tons or more detailed estimates are 1.7 million tons per year specifically for Taiwan Power Company, which will be implemented immediately when the policy is implemented. And there are also a number of independent power plants (IPP) that use coal boilers to generate electricity, especially the plastic industry, petroleum refineries and papermaking. Currently, renewable energy accounts for less than 10% of the total energy output in Taiwan. Meanwhile, the government aims to have 778 megawatts (MW) of biomass-based power plants by 2025, allowing production of 4.1 billion kWh.

The world's major wood pellets producing countries are looking to Taiwan, such as the United States, Vietnam and Canada. Vietnam has even become the second largest wood pellet producer in the world, overtaking Canada. And nationally, Vietnam's wood product exports are more than 70% for furniture and interior applications, 7% for wood-based panels, 17% wood chips and 5% for wood pellets. And to produce these products, Vietnam also imports large amounts of wood from more than 114 countries and 700 species / subspecies, amounting to $ 3.1 billion in the form of logs, sawnwood and plywood and imports almost 2 million cubic meters of tropical hardwood.

Basically, the major wood pellet producing countries are competing to convince Taiwan as a user or buyer of wood pellets about the supply capability, including quantity and quality, logistics reliability and sustainability of its supply. Although the Japanese and Korean markets continue to grow, penetration into a new market will add an opportunity to these producers. Even in Japan, many new power plants are being built so that the need for wood pellets is also increasing. In addition, the increase in the cofiring ratio in power plants in Japan will also increase the demand for wood pellets.

And globally according to Hawkin Wright, wood pellet sales are the highest among other biomass fuels, which is more than 27 million tons/year in 2025. While FutureMetric that the market for wood pellets for industry (industrial pellet fuel) can reach 55 million tons in 2030. Thus the need for wood pellets will continue to increase with an average of more than 5.5 million tons per year so that the production of wood pellets. Indonesia still has great potential to become a world wood pellet producer because of the potential raw materials that can be sought, both from wood and forestry industry waste and from energy plantations. With a location that is not too far from Taiwan (compared to wood pellet producing countries such as the United States and Canada) so that logistics or transportation costs are cheaper, the opportunity to compete is also quite large. In addition, PKS (palm kernel shell) are also an alternative biomass fuel besides wood pellets and as a producer of palm oil / CPO or the owner of the largest palm oil plantation in the world, Indonesia is number one for that. 

Cogeneration in Palm Oil Mills with Pyrolysis, Initial Steps in Biochar Production and Implementation

The analogy is like cofiring carried out in coal-fired power plants by mixing biomass fuels with a certain ratio as an effort to decarbonize the energy sector in power plants. While in palm oil mills, cogeneration with pyrolysis is an innovative initial step to enter the carbon negative era with the application of biochar, the main product of pyrolysis. And because all palm oil mills use biomass fuel for their mill operations, they are already based on carbon neutral fuel, unlike coal-fired power plants which are based on carbon positive fuels because they come from fossils.

Unlike cofiring which mixes coal and biomass fuels with a certain ratio and then burns them together in a furnace such as pulverized combustion, cogeneration is done by producing energy separately but the energy output is for the same use or especially the same boiler. This is done because the types of fuels may be different, such as solid fuels with liquid fuels or the technology for producing the energy is different. With this cogeneration, it means that not all energy is produced from one energy source or energy from cogeneration is a secondary energy source to meet total energy needs, and in the case of cogeneration in this palm oil mill, energy from combustion is still the primary energy.

Then why not just do full pyrolysis? It is easier, gradually for palm oil mills to adopt pyrolysis technology and its characteristics. Because (slow) pyrolysis aims to maximize solid / biochar, the by-products in the form of excess energy (syngas and biooil) as a source of boiler fuel, the calorific value is not as much as combustion which is indeed intended to maximize heat. Only about 1/3 of the excess energy contributes (cogeneration) as boiler fuel. In other words, if full pyrolysis is carried out directly, the amount of biomass as raw material for pyrolysis becomes 3 times greater or the pyrolysis unit becomes very large so that all palm oil mill biomass waste is used, and the mill cannot sell its palm kernel shells.

What are the benefits obtained by palm oil mills if they carry out cogeneration with pyrolysis for biochar production? Among the biochar products, it can save fertilizer use in oil palm plantations, overcome the problem of empty oil palm bunches (EFB) so that palm oil mills can achieve zero waste, palm kernel shells (PKS) that have been used for boiler fuel can be sold to increase income, the productivity of fresh fruit bunches (FFB) of palm oil increases, the application of biochar in palm oil plantations is also a climate solution (carbon sequestration / carbon sink) so that it can get carbon credit compensation and with good waste management, even zero waste and the application of biochar in palm oil plantations, palm oil companies will get a good image in terms of the environment and sustainability.
 

Urgency of Biochar Production Industrial Capacity

The provision or application of biochar to agricultural land follows the 4Rs rule, namely the right source (appropriate biochar raw material), right place (appropriate application area), right rate (appropriate dosage) and right timing (appropriate time). The physical and chemical properties of biochar differ depending on the raw material and production process. By following the 4R rules, biochar performance can be maximized. The effect of biochar on plants will be clearly visible (significant) when the 4R rules are met. With a dose / rate reaching 20 tons / ha (depending on the influencing condition factors), the need for biochar is also large. This is why biochar products are rarely sold online, namely because of the large volume.

Unlike soil amendments such as compost, the effects of biochar can be felt for quite a long time or for several types of agricultural crops, namely not only in one planting season, but repeatedly. This also makes the provision or application of biochar not as frequent as compost. And in the end, of course, the economic aspect is a determining parameter whether biochar makes agricultural businesses more profitable or not. The price of biochar on the market is an important concern for users or farmers.

The lack of biochar production in Indonesia is currently a barrier to biochar application in large agricultural lands, even when farmers' awareness of biochar is also increasing. This is the driving force for the importance of adequate biochar production, especially industrial capacity. Only with adequate biochar production can biochar application in agricultural lands or degraded lands be carried out optimally. The urgency of industrial capacity biochar production is even greater, especially when the biochar production also gets carbon credit, of course this will be even more interesting.

Biochar and Food & Energy Security

As the population increases, so does the need for food and energy. This is why food and energy production must also be increased. Increasing food production is closely related to the quality and quantity of land. However, although the quantity of land is very large, its quality tends to decline so that plant productivity automatically also decreases. The decline in land quality or land damage occurs on very large areas of land up to millions of hectares. With the area of ​​sub-optimal and degraded lands reaching hundreds of millions of hectares consisting of 122.1 million hectares of dry land; 8 million hectares of post-mining land; 24.3 million hectares of critical land; a total of around 154.4 million ha, it can be said that the potential loss of food products also reaches millions of tons. Meanwhile, damaged land will be further damaged if no repair efforts are made. Efforts to upgrade or improve the quality of this land should be an important priority in efforts to achieve food and energy security.

Biochar application is a solution for improving these lands. Raw materials for biochar production are also very abundant, including dry palm oil EFB of around 30 million tons/year, bagasse of 2 million tons/year, corn cobs of 5 million tons/year, cassava stalks of 3 million tons/year, waste wood of 50 million tons/year, rice husks of 15 million tons/year, cocoa shells and so on. With the application of biochar, agricultural productivity can increase by an average of 20% or even up to 100%. If applied on a macro or national scale, say with a 20% increase in production, for example, rice production will increase to 36 million tons/year from the previous 30 million tons/year, corn will increase to 18 million tons/year from the previous 15 million tons/year, crude palm oil or CPO to 60 million tons/year from the previous 50 million tons/year. This will save land use so that the opening of forest land for food crops and (bio)energy such as food estates may not be necessary or at least slow it down. But why until now has biochar not received attention and been used as a solution?

In addition, biochar production with pyrolysis will also produce a number of by-products that can be used for energy applications or others, as in the diagram above. Many agro-industries require drying in their production processes, so this is an additional advantage of using pyrolysis technology for biochar production. While from the environmental aspect, biochar is also a carbon sequestration so that it is a climate solution and can get carbon credit. Likewise in waste management, because the raw material for biochar is biomass waste from agriculture, plantations and forestry, even from organic waste, the pyrolysis and biochar business is also a solution to this problem.

Optimizing Pyrolysis and Biochar in the Palm Oil Industry

Indonesia's CPO production currently reaches around 50 million tons per year with a land area of ​​around 17.3 million hectares. This means that the average CPO production per hectare is only 2.9 tons or per million hectares produces 2.9 million tons. If biochar is used and there is a 20% increase, it means there is an increase of 10 million tons of CPO per year and this is equivalent to saving around 3.5 million hectares of land, or the use of biochar will slow down forest clearing (deforestation) for palm oil plantations.

The average speed of Indonesian palm oil plantation area is 6.5% per year or equivalent to about 1 million hectares per year for the last 5 years, while the increase in palm oil fruit production or FFB (fresh fruit bunches) is only 11% on average. Even the largest expansion of palm oil land occurred in 2017, which increased by 2.8 million hectares. By opening 1 million hectares of forest, national CPO production only increased by 11%, while without the need to open forests, namely with the application of biochar, there could be a 20% increase in productivity. And the 20% increase in FFB yield (fresh fruit bunches) using biochar is a low estimate.

With the number of palm oil mills in Indonesia reaching more than 1000 units and tens of millions of tons of biomass waste, especially empty palm fruit bunches (EFB), the volume of biochar production produced is certainly very large. In addition, pyrolysis technology can replace combustion technology which is generally used in palm oil mills to produce steam for electricity production and sterilization of fresh fruit bunches (FFB) in CPO production. With pyrolysis raw materials using palm oil tankos and being able to replace palm kernel shells, 100% of palm kernel shells (PKS) can be sold or exported. The sale of palm kernel shells or PKS (palm kernel shells) will certainly provide additional attractive benefits for the palm oil company. Palm kernel shells or PKS are the main competitors of wood pellets in the global biomass market.

In addition, the use of biochar also saves fertilizer use and the highest operational cost on oil palm plantations is fertilizer so this is very relevant. Tens of billions of costs spent on fertilizer can be reduced by using biochar, especially since the biochar comes from its own waste so that it will automatically become a solution for biomass waste management. Including biopesticides and liquid organic fertilizers can also be produced from the pyrolysis process. Carbon credit is the next business potential. This is because the application of biochar to the soil for agriculture or plantations is an effort for carbon sequestration / carbon sink.

The benefits that can be obtained from this biochar carbon credit are also large, even globally biochar carbon credit ranks first or more than 90% in Carbon Dioxide Removal (CDR) recorded in cdr.fyi. However, there are indeed many large biochar producers who do not sell their carbon credits because of the methodological requirements of standard carbon companies such as Puro Earth and Verra, and these biochar producers are comfortable with their biochar sales business, especially since these producers have existed (established) since before carbon credits were available for biochar. 

Problems of Wood Harvesting from Calliandra Energy Plantation and High Potassium Content in Wood Pellet Ash: Two Things That Need Attention

The factor of production efficiency and standard and stable product quality is the mindset of the industry, including for the wood pellet industry from the calliandra energy plantation. Manual wood harvesting operations make production efficiency low. The high daily need for wood pellet raw materials from energy plantations requires mechanization equipments for harvesting the calliandra plantation. Meanwhile, calliandra wood pellet products with high ash content containing potassium also require certain treatments so that the wood pellet products meet the standards for power plants in general. The stability of production quality and quantity is closely related to the quality of the production equipment used. These two things must be an important concern for wood pellet producers from calliandra energy plantations with large capacity and export orientation.

The wood pellet industry from the calliandra energy plantation is new, so there are not many references. The history or the origin of this industry comes from the project of the Ministry of Forestry of the Republic of Indonesia at that time which created an incubator-scale industry as a pilot for the production of wood pellets from the calliandra energy plantation located around Geger Hill, Bangkalan, Madura, East Java about 12 years ago. At that time, there were actually several wood pellet industries operating, but all of these wood pellet factories or industries used raw materials from wood industry waste, such as sawmill industry waste, barecore industry waste, plywood industry waste and so on.

Calliandra trees are also not new plants to the public. This tree has been widely planted but previously with different purposes, namely for reforestation, for animal feed or for honey bee farming. While for bioenergy purposes or wood pellet production, planting calliandra trees in the form of energy plantations is something new. That is why in the early stages, calliandra wood harvesting was still done manually and this was ineffective and inefficient on large-capacity plantations. In addition, the wood pellet product has not been analyzed or examined completely / comprehensively so that the high potassium content (ash chemistry) in the ash has not been detected. When the requirements for the maximum content of potassium / potassium must be met, special treatment needs to be done.

In addition, an important thing to note is the target types of products produced. If the calliandra plantation not only produces wood as raw material for wood pellet products, but also processes leaves for animal feed, then the harvesting mechanism is very influential. The leaves from the calliandra plantation must also be harvested effectively and efficiently or the same as the wood products. This could be, for example, the trees and leaves are harvested together and then taken to a place and separated to be processed individually. Or it could be that the wood and leaf products have been separated at the time of harvesting, then each goes to its respective processing unit. The equipment used must also be different according to the choice of the harvesting mechanism. Meanwhile, honey products from bee farms that utilize calliandra nectar are not affected by this mechanism, this is a separate honey production process and is related to the flowering season of the calliandra tree itself.

Along with the global decarbonization trend, the prospects for calliandra plantations are increasingly bright. It is predicted that many calliandra plantations will be created, which are intended primarily for bioenergy production such as wood pellet production, and this is in line with the carbon neutral scenario that supports the net zero emission program. The use of wood pellets is mainly for fuel in coal-fired power plants through the cofiring mechanism. In the next stage, it is possible to use 100% of the power plant fuel using wood pellets (fulfiring). The high potassium content is generally a problem in applications for this power plant, although there are types of power plants that technically do not have a problem with the potassium content, but the production of wood pellets from calliandra with low potassium content is certainly preferred.