Assumptions & Design Calculations for Effluent5

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SAPI PLANTATIONS SDN BHDSAPI PALM OIL MILL

PROPOSAL OF BIOGAS PLANT PROJECT

DATE OF PREPARED : 18TH NOVEMBER 2009

TABLE OF CONTENTS

NO PAGE

1.0 INTRODUCTION. 4

1.1 PPB OIL PALM BERHAD En!"#n$%n& P#'!(). *

1.2 A(+n#,'%-%$%n& L%&&%"/

2.0 BIOGAS PLANT PROJECT

2.1 P"#%(& C#n(%&...

2.2 B3(+"#n- #5 C#n(%&..

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2.6 L#(3&!#n #5 S3! P3'$ O!' M!'' !n E37& C#37& S33.......8

2.4 L#(3&!#n #5 B!#37 P'3n& !n S3! P3'$ O!' M!''........9

6.0 FLO; CHART OF NE; PROPOSED ;ASTE;ATER

TREATMENT PLANT...10

6.1 D%7("!&!#n #5 N%, P"##7%- ;37&%,3&%" T"%3&$%n&

P'3n& F'#,..11

4.0 NE; PROPOSED BIOGAS PLANT FLO; DIAGRAM..12

4.1 D%7("!&!#n #5 N%, P"##7%- B!#37 P'3n& D!3"3$.................................16

*.0 METHODICAL TABULATION ...........1/

*.1 C#$&3&!#n B!#(%$!(3' O


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1.0 INTRODUCTION

As the Sapi Palm Oil Mill ( 60 mt/ hrs ) has started with combination of effluent treatment ponding

system and land irrigation from May 00!" the final effluent is considerable #ery well treated and almost

achie#ed the $ero discharge to water course% &he palm oil mill effluent ( POM' ) is no longer considered

as a source of pollution of ri#er and nowadays e#ery single drops of POM' was transferred into field for

impro#ing the soil condition and subseuently" reducing the tonnage of nonorganic fertili$er application

which is nightmare for e#ery plantation company%

*or further preser#ing the en#ironment climate and eliminate any potential ad#erse global

warming impact on our planet" the management of Sapi Palm Oil Mill ( PP+ Oil Palms +erhad ) has

decided to de#elop of Sapi Methane ,eco#ery in -astewater &reatment and .tili$ation for electricity

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proect at Sapi Palm Oil Mill% &his proect will register as part of the lean 1e#elopment Mechanisms

( 1M ) under the .nited 2ations *ramewor3 on#ection on limate hange ( .2* )% &he

proposed Palm Oil Mill Methane ,eco#ery and Power 4eneration will apply inno#ation en#ironment

technology to impro#e waste management at the mill and reduce the emission of methane to the

atmosphere% &his proect also contributes to Malaysia5s sustainable de#elopment policy on efficient waste

management in the palm oil industry and help to reduce the green house gas emissions ( 44s )% &o

implement this proect" we do had sur#eyed e#ery single corner of our area where is best suit to the proect

implementation% &he details will present on the following this proposal%

1.1 PPB OIL PALMS BERHAD ENVIRONMENTAL POLIC=:

ENVIRONMENTAL POLIC=

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PP+ Oil Palms +erhad has assle" to minimi$e the en#ironmental impacts of all our acti#ities and we shallachie#e this through 7

89 ompliance with all rele#ant en#ironmental laws and their reuirements:

89 1e#eloping oil palm plantations only on degraded and logged o#er land% Oil palm de#elopment

on pristine unlogged forest is totally prohibited:

;

89 Adherence by all concerned to the 4ood Agricultural and Manufacturing ode of Practices which are based on principles of sustainability and these are documented in the Agricultural

; and Milling Manuals:

89 Preser#ing unplantable areas (where applicable) as highly protected conser#ation areas to

enhance biodi#ersity in the plantation en#ironment:

89 'mployees (directly or indirectly employed) ta3ing all reasonable measures to cooperate with

management and complying with the rele#ant laws" instructions and/ or measures instituted

; concerning the en#ironment:

89 Ma3ing all rele#ant information and instructions on minimi$ing en#ironmental impacts in all related agricultural and milling operations a#ailable to all concerned:

89 ,egularly educating and updating all concerned on issues related to the en#ironment and

adopting a concept of continuous impro#ement in minimi$ing their impact through all practical; means%

+y Order of the +oard of 1irectors

of PPB OIL PALMS BERHAD

'n#ironmental Policy (86


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2.0 BIOGAS PLANT PROJECT

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&he main obecti#e of +=O4AS P>A2& proect is helping to protect the ecoclimate and eco

friendly en#ironment for the sustainable palm oil industries% &he growing palm oil industries and e?tracts

oil from the *resh *ruit +unches ( **+ ) at its processing plant% &his creates solid waste ( fibre" decanter

ca3e" boiler ash and empty fruit bunches) and effluent that contains potentially emission gases such as

methane ( @)" carbon dio?ide ( O) and etc%

Methane ( @ ) in the atmosphere is an important 4reen ouse 4as ( 44 ) with global warming

potential of


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2.6 LOCATION OF SAPI PALM OIL MILL IN EAST COAST SABAH:

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2.4 LOCATION OF BIOGAS PLANT IN SAPI PALM OIL MILL:

NE; PROPOSED BIOGAS PLANT

MIXING POND

2

AEROBIC

POND 1

AEROBIC

POND 2

FACULTATIVE

POND 1 2

FACULTATIVE

POND 2

POLISHING

POND

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6.0 FLO; CHART OF NE; PROPOSED ;ASTE;ATER TREATMENT

PLANT

10

PALM OIL

MILL

EFFLUENT( POME )

MIXING POND

NO:1 & NO:2


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6.1 DESCRIPTION OF NE; PROPOSED ;ASTE;ATER TREATMENT PLANT FLO;:

*irst stage" the palm oil mill effluent ( POM' ) will flow out from mill itself to the mi?ing pond

no7 8 and no7 for purposes of cooling and readily further digestion treatment% 2e?t step" the #ery hea#y

acidic sludge POM' ( O1 C ;0"000 PPM ) from mi?ing pond no7 will pump to +iodigester &an3 of

+iogas Plant and the anaerobic digestion process which is brought about by the complementary acti#ities

( A ) BURNER ( PHASEI )

( B ) BIOGAS

GENERATOR (

PHASE II )

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New Proo!e"BIOGAS PLANT

( CLOSED TAN#ANAEROBIC

DIGESTION S$STEM )

SOIL INFILTRATION

&EVAPOTRANSPIRATI

ON

CONVERT

METHANE

( CH%) TO

CARBON

DIOXIDE ( CO2)

AND RELEASE

TO OONE

LAND IRRIGATION AREA

( 2'% HA )

AEROBIC POND 1 & 2 ( er*o+!

A,-ero.*/ Po," 1 & 2 )

FACULATATIVE POND 1 & 2

POLISHING POND ( FINAL DISCHARGE

POINT X )


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of acti#e bacteria will be begin% =n a biogas plant" fermentation and decomposition processes produce

biogas ( #aluable gas of methane ) which is used to generate electricity as efficiently as possible% &he

produced methane (@) gases ( point A ) will be burn off at the burner for the phase one ( = )% *or phase

two ( == ) methane gas will be filter up and compress before supply to biogas generator ( internal

combustion engine )% +y doing so" the potent methane ( point + ) will con#ert into the carbon dio?ide

(O) and water ( O )%

After anaerobic digestion processes in +iogas Plant and turn it to be a less hea#y sludge and more

on al3aline condition ( +O1 D 8000 PPM and O1 D 000 PPM )% At this moment" all the POM' will

transfer into the aerobic ponds ( per#ious anaerobic ponds )" then facultati#e ponds and the final polishing

pond ( final discharge point E located )%

&he POM' only can discharge to the land irrigation area ( !%@ A ) in the field when its meet

minimum reuirement ( +O1 F 800 PPM ) as stated on the licenses of 1epartment of 'n#ironment ( 1O'

)% &he POM' will store in the drainage or trenches and slowly absorbed by soil infiltration or

e#apotranspiration processes% &he monthly sample will ta3en at the upstream" downstream and final

discharge ( point E ) for analysis purposes to ensure that all parameter of the sample must been

satisfaction for all parties%

4.0 NE; PROPOSED BIOGAS PLANT FLO; DIAGRAM

BIOGAS

12

SLUDGE

PITMIXING

POND 1

MIXING

POND 2


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CH4 CO2 H2S @ %&(.

4.1 DESCRIPTION OF SAPI BIOGAS PLANT

DIAGRAM:

=n recent years" increasing awareness that anaerobic digesters can help to control disposal and odor

of food processing waste has stimulated renewed interest in the technology" namely anaerobic digestion%

Anaerobic digestion is a biochemical process in which particular 3inds of bacteria digest biomass in an

o?ygenfree en#ironment% Se#eral different types of bacteria wor3 together to brea3 down comple?

organic wastes in stages resulting in the production of biogas ( mostly methane @)%Symbiotic groups of bacteria perform different functions at different stages of the anaerobic

digestion process% &here four basic types of microorganisms in#ol#ed% ydrolytic bacteria brea3 down

comple? organic wastes into sugars and acid amino acids% *ermentati#e bacteria then con#ert those

products into organic acids% &he biological process of acidogenesis is where there is further brea3down of

the remaining components by acidogenic microorganisms to con#ert the acids into hydrogen" carbon

dio?ide and acetate% ere" #olatile fatty acids ( G*A ) are created along with ammonia and hydrogen

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ANAEROBIC

DIGESTER

TAN# A1

( 0 MT )

CLARIFIER

TAN# B

( 1 MT )

ANAEROBIC

DIGESTER

TAN# D

( 0 MT )

ANAEROBIC

DIGESTER

TAN# A2

( 0 MT )

AEROBIC POND 1

CLARIFIER

TAN# E

( 1 MT )TAN#

C

( 3

MT )


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sulfide ( S ) as well as other byproducts% *inally" the methanogenic bacteria produce biogas from

acetic" hydrogen and carbon dio?ide% =t is these components that ma3es up maority of the biogas emitted

from the system% Methanogenesis stage is sensiti#e to both high and low ps and occurs between p 6%e8 F ;0"000/ 8 ( 0%@ ? B%0 )

F 829mg/ 8tr

*.6 CALCULATION OF BOD FOR AEROBIC PONDS P%"!#7 An3%"#!( P#n-7 :

&here are two ( ) aerobic ponds in Sapi Palm Oil Mill and their appro?imate si$e for

Aerobic Pond 8 F !m ? B


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&otal #olume of Aerobic Ponds F 0"B00 8!"B80

F 40410m;

Surface area of Aerobic Pond 8 and F ( ! ? B< ) ( B%6 ? B< )

F 1/10m

+ased on per#ious year ( yr 00 ) rainfall in Sapi area"

the ma?imum rainfall per day F 68%< mm

&herefore" total #olume of rain water will collected in Aerobic Ponds alone

F 86"8B0 ? 68%< ? 8/ 8000

F 1028 m;/ day

ydraulic ,etention &ime ( ,& ) for Aerobic Ponds" t F @0"@80/ ( 8"@@0 8"0 )

F 1/./4days

+O1 anticipated e? H Aerobic pond" >e F B"!/ 8 ( 0%@ ? 86%6@ )

F 1026mg/ 8tr

*.4 CALCULATION OF BOD FOR FACULTATIVE PONDS:

&here are two ( ) facultati#e ponds and their appro?imate si$e for

*acultati#e Pond 8 F 86


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F 906m;/ day

ydraulic ,etention &ime ( ,& ) for *acultati#e Ponds" t; F 6


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/.0 CONCLUSION

&heoretically" the biochemical o?ygen demand ( +O1 ) shall be ! ppm and well below minimum

reuirement of 1epartment of 'n#ironment ( 1O' ) based on the tabulation% ompared year 00 and

year 00! ( an H Oct% ) the a#erage of +O1 is B ppm and


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.0 GLOSSAR= OF TERMS

DOE DEPARTMENT OF ENVIRONMENT

MPOB MALA=SIA PALM OIL BOARD

UNFCCC UNITED NATION FRAME;OR? CONVENTION ON CLIMATE CHANGE

CER CERTIFIED EMISSION REDUCTION

FFB FRESH FRUIT BUNCH

CDM CLEAN DEVELOPMENT MECHANISM

GHG GREEN HOUSE GASES

BOD BIOCHEMICAL O>=GEN DEMAND

HRT H=DRAULIC RETENTION TIME

COD CHEMICAL O>=GEN DEMAND

VFA VOLATILE FATT= ACID

POME PALM OIL MILL EFFLUENT

BTU BRITISH THERMAL UNIT

PPM PART PER MILLION

CH4 METHANE GAS

CO2 CARBON DIO>IDE

H2S H=DROGEN SULFIDE

H2O ;ATER

TS TOTAL SOLID

SS SUSPENDED SOLID

N NITROGEN

P PHOSPHORUS

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APPENDI> A8.1

RAINFALL CHART

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APPENDI> A8.2

RESULT OF BOD FOR 2008 AND 2009

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APPENDI> A8.6

BIOGAS PLANT LA=OUT PLAN

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APPENDI> A8.4

ARRANGEMENT OF BIOGAS PLANT S=STEM

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Assumptions & Design Calculations for Effluent5