Development of Biodiesel Plant Design Integrated with Palm Oil Mill for Diesel Fuel Substitution in Oil Palm

Industry
Imam Paryanto, Agus Kismanto, Maharani Dewi S., Hariana ( Engineering Center BPPT )

TECHNOLOGY FOR BIOFUELS

EBTKE-CONEX Jakarta, 21-23 August 2013

TECHNOLOGY FOR BIOFUEL

Outline
Background Objective Methodology Result & Discussion Conclusion

EBTKE-CONEX Jakarta, 21-23 August 2013

TECHNOLOGY FOR BIOFUEL

Background
Availability of raw material : CPO, CPO Off-spek and CPO recovered from POME (POM Effluent) in Palm Oil Mill (POM). (Note : Availability of CPO from POME ranging 1.5 3 TPD depending on POM capacity) Availability of spare : electricity, water and steam from POM. Availability of other facilities and infrastructures : road, workshop, etc. in POM. Palm Plantation and POM need diesel fuel substitution for genset and transportation (cost reduction).

Objective
To assess and develop the design of biodiesel plant integrated with POM to utilize some of the oil raw material so that biodiesel product can be used for diesel fuel substitution in oil palm industry.
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TECHNOLOGY FOR BIOFUEL

Methodology
Comparison of three scenarios was based on the assumptions of utilization of different raw materials :
No Assumptions 1 Raw material of oil 2 Scenario 1 CPO 6,500 Not integrated with palm oil mill Steam supplied from purchased boiler Supplied from genset Scenario 2 CPO 6,000 Integrated with palm oil mill Scenario 3 Off-grade CPO from POME 3,500 Integrated with palm oil mill

Cost of oil (raw material), IDR/kg

3 Location 4 Heat source 5 Electricity

Steam supplied Steam supplied from palm oil mill from palm oil mill Supplied from palm oil mill Supplied from palm oil mill

Then, the biodiesel production technology and estimated calculation of investment and production costs were compared.
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TECHNOLOGY FOR BIOFUEL

PALM OIL MILL

FRESH FRUIT BUNCH

CPO MILL

CPO

PALM KERNEL

PALM SHELL

EMPTY FRUIT BUNCH

PALM OIL MILL EFFLUENT

PALM KERNEL OIL

PALM KERNEL MEAL

EBTKE-CONEX Jakarta, 21-23 August 2013

TECHNOLOGY FOR BIOFUEL

BIODIESEL PLANT INTEGRATED WITH OIL PALM INDUSTRY

EBTKE-CONEX Jakarta, 21-23 August 2013

TECHNOLOGY FOR BIOFUEL

Raw Material
No Sample Sample Sample CPOa CPO Paritb CPO Parita 1 FFA Content, %w/w 4.2 50 60-64 2 Water Content, %w/w 0.39 4.2 1.1-3.8 3 Solid Impurity Content, %w/w 0.2 0.4 0.9-2.6 Test Parameter
b

Lab Test BRDST-BPPT

Lab Test by PTPN V

CPO without installed heater with heated piping system to transfer/ unloading Storage tanks installed with heater and piping is heated for transfer Usually not required Off-Grade CPO with installed heater with heated piping system to transfer/ unloading Storage tanks installed with heater and piping is heated for transfer Required to remove solid and water impurities as well as gum content
7

No 1 2 3

Handling Activities Oil transportation tank Unloading Storage

Pretreatment

EBTKE-CONEX Jakarta, 21-23 August 2013

TECHNOLOGY FOR BIOFUEL

Principle of Biodiesel Production from Oil Based on FFA Content

Trans-esterification
C-OOC-R1 C-OOC-R2 C-OOC-R3 Triglyceride + Base Catalyst R1-COO-R 3ROH Alcohol (methanol) R2-COO-R R3-COO-R Fatty Acid Ester + C-OH C-OH C-OH Glycerin

Contoh R

Esterification
Acid Catalyst

C-OOC-R Fatty Acid

ROH Alcohol (methanol)

R-COO-R + Alkil Ester (Methyl Ester)

H-OH

Water

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Biodiesel Production Technology

POME Acid Catalyst Base Catalyst

TREATMENT

METHANOL

Off-Grade CPO PFAD

TREATMENT

MIXING

MIXING

ESTERIFICATION

CPO or olein

TRANSESTERIFICATION

Crude Glycerol

SEPARATION AND PURIFICATION

RECOVERY

BIODIESEL

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TECHNOLOGY FOR BIOFUEL

Valid Data from Laboratory (Optimized Process)
Process Block Diagram & Process Flow Diagram Material & Heat Balances

Step of Engineering Design for Biodiesel Production Plant

BQ & Cost Estimation I

Piping & Instrumentation Diagram (P&ID)

Detail Design I
(Equipment List & Data Sheet, Material Selection, Pumps, Instruments, Utilities, SOP/Process Manual)

TOTAL COST

BQ & Cost Estimation II

Detail Design II
(Electrical, Structure, Piping, Plant Layout, Waste Treatment)

BQ & Cost Estimation III

Detail Design III

(Civil Works & Building)

Complete Biodiesel Plant Design EBTKE-CONEX Jakarta, 21-23 August 2013 10

TECHNOLOGY FOR BIOFUEL

Project Execution of Biodiesel Plant

Complete Plant Design Procurement

Target : - Raw material used - Spesification of product - Process specification: pretreatment, batch/kontinu, wet/dry washing, catalyst used, etc - Production capacity - Utilities used - By-product handling - Waste treatment

Fabrication & Instalation (Construction)

Testing & Commissioning

Training for Operators

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TECHNOLOGY FOR BIOFUEL

Research

Development

Engineering
FRESH SETTLING SETTLING MEOH MEOH ACYD CLAY TANK TANK EVAPORATOR EVAPORATOR M LIC SETTLING DRY TANK POMPA PURIFILIC TRANSFER 1 CATION POMPA TRANSFER 1 POMPA Glycerol TRANSFER 1

Operation

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Layout Biodiesel Plant in Palm Oil Mill

Biodiesel Plant Fat-Pit Pond

Palm Oil Mill

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TECHNOLOGY FOR BIOFUEL

Estimated Investement Cost Biodiesel Plant : 1 TPD

No Item Estimated Investment Cost of 1 TPD Biodiesel Plant, IDR Scenario 3 Scenario 1 Scenario 2 (Integrated with palm oil (Not integrated with (Integrated with palm mill & off-grade CPO palm oil mill & CPO as oil mill & CPO as raw from POME as raw raw material) material) material) 400,000,000 650,000,000 160,000,000 195,000,000 415,000,000 165,000,000 335,000,000 250,000,000 100,000,000 125,000,000 2,795,000,000 400,000,000 650,000,000 70,000,000 130,000,000 100,000,000 100,000,000 185,000,000 250,000,000 100,000,000 125,000,000 2,110,000,000 25% 400,000,000 745,000,000 90,000,000 170,000,000 100,000,000 125,000,000 270,000,000 250,000,000 110,000,000 125,000,000 2,385,000,000 15%

1 2 3 4 5 6 7 8 9 10

Building & civil works Equipment (including accessories & structures) Storage tanks (raw material & product) Pumps & motors Utilities (steam, electricity/genset, water) Electrical & Instrumentation Piping (including support & insulation) Feasibility study (internal) & engineering Commissioning & training Overhead Total Estimated Reduction of Investment Cost

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TECHNOLOGY FOR BIOFUEL

Estimated Production Cost Biodiesel Plant : 1 TPD

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CONCLUSION
Biodiesel plant integrated with palm oil mill using CPO off-grade from POME as raw material was one of the strategies to produce biodiesel fuel with lower investment and production costs, and the biodiesel product could be used for substituting diesel fuel for internal use in the oil palm industry. Development of biodiesel plant with appropriate capacity will ensure the supply of biodiesel fuel for diesel fuel substitution in oil palm industry.

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