Wood Pellet Stove for the Community

Wood-fired stoves are still commonly found in various regions in Indonesia. In addition to being inefficient, the stove also produces smoke pollution which pollutes the environment and is detrimental to health. Smoke pollution from wood-fired stoves is reported as the cause of death for millions of people in the world each year. In addition, many of the firewood used comes from forest wood which causes deforestation. While the further impact of deforestation is the occurrence of natural disasters such as floods and landslides.

Cooking is one of the important human activities to get food, so it is also important to be able to do well. Included as part of that effort is maintaining fuel sustainability, affordable fuel prices, health and environmental aspects. Currently, most of the fuel for cooking in Indonesia is LPG, but in reality, nearly 80% of the LPG used comes from imports or a value of around 60 trillion rupiah. Pertamina, as the sole producer of LPG in Indonesia, currently supplies tend to decrease. However, the demand for LPG continues to increase. LPG demand in 2011 was recorded at 4.35 million tonnes. This need continues to increase every year until it has doubled to 8.55 million tons in 2021. This condition is certainly not good, because it creates dependence on imports, even though in Indonesia there are a number of resources that can be used to overcome this.

Various things based on Indonesia's potential to overcome this include adding new oil refineries so that LPG production can be boosted, coal gasification to produce DME (Dimethyl Ether) whose characteristics are similar to LPG, or using natural gas with gas pipelines. From an energy independence standpoint, this can be done, especially since the raw materials are sufficiently available, but from a bioeconomic and decarbonization point of view (replacing fossil fuels with renewable energy), which is also increasing, this is not appropriate. Renewable energy should be as much as possible as a solution. Wood pellets are fuel or renewable energy from biomass which is ideal for substituting LPG. As a tropical country, Indonesia is rich in biomass because the sun shines all year round, whereas in sub-tropical countries when it's winter the plants stop growing. It can even be said that the biggest producers of biomass are tropical areas or areas where the equator passes, so as a gift from Allah SWT we must be grateful for it.

An efficient and low emission wood pellet stove is the best solution. Why not just a biomass stove? Why does biomass waste, especially wood waste, need to be processed into wood pellets first? By making wood pellets, in addition to uniform shape and size, dry, high density, it is also easy to store and use. Even in the rainy season it can be difficult to find dry firewood in a number of areas, on the other hand wood pellets can be very practical to use. So with standard products according to the specifications mentioned above, wood pellets will be a superior and renewable solid fuel, so that wood pellet stoves will work optimally. Meanwhile, if the fuel is from any biomass with various specifications, then the performance of the stove will not be optimal.

Raw materials for the production of wood pellets can use wood wastes from sawmills, wood processing industries and forest wastes. Many of these wastes have not been utilized and even polluted the environment to become useful and have economic value. The production capacity of the wood pellet factory also needs to be determined so that it meets the needs of its use. To meet the needs of the community at the village or sub-district level, a wood pellet factory can be built with a capacity of 500-1000 tons/month.

Regarding reducing CO2 in the atmosphere in line with decarbonization and bio-economy, a number of companies are currently also carrying out carbon projects, namely by making conservation forests as a medium for absorbing CO2 from the atmosphere (carbon sinks) by receiving compensation in the form of carbon credits. The conservation forest is maintained in such a way that the carbon project is a success. The occurrence of deforestation in conservation forest areas is something that must be avoided. To avoid this, the wood pellet stove program can be a solution. Communities around the conservation forest who use wood pellets for their cooking stoves make firewood no longer used and deforestation does not occur.

Biochar for Palm Oil Nurseries

There are about 250 producers of palm oil seedlings in Indonesia, and with an area of the palm oil plantation reaching around 15 million hectares, these seedling producers are actually not many either. More specifically, Sumatra island has the largest area of palm oil plantations in Indonesia, making it the main economic activity in the area, because 70 percent of palm oil land in Indonesia is in Sumatra. With a cropping pattern, for example, 125 trees per hectare, 125,000 trees are needed for every 1,000 hectares or 1 million hectares for 125 million trees, while 15 million hectares means more than 1.8 trillion palm oil trees with current crude palm oil (CPO) production reaching more than 40 million tons per year. A very large number, of course. But not only the quantity factor, the seed quality factor is prioritized so that it has optimal productivity. Of course, the need for seeds does not necessarily mean millions or trillions of trees at the same time, depending on needs such as new plantings from new plantations (extensification) - which is currently being carried out in Indonesia or rejuvenation of palm oil plantations (replanting) which is carried out periodically.

One of the good palm oil seeds is determined by the quality of the growing media. The growing medium for palm oil seedlings generally consists of topsoil mixed with sand or organic matter to obtain a fertile medium. Compost or manure is often used to improve soil fertility by supplying nutrients to plants. With a tropical climate with high rainfall, nutrients can be easily washed away, besides that, low soil pH is also a separate obstacle for the growth of these seeds. By using biochar, nutrients or plant nutrients become more available, humidity and microbial activity will increase. This makes the quality of the planting medium high quality, so that the resulting palm oil seed products in the form of roots, plant height, number of leaves and plant weight are the parameters observed with the use of biochar which are also getting better.

Compared to using cocopeat, biochar has a number of advantages. Both cocopeat and biochar have uses in agriculture, but there are a number of differences between the two. Cocopeat has uses mainly as a planting medium because of its water holding capacity, while biochar besides having the ability to hold water like cocopeat also raises soil pH, holds or makes nutrients more available (nutrient retention), and also becomes a soil microbial colony so that Organic materials become quickly decomposed and absorbed by plants. Cocopeat will also decompose in a short time like compost, while biochar can survive and not decompose for hundreds of years. Under these conditions, biochar is also used to store CO2 (carbon sequestration) and obtain carbon credits with the carbon sink mechanism.

The palm oil nursery is the starting point that most determines the further growth of the palm oil in the field. The success of growing palm oil plants in the field is largely determined by the quality of the seeds planted. Seedlings that grow well in nurseries have high adaptability in the field. In practice, it has been proven by a number of studies that the use of biochar has a positive effect on palm seed products. The use of biochar in the range of 40% has become the best composition for the planting medium for the palm oil seeds. This should encourage producers of palm oil seeds to use biochar. If there is a need for biochar in large quantities for this purpose, please contact us. We can also provide technical specification data (COA) and also the biochar samples.

Palm Oil Mill Redesign for IVO Production: Using Pyrolysis, Gasification or Biogas?

The production of biodiesel / green diesel using raw material of RBD PO is too good (overspec) and too expensive, so it needs to be replaced with a cheaper raw material, namely IVO (industrial vegetable oil). For this purpose, it is necessary to redesign the palm oil mill so that a number of FFB extraction production into CPO carried out at the palm oil mill need to modify the process flow. The sterilization process can be eliminated so that there is no need for water for steam production as well as boilers and steam turbines for electricity production. Water treatment units may also be no longer needed or may still be needed but for different processes.

Another important thing is the supply of energy, especially electricity, for this new type of palm oil mill. This is because most of the equipments used in the palm oil mill are mechanical equipments that work by consuming electricity. As the mill that has a lot of biomass waste, it's certainly not a difficult thing to do, even so far, palm oil mills produce their own electricity by burning palm mesocarp fiber and palm kernel shell in the boiler. But in a new type of palm oil mill with a different configuration, the boiler may not be needed or it is still needed but there are differences from before. Basically, of course, how to achieve the highest level of efficiency with the new process.

Another factor is how the new production process also provides greater benefits for the palm oil industry, for example biochar products are also produced. The biochar product will later be used in palm oil plantations to improve soil fertility and also as a carbon sink and absorb N2O gas, which is a greenhouse gas. Carbon credits from the application of biochar as a carbon sink will also provide additional income for the palm oil industry, which is also not a small amount. Currently, many palm oil plantations are located on acid soils or with low pH, which results in low productivity of palm oil yield, so it needs to be increased. Also, in the operation of palm oil plantations, the cost of fertilizer is the highest cost component, and for this reason, biochar is the solution to this problem. With the high productivity of FFB with this treatment, the clearing of palm oil land is no longer needed, so that the focus on palm oil plantations which causes deforestation is also reduced, more info read here.

For electricity production, apart from burning palm nesocarp fiber and palm kernel shell in the boiler, then the resulting steam drives a steam turbine, another way is pyrolysis and gasification of biomass. With pyrolysis (slow pyrolysis) more biochar production or as the main product. Whereas with gasification the product of biochar is less with more main gas product. Biogas from liquid waste (POME) is another energy source that can be used. Basically it depends on the goals and needs, how much electricity is needed, how much biochar is needed and so on. But with the area of palm oil plantations reaching tens of thousands of hectares, the need for biochar will be very large, so pyrolysis will be more suitable to be applied. And if the demand for electricity is large enough, then electricity from biogas can also be used as an addition to electricity from pyrolysis. 

Even with this pyrolysis, other useful products for palm oil plantations will also be produced, such as liquid smoke. This liquid smoke can be used as a biopesticide whose application can use agricultural drones at speeds of 16 hectares/hour or more. Biooil products from pyrolysis can also be used for direct fuel using a burner or further refined to become vehicle fuel. Burning gas or liquid fuels will give cleaner emissions to palm oil mills compared to burning solid fuel that has been done so far.

Digestate from biogas can be used together with biochar so that it can provide maximum results in palm oil plantations. With a porous biochar structure, digestate plus biochar will become a slow release organic fertilizer so that fertilizer use will be more efficient. Apart from that, with the large amount of potential for biomass waste in the palm oil industry, it also allows for a number of business developments, especially if there is an adequate supply of energy. An example is the production of activated carbon from palm kernel shells (PKS) or the processing of kernels into kernel oil (crude palm kernel oil). By optimizing all the potential, especially biomass waste so that it can provide economic and environmental benefits, the palm oil industry will be even more attractive.

Wood Pellet Production to Penetrate the European Market

The condition of the Russian-Ukrainian war that occurred had an impact on the wood pellet industry, namely the shortage of supply in England and other European countries. They have made efforts to increase supply to secure the availability of these wood pellets. The shortage of wood pellets both for industrial and household use (room heating / pellet heating). Wood pellet production from Russia cannot be accepted by the European market even though the amount is large (Russia exported more than 870,000 tons to Denmark alone last year) and this condition is expected to occur for at least the next 12 months. The supply shortage of wood pellets is estimated at 3.4 million tons, which is production from Russia, Ukraine and Belarus. The Russia-Ukraine conflict has led to high wood pellet prices for various reasons, mainly due to the scarcity of wood pellets and other fuels coming to Europe and high electricity prices.

The need for wood pellets also continues to increase along with the decarbonization program (substitution of fossil fuels for renewable energy). According to Hawkins Wright's data, from 2020-'21, demand for wood pellets for the global industry grew by 18.4%, with production only growing 8.4%. Especially now with the disappearance of Russia, the price of wood pellets is higher, which reaches $ 300 per ton, but even at high prices, the supply of wood pellets is still constrained. The high price of fossil fuels has also created an increase in demand for wood pellets, especially households in Europe who have switched to wood pellets for space heating and it is estimated that the increase in demand will reach 2.5 million tons in 2022, according to the Austrian proPellets report. In Austria—and most of their representatives across Europe—wood pellet prices broke records by increasing more than 53% over the previous year with no signs of slowing down anytime soon. Even the June 2022 survey completed by Austrian proPellets resulted in an average price of wood pellets rising 66% compared to the previous year. However, despite the increase, wood pellets still offer a price advantage of 82.7% compared to heating oil and 18.3% compared to natural gas. Meanwhile, packaged wood pellets (bagged pellets) increased 52.8% compared to last year.

ProPellets Austria also reported that to respond to the demand for wood pellets, especially to ensure long-term needs, the Austrian wood pellet industry built 11 new wood pellet factories by accelerating the utilization of wood residue. The international energy market is in a state of upheaval, not least because of Russia's invasion of Ukraine, and this also affects the wood pellet market globally, especially in Europe. Whereas the UK has also faced a shortage of 200,000 tonnes of wood pellets in the domestic/household heating market and that new supply chain pathways are being explored, importing larger volumes is one solution. With a very tight market, supply chain bottlenecks, inflation and the ripple effects of ongoing wars, strategy, creativity and supply chain flexibility will be required from wood pellet stakeholders. As for whether global wood pellet supply is expected to be closer to meeting demand, that likely won't be in the near future, according to Matthews, biomass consultant from Hawkins Wright. . Economic strength will have an effect over time — high prices are the driving force of investment in a new wood pellet plant. The wood pellet industry is currently investing hundreds of millions of Euros so that supply is guaranteed in the long term, but they also need support from political decision makers.

Indonesia, with its vast territory and tropical climate, has the potential to develop large capacity wood pellet production, including the use of energy plantations. Indonesia's wood pellet production, which is currently still small or estimated at only 200 thousand tons per year, needs to be boosted so that it responds to European needs. Even though so far Asia, Japan and Korea are the target markets for wood pellets, recent developments in European conditions have also become a new impetus. The high price of wood pellets in Europe due to the Russia-Ukraine war made suppliers in North America (United States and Canada) also start supplying Europe. In fact, this opportunity was also seized by a number of suppliers from Asia. Vietnam is the second largest exporting country in the world for wood pellets. The volume and value of wood pellet exports has continued to increase since October 2021 and export prices have soared to an average of nearly US$150 per tonne, up more than 27% compared to the average price recorded last year. The sharp rise in export volumes and prices can be attributed to the sudden increase in demand from the European Union. With this extraordinary production capacity, Vietnam's wood pellet industry is starting to face a number of challenges, namely limited raw materials and more stringent requirements demanded by importers such as sustainability certification. This condition should be seen as an opportunity for the wood pellet industry in Indonesia.

Drying Palm Kernel Shells (PKS) by Utilizing Waste Heat from Palm Oil Mills and POME Biogas Units

The need for palm kernel shells or PKS is getting bigger because its use is increasing and diversifying. PKS can be used as boiler fuel in industry and in power plants. In addition, it can also be used as a raw material for activated carbon whose needs are also increasing, for more details, read here. The global trend to decarbonize or replace fossil fuels with renewable energy including biomass fuels, especially PKS is the main driving force for the increasing demand for PKS. Even oil-rich countries with economies driven from oil (petrodollars) are also gradually implementing the decarbonization program.

To be used as fuel or further processed into a number of derivative products such as torrified PKS, PKSC or palm kernel shell charcoal and activated carbon, the PKS must be dried first. The process of drying or reducing the moisture content to a certain level requires energy. PKS, which are palm oil mill waste, are generally just piled up in the backyard of the palm oil mill, so they are usually dirty and wet, resulting in a low selling price. If the palm oil mill can dry and clean its PKS, the selling price will also increase, so that there is added value as well as additional income for the palm oil mill. A number of energy sources from waste heat from palm oil mills can be used for the drying process.

Heat is an energy source that can be used for various purposes, either heat generated directly from the combustion process or from waste heat which is the residual heat from the combustion or other sources such as electricity and so on. In palm oil mill operations there is a certain amount of waste heat that can be extracted or harvested or recovered as a heat source for drying such as heat from combustion in the boiler, heat from steam turbine and heat from the FFB sterilization process. If the palm oil mill also processes its liquid waste for electricity production, the waste heat from burning biogas in the generator can also be used as a heat source for drying the PKS. A number of heat sources which are waste heat when integrated, the amount is large so that it can be sufficient for drying the PKS.

In addition to producing CPO (Crude Palm Oil) as the main product, palm oil mills generally also produce palm kernel. Currently, there are still a few palm oil mills (CPO mills) that also have PKO (Palm Kernel Oil) mills , meaning that there are palm oil mills that process fiber for CPO production and palm kernel for PKO production. The palm kernel is produced from the separation of palm kernel with its shell (PKS). Separation is done by breaking the palm kernel shell in a nut cracker drum, then it can be separated between the palm kernel shell and the kernel or core based on differences in specific gravity. If the palm oil mill wants to get added value from its palm kernel shells (PKS), then as soon as it leaves the palm oil mill it goes straight into the dryer (with waste heat as the heat source) after which it is cleaned with a sieve (screening) so that it becomes the final product in the form of dry and clean PKS, so that higher sale value. The size of the shell and fibers that pass the sieve (undersize), can also be used as boiler fuel. Palm oil mill boilers currently operate using fiber fuel (mesocarp fiber) and part of the palm kernel shell (PKS). The rejected material in the form of undersize can be used as boiler fuel so that less PKS are used.

Post Mining Land Reclamation With Bamboo

Bamboo is a tree that is easy to grow, tall quickly and has many benefits. One of them is the use of bamboo trees for post-mining land reclamation. Damaged and barren post-mining land is indeed not easy to plant directly. Certain treatments or efforts are needed so that the land can be planted with certain plants. When the land has become fertile soil, of course almost all plants can be planted on the land. And to achieve these conditions it takes time and a process that is not short.

Soil improvement efforts in the sense of improving soil fertility are the first thing to do so that plants can grow well on the land. Plants that can be planted at this stage are also only certain types of plants such as pioneer plants in the form of fast growing plants such as legumes. And bamboo as a group of grass plants is also easy to plant and grow on marginal lands such as post-mining land. Availability of water, adequate nutrients, pH or adequate soil acidity are some of the things needed to achieve optimal growth.

As an illustration, sand is a bad planting medium because there are almost no nutrients in it and this is almost the same as the condition of post-mining land in general. Substances or organic materials need to be added so that they become fertilizers or nutrients for the land. Animal dung is the best organic material for this, so integration with livestock is the best concept for post-mining land reclamation. Biochar with its various advantages also needs to be added to the land. Biochar can be produced from biomass wastes from plantations, agriculture and forestry for this purpose. The use of biochar on a wide scale can also provide income in the form of carbon credits because biochar is applied to the soil as a carbon sink with carbon sequestration.

Bamboo trees as a type of grass plant have fibrous roots. Large bamboo clumps have a large network of fibrous roots as well. The success of bamboo roots is one of the keys to bamboo growth. The use of biochar in bamboo nurseries will also improve the roots of the bamboo seedlings produced. While in bamboo plantations, the use of biochar also has many benefits, especially on post-mining land the results will look more real, such as maintaining moisture, more available nutrients, not acidic soil pH and so on. Biochar is useful for improving soil fertility, so it can be used in nurseries and plantations.

Currently a number of mining companies have carried out land reclamation with these trees, but most of them are still testing and do not yet have a comprehensive concept. Post-mining land reclamation with bamboo in Indonesia is estimated to start in 2010 or has been going on for about 12 years until now. A number of bamboo species have also been identified as suitable for the post-mining area. Scale up or capacity enlargement is an important and current challenge, especially when it is supported by information on 12 years of reclamation with these bamboo trees. With this capacity expansion, besides bamboo production, commercial production can also be achieved, the application of biochar will also find its optimum benefits, namely improving soil fertility and carbon sinks (carbon sequenstration).

The use of bamboo in particular is an aspect that has not received serious attention in these reclamation projects. Whereas only with the use of bamboo which is a plantation product can the reclamation effort be known to provide economic benefits or not. The lack of serious attention to the use of bamboo is thought to be because the bamboo reclamation is still in the experimental stage with a small area. But if it has been pursued professionally, the economic aspect will become an important concern.

The use of bamboo, for example, is to make people's houses around the mine. With bamboo treated first and also using the art of building architecture, the bamboo house produced will be of high quality, in the sense of being sturdy and beautiful and far from being cheap. This will reduce the use of certain wood for houses, some of which have limited types, such as ironwood in Kalimantan. Indeed, there are many ways to use the bamboo, but it is necessary to choose the best one based on the related conditions and situations. Ruminant farming, especially for the production of organic matter or land fertilizers, will also require cages or in rotational grazing, poles for paddock will also be required. The cages and poles can also be made with these bamboo products.

And when bamboo production is used for biomass production and then used for biochar production, it is also technically possible. But economically, it is necessary to study whether it also provides benefits, both from the effect of improving soil fertility and carbon credit. In this case, the most important thing is the production of the biomass itself so that the bamboo species that produce the most biomass are selected. The more soils that can be repaired with biochar treatment, the more land that can be recovered so that it becomes productive land. When the soil is fertile again, various food crops are also very possible to be planted on the land. The increasing population also demands more food needs, so food production needs to be increased, including the use of these recoverable lands.

Wood Pellet Production from Acacia Industrial Plantation Forest (HTI) Waste

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 forest with an area of ​​​​thousands of hectares to meet 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 cut down, then a new planting is carried out (replanting). If every one hectare produces 20 tons of acacia wood waste, then with an area of ​​20,000 hectares, 400,000 tons of acacia wood waste is 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 which cover an area of ​​hundreds of thousands of hectares, so the volume of wood waste produced is also very large. The wood waste is very potential for the production of wood pellets. The need for wood pellets is also increasing along with the decarbonization program or fossil fuel substitution.

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.

For the production of wood pellets, you can use raw materials from wood waste or wood that worth of waste wood. This is why wood that is valuable or has a high economy is not suitable for the production of wood pellets (from an economic point of view). Users of wood pellets are mainly for power plants so that the volume of their needs is large. Waste wood such as from acacia plantations is very potential and suitable for the production of large capacity wood pellets. In addition to Japan and Korea as the largest wood pellet market in Asia, currently Europe is also increasingly being encouraged to use wood pellets. The occurrence of the Russia-Ukraine war was one of the driving forces. The dependence on fossil fuels from Russia has become a concern for European countries in particular, so that the urge to use renewable energy is getting bigger. Biomass, especially wood pellets, also has a large portion in the plan to use renewable energy in Europe, especially in the RED (Renewable Energy Directive) II. Even in the current war conditions, the need for wood pellets for space heating is also getting bigger, although for this segment, especially firewood is their main fuel. With the disruption of energy supply from Russia, it is predicted that this winter will be a tough winter in Europe.

PKSC For Activated Carbon Production

The production of palm kernel shells (PKS) in Indonesia and Malaysia is very large, with more than 15 million tons annually which comes from palm oil mill waste. There are about 20 million hectares of palm oil plantation from these two countries (Indonesia and Malaysia) as sources of crude palm oil and are the largest in the world today. Utilization of PKS can be optimized for the production of activated carbon. The demand for activated carbon is predicted to increase by around 10% per year and the demand will reach nearly 4 million tons in 2021 worth 8.12 billion USD, while data in 2015 recorded global activated carbon production of around 2.7 million tons worth 4.74 billion USD. Powdered activated carbon (PAC) has the largest market share followed by granular activated carbon (GAC). The high demand for PAC is mainly driven by the need in a number of industries such as chemical, petrochemical, food and beverage for decolorizarion and deodorization applications. More specifically, the use in the liquid phase has the largest portion.

However, it is recognized that coconut shell is the current favorite material for activated charcoal production, and PKS is likely to be the next priority. The area of ​​Indonesian coconut plantations is estimated at around 3.7 million hectares so that the number of coconut shells that can be used as activated carbon is also not as much as PKS because the area of Indonesian palm oil plantations has also reached approximately 15 million hectares. With a coconut plantation area of 3.7 million hectares, coconut shells have a composition of 12% of coconuts so that the total coconut shells that can be produced are around 23,000 tons/year. This is in stark contrast to PKS which have the potential to reach tens of millions of tons every year.

The characteristics of coconut shells are also almost the same as PKS. Likewise for the use of activated carbon which emphasizes factors such as hardness and ash content. The harder the material and the smaller the ash content, the better the quality of activated carbon produced. Currently there is a need for palm kernel shell charcoal / PKSC  of 20,000 tons / year for the raw material for the production of activated carbon. Groups of palm oil companies that have a number of palm oil mills (1 group of palm oil companies having 5 palm oil mills is common in Indonesia) or other private parties by taking raw material for PKS from these palm oil mills to be able to produce PKSC to be exported as raw material for the activated production. The use of a large capacity carbonization (pyrolysis) equipment that works continuously is needed to meet these needs. This will be a business development for the palm oil companies and will be more environmentally friendly because less solid biomass waste is produced.

Complete Pellet Production Line (Fuel and Feed) Small Capacity For Research and Experiment

Laboratory equipment as a production unit or as a small factory (mini-mill) is needed both for learning (research and experiment) and as a production stage before reaching the commercial stage of a business. By observing and conducting trials on the mini-mill, in addition to getting a complete understanding of the production process from A to Z, we can also make detailed and in-depth observations of each stage of production in an easy and inexpensive way and provide a more complete picture for the commercial production process later. It is also easy to do research and experimentation on various kinds of raw materials, both single material and a mixture of several raw materials. Currently, there are many researchers and practitioners who want to try a raw material to make pellets but have difficulty finding partners or companies that can do it. Setting up equipment with mini-mill facilities is also much easier, in contrast to large factories. This is why in general large factories do not want to accept trials of making pellets from a certain material, because their focus is on production targets, unless they have R & D facilities for these trials.

Meanwhile, if the laboratory equipment is only in the form of functional tools such as cutting tools, crushing tools and so on but is not integrated into a production unit (even though the capacity is small), it will be difficult to imagine even more accurately designing an industrial or commercial factory. Even if a number of functional tools in the laboratory are integrated, which usually come from a number of manufacturers and have different capacities, operating the assembled mini mill is also not easy. That is why it is important to establish a complete line for the production of these pellets. The resulting pellet production can also be of two kinds, namely fuel pellets such as wood pellets and feed pellets such as leaf pellets, depending on the raw materials used.

And indeed on a commercial scale or large factory the pelletiser specification for fuel pellets such as wood pellets is different from the pelletiser for feed pellets. Pelletisers for fuel pellets such as in wood pellet production have a greater electric motor power about 3 times than a pelletiser for feed pellet production, for example for 1 ton/hour wood pellets need 150 KW while for feed pellets it is only 50 KW. In addition, the quality of the metal used for the production of the pelletiser is usually also different because the level of hardness of the raw materials is also different. Pelletiser is the main equipment or the heart of the process in pellet production, both fuel pellets (wood pellets) and feed pellets. Based on experience in the field, it turns out that there are many cases of failure of commercial wood pellet production due to errors in the selection of this pelletiser, namely the pelletiser for feed is used for wood pellets besides being not optimal, the machine life is short, even in a number of cases wood pellets are not formed so that the target production is not achieved. The main reason why this happened is because of being tempted by the price issue, namely the feed pelletiser is cheaper and in appearance it is also difficult to distinguish (especially the common people).

In this small capacity pellet production, only one type of pelletiser is used, because the main purpose is more on the qualitative aspect, not on the quantitative aspect. A number of process stages in the production of fuel pellets (wood pellets) are also very similar to the production of feed pellets, so the equipment used is also similar or even the same. This is mainly so that the price of the production unit is not too expensive. In commercial pellet production, ring die pelletisers are more widely and commonly used than flat die types. However, because the ring die pelletiser is more expensive even though it is close to the real conditions of the pellet industry, the flat die pelletiser is also sufficient for the purpose at this stage.

Feed pellets have a longer history than fuel pellets, especially wood pellets, namely in the 1920s when Purina Animal Nutrition, one of the largest animal feed producers in the world today. With this pelletization, the material is in powder form, unpalatable by livestock , different densities become easier to use and increase uniformity. This pelletization technique was quickly in great demand by many feed producers, so that in 1930 there were a number of feed factories specializing in the production of these feed pellets. World feed pellet production also far exceeds fuel pellets (wood pellets), which is in the range of 1 billion tons per year, while wood pellets are in the range of 50 million tons per year. Both have strategic functions in human life. Feed pellets as a food chain for humans are needed and their production continues to be increased. 

It is estimated that protein needs in 2050 need an additional 250 million tons per year, an increase of 50% compared to today. This is because according to the United Nations, the global human population is predicted to reach 9 billion people by 2050. The food sector is looking for a solution to the protein deficit due to protein demand per capita and population growth. Meanwhile, fuel pellets (wood pellets) are needed to save the earth from climate change. Wood pellets as carbon neutral fuel make it not increase the concentration of CO2 in the atmosphere which is a greenhouse gas that heats the earth's temperature. Decarbonization programs or substitution of fossil fuels for renewable energy, especially biomass fuel or wood pellets, continue to be improved throughout the world, as a reference you can read here and here. Energy plantations or legume plantations will be the solution to this problem, read in more detail here. 

 

In addition to pellet production (both fuel pellets and feed pellets) with a slight modification, namely replacing the pelletiser with a briquette machine, it can also be used for briquette production. This is because the production process is almost the same, the two technologies are the same, namely the biomass densification technology group. The use of these briquettes is also for fuel the same as wood pellets, but these briquettes can also be charred (carbonized) so that they become charcoal briquettes. The production of charcoal briquettes in this way produces better quality than the production of charcoal briquettes with charcoal as raw material and then added adhesive and pressed. This charcoal briquette product is commonly known in the market as sawdust charcoal briquette, the production of which does not require additional adhesive (binderless briquette).

Mini Palm Oil Mill Solution to Maximize FFB Processing

It is estimated that around 40% of palm oil plantations in Indonesia are owned by the people, this means that with the current area of palm oil plantations reaching around 15 million hectares, smallholder palm oil plantations reach about 6 million hectares with a total of 16 million smallholders. Of course the amount is not small, so if the palm fruit produced (Fresh Fruit Bunch / FFB) from the plantation can be processed optimally, it will increase the national production of crude palm oil or CPO. The area of ​6 million hectares itself is larger than Malaysia's palm oil plantation, which is the second largest producer of palm oil in the world, after Indonesia.

A number of FFB production from smallholder palm oil plantations are often constrained to supply to palm oil mills related to infrastructure and distance. This makes it take a long time or even too late to supply to the nearest palm oil mill, thus reducing the quality of palm fruit / FFB, automatically producing the crude palm oil. Low quality makes FFB prices cheap and even rejected by palm oil mills because they do not meet the required quality standards. This is certainly detrimental to farmers so that efforts are needed to overcome them.

Palm oil mills usually have a capacity of between 30 tons of FFB/hour to 120 tons of FFB/hour or it can be said that the average capacity is 60 tons of FFB/hour. The palm oil mill is owned by a palm oil company and with this capacity is very large for smallholders with limited palm oil plantation area. A mini palm oil mill with a capacity of 1 - 4 tons of FFB/hour is likely to be suitable for these smallholders. With this capacity, besides being cheaper, it requires narrower land and simpler production techniques so that FFB production from remote locations can be processed easily.

The palm oil production process can also be simplified or simplified so that it can be safe and easy to operate, for example in a large factory that uses high pressure steam, it can be simplified to only use low pressure steam. In large factories, high pressure steam is used to drive a steam turbine which is connected to a generator so as to generate electricity for the palm oil mill operation itself and the steam output from a low-pressure steam turbine is used for FFB sterilization. Meanwhile, if the mini mill has low pressure steam or only atmospheric steam, the steam is directly used for FFB sterilization, while the electricity for the operation of the mini palm oil mill comes from outside (external). With this mini capacity, the need for electricity for these operations is also not big.

The high quality of the palm oil produced can be obtained due to the quality of the raw materials and processes carried out. Good equipment performance also makes the process carried out according to the desired operating conditions. With the capacity of small palm oil mills, the volume of products produced is also small, so to achieve large volumes, it must be collected from a number of these mini palm oil mills. With more and more mini palm oil mills scattered in various locations, less FFB is wasted and quality palm oil products can be maintained. Cheap or falling FFB prices at the farmer level can also be overcome by mini palm oil mills that have good market access for their palm oil products.

Cocopeat and Biochar

Both cocopeat and biochar have uses in agriculture, but there are a number of differences between the two. Cocopeat is mainly used as a planting medium because of its water holding capacity, while biochar in addition to having the ability to hold water like cocopeat also raises soil pH, holds or makes nutrients more available (nutrient retention), and also becomes a colony of soil microbes so that organic matter becomes rapidly decomposed and absorbed by plants. Cocopeat will also decompose in a not too long time like compost while biochar can exist and not decompose for hundreds of years. Under these conditions, biochar is also used to store CO2 (carbon sequenstration) and obtain carbon credits with a carbon sink mechanism.

 

Choose Biochar or Cocopeat?
With these advantages, choosing biochar would be better. Moreover, the cocopeat can also be used for biochar production. The carbon removal program to reduce the concentration of CO2 in the atmosphere is also in line with the application of the biochar. Increasing global awareness of climate change and global warming makes carbon removal programs that also provide economic benefits from carbon credits likely to continue to increase in the near future. This cannot be done with cocopeat.

Converting cocopeat into biochar is also not difficult, even with a variety of simple (low tech) equipments it can be done. But for a large capacity so that the carbon credit program can run, it requires modern pyrolysis equipment with a large capacity. With this equipment, in addition to biochar production, there is also a number of excess energy that can be used for various purposes, one of which is drying cocopeat before it becomes raw material for biochar with such pyrolysis equipment.

Case Study India: Priority of Biomass Pellet Production Over Biomass Briquette

There are dozens of biomass briquette machine manufacturers in India and almost all of these machine manufacturers use mechanical press technology for the production of these briquettes. With this technology, briquettes will be formed due to mechanical press such as repeated strokes every minute (about 220 strokes per minute). This briquette machine manufacturer industry has also existed for decades in India so that biomass briquette products have also been widely known in India. Technically, there are actually 2 other technologies for the production of biomass briquettes, namely screw press and hydraulic press. Based on the briquette production technology, the briquette product output is also slightly different, for more details, read here.

The Indian government launched a decarbonization program at their coal power plants, recently, namely on October 8, 2021 which ordered the use of 5% to 10% biomass pellets for cofiring at all power plants and took effect in October 2022 or one year is the target time set. For example, in the early stages, the Indian government targeted only 5% for the cofiring ratio in their coal power plants, where the 5% figure when translated into biomass pellet production would reach around 50 million tons of biomass pellets per year. A very large number especially with a very short target time. And with a cofiring ratio of 5%, coal power plants also do not need to modify their equipment even though the biomass pellets used come from agricultural wastes, whose quality is below that of woody biomass.

With the number of power plants reaching about 900 units with an average consumption of 50 thousand tons of biomass pellets per year or a total of almost 50 million tons per year, so that a biomass pellet factory with a capacity of around 5 thousand tons / month seems to be suitable, and even if each factory supplying one power plant, the need for a biomass pellet plant will also be the same as the number of power plants, which is 900 units. A huge amount.

Production of biomass briquettes or biomass pellets?
In India, biomass briquette is indeed more popular than biomass pellets, but for the world level pellets are much more popular than briquette, even in 2021 alone, the need for pellets for global power generation alone is estimated to have reached 23 million tons. In addition, the production or pellet factory in general is also larger than the briquette factory. There are many pellet factories with a capacity of 5 thousand tons or even 10 thousand tons per month, while for briquettes it is very rare for a biomass briquette factory to have a capacity like the pellets above. Pelletisers for pellet production for commercial capacity have a capacity of 3 tons/hour or more, while briquette machines are generally less than 2.5 tons per hour, even for the screw press type the average machine capacity is only 300 kg/hour. Technically, even though they are both products of biomass densification technology with the difference that the size of the briquettes is larger than pellets, the production of briquettes is easier than pellets. 

The driving force from the business side makes biomass pellet production more attractive, especially because of its need as cofiring fuel in coal power plants as part of the decarbonization program. The need for biomass pellets can be a driving force for the production of biomass pellets or in general, namely the economy in various regions. The program should also be able to provide three benefits at once, namely environmental, social and economic. In addition, because briquette products are mainly used for boilers in industry, while pellets are for power generation, both of them also have their own market segments so that there is no market competition.

What about the Briquette Machine Manufacturing Industry?
Dozens of industries producing biomass briquette machines should now see this as an opportunity so that they can respond to it. These industries can adapt by creating a new line of business, namely helping the manufacture of a biomass pellet factory. Technically, the biomass briquette production line with biomass pellets also has many similarities (both use biomass densification technology) with the main difference being the pelletiser and briquetter. A number of equipment that can be made themself will reduce imported machines. Pelletisers are almost certain to be imported, so the selection of pelletisers as the heart of the pellet production process must be of high quality so that the pellet production target can be achieved. In the production of large capacity pellets, a number of equipments come from a number of providers, as is common in wood pellet factories with a more detailed explanation here.

In the long term, the goal is to minimize import spending, and even 100% can be made or fabricated by themself. This effort will usually take longer because the complexity of the pelletiser is higher than that of the briquetter. These briquette machine-producing industries can also cooperate with machine manufacturers in Europe who are more experienced and proven with pellet production as an effort to accelerate the transfer of the technology. Within one year as the target was set, it is very difficult to do this, so the practical effort is to buy a 100% complete line from a proven vendor, or sort out a number of equipment that can be produced yourself as above and gradually substitute the imported equipment. This is because achieving the production target for the decarbonization effort is a priority.

In conclusion, at this time India has to maximize efforts to accelerate the construction of biomass pellet factories to achieve this target. However, 1 year to achieve this target is very difficult. With these conditions in the future, it is possible that power plants in India will import biomass fuels such as wood pellets and PKS (palm kernel shell) to meet their needs. With the planned cofiring ratio, which is the lowest target of 5%, the need for biomass pellets reaches around 50 million tons, if only 2% of the biomass fuel needs are imported, both PKS and / or wood pellets, it will reach 1 million tons, a fixed amount still quite big.

Ruminant Farming and Post-Mining Reclamation

To fertilize post-mining soil, organic matter or compost is important and much needed. Land or post-mining land is damaged with a very low fertility level so it needs to be processed (treatment) first before it can be planted. The choice of plants depends on the purpose of using the post-mining land, whether for agriculture, forestry or others. Planting fast growing trees and short rotation coppice i.e. legume group trees is the best option. In addition to the ability to survive, its deep roots are also able to withstand erosion and the ability to symbiotic with azetobacter so that it binds nitrogen in root nodules so that it fertilizes the soil. And furthermore, the legume tree can be used as a source of animal feed (the leaves), bioenergy (the wood) and honey (the flowers).

The creation of livestock and their supporters such as forage plantations is like an ammunition factory to reclaim the post-mining land. The wider and faster the target time for reclaiming the land, the larger the farm required. Ruminant farms with thousands or even tens of thousands of livestock can be made with this purpose. Although the main objective is to produce compost for post-mining land reclamation, the indirect benefits from the farm are no less large. Even from the farm business can get big financial benefits. The main and common problem faced by mining entrepreneurs is that they are reluctant to do reclamation because it costs a lot and does not provide financial benefits. But when the reclamation activity does not reduce the company's finances even provide large profit, of course it will be a different story. The volume of mining carried out should also be proportional to the repair or post-mining reclamation.

To maximize the reclamation, biochar needs to be used. The use of biochar will make compost in post-mining land not easily lost after being washed by rain, maintain soil moisture because biochar is able to hold water (water holding capacity), raise soil pH so that soil microbial activity is more optimal and more nutrients are absorbed by plants, and biochar also will become a home or colony for soil microbes so that it will further fertilize the soil. Meanwhile, in terms of climate change mitigation, the use of biochar in the soil will also store carbon (carbon sequestration) for a very long time, up to hundreds of years. Carbon credits with a carbon sink mechanism as part of the CCS (carbon capture and storage) application can also be obtained. The carbon trading market is predicted to get bigger as global awareness of climate change and biochar as one of the solutions are also increasingly being applied, discussed and paid attention to by the earth's population.

The extent of post-mining land that reaches millions of hectares, the high demand for domestic meat as well as the export market, and the large amount of biomass waste that can be converted into biochar, post-mining reclamation should be a priority for mining entrepreneurs moreover, the reclamation activity does not reduce the company's profit but instead gives more profits. If this can be done, the environmental damage caused by mining can be minimized. Indeed, humans need various products that come from the mining to make their lives easier, but also not to the point that on the other hand the mining business actually damages the environment which will lead to disasters in the future.