Benefits of Palm Oil Company When Produce Biochar

There are at least four things that become motivation for biochar production, namely as in the chart above. There are a number of slices that make the impact of biochar application multi-benefits, which is very much in line with today's world problems, namely climate change and global warming. Biochar has also been accepted as an instrument to reduce the concentration of CO2 in the atmosphere which causes the two big problems above, namely in 2018 biochar was included in the Intergovermental Panel on Climate Change (IPCC) as one of the negative emissions technologies (NETs). Biochar application is a carbon negative scenario because biochar can absorb CO2 from the atmosphere. This is slightly different from the use of biomass fuels such as wood pellets, wood briquette and palm kernel shell (PKS) in industrial boilers or power plants, which are carbon neutral scenarios. Indeed, basically there are 3 big scenarios to reduce the concentration of CO2 in the atmosphere, namely increasing the efficiency of equipment that uses fossil fuels, using carbon neutral fuels and carbon negative scenarios such as biochar.

Palm oil trees are known to require a lot of water and fertilizer to maintain the life sustainability and productivity of their fruit, so practical efforts in the form of increasing fertilizer nutrient efficiency and increasing fruit productivity are important. Besides that, palm oil mills produce a lot of biomass waste, especially empty fruit bunches (EFB ) and mesocarp fiber, which are very potential for biochar raw materials. The biochar is then applied in palm oil plantations which can be used with chemical fertilizers or with compost / organic fertilizers.

Pyrolysis and gasification technologies are commonly used for the production of the biochar. Apart from producing biochar by pyrolysis or gasification, energy is also produced which can be used for the business development of the palm oil industry or for electricity production. Production of PKO (Palm kernel oil) from kernel processing at KCP (kernel crushing plant) or production of torrefied PKS from PKS processing with torrefaction can be done by utilizing excess energy from the production of biochar. Most of the palm oil mills or CPO mills do not have kernel processing or KCP to produce PKO. And by making torrefied PKS, the caloric value of PKS will increase, it is easy to downsizing (increased grindability), for example in the use of cofiring and does not absorb water (hydrophobic property). In general, palm oil mills will have many advantages, both economically / financially and environmentally, with this biochar production.

Apart from being used for business development like the diagram above, excess energy from pyrolysis or gasification can also be used as boiler fuel in the palm oil mill. In this way the energy to heat the boiler, which is usually with palm kernel shell and mesocarp fiber, can be replaced by energy from pyrolysis or gasification. After that, all of the palm kernel shells / PKS can be sold or exported, thus providing additional profits for the palm oil company. The need for biomass fuel, especially palm kernel shell / PKS, is predicted to increase, both in the domestic market and in the export market. Japan is currently the largest consumer or user of palm kernel shells and it is predicted that the demand will also increase. Japan will also impose stricter standards on imports of palm kernel shells to ensure environmental sustainability by applying the GGL (Green Gold Label) certification which will be effective starting April 2023. This is like the wood pellets with FSC certification. If anyone is interested in an economic analysis of the use of biochar in palm oil business, please contact us.  

Fertilizer Savings in Palm Oil Plantations with Biochar and Compost from Biogas Waste

Although Indonesia is the largest CPO producer in the world with an area of ​​approximately 13 million hectares of palm oil plantations, but it is estimated that less than 10% have a biogas facility from POME (Palm oil mill effluent). Whereas by utilizing POME for biogas production, besides being able to be converted into electricity or heat, it also produces organic fertilizer in the form of compost and liquid organic fertilizer. The compost can be used as fertilizer in oil palm plantations, where the cost of fertilizer for palm oil operations is the highest cost component. It is estimated that every 10,000 hectares costs approximately Rp. 35.75 billion (around US$ 2.25 million) for fertilizer and for more details, you can read here. The use of compost will certainly reduce the need for fertilizer.

Palm oil utilization scheme for optimizing CPO production

Besides that, solid wastes such as palm oil empty fruit bunch, fiber and palm oil frond are also very potential for the production of energy (electricity and heat) and biochar. Energy production in the form of electricity and heat is by burning pyrolysis byproducts in the form of syngas and biooil into the furnace to heat the boiler. And because the syngas and liquid fuels used in the furnace, so that the combustion process is more perfect and clean emissions. Steam generated from the boiler will then drive the steam turbine and generator so as to produce electricity. Low pressure steam from steam turbine is then used for sterilization or boiling the fresh fruit bunches (FFB). While biochar will be used together with compost and chemical fertilizers to make fertilizer effective in the palm oil plantations so that it becomes a slow release fertilizer. Costs for fertilization are also expected to be significantly reduced, for example by up to 50% by this way. Although biochar is not a fertilizer, it has a function that makes fertilizer use effectively because it holds fertilizer nutrients from leaching, for example from rain water, also maintains moisture and so on.

PKS loading for export in Indonesia

PKS (palm kernel shell) can even be sold or exported. This is because previously or in general the palm kernel shells used to fuel boilers with fiber, have been substituted with products from the pyrolysis process namely syngas and biooil. The need for palm kernel shells for both the domestic / local and export markets continues to increase all the time. Palm kernel shells / PKS are environmentally friendly fuels because they come from biomass so they are carbon neutral fuels. The use of PKS as a fuel is widely used by a number of industries starting as a heat source for the drying process such as spray dryers in detergent and ceramic plants, boilers in food industries such as soy sauce factory, to power plants such as in Japan, can be read in more detail here. In the world of biomass fuel commodity trading, especially in the international market, PKS is the main competitor of wood pellets. Although the specifications are not much different, the price of PKS is also cheaper because it comes from palm oil mill waste and does not need complex processing units such as wood pellets. And basically with the scheme of utilizing palm oil mill wastes as above, it will maximize the profit from the palm oil mill or CPO mill.

Large Plantations and Large Farms

Fertilizer problems or soil fertility have always been the main topic or discussion for a large plantation business. This is very reasonable because maintaining productivity of crops can only be done by maintaining soil fertility or providing adequate fertilizer. For this reason, the budget for the supply of fertilizer is always a large portion of the plantation business. Then the condition leads to the question of how to make efficiency or save the fertilizer budget? Of course many techniques can be used for this purpose, but basically the selection or use of fertilizer that is appropriate and the effectiveness or absorption of fertilizer for plants is a key success factor in maintaining soil fertility. Let's try to answer the main question above.

When chemical fertilizers are increasingly abandoned because of their effects which damage the environment, there is no other choice but to use organic fertilizer. In large plantations such as oil palm plantations, basically there are also many biomass wastes from palm oil mills that can be used as fertilizer, such as fronds and palm oil trunks. But when these ingredients are also processed to become a particular product, and also the composting process of fibrous wood species takes a long time, the best choice is with organic manure. The question is where do you get livestock manure compost for the oil palm plantation? Actually there are more sources of organic fertilizer or compost that can be produced from palm oil mill effluent, namely from liquid waste. If the palm oil mill has an anaerobic digester, the biogas residue from the sludge can be used as organic fertilizer. At present there are not many palm oil mills that process liquid waste with the biogas unit, with the reason that the unit is considered expensive.

The history and experience of our predecessors before the use of chemical fertilizers can be used as a reference for this. At that time they were able to meet the fertilizer needs of their agricultural businesses, namely by sheep, goats, cattle and buffalo farming. The livestock manure is used for agricultural fertilizer and agricultural waste is used for animal feed. The basic pattern can also be developed for large plantations with several adjustment techniques to improve efficiency. Technical applications in the field that can be done, namely large plantations must cooperate with large farms or even ideally have a large farm to meet the needs of fertilizer for its plantations. For example, a palm oil plantation that has 10,000 hectares of plantation area, 100-200 (1-2%) hectares are used for sheep farming. The sheep breeding, not by just being caged, but grazing in the fields of pasture.

Why is sheep farming done in the pasture fields? This is because by grazing the cost of feed can be suppressed very large or the business becomes very economical. The biggest cost component of livestock business is feed. If the availability and supply of feed can be overcome then the other components become easier. The pasture is in the form of grass and shade trees. Making grass always available is the essence of the business, even it can be said that the pasture is grass farming itself. Rotational grazing is the best grazing technique at the moment. When the grass is fertilized with sheep dung during the grazing, the dirt produced when in the cage can be used for fertilizer on large plantations such as the oil palm. The biogas unit can be used to optimize the utilization of dirt from the cage.

Basically, sheep farming can also stand alone and also be profitable. Therefore, sheep farming can be done separately. In the case when an energy plantation is used for the production of wood pellets, it is still constrained by various things such as the presence and supply of electricity, so the farm business can still be run properly. The production of large-scale wood pellets in various regions in Indonesia is currently still constrained due to the electricity supply. This will certainly hamper the growth of the wood pellet industry so there needs to be another way to overcome this, which insha Allah will be discussed later.

With this concept, not only increases plantation and meat production, but also a complete closed cycle business that is environmentally friendly and sustainable. Honey bee farming can also be added for optimization because obviously the bees besides helping the pollination process will also produce honey, a superior product of high economic value. Various food problems, insha Allah, can be overcome with this concept. This is because from the production side it can be made very efficient with the 2 biggest cost components being reduced significantly by fertilizer and animal feed with the integration of large plantations and large farms.

Although it has used compost from livestock manure, there are still more techniques that can be applied to improve fertilizer efficiency by using biochar. With biochar, the fertilizer will be retained in the biochar pores so that slow release makes it effective for fertilization. In addition, biochar will also hold the fertilizer from leaching due to high rainfall, so that the use of fertilizer can also be saved significantly. Biochar will also be the home of microbes to decompose organic matter into nutrients needed for plants. So, in short, with biochar, the productivity of plantations is high, but the use of fertilizer is minimal because it is efficient, especially when fertilizer is produced from the farm itself. This biochar can be produced by processing the plantation biomass wastes by pyrolysis. For more details about pyrolysis can be read here.

The Big Vision of the Palm Oil Mill: Not Only Generating Electricity with Steam Turbine Generators but also Biochar and Bio-Oil

At the palm oil mill, electricity is generated from a steam turbine generator so a water treatment unit is needed to provide boiler feed water and a boiler unit to produce steam. The specifications of the steam produced are superheated steam with a pressure of 30 bar or equivalent to a temperature of 240 C. The steam then powers the turbine and drives the generator to produce electricity. Steam that comes out of the turbine with a decrease in temperature and pressure is not thrown away, but is used for steamming fresh fruit bunches (TBS) in the sterilizer unit. That is the reason why electricity production in palm oil mills uses steam turbine generators, even though actually producing electricity does not have to use the steam turbine. There are a number of technologies that can be used for electricity production.

The boiler fuel for steam production also does not use fossil fuels but uses palm oil mill waste itself (mesocarp) fiber and palm kernel shell (palm kernel shell). This is what makes palm oil mills very environmentally friendly in terms of their use of energy sources because they use biomass fuels, namely solid waste in the form of (mesocarp) fiber and palm kernel shells. Judging from the environmental aspects of the use of biomass fuel is carbon neutral, so it does not add CO2 in the atmosphere. Environmental issues are very prevalent today due to a number of environmental damage, to the peak of climate change and global warming. This encourages various industrial activities to increasingly pay attention to these environmental aspects.

When a palm oil mill uses its biomass waste as fuel to produce electricity and steam for the operation of the plant and it produces waste or residue in the form of ash, that is something that is common to almost all palm oil mills today. But when the palm oil company has a bigger vision, what is produced besides electricity and steam is biochar, not ash. Why Biochar? Although the management of the palm oil company that separates the plantation and mill divisions is common, the implementation of biochar is also expected to make a better reciprocal relationship. At present the palm oil fruits or fresh fruit bunches are supplied to the mill for oil extraction, so when biochar is produced by the mill the biochar will be supplied nto the  plantation to increase the productivity of the palm oil fruits. When a palm oil company will optimize its CPO products it also means maximizing the productivity of its palm oil  fruit. Palm  oil fruits productivity can be maximized if the cultivation aspects are also maximum. Biochar can be used to maximize fertilization and even reduce the use of fertilizers in oil palm plantations which amount to tens of billions of rupiah, for more details, please read here.

Are there palm oil mills that dare to take up the challenge? God knows Nature. But oil palm companies that have a big vision and understand the importance of increasing the productivity of oil palm fruit in line with environmental aspects, should be challenged with this. Oil palm companies that have big visions will also see this as an effective (pro-planet) environmental solution. This is because besides having a positive effect on the productivity of oil palm, also with environmental aspects. The application of biochar is carbon negative, so that CO2 in the atmosphere will be absorbed into the pores of the biochar, thereby reducing greenhouse gases in the form of CO2 in the atmosphere. When tens to hundreds or even thousands of tons of biochar are applied to oil palm plantations, so much CO2 in the atmosphere is absorbed into the soil. Biochar can also survive tens or even hundreds of years so that the carbon content in the soil increases or is not damaged along with the productivity of the palm oil plantation.

In addition to the production of biochar with continuous pyrolysis also produced biooil which can also be used as fuel or processed into various other biomaterials. With characteristics close to crude oil, it also means that all materials that can be produced from crude oil can be produced with biooil. Another application of biooil is for blending with ship oil (marine fuel oil). Other liquid products in the form of biomass vinegar, its use is also very supportive in palm oil plantations, namely as bio-insecticides and bio-pesticides. Rats that attack many palm fruit can also be overcome with the vinegar biomass, for more details, please read here.