Design of Biogas Electricity Generator Pilot Plant by Cow-Palm

  

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  [0] Design of Biogas Electricity Generator Pilot Plant by Cow-Palm Plantation Integration

• ) *) *) **) **)

  Irvan , Bambang Trisakti , Fahmi , Yusuf Husni , and Nevi Diana Hanafi

• ) Engineering Faculty, University of Sumatera Utara Medan , 20155, Indonesia **) Agriculture Faculty, University of Sumatera Utara, Medan 20155, Indonesia

  

ABSTRACT

Wastewater treatment utility is one of the most important components in the palm oil

  [2]

  

production. This utility is normally used to treat a large volume of palm oil mill effluent

(POME) generated during the production of crude palm oil (CPO) before the effluent is

  [0]

  

safely discharged to the surrounding environment through water ditch or river. The

  ]

  

production of POME in Indonesia is estimated around 28. 7 million tonnes per Most of

the palm oil mills use conventional pond system to treat their POME. However this system

  [2] has many disadvantages such as: long retention time (90-120 days), large area required, high _[0] demand for maintenance, loss of nutrition and high emission of methane.

  Previous research in the laboratory scale have produced large volume of biogas

and high decomposition rate of COD, however prior to be filled to the fermentor tank

  [0]

  

POME should be added by ammonium bicarbonate as nitrogen source . In order to be

applied to the industry, this method should find the alternative nitrogen source which has

  [2]

  

criterch as; cheap, easy to obtain, and available in any time (continuity). One of the

nitrogen sources which fulfill this criteria is cow manure or dung.

  [1]

  The objective of the project is to design a more efficient POME treatment plant

  [2]

  

ng an anaerobic continous stirred tank reactor (CSTR) in the pilot plant scale . The

produced methane gas will be used to generate electricity with capacity of 15-20 kWh.

  [0]

  

For natural nitrogen source cow manure will be used , and in order to obtain them easily

and cheaply, cow-palm plantation integration concept will be adopted.

  Biogas electricity generator pilot plant will be operated by making variation of [0] hydrolic retention time (HRT), namely HRT 10, 8, 6 and 4 days. Quality and quantity of

  

produced biogas will be recorded daily on each HRT, produced electricity will be

recorded as well.

  [7] Keyword: Biogas, Palm oil mill effluent (POME ), Electricity generator, Pilot plant, Cow-

  palm plantation integration

  

INTRODUCTION

World consumption for palm oil in 2003-2007 was around 117. 88 million tonnes.

  [2]

  

Indonesia as the second largest palm oil producer can only supply around 6 million

  [1]

  

tonnes CPO while Malaysia can supply more or less 8-9 million tonnes of CPO. High

production of POME concomitantly is followed by the high production of the mill waste,

either of waste water so-called palm oil mill effluent (POME ) or solid waste such as

  [1]

empty fruits bunch (EFB), shell, fibre etc. POME production is estimated about 28.

  7

million tonnes/year and production of solid waste is about 15. 2 million tonnes/year. This

  [0] high production of POME is surely the potential source to produce bigas. (Igwe, 2007)

  Researchs to prodbiogas from POME have been explored by many

  [0]

  

researchers. However, POME decomposition rate is achieved only 60-70% or smaller

  [0]

  

then the ideal decomposition rate that is 80%. This ideal decomposition rate will be

achieved if the ratio of COD, nitrogen (N) and phosphorus (N) is 350: 7: 1. (Speece,

  1996). Based on the previous experiment using POME from palm oil mill Pagar Merbau PTPN II, the ratio of COD: N: P was 350:4:1. This means POME from Pagar Merbau is lack of nitrogen, therefore the decomposition rate is relatively low.

  Nitrogen content in POME usually was enlarged by adding with other nitrogen source such as urea. However, since the amount of POME is very big, of course, urea needed in the big amount as well. As we know, the need of urea as fertilizer increases everyday. Alternatively, nitrogen content in POME can be increased by adding the POME with other waste which contains rich nitrogen sources. One of the wastes is cow manure.

  Cow-palm plantation integration which raising cows in the palm plantation area is the ideal solution. The rich nitrogen content in cow manure will be available in the big amount and the continuity is guaranteed. This integration system will also increase the production of cow meat in big amount.

  Agriculture Department of Republic Indonesia has introduced the cow-palm oil plantation program. This program has succeeded in many plantations. Therefore Agriculture Department prepared budget of 150 billion rupiah for buying cows to be especially big plantation consider cows as plant disease. When the cows enter the plantation area which surrounded by young palm trees, then the leaves of the young trees will be ate by the cows, of course the growth of the young trees will be disturbed. This problem can be solved by applying intensive or semi intensive methods. Intensive method more expensive because the entire foodstuff should be available, but the cow manure whether the solid or the liquid manure can be collected. Other method is semi intensive method where the cows are released in the palm plantation, but their wastes especially the liquid will scatter on the area.(Batubara, 1999)

  This research will study the improvement of biogas production using combination of POME and cow manure. Then, the gas production will be used as fuel to generate

• – electricity of 15 20 kWh. In order to achieve this target, this system will be designed in the pilot plant scale.

ANAEROBIC TREATMENT OF POME

  The research of biogas production from anaerobic tank fermentor of POME has been performed for two years. Experiments are conducted in laboratory scale and pilot plant scale (on going).

  A. Laboratory scale of anaerobic treatment of POME It was started in 2008 when Lembaga Penelitian dan Pengabdian Pada Masyarakat

  (LP3M) USU collaborated with Metawater Co. Ltd, one of Japanese big companies to perform joint research to study the fermentation of POME to biogas. The purpose of this joint research is to obtain the baseline data needed by palm oil companies in order to apply clean development mechanism (CDM) project for their plant. Therefore besides to reduce gas house gasses (GHG) emission, the plant can produce biogas as fuel to _[3] nerate electricity.

  The experiment was conducted in Ecology Laboratory, Chemical Engineering

Department USU. Besides lending their equipments Metar Co., Ltd-Japan also sends

  [5] their experts to USU. The fermentation process took place in a 2-litres-capacity

  

transparent jar digester (EYELA, Model MBF 300ME) which is provided with

  [5]

  

turbine agitator as well as alarm indicator bulb anticipating temperature disorder . A data

logger (KEYENCE, Model NR-250 ) is connected to computer to enable automatic

ording of temperature and pH provided by sensoring equipments attached to digester .

  [3] The experimental equipment for the 2-L digester is shown in Figure 1 .

  Figure 1. Two litters fermentor used in this research As the raw material for the experimental anaerobic digestion observed, a real POME

   obtained from Pagar Merbau Mill of PTPN II anisirau Mill waste water treatment

  [18]

  

facilities were used. Table 1 summarizes the main physical and chemical properties of

s material, while biogas production is shown in Table 2 .

  [9]

  From Table 1, it can be seen that ratio of COD, N and P is not similar to ideal

ratio recommended by some literature that is 350: 7:1. It is clearly seen that both POME is

  still lack of nitrogen, therefore in this experiment ammonium bicarbonate was added as nitrogen source.

  60

  ） 0,26 - 0,27 - 0,24 0,19

  44

  N mg/L -

  T mg/L 62,540 75,240 67,700 OD Kj-N mg/L 760 720 1,200 1,100

  BOD mg/L 33,000 33,000 59,000 50,000 CODｃｒ mg/L 59,000 56,000 99,000 76,000

  VS mg/L 39,700 40,200 53,900 52,300 SS mg/L 26,600 29,700 34,400

  2008.2.27 2008. 2008.6.1 2008.7 2.27（4.25再度測定） TS mg/L 45,300 46,400 64,700 63,000

  4 /kgTOD

  60

  kgCH （

  4 generation per TOD

  70 CH

  64

  66

  67

  83

  90 H4-N T-P mg/L - 150 250 250

  Oil & grease* mg/L 7,900 7,900 9,200 7,200 C wt%

• 49.2

  42.8 H wt%

• 7.04

  6.42

  6.35 N wt%

• 1.71

  2.16

  1.87 S wt%

• 0.23

  0.43 - P wt%

• 0.33 - -

  COD：N:P - - 350：4.5：0.9 350：4.2：0.9 carbohydrate wt% 60.5% 58.3% 61.6% glucide wt% 41.3% 47.6% - cellulose wt%

  46.2

  Protein wt% 9.1% 10.8% 10.0%

  Lipid* wt% 17.0% 14.2% 11.4%

  8.1% 6.2% - hemicellulose wt% 0.8% 0.0% - lignin wt% 10.3% 4.5% -

• )n-Hex used afterl Jun 18 used at Japan Name of Mill Sampling date Samping point

  /t-VS) 670 750 660 590 610 650 CH

  61

  61

  Tabel 1. Properties of POME from Pagar Merbau and PT.Sisirau Tabel 2. Experimental results of laboratory scale

  POME PKS PT. Sisirau PKS Pagar Merbau HRT (days)

  8

  10

  20

  4

  6

  8

  10 VS decomposition rate (%)

  49

  64

  65

  54

  64

  conc. (%)

  63 VS+VFA decomposition rate (%)

  58

  68

  70 58 -

  68

  66 TOD(CODcr) decomposition rate (%) -

  74 70 -

  77

  79 TOD(+VFA) decomposition rate (%) -

  73 71 -

  78

  80 Gas generation (Nm

  3

  4

  Pargar Marbau PTP　Ⅱ used after Mar 1 ^{Seeding (2nd) pond inlet 2nd pond inlet} PT.Sisirau From table 2 shows that although biogas production from both POME are relatively high, but decomposition rate of POME solid are still low if compared with othpe of [8] substrate (e.q. kitchen waste). Figure 2 shows the relationship between HRT and decomposition rate.

  VS(Kitchen waste) 1 0 0

  VS(Pagar Marbau)

  VS+VFA(Pagar Marbau) 9 5

  TOD(Pagar Marbau)

9 0 TOD+VFA(Pagar Marbau)

  ) (% 8 5 te a r

  8 0 n io it

  7 5 s o p

  7 0 m o c

  6 5 e D

  6 0 5 5 5 0

  2

  4

  6 8 1 0 1 2 HRT(days)

  Figure 2. Relationship between HRT and decomposition rate

  B. Pilot plant of anaerobic treatment of POME Another anaerobic treatment of POME will be performed using a pilot plant equipped with a fermentor type continuous stirred tank reactor (CSTR). The CSTR type was chosen, because this type of fermentor has relatively low energy consumption, less in operation and an easy start up. Furthermore a high performance could be expected.

  [0]

  The following aspects are considered:

  [1]

  a. performance (max. loading rate, efficiency, min. hydraulic retention time )

  b. of plugging

  pecific biogas production, composition of the biogas. [1]

  

The pilot plant was located at Pusdiklat LP3M USU Jl. Dr. Mansyur. Figure 3 shows the

  flowsheet of the pilot plant. The pilot consists of main equipment such as: the mixture tank, biogas fermentor, gas storage, compressor, biogas generator set.

  Figure 3. Flowsheet of pilot plant in this research The technical data of the pilot plant components:

  1. Mixture Tank: Volume : 1000 L Motor : 1400 rpm Power : 1 Hp Gear Box : ratio 1: 60 Accesories: Baffle, level controller, main hole, sampling hole

  2. Pump: Type : Centrifugal Power : 1 Hp Accessories: ball valve, check valve

  3. Fermentor Tank: Volume : 3000 L Motor : 1400 rpm Power : 3 Hp

  Gear Box : ratio 1: 60 Heater : 3 kW Accessories: main hole, sampling hole, insulator,

  4. Biogas Tank: Volume : 2000 L Accessories : man hole, water trap.

  5. Compressor: Type: Reciprocating Power : 1 Hp

  6. Generator set Machine: ex engine of Daihatsu car Cylinder: 1600 cc Combustion: Carburetor Dynamo: 12 kVa

  7. Others: Co ntrol Panel, Controller, wet gas meter, analysis equipments The fresh POME and cow manure are filled into the mixture tank, where the POME is maintained to pH 7 using the manure. The pump sucks the mixture wastes from the mixture tank and fed into the upper of the fermentor tank. Nearly all equipments involved were electricity driven. Feeding and temperature recordings were done automatically, as well as mixing and operations of reactor. The mode of the fermentor operation is intermitten, where POME from mixture tank is flown into the fermentor four times

  o

  maintained by using timer. The fermentor occurs at thermophilic condition of 55

  C. The [1] liquid inside the fermentor are analyzed periodically. Variables checked and analyzed

  

here consisted of volume of biogas produced, pH, M-alkalinity, total solid, volatile solid

and rough measurement of CO 2 and H

  CODcr, T-N, elemental composition analysis (C,H,N,S) and gas composition (CH

  4 , CO 2 ,

  H 2 S) were completed at the external laboratory.

  Produced gases are then flown into the water trap to collect the unexpected water in the bogas. The flow of the produced biogas is measured by using gas meter. Biogas are [19] sucked by compressor then flown to the generator set to generate the electricity. Acknowledgements This research was developed thanks to a research grant from Hibah Kompetitif

  

Penelitian Unggulan Strategis Nasional No: 429/SP2H/PP/DP2M/VI/2009 date 25 June

  2009, and also special thanks to Prof. Darwin Dalimunthe for his supervision References Speece, R.E. 1996. Anaerobic Biotechnology for Industrial Wastewaters. USA: Archae Press.

  th APHA. 1992. Standard Methods for the Examination of Water and waste water. 18 ed.

  New York. American Public Health Association. Batubara, A., I. Kasup, A.A. Kesma. A. Irfan, H. Simanjuntak dan Harahap. 1999. Kajian integrasi penggemukan ternak sapi potong di lahan perkebunan kelapa sawit.

  Laporan Hasil Kegiatan BPTP Riau. 2000 Dinas Pertanian, Direktorat Jenderal Perkebunan, 2006. Statistik Perkebunan Indonesia,

  Kelapa Sawit ( Oil Palm a). Igwe JC dan Onyegbado CC. 2007. A review of Palm Oil Mill Effluent (POME) Water Treatment. Global Journal of Environmental Research 1 (2): 54-62.

  Metcalf dan Eddy. 1991. Wastewater Engineering: Treatment Disposal Reuse.

  Singapore: McGraw-Hill Book Co.