Empty Fruit Bunch of Palm Oil Processing: for Pellets, Briquettes or Biochar ?

Empty fruit bunches (EFB) are solid waste from palm oil mills or CPO production which is the largest in number. This is what makes many machine manufacturers make these EFB processing machines. Most of the machines made are equipments for cutting and pressing the EFB so that the water content decreases and the size becomes smaller. However, both the water content and the size of the EFB as the output of the machine or equipment still do not meet the requirements to be further processed into pellets, briquettes or even biochar. The typical output is more than 4 inches and the water content is more than 45%. EFB must have a low water content of 10% and a size of 5-6 mm to be able to make pellets or briquettes, and less than 1 inch for biochar production.

To obtain suitable raw materials for pellet, briquette and biochar production, the EFB that has been cut and pressed still needs to be reduced in size (size reduction) and its water content reduced to about 1/3 so that it is dry enough. Equipments such as a hammer mill or crusher is needed to reduce the size and a drying tool such as a rotary dryer is needed to reduce the water content. The smaller the size of the material (particle size) and the lower the water content or the drier it is, the more energy is needed. Equipment such as hammer mills and rotary dryers have not become an integral part of EFB processing at this time. However, usually EFB palm oil processing producers also produce press equipments for kernels for the production of kernel oil or PKO in kernel processing plants or KCP (kernel crushing plants) with by-products in the form of palm kernel meal or PKE (palm kernel expeller). 

Considerations for selecting pellet, briquette or biochar production from EFB palm oil depend heavily on the readiness of the business. It is estimated that there are 30 million tons per year of dry EFB palm oil in Indonesia and 10 million tons per year of dry EFB palm oil in Malaysia for raw materials for these products. The use of EFB palm oil waste, in addition to being a solution to waste problems in palm oil mills, will also provide additional benefits for the palm oil mill or company. How much profit is usually also proportional to the investment and production capacity made. With the abundance of potential raw materials and the driving force of sustainability and zero waste, EFB palm oil waste will become an attractive new business. 

EFB Pellets as Biomass Fuel Transition from PKS to Wood Pellet Energy Plantations?

The high demand for palm kernel shells or PKS makes their availability or supply increasingly limited. The properties of palm kernel shells or PKS which have many similarities to wood pellets make them the main competitor for biomass fuel in the global market. The high demand for palm kernel shells is not only because the price is usually cheaper than wood pellets, but also the large availability can be achieved because of the large number of palm oil mills, also especially the many new biomass power plant developments that can use 100% palm kernel shells, namely biomass power plants with fluidized bed combustion (CFBC or BFBC) technology, read more details here. 

Under these conditions, efforts to obtain new biomass fuel become important. The palm oil industry itself produces a lot of biomass waste so it has potential as raw material for new biomass fuel. One of the biomass wastes that has not yet been utilized and is large in volume and has the potential to pollute the environment is palm oil empty bunches or EFB (empty fruit bunch). Every ton of crude palm oil or CPO production will produce approximately 1 ton of EFB waste. This means that with an average palm oil mill capacity of 45 tonnes of FFB/hour, around 10 tonnes/hour of crude palm oil (CPO) will be produced and 10 tonnes/hour of EFB waste. So, for example, if a palm oil mill operates 20 hours/day, approximately 200 tons of EFB waste will be produced/day. And with the number of palm oil mills in Indonesia estimated at 1,000 units, the amount of EFB waste will also huge.

PKS and EFB are both biomass waste from palm oil mills. Both can be easily obtained from palm oil mills in abundant quantities. PKS can even be used directly as biomass fuel, whereas EFB requires pre-treatment first. The EFB that comes out of the palm oil mill is very wet and the shape and size still need to be adjusted to make the follow-up process easier. EFB pellet production is a solution for EFB waste. But apart from that, so that this EFB pellet product can be used more widely or like wood pellets in general, there is an additional process to reduce the amount of mineral content in the ash.

Meanwhile, wood pellets from energy plantations could become the next source of biomass fuel, although currently someone has already started doing so. Because the raw material for EFB pellets is palm oil mill waste and is abundant, it requires a smaller investment, so EFB pellets can be used as transitional biomass fuel before biomass fuel in the form of wood pellets from energy plantations. Investing in land and its preparation as well as creating an energy plantation costs a lot of money. But the advantage of wood pellets from this energy plantation is that the availability of raw materials, even in very large volumes, can be more guaranteed. Apart from that, there are also other benefits from using the leaves as animal feed, especially ruminants and the flowers for honey bee farming.

Production of EFB Pellet EFB or EFB Biochar ?

One of the main obstacles for palm oil mills to develop their business is the availability of electricity. With locations that are generally located in remote areas in the middle of palm oil plantations, palm oil mills do not get electricity supply from PLN (Indonesia State Owned Electricity Company). Eventhough electricity is very important in a production process, such as in the production of EFB pellets. Even though empty bunches or EFB in general are an environmental problem for palm oil mills. If every ton / hour of EFB pellet production takes 300 KW, then for production of 10 tonnes / hour (5,000 tonnes / month) 3 MW of electricity is needed, export of biomass fuels such as wood pellets and PKS (palm kernel shell)  with bulk shipments usually requires 10 thousand tons / shipment. So if the production of EFB pellets is planned for 10 thousand tons / month so that every month can export the EFB pellets, the factory capacity or EFB pellet production is 20 tons / hour (10,000 tons / month) 6 MW of electricity is needed. For palm oil mills, utilizing liquid waste or POME to become biogas is a potential source of energy for the production of electricity. However, with a palm oil mill capacity of 30 tonnes of FFB / hour, only about 1 MW of electricity is generated from POME biogas, so to produce 6 MW of palm oil mills with a capacity of 6 x 30 tonnes of FFB / hour are generated equal to 180 tonnes of FFB / hour. In fact, the average palm oil mill has a capacity of 45 - 60 tonnes of FFB / hour, so it is impossible to generate 6 MW of electricity from the palm oil mill's POME biogas.

The use of EFB pellets is the same as wood pellets and PKS is mainly for power generation. All three are biomass fuels. The high chlorine and potassium content in empty palm fruit bunches or EFB makes their use limited to power plants due to corrosion and scale causes. Not all power plants can use EFB pellets at large capacities or quantities. The use of coal-fired power plants with pulverized combustion technology can only be used with a small ratio or an estimate of less than 5%, but can be used more or even 100% in fluidized bed and stoker types of power plants. The capacity of fluidized bed and stoker type PLTU is generally much smaller than pulverized combustion.

When the biomass source is managed properly, the use of biomass fuel is an environmentally friendly and sustainable fuel. Biomass fuels like this are carbon neutral fuels, because they do not increase the concentration of CO2 in the atmosphere. This is because the biomass as a fuel source comes from plants whose growth is from the photosynthesis process, one of which uses CO2 from the atmosphere, so that when the biomass is burned, there is practically no addition of CO2 to the atmosphere. In general, there are 2 ways to overcome the CO2 concentration in the atmosphere which causes climate change and global warming, namely the carbon neutral scenario and the carbon negative scenario. In a carbon negative scenario, CO2 in the atmosphere will be captured and absorbed so that it is no longer released and the concentration of CO2 in the atmosphere can be reduced, as in the biochar application below.

Whereas in the production of biochar with pyrolysis, besides not requiring a large amount of electrical power for its operation, electricity can also be generated from the use of excess energy from pyrolysis itself. By using the excess energy from pyrolysis, the palm oil mill boiler fuel does not need to use palm kernel shells and fiber. The use of gas or liquid fuels from the excess energy of the pyrolysis process also makes burning emissions cleaner. To achieve more complete combustion, gaseous or liquid fuels are better than solid fuels. Palm kernel shells so that everything can be sold or even exported. The biochar product applied to palm oil plantations will also improve the quality of the soil so that fertilizer use can be reduced and the productivity of palm oil fruit will increase. Biochar also absorbs CO2 from the atmosphere so that the use of biochar in large palm oil plantations means that with massive applications it can also be used for carbon trading. Recent developments indicate that the use of biochar is increasingly widespread, such as biomaterials for construction, transportation, plastics, packaging, furniture and so on. The use of biomaterials for these products means substituting the use of fossil-derived raw materials.

So based on the above review, the production of biochar with pyrolysis is more profitable and easy to implement for palm oil mills compared to EFB pellet production. The addition of electricity production with a large capacity and the availability of sufficient raw materials is not easy and cheap for the average palm oil mill in Indonesia with a capacity of 45 - 60 tons of FFB / hour. Whereas in the production of biochar with pyrolysis, a certain amount of energy is produced which can be used for various purposes and the use of biochar is also multi-beneficial. Palm oil mills should consider this in particular in the aspects of waste management, plantation productivity, environmental aspects and business development, for more read here. Based on experience, the cost structure of the CPO or palm oil production business consists of about 80% of the cost of production is the cost of crops or plantation aspects, while the other 20% is the cost of processing or mill aspects. And the highest cost aspect of palm oil plantations is the cost of fertilization so that if the need for fertilizer can be reduced and the productivity of palm oil can be increased, of course it is very profitable, biochar is effective and efficient to use for this.

Why Palm Oil Mills Uninterested in Production of EFB Pellets or Fiber Pellets?

EFB (empty fruit bunch) produced by palm oil mills and even tend to be waste that pollutes the environment. Empty bunches are generally just thrown away around the area of ​​their palm oil plantations. In addition, there are also many palm oil mills that produce fiber waste which also pollute the environment. A number of palm oil mills that use high efficiency boilers generally produce this fiber waste due to reduced fuel consumption for the boiler. From the perspective of biomass energy both types of palm oil waste are potential sources of raw materials. Processing both types of waste into pellets for energy is a surefire solution to addressing environmental problems while providing added value economically. But why are almost all palm oil mills currently not interested in the production of EFBpellets and Fiber pellets from these wastes? There are at least 3 factors of analysis in answer to this question, as described below.

A. Electricity needs for the production of EFB pellets or Fiber pellets

Palm oil mills are generally located in rural areas or in the middle of the palm oil plantations, so they have to meet their own electricity needs. In addition to generating electricity at the palm oil mill, it also produces steam, because the technology used is steam turbine. And there are specific reasons why palm oil mills must use the steam turbine technology, for more details, please read here. The electricity production from the palm oil mills generally only meets the needs for the operation of the palm oil mills, so it will not be sufficient if used for the production of these pellets. Electricity needs for the production of each ton / hour of pellet is estimated to require 300 kW (0.3 MW) so that for production of 3 tons / hour requires almost 1 MW. Electricity production from biogas by utilizing liquid waste (POME: palm oil mill effluent) can be a solution to this, for more details, please read here.

B. Ignorance of the biomass fuel business and specifically fuel pellets

Palm oil mills which produce the main product in the form of crude palm oil (CPO) with the use mainly for food products, so that they tend to be less concerned with the energy sector, especially renewable energy and more specifically biomass energy in the form of pellets. Fuel pellets especially wood pellets are being "hot" and are widely used as an energy source in various parts of the world. Indeed, the characteristics of wood pellets derived from woody biomass differ slightly from pellets derived from agricultural wastes such as empty fruit bunches (EFB) and coir (fiber). This affects the users of electricity generation and also the portion of its use.

Another indication that palm oil mills only focus on CPO production is that they are not interested in exporting palm kernel shells (PKS) themselves. In general, palm oil mills only sell these PKS to exporters in their mills. The exporters will then export the PKS to the users namely power plants. Though PKS is also very much needed and as a competitor of wood pellets, because there are many similarities with wood pellets.

C. Need to create a new department for pellet production

Of course it is common to do that a new business unit would require management with new management. Palm oil mills or companies usually operate in two divisions or departments, namely the mill division for CPO production and the plantation division for the production of palm fruit (fresh fruit bunch) as raw material for CPO. Pellets production from empty fruit bunches and fiber also requires separate management to be effective and efficient.

D. Priority scale with the development of CPO derivative products

CPO or crude palm oil is the raw material for a number of palm-derived products. CPO exports are also urged to be reduced and recommended with various other CPO derivative products such as cooking oil, oleochemicals and biodiesel. In addition to increasing added value, exports of raw materials are also less prestigious. That is because the characteristics of developing countries are exporting raw materials to other countries, while the characteristics of developed countries are exporting final products. That is why the production of various CPO-derived products continues to be encouraged. For palm oil mills that are more focused and familiar with CPO production and the development of the CPO derivative industry, then the option to develop their company towards a variety of CPO derivative products may be a priority, compared to processing empty fruit bunches and fibers to produce pellets.