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DR. HJ. ZULKIFLI AB. RAHMAN Malaysian Palm Oil Board

CH00 HUAN BOON Genting Plantations Bhd

ZERO WASTE TECHNOLOGYFOR PALM OIL MILLS: LATEST

INNOVATION AND HOLISTIC COMPOSTING SYSTEM (POMEDfree®)

M P O B

1. PRESENTATION OUTLINE

1. CONCEPT OF POMEDfree TECHNOLOGY2. DEVELOPMENT OF TECHNOLOGY3. KEY BENEFITS OF THE TECHNOLOGY TO

THE INDUSTRY4. POMEDfree PLANT PERFORMANCE

OVERVIEW (GJOM)5. ECONOMICS6. CONCLUSION7. WAY FORWARD

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2. PRESENTATION OUTLINE(Choo Huan Boon)

1. INTRODUCTION TO ZERO WASTE TECHNOLOGY

2. CHALLENGES IN ACHIEVING ZERO WASTE TECHNOLOGY

3. OPERATION & PERFORMANCE EXPERIENCES

4. FIELD APPLICATION

Thermophilic & Bio Control Inoculants

High microbial activity

MAXIMIZE Water Out

MINIMIZE POME

Zero Discharge

CONCEPT OF TECHNOLOGY-ZERO POME DISCHARGE-

POMEDfreePLANT

Controlled / reduced POME Production Prevent Rain Water

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CONCEPT OF TECHNOLOGY

A. Minimize POME production1. Continuous sterilization

2. Zero dilution process

3. 5 –stage dry separation winnowing column

4. Reuse condensate for mill usage

5. Prevent excessive mill washing

B. Maximize water evaporation1. Using thermophilic temperature ( 65 – 80 ºC)

2. Massive evaporation through mechanical turning of compost heap

3. Roofing to prevent rain water

4. Innovative blower system

MAXIMIZE Water Out

100% EFB

100% SLUDGE

100% POME

CONCEPT OF TECHNOLOGY-100% RECYCLING OF NUTRIENTS-

From Mill

Zero Discharge

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POMEDfree® Zero Waste Technology Flow Chart

Flowchart of Genting Jambongan Palm Oil MillZero Waste Technology

WindrowBuilding 1

WindrowBuilding 2

Mill Influent

Buffer Tanks

Mixed EFB+Decanter

Slurry Input

WindrowBuilding 2

Mature Compost Output

Leachate Pt 1

Leachate Pt 2

Air Blowers 1 & 2

ConditioningTanks

Air Blower

2

Air Blower 1

Mature Compost OutputMixed

EFB+DecantSlurry Input

Pumps 1/2

Pumps 3/4

Hydrolysis Tank

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KEY BENEFITS OF POMEDfree

TECHNOLOGY TO OIL PALM OIL INDUSTRY

PROFIT

100% Nutrients Recycling

ZERO POLLUTION

(All POME Evaporated

Away)

DISEASE CONTROL

(Prevent Ganoderma

Attack)

SUSTAIN-ABILITY

(Sustainable Palm Oil –

Change World’s

Perception)

KEY BENEFITS OF POMEDfree TECHNOLOGY

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POMEDfree PLANT PERFORMANCE

OVERVIEW (GJOM)

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ECONOMICS

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Nutrient Content Studies

Nutrient content of POME 

Study 1 Study 2 Study 3 Study 4 Study 5 Study 6 Study 7 Study 8 Average

N (kg/t POME) 0.75 0.97 1.11 1.04 1.13 1.05 0.75 0.75 0.94

P (kg/t POME) 0.18 0.18 0.18 0.19 0.18 0.16 0.18 0.18 0.18

K (kg/t POME) 2.27 2.36 2.12 2.97 2.06 1.90 2.27 na 2.28

Mg (kg/t POME) 0.62 0.69 0.73 0.76 0.67 0.48 0.62 0.62 0.65

Ca (kg/t POME) 0.44 0.37 0.39 0.40 0.51 0.58 0.44 0.44 0.44

Nutrient content of EFB

Study 1 Study 2 Study 3 Study 4 Study 5 Study 6 Study 7 Study 8 Average

N (kg/t EFB) 3.20 2.80 2.80 2.22 3.14 1.32 3.70 2.77 2.74

P (kg/t EFB) 0.88 0.77 0.34 0.18 0.22 0.43 0.40 0.36 0.45

K (kg/t EFB) 11.60 10.15 8.40 6.03 6.98 6.72 9.10 10.01 8.62

Mg (kg/t EFB) 1.20 1.05 0.63 0.39 0.48 1.08 0.80 na 0.80

Ca (kg/t EFB) 1.00 0.88 0.63 0.48 1.28 1.08 na na 0.89

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Nutrient Content Analysis

Nutrient

minimum maximum minimum maximum minimum maximum

N (kg) 1.19 1.41 214,524 254,043 429,048 508,086

P (kg) 0.15 0.33 26,172 58,662 52,344 117,324

K (kg) 2.62 4.60 471,591 827,496 943,182 1,654,992

Mg (kg) 0.40 0.77 72,306 138,717 144,612 277,434

Ca (kg) 0.49 0.49 87,498 87,966 174,996 175,932

Total (kg) 4.84 7.59 872,091 1,366,884 1,744,182 2,733,768

180000 360000

per mt FFB* 30mt/hr mill 60mt/hr mill

Nutrient Value Analysis

Nutrient Price (RM/mt)

minimum maximum minimum maximum minimum maximum

N (RM) 4,262 5.08 6.02 914,281 1,082,707 1,828,562 2,165,414

P (RM) 1,823 0.27 0.59 47,720 106,960 95,441 213,921

K (RM) 2,757 7.22 12.67 1,300,019 2,281,131 2,600,038 4,562,261

Mg (RM) 2,911 1.17 2.24 210,491 403,821 420,982 807,641

Ca (RM) 874 0.42 0.43 76,478 76,887 152,956 153,774

TOTAL VALUE (RM) 14.16 21.95 2,548,989 3,951,506 5,097,979 7,903,012

* 1mt FFB produces 0.65mt POME and 0.23mt EFB

per mt FFB* 30mt/hr mill 60mt/hr mill

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Cash Payback Period and ROI analysis

POME (mt per FFB) 0.45 0.55 0.65 0.45 0.55 0.65

Required Building Size (sq m) 7,200 10,000 13,000 14,300 20,000 25,700

Investment Cost (RM m) 17.5 20.5 23.5 29.0 35.0 41.0

Recoverable Fertilizer Value

Less operating cost

Savings in fertilizer

Payback Period (years) ‐ Min* 9.03 10.58 12.13 7.49 9.03 10.58

ROI  (%) ‐ Min* 11.1% 9.5% 8.2% 13.35 11.07 9.45

Recoverable Fertilizer Value

Less operating cost

Savings in fertilizer

Payback Period (years) ‐ Max* 5.24 6.14 7.04 4.34 5.24 6.14

ROI (%) ‐ Max* 19.1% 16.3% 14.2% 23.0 19.1 16.3

30mt/hr mill  60mt/hr mill 

3,951,506.00

612,000.00

3,339,506.00

7,903,012

1,224,000

6,679,012

2,548,989

612,000

1,936,989

5,097,979

1,224,000

3,873,979

CONCLUSION

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CONCLUSION1. The performance of the Jambongan

POMEDfree Plant is outstanding, all the POME produced has been evaporated away. POMEDfree Technology has been proven with a full size plant in operation.

2. The biggest beneficiary is the environment. The savings in ecology cost from reduced air pollution and zero water pollution are very substantial.

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CONCLUSION3. Investment in the POMEDfree Technology is

economically feasible.

4. Benefits to yield, disease control and sustainability are very significant.

5. In-house studies have shown that the use of biofertilizer can increase FFB yields by as much as 9% to 17%.

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WAY FORWARD

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WAY FORWARD1) Further collaboration R&D between

MPOB and Nexusa) To determine whether POMEDfree can co-

exist with Biogas to recover nutrients and energy.

b) To increase nutrients recovery from Mesocarp Fibre

c) To conduct Research on Compost Application

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POMEDfree Zero Waste Technology

POMEdfree plant Shredded EFB

Compost heap Turner machine in operation

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