Stages in the Utilization of Empty Fruit Bunches at Indonesian Palm Oil Mills

In addition to palm kernel shells (PKS) and mesocarp fiber, another solid biomass waste product available in large quantities at palm oil mills is the empty fruit bunch (EFB). EFB represents the largest volume of biomass waste generated by these mills. Mesocarp fiber, along with a portion of the palm kernel shells (PKS), is typically consumed as fuel for boilers. In fact, the volume of EFB produced exceeds that of the mill's primary product, crude palm oil (CPO). Despite this, EFB—which accounts for approximately 20% of the fresh fruit bunch (FFB) weight—remains largely unutilized. Given its substantial volume, it also poses a significant potential for environmental pollution. 

Many mills are striving to achieve a "zero waste" status, which necessitates the processing of empty fruit bunches (EFB). However, the challenges lie in determining the appropriate processing methods, the resulting products, and the overall economic viability. Ideally, this waste should not only cease to be an environmental pollutant but also generate additional profit—ideally, by produce products that maximize returns. A realistic approach, therefore, involves processing EFB in a way that prevents environmental pollution while minimizing the capital investment required for the necessary processing equipment. These factors are critical considerations, grounded in both current realities and future developments.

Empty Fruit Bunches (EFB) have significant potential for use in various bioenergy and biochar products. Through a process of biomass densification, EFB can be converted into pellets, which—much like palm kernel shells (PKS)—can be utilized within the energy sector. Given the massive volume of EFB available, the potential for EFB pellet production is substantial. EFB pellets are expected to emerge as a future trend, following in the footsteps of palm kernel shells (PKS), primarily due to their abundant availability and the fact that the vast majority remains unutilized. When compared to other potential raw materials for pellets—such as wood waste from forestry or the wood working industry—the volume of EFB is highly competitive, if not greater. Furthermore, unlike wood pellets derived from energy plantation (which require the cultivation of species such as calliandra or gliricidia), the production route for EFB pellets is significantly faster.

Another use for EFB (Empty Fruit Bunches) is the production of biochar. Biochar can serve as a soil amendment in the agricultural sector—specifically within oil palm plantations, whether company-owned or managed by smallholders. The application of biochar enhances nutrient use efficiency (NUE) by effectively turning fertilizers into slow-release products. Furthermore, biochar producers can generate revenue through carbon credits by adhering to methodologies established by recognized carbon standards, such as Puro, Verra, or Isometric. Industrial-scale slow pyrolysis equipment used for biochar production also generates excess energy—such as syngas—which can be utilized as fuel for palm oil mill boilers (via co-firing) or for other applications.

Currently, many palm oil mills utilize empty fruit bunches (EFB) by burning them in simple incinerators (as shown in the photo), which yields EFB ash—a substance rich in potassium that can be used as fertilizer. However, these simple incinerators not only generate smoke pollution but also fail to harness the heat produced during combustion. Upgrading to more efficient incineration systems—such as those employing reciprocating grate combustors—and incorporating pollution control equipment, like water scrubbers, would render the utilization of EFB environmentally friendly. Furthermore, the heat generated from combustion (waste heat recovery) can be harnessed for various purposes, including cogeneration with palm oil mill boilers, electricity generation, or other applications. 

Biochar, Soil Health, and the Sustainability of Palm Oil Productivity

Healthy soil is invariably fertile, but fertile soil is not necessarily healthy. Healthy soil teems with life—such as earthworms and other organisms—that naturally provides nutrients. Continuous use of chemical fertilizers without a corresponding addition of organic matter depletes soil microorganism populations. Over the long term, this causes the soil to harden, reduces its nutrient-supplying capacity, and increases crop dependence on chemical fertilizers. Consequently, production costs rise while land quality steadily declines.

The future of the palm oil industry is no longer solely about increasing production; it is also required to demonstrate that productivity can go hand-in-hand with environmental protection and social acceptance. Palm oil plantations must be grounded in the three pillars of sustainability: generating economic profit, gaining social acceptance, and preserving the environment. These principles also guide the implementation of the Indonesia Sustainable Palm Oil (ISPO) standard. Balanced fertilization—combining chemical (inorganic) and organic fertilizers—serves as one such solution.

These two types of fertilizers serve complementary functions. Chemical or inorganic fertilizers provide nutrients rapidly, whereas organic fertilizers improve soil structure and health, thereby sustaining productivity over the long term. A well-balanced combination of the two can maintain high productivity while ensuring land sustainability. Another equally important factor is the use of superior-quality seedlings that are certified or come from reliable sources with proven quality; if the seedlings are unsuitable, the results will not be optimal, regardless of how well they are fertilized.

Biochar is not a fertilizer, so its nutrient content is very low. While some types of biochar do possess relatively high nutrient levels, these are exceptions or added bonuses. As an organic material, biochar is environmentally friendly and derived from renewable sources. Its use also enhances fertilization efficiency—specifically Nutrient Use Efficiency (NUE)—for both chemical (inorganic) and organic fertilizers. This is because biochar transforms fertilizers into slow-release products, allowing nutrient availability to better align with plant needs; read more details here.

Biochar significantly supports soil health due to its favorable physical, chemical, and biological properties. Physically, it features high porosity and low bulk density; chemically, it offers high cation exchange capacity (CEC), alkalinity (high pH), and high carbon stability; and biologically, it serves as a habitat for microorganisms and stimulates soil enzyme activity. Furthermore, biochar is capable of binding toxic substances. This is due to its strong adsorption capacity, which allows it to capture heavy metals (such as lead or cadmium) and chemical pesticide residues present in the soil. These harmful substances are trapped within the biochar's pores, preventing their uptake by plant roots. For more details on biochar quality parameters, read here.

Biochar application is also a climate solution. Biochar can store carbon for hundreds of years in the soil. Each ton of biochar can store up to 3 tons of carbon / CO2 equivalent. This makes it very possible to get carbon credits. For this reason, biochar producers must use methodologies created by carbon standard institutions such as Verra, Puro, CSI (Carbon Standard International), Isometric and so on. By using biochar, fertilizer application becomes optimal, environmentally friendly and improves social acceptance in the community. Economically, the use of biochar can also be very profitable. So regarding biochar, soil health and sustainable palm oil productivity, biochar is very suitable and relevant so its use needs to be widely socialized and increased.

When the soil is healthy, fertilizer use becomes more efficient. High dosages are not always necessary, yet productivity can still increase because the soil functions naturally. Shifting the paradigm to recognize that sustainable productivity depends on soil health is no longer merely an option, but a necessity. Global markets are increasingly scrutinizing production methods, making environmentally friendly cultivation practices a key factor in the competitiveness of Indonesian palm oil. A model that successfully boosts productivity while lowering production costs—all while preserving the environment for long-term sustainability—naturally serves as an exemplary standard.

Liquid Smoke-Based Biostimulant (Foliar Fertilizer) for Application to Palm Oil Plantations Using Drones

In palm oil plantations, fertilizer is the highest cost component of their operations. Therefore, various efforts are made to optimize fertilization to ensure its maximum efficiency, including the use of slow-release fertilizers. For more details, read here. To maximize fertilization and maximize fresh fruit bunch (FFB) yields, the use of foliar fertilizers is also worth considering. Liquid smoke (pyroligneous acid) is one such foliar fertilizer, although a more accurate term is biostimulant (booster).

This is because liquid smoke does not provide nutrients such as nitrogen (N), phosphorus (P), and potassium (K). However, liquid smoke acts as a biostimulant, plant growth regulator (PGR), and natural protectant, promoting optimal leaf growth. Optimal leaf growth exponentially increases the growth of all plant organs, including stems, roots, flowers, fruit, and so on. Leaves are the primary "kitchen" of a plant, so leaf health determines the health of the entire plant system. Optimal leaf growth also increases the efficiency of fertilizer absorption (a "pump engine" effect) in the soil.

Furthermore, liquid smoke is not only used as "leaf fertilizer", it turns out that liquid smoke also functions as an organic pesticide (fungicide/insecticide). This repels pests (such as ticks and flies), and prevents leaf diseases. The phenol and acetic acid content is toxic to insects (aphids, thrips, caterpillars) and is effective in suppressing fungi that cause plant diseases. And the distinctive smell of smoke makes insects reluctant to approach and lay their eggs on the surface of the leaves. In addition, its binding properties make it difficult for pathogenic fungal spores to attach and develop on the surface of the leaves

Regarding this dual function, the use of liquid smoke for application to leaves (foliar) can be prioritized, whether it is more specifically used as a "foliar fertilizer" or as a biopesticide. This requires a number of adjustments such as dosage, additional formulations and application time. To maximize the function of liquid smoke as a leaf fertilizer, you must mix it with additional nutrients (such as liquid organic fertilizer / LOF) and apply it when the leaf stomata are fully open. Liquid smoke is able to reduce water molecules. When diluted or mixed with Liquid Organic Fertilizer (LOF), the nutritional content of the fertilizer becomes easier to enter and be absorbed through the stomata (leaf mouth). Meanwhile, to maximize its function as a biopesticide, liquid smoke needs to be combined with other vegetable pesticides. The frequency of spraying for prevention is once a week, while pest attacks are high, namely 2-3 times a week until the pest population is under control.

The use of drones for spraying pesticides and liquid fertilizer has been widely used on various agricultural crops such as rice, corn, sugar cane and palm oil. More specifically in palm oil plantations, drone applications are a modern solution for spraying fertilizers and pesticides. And in Indonesia more than 80% of drone applications are for the forestry and agricultural sectors. Efficiency factors (time, energy, operational costs, fertilizers, pesticides) and precision are the main driving forces for this drone application. This means that drone technology is expected to be an effective solution in controlling pests and diseases, fertilizing and cultivating palm oil plants. Drones are effective in increasing plantation efficiency, especially in areas that are difficult to reach. As a technology, various improvements have been made to improve its functions such as carrying capacity, spray speed, safety features and work efficiency. The use of drones supports precision agriculture and global food security with an environmentally friendly technological approach.

Spraying liquid fertilizer on the underside of leaves (underside spraying) using a drone requires special techniques. This is because drone propellers naturally produce strong downwash. This downwash effect is used to gently move and turn the leaves, so that the droplets can hit the bottom of the leaves. This is because on the bottom of the leaf, where the stomata are located the most are gathered around 80%. The spray texture is also made into mist mode (the finest dew) so that the liquid sticks evenly and doesn't drip onto the ground. Next, the drone's height, speed and nozzle angle need to be adjusted in such a way to achieve this goal. Environmental factors in the form of strong winds need to be avoided so it is necessary to adjust the right time and conditions.

As the use of biochar grows as a solution for health and soil fertility as well as a climate solution, this should also be the case with the application of liquid smoke. Liquid smoke as a by-product in the form of a liquid product from biochar production will increase along with increasing biochar production. Liquid smoke as a product produced from biomass raw materials through a pyrolysis process also encourages the use of natural materials based on renewable resources so that it is environmentally friendly and sustainable. 

Electricity Production from Pyrolysis, Using a Gas Engine or ORC Generator?

The more efficient the equipment, the greater the benefits or profits that can be obtained. This includes equipment for biochar production, namely pyrolysis. The more efficient the pyrolysis equipment, the cheaper it will be to produce biochar but also produce development products. An example is the use of byproducts from the pyrolysis process such as syngas, biooil, pyroligneous acid and excess heat. Harvesting or utilizing energy from waste heat sources that would normally be wasted is also part of efficiency as well. A number of products that can be used for energy production can be used for electricity production, namely syngas, biooil and excess heat. But there are a number of technologies for producing electricity, so which one do you choose?

A. Gas Engine

Gas engines such as the GE Jenbacher are commonly used to produce electricity from biogas. Biogas, which is a product of bioprocess, has a very dominant methane gas content, while syngas from pyrolysis, which is a thermal process, contains only a small amount of methane and more hydrogen (H2) and carbon monoxide (CO), this means that gas engines are not suitable for producing electricity from syngas pyrolysis. Apart from being suitable for biogas, gas engines such as the GE Jenbacher are also suitable for natural gas, which also contains methane gas.

B. ORC (Organic Rankine Cycle)

The main difference between the Organic Rankine Cycle (ORC) and the ordinary Rankine cycle lies in the working fluid and the temperature of the heat source used. ORC was specifically designed as a modification of the conventional Rankine cycle. The difference with the ordinary Rankine Cycle which uses steam from the boiler as the working fluid which is widely used in large capacity coal powerplants, the ORC uses a working fluid in the form of an organic fluid which has a low boiling point such as hydrocarbons or refrigerants. This low boiling point means that you can use a heat source whose temperature is not too high, such as waste heat or residual heat and so on.

And because there are many organic fluids available, selecting organic materials as suitable working fluids for ORC is no less important. In fact, the choice of working fluid for the ORC generator is very crucial because it affects thermodynamic efficiency, operational costs and safety aspects. The main factors considered are the thermophysical properties of the fluid, compatibility with the heat source, environmental impact, and commercial availability (economic aspects). So the selection of ORC fluid must balance energy efficiency, safety, environmental impact and cost.

Waste heat from pyrolysis can be recovered and used for electricity production with this ORC. Likewise, pyrolysis byproducts that can be used as energy sources are excess syngas and bio-oil. The excess syngas and bio-oil are used as fuel and the heat is used as an energy source for the ORC generator. Basically, the selection of an ORC power plant is based on electricity needs and available energy sources. 

For small electricity needs, namely in the range of 0.5 MW - 10 MW and low temperature energy sources, namely those whose temperature is below 350 C (low to medium temperature range (80 C - 350 C)), then the choice of ORC is suitable. As a comparison, steam turbines require temperatures well above 400 C and a power output of 10 MW to above 1,000 MW (as in coal-fired power plants or nuclear power plants). But why do almost all palm oil mills (CPO / crude palm oil mills), even though their electrical power production is small or an average of less than 5 MW, still use steam turbines? For an explanation, read here.

The application of an Organic Rankine Cycle (ORC) generator as waste heat to power (WHP) from the pyrolysis process is a very effective combination to increase the total energy efficiency of the system (co-generation). And modern pyrolysis units are widely used in continuous system biomass pyrolysis, namely for biochar production, which work autothermally or self-sustainably, so it is possible that the pyrolysis unit can also operate independently from the electricity generator from the ORC. This means it will reduce operational costs, because the electricity to run electric motors, pumps and so on comes from its own production. In other words, the pyrolysis unit operates independently without depending on the electricity network or PLN (Indonesia state owned company). From a climate perspective, these conditions are ideal, because the energy source comes from renewable sources (carbon neutral) and if biochar is used for carbon sequestration it means it is carbon negative. Optimizing the system so that it produces an optimal and profitable configuration is the task of engineers.

An American company, namely Quonset Soil Solutions, LLC in Rhode Island, has recently successfully installed an ORC unit to harvest waste heat from their pyrolysis unit with a capacity of 1.8 MW. Apart from that, several pyrolysis units in Europe are also reported to be using ORC with a smaller capacity. These successes will inspire and the installation of ORC units as part of biochar production with (slow) pyrolysis will continue to grow.

Conclusion:
-The ORC system is highly recommended for continuous scale pyrolysis plants (not small batch types) because it is able to convert heat pollution (waste heat) into valuable electrical energy assets constantly. ORC operations are environmentally friendly and support decarbonization targets.

-The ORC generator from waste heat pyrolysis is an efficient, safe and sustainable solution for generating electricity from waste heat energy (residual heat). This technology is also ideal for various industries that produce intermediate heat, so that energy is not wasted.

Biochar Needs for the Iron and Steel Industry

As awareness of climate change and global warming grows, along with the Paris Agreement and Net Zero Emissions (NZE) 2050 targets for decarbonization, the use of biomass to produce biocarbon products is increasing. The iron and steel industry, in particular, faces significant demand, while supply remains limited. This has prompted several large companies to invest in large-scale biocarbon production, particularly biochar/biocoke.

Such large-scale production naturally requires abundant biomass feedstock. Specifically, in Indonesia, biocoke/biochar production from palm kernel shells (PKS) reportedly began last year. PKS was chosen because it is a readily available biomass waste product from palm oil mills. PKS and palm oil mill production in Indonesia is estimated to be around 12.5 million tons/year, but because some of the PKS is used as boiler fuel, the estimated usable PKS or remaining boiler fuel is around 6.25 million tons/year. To increase the supply of PKS from palm oil mills, cogeneration of empty fruit bunches (EFB) can be used. For more details, read here.

In addition to the PKS, biocoke/biochar and even black pellets (torrified pellets) are also produced using wood from energy plantations. Energy plantations with short-rotating crops like calliandra and gliricidia have great potential to produce this wood. Currently, wood pellets (white pellets) are being produced from these wood plantations. For more details on whether wood from energy plantations is better for wood pellets (white pellets) or biocoke/biochar/charcoal, read here.

Biocoke, biochar, and charcoal are used in the iron and steel industry as a substitute for coal-based coke in blast furnaces, while wood pellets (white pellets) and torrified pellets (black pellets) are used in power plants using both cofiring and fulfiring. In addition to their higher calorific value (around 20% higher than wood pellets (white pellets)), torrefied pellets (black pellets) are also hydrophobic, allowing them to be stored outdoors, like coal.

In today's era, the use of biocoke / biochar / charcoal to replace coal coke in blast furnaces is becoming important. Biocoke / biochar / charcoal derived from biomass is a renewable material that is sustainable as a reducing agent or fuel in blast furnaces. The chemical reaction will separate oxygen atoms from iron atoms and this will emit CO2. This will convert iron ore (Fe2O3) into crude (pig) iron.

However, the difference lies in the fact that the carbon source used as a reducing agent or fuel in a blast furnace comes from renewable and sustainable sources, making it a carbon-neutral process. Conversely, using coke from coal, as it comes from a fossil source, makes it a carbon-positive process. Similarly, using natural gas, a fossil fuel, as a carbon source for the reducing agent or fuel in a blast furnace, despite its lower carbon intensity, is considered less carbon intensive. 

The Role of Biochar in Increasing Palm Oil Productivity, Among the Use of Superior Seeds and Replanting

Palm oil productivity continues to be pushed to its most optimal point. This is because it is to meet the increasing needs, especially the mandatory B-50 biodiesel program. Of course, efforts to optimize productivity are not easy and instant. Although the key points for its realization have also been mapped, namely by replanting old palm oils, using superior seeds and intensification, the practice also requires the right method or approach and takes time. Replanting old palm oils is still very slow and has many obstacles, while the use of superior seeds has received more attention and continues to be encouraged. The analogy of using superior seeds is like comparing local cattle and superior breeds. So no matter how well the Javanese cow is cared for, its weight will not match that of the Limousin cow. Likewise with palm oil seeds.

Land intensification efforts through optimizing inputs, technology and modern cultivation methods also still need to be developed. Meanwhile, extensification or land expansion should be avoided or slowed down as much as possible, for more details, read here. Biochar can have an important role in this area of ​​intensification. Apart from the application of biochar it will improve soil health, which is an important prerequisite for plants to be able to produce optimally, it is also very environmentally friendly because the raw material for biochar is from renewable sources, namely biomass and increases fertilization efficiency (NUE = Nutrient Use Efficiency). And even the application of biochar is also a climate solution, namely as carbon sequestration. Optimizing productivity can be done by applying biochar plus using superior seeds using modern and environmentally friendly agricultural methods. So basically optimization is a comprehensive and measurable effort.

Indonesia contributes 25% to the world's vegetable oil supply, making it a key actor in the stability of the world's vegetable oil supply. With this position, any changes in production, export policies and Indonesia's domestic dynamics will directly impact prices and international market balance. Indonesia is currently the largest or number one producer of palm oil in the world, but it is not the best or most productive because its productivity is not yet optimal. Compared to neighboring countries, namely Malaysia, it is still inferior and slightly superior to Thailand, even though geographical factors, namely the climate in Indonesia, are much more supportive. Currently, Indonesia's CPO productivity is around 3.3 tons/hectare, while Malaysia's is around 3.8 tons/hectare, while Thailand's is around 3 tons/hectare.

Yield gap, namely the difference or gap between actual production and maximum production potential, is sometimes quite large. Several main factors that trigger yield gaps include non-optimal environmental factors such as drought conditions, to errors in cultivation practices such as errors in land clearing and planting, as well as inaccuracies in diagnosis and fertilizer recommendations. This yield gap must be minimized so that palm oil productivity can be maximized.

Sometimes the role of biochar cannot be found or seen directly in various efforts to increase palm oil productivity, but the application of biochar is very much in line with this goal. For example, the success of an palm oil replanting program depends, among other things, on the quality of seeds, fertilization, plant population and soil health. Soil health and fertilization factors can be closely related to biochar. And related to biofungicides to treat ganoderma fungus disorders, biochar can be used as a carrier formulated with other elements such as humus, amino acids, humates, hormones and so on. And because the only effective way to control the ganoderma fungus is to introduce its natural enemies in the form of biofungicides based on Trichoderma spp and arbuscular mycorrhizal fungi into the soil. However, there are still many parties who do not have adequate knowledge regarding the application of biochar.

Apart from boosting production, implementing best management practices is also important to meet sustainability standards amidst increasing pressure from environmental issues. And the application of biochar is very much in line with that point. In fact, regarding low carbon palm oil technology in the application of biochar, it is very relevant to the CECC (Controlled Emission Composting Chamber) and for more details on the application of biochar for composting, read here. Meanwhile, the trend of fertilization in palm oil plantations with the application of slow release fertilizer is also very relevant to biochar, for more details, read here. 

Indonesia's 2026 Palm Oil Replanting Target and Solutions for Utilizing Palm Oil Trunk Waste

Indonesia's stagnant national palm oil productivity requires an immediate solution. If this situation is not addressed promptly, Indonesian palm oil productivity will decline in the future. This is undesirable given the increasing demand for palm oil as a vegetable oil, including its use in biofuel, namely biodiesel. The launch of the B50 biodiesel program demands increased palm oil productivity. However, the question remains: why palm oil? Aren't there other crops that can produce oil with a comparable yield for biodiesel production? Nyamplung is a strong candidate for this; read more details here.

In palm oil, productivity can be increased through the use of superior seeds, replanting, and land intensification. In terms of land area, replanting palm oil plantations, with an ideal target of 5% per year, is very significant. With Indonesia's current 16.8 million hectares of oil palm plantations, that translates to 0.84 million hectares per year. Besides the high costs, the resulting biomass waste, or palm oil trunks, is also substantial. This clearly holds potential for an environmentally friendly bioeconomy-based industry, or circular economy.

With an area of Indonesia's palm oil plantations of around 16.8 million hectares, 9 million hectares are managed by private companies, 550 thousand hectares are owned by state-owned companies (PTPN), 6.1 million hectares belong to people's plantations or small farmers and the rest have not been verified. And based on data from the Central Statistics Agency (2024), recorded 10 provinces in Indonesia with the largest oil palm plantations in sequence, namely Riau province with 3.49 million ha, Central Kalimantan province with 2.03 million ha, North Sumatra province with 2.01 million ha, West Kalimantan province with 1.82 million ha, South Sumatra province with 1.40 million ha, East Kalimantan province with 1.32 million ha, Jambi province with 1.19 million ha, South Kalimantan province with 497.2 thousand ha, Aceh province with 487.5 thousand ha, and West Sumatra province with 379.6 thousand ha. And a total of 26 provinces in Indonesia as centers of palm oil plantations.

The palm oil industry, as one of the national strategic industries, receives significant government support, including the People's Palm Oil Replanting (PSR), which remains a national strategic program, although its realization has not yet reached the target. South Sumatra, as one of the national palm oil plantation centers, also recorded the highest PSR realization. PSR realization in 2025 is approximately 40,000 hectares, or 33% (one-third) of the target of 120,000 ha. This represents a slight increase compared to 2024, which was only 31% of that year's target. Specifically, South Sumatra has replanted approximately 75,000 ha of smallholder palm oil plantations from 2017 to 2025.

The government is targeting a national PSR of 50,000 ha for 2026, a much more realistic figure than in previous years, with South Sumatra province targeting 5,750 ha. However, given Indonesia's oil palm plantation area, the 2024 and 2025 targets of 120,000 ha are very low, especially for 2026, which is only 50,000 ha. Under these conditions, efforts that can be accelerated to increase national palm oil productivity are through the use of superior seeds and land intensification.

Furthermore, ganoderma can lead to the death of palm oil trees. Ganoderma, caused by the fungus Ganoderma boninense, attacks the palm oil's root system, disrupting nutrient and water transport. The process is very slow and is only detected when the infection is severe, resulting in yellowing leaves, drooping crowns, and even plant death. Waste from ganoderma-infected trunks must be removed or destroyed from the plantation to prevent further spread. Like waste from palm oil trunks from replanting, this waste must also be properly managed.

The issue of biomass waste from palm oil trees, which covers thousands of hectares, also presents a challenge. With such a large volume of old palm oil trees, utilizing them to create value-added products is crucial. With such a large volume, biomass processing plants or industries can be established and operate optimally, without worrying about raw material shortages. Products such as pellets, briquettes, and biochar are made from this waste biomass from old palm oil trunks. Old, dead palm oil trunks, often left unattended on land, should be utilized to create these useful, value-added products.

As shown in the diagram above, the potential for utilizing biomass waste, particularly oil palm trunks, is enormous. In the future, industrializing bioeconomics into various products is highly feasible. Palm oil trunk waste should not only pollute the environment and increase costs for palm oil farmers, but instead, it should become a profitable industrial raw material.

Washed PKS for Decarbonization of Iron and Steel Plants

The steel industry contributes 8% of global CO2 emissions, with each ton of steel produced producing an average of 1.85 tons of CO2 emissions. Compared to iron ore mining, iron and steel production contributes significantly more to CO2 emissions. Decarbonization efforts in the steel industry begin with the use of renewable energy for smelting. Biomass-based fuels, such as charcoal, which has a high carbon value, can replace the use of coke derived from coal. The use of hydrogen from renewable energy sources is the ultimate decarbonization target for the steel industry.

Currently, the steel industry largely uses coal as an energy source or reducing agent. This coal is processed into coke and used in blast furnaces. It is estimated that approximately 70% of global steel production uses the blast furnace or BF-BO process, and in China, over 90% of steel production uses the BF-BOF process. To reduce carbon intensity, natural gas is used as the fuel. The use of natural gas as a gaseous fuel also acts as a transition medium and, because it is derived from fossil fuels, is also a carbon-positive fuel.

Nearly all CO2 emissions in the steel production sector come from blast furnaces (BFs), which refine iron ore into crude iron or pig iron. The challenge is significant: there are approximately 1,850 steel mills worldwide, with approximately 1,000 using blast furnaces, producing approximately 1.5 billion tons of pig iron annually.

The use of charcoal in a blast furnace not only reduces carbon dioxide (CO2) emissions but also sulfur dioxide (SO2) emissions due to its very low sulfur content (approximately 100 times lower) than coke. Likewise, the use of limestone is reduced, thereby automatically reducing slag production. This also makes the blast furnace's operation acidic.

The use of biomass-based carbon fuel (biocarbon) in the form of charcoal has a better climate impact because it is carbon-neutral. Furthermore, technically, because it is a solid fuel, similar to coke derived from coal, it requires little or no changes or modifications to the smelting furnace. However, the availability of high-quality charcoal, large volumes, and a continuous supply remain major constraints.

This makes the use of charcoal to replace coal-based coke in blast furnaces crucial. Charcoal, derived from biomass, is a renewable, sustainable material used as a reducing agent or fuel in blast furnaces. The chemical reaction separates oxygen atoms from iron atoms, emitting CO2. This converts iron ore (Fe2O3) into crude (pig) iron.

However, the difference lies in the fact that the carbon source used as a reducing agent or fuel in a blast furnace comes from renewable and sustainable sources, making it a carbon-neutral process. Conversely, using coke from coal, as it comes from a fossil fuel, is a carbon-positive process. Similarly, using natural gas as a carbon source for reducing agents or fuel in a blast furnace, although it is said to have lower carbon intensity, is also considered a carbon-neutral process.

The use of charcoal or biocarbon materials for metallurgy or steelmaking has actually been commonplace for some time. In the early 1900s, global charcoal production reached its peak, exceeding 500,000 tons. In the 1940s, charcoal production declined to nearly half its early 1900s levels due to the replacement of other carbon materials, such as coke from coal, in the manufacture of steel and other metals.

Charcoal is a fuel and reducing agent derived from biomass that has significant potential for use during this transition phase. Palm kernel shells (PKS) are a potential biomass raw material for charcoal production. Palm kernel shells (PKS) are available in the millions of tons, ensuring a reliable supply. Charcoal, a product of biomass carbonization or pyrolysis, has a high calorific value, high fixed carbon content, and stability. However, another factor, ash chemistry, influences the quality of the resulting steel. This is somewhat similar to the ash chemistry of wood pellets from calliandra or gliricidia energy plantations.

When used as a reducing agent in blast furnaces, charcoal must have a low phosphorus content, while wood pellets from calliandra or gliricidia energy plantations must have low potassium, sodium, and chlorine content. The potassium, sodium, and chlorine content of wood pellets affects the quality of the wood pellets and their use in power generation. Pulverized combustion power plants, widely used worldwide, will reject wood pellets with this quality. Similarly, blast furnaces will reject charcoal with a high phosphorus content.

To achieve this quality, low-phosphorus content, the palm kernel shells (PKS) must first be washed. After washing, the phosphorus content decreases, and they are then dried and pyrolyzed, or carbonized, to produce palm kernel shell charcoal (PKSC). The same applies to wood pellets. The only difference is that wood pellet production doesn't involve pyrolysis or carbonization; instead, after drying and achieving the desired particle size, the pellets undergo biomass densification in a pelletizer.

Steel production requires an average of 6,000 MJ of energy per ton (equivalent to 50 kg of hydrogen) or 200 kg of charcoal, and requires approximately 600-800 kg of woody biomass as raw material. With a calorific value nearly identical to woody biomass, this is equivalent to using palm oil mills (PKS), which are plantation or agro-industrial waste.

Meanwhile, demand for low-carbon steel is growing rapidly as steel industries and governments worldwide commit to reducing carbon emissions from fossil fuels. The use of charcoal or biocarbon in blast furnaces is a key component of low-carbon steel production, as 100% of the steel is not yet produced using renewable energy. 

Slow-Release Fertilizer: A New Trend in the Palm Oil Industry

Fertilizer is crucial for plant growth, especially for palm oils. Palm oil trees won't even bear fruit without fertilization. Fertilization is the highest cost component of palm oil plantation operations. Fertilizer efficiency is clearly a key consideration. This is why innovation in palm oil fertilization is rapidly developing.

Regarding innovations to increase fertilizer efficiency in palm oil plantations, the concept of slow-release fertilizer (SRF), or controlled-release fertilizer (CRF), is gaining increasing attention. By engineering the slow or controlled release of nutrients, the plant's nutrient use efficiency (NUE) increases. Fertilizer becomes more economical and environmental pollution is reduced. Indonesia's tropical climate, with its high rainfall, also results in high fertilizer leaching.

Several materials have been developed as SRF/CRF agents to achieve the desired nutrient release levels. These include polymers, sulfur, chemical compounds, and even compost. The characteristics of SRF/CRF agents vary depending on the material and product type. In addition to performance, the price of the SRF/CRF agent is also an important consideration.

Biochar is a renewable SRF/CRF agent and a climate solution. Biochar can persist for hundreds of years in the soil as a carbon sequestration. In addition to synthetic materials derived from non-renewable sources, biochar is an alternative SRF/CRF agent derived from renewable sources. Biomass from agricultural, plantation, and forestry waste is the main source of biochar production through the pyrolysis process. A number of SRF/CRFs with slow-release biochar agents have also begun production. This will increase biochar production, which has so far been less popular. It will also provide a solution to the biomass waste problem and be economically valuable. 

Slowing Palm Oil Land Expansion: Replanting or Biochar ?

The reckless expansion of palm oi plantations is definitely offside sustainability. Instead of palm oil being a blessing due to their highest productivity among other vegetable oil sources (soybeans, sunflowers, rapeseed, coconuts, etc.), growing only in tropical regions and contributing 40% of the global vegetable oil supply, they have instead become a natural disaster. The cost of this disaster is no small matter, costing thousands of lives, in addition to other material losses. This issue was particularly highlighted during the recent floods in Sumatra. Are the profits from palm oil worth the loss of life?

Clearing tens or even hundreds of thousands of hectares of oil palm plantations produces valuable timber. It's even possible to generate substantial profits from land clearing alone, even though palm oil plantations and production haven't even begun. This is what drives entrepreneurs to flock to this plantation sector, driven by the sole goal of maximizing profits without considering their own needs, resulting in widespread disasters. Furthermore, the implementation of mandatory B-40 or even B-50 biodiesel, currently being discussed, will undoubtedly create a new market for palm oil/CPO, much easier and more flexible than exporting to Europe, which is subject to the European Union Deforestation Regulation (EUDR), or to the US, which faces high tariffs.

Moreover, it has already been established that palm oil/CPO consumption for biodiesel has exceeded food demand. The mandatory implementation of the B-50 program also requires a 20% increase in CPO production capacity, or 60 million tons per year. The most profitable and fastest way to do this is through extensive deforestation, as the timber from cleared forests can be sold directly.

When the goal is to increase palm oil production gradually, safely, in a planned, and sustainable manner, adequate consideration is required, not blindly and recklessly clearing forest areas (deforestation) under the guise of land conversion. Besides the use of superior seeds, there are at least two ways to increase palm oil productivity: replanting and biochar application (part of land intensification).

According to Joko Supriyono, former chairman of GAPKI (Indonesian Palm Oil Producers Association) for the 2015-2018 and 2018-2023 periods, in his book "Is Indonesian Palm Oil Still Successful?", it is stated that if replanting of palm oil in Indonesia successfully reaches 300 thousand hectares per year, it is estimated that CPO and CPKO production in 2045 will reach 80 million tons. While currently CPO and CPKO production is around 55 million tons. And with the use of biochar, palm oil productivity will increase by an average of 30% in 5-10 years, meaning that by 2035 CPO and CPKO production will reach 71.5 million tons. Moreover, if the two methods are combined, the results should be even better.

Indonesia's current CPO production reaches approximately 50 million tons/year, covering a land area of ​​16.8 million hectares with an average CPO production of 3.55 tons/ha per hectare, or 3.55 million tons per million hectares. If biochar is used and productivity increases by 30%, this means an increase of 15 million tons of CPO (a total of 65 million tons of CPO/year) and this saves approximately 4.2 million hectares of land, or the use of biochar will slow down forest clearing for palm oil plantations. The application of biochar with compost will improve the quality of the compost to become premium compost. For more details, read here. This allows the palm oil industry to operate by utilizing all its biomass waste.

The replanting movement of palm oil plantations must be encouraged to continuously increase palm oil production. The problem of biomass waste from palm oil trees, which cover thousands of hectares, also poses a challenge. With such a large volume of old palm oil trees, utilizing them for value-added products is crucial. With an average hectare of palm oil plantations consisting of 125 trees, each tree having an average dry weight of 0.4 tons, this yields 50 tons of dry weight of biomass per hectare. For an area of ​​10,000 hectares, this yields 0.5 million tons of dry weight, and for an area of ​​100,000 hectares, this translates to 5 million tons of dry weight. An optimistic estimate suggests that Indonesia could achieve 5% replanting (very optimistic) or 820,000 hectares, which would yield 41 million tons of dry weight of biomass per year. Similarly, Malaysia, with 5% replanting or 285,000 hectares, would produce 14.25 million tons of dry weight per year.

Business readiness factors, both technologically and in terms of the market or user base, need to be carefully assessed. With such a large volume, biomass processing plants or industries can be established and operate optimally without worrying about raw material shortages. Products such as pellets, briquettes, biochar, and other bioproducts, such as other biocarbons, biomaterials, biofuels, and biochemicals, are also possible from this old palm oil trunk biomass waste. Old, dead oil palm trunks, often left unattended on land, should be utilized to produce these useful, value-added products. For more details on utilizing trunk waste for fuel pellet production (OPT Pellets), please read here.