Co-composting is one of the important bio-waste treatments in the palm oil industry for achieving sustainable process and zero waste. Improper conditions of composting may cause several problems such as gas emission, bad odour, low quality product, production delay and high handling cost.
Co-composting is one of the important bio-waste treatments in the palm oil industry for achieving sustainable process and zero waste. Improper conditions of composting may cause several problems such as gas emission, bad odour, low quality product, production delay and high handling cost.
Co-composting is one of the important bio-waste treatments in the palm oil industry for achieving sustainable process and zero waste. Improper conditions of composting may cause several problems such as gas emission, bad odour, low quality product, production delay and high handling cost.
880 Journal of Food, Agriculture & Environment, Vol.
9 (3&4), July-October 2011
www.world-food.net Journal of Food, Agriculture & Environment Vol.9 (3&4): 880-885. 2011 WFL Publisher Science and Technology Meri-Rastilantie 3 B, FI-00980 Helsinki, Finland e-mail: info@world-food.net Received 24 June 2011, accepted 3 October 2011. Co-composting of palm oil mill wastes C. Y. Yeoh 1 , N. L. Chin 1 * and C. S. Tan 2
1 Department of Process and Food Engineering, Faculty of Engineering,Universiti Putra Malaysia, 43400 UPM Serdang, Selangor, Malaysia. 2 Biotechnology Research Centre,Malaysian Agricultural Research and Development Institute, 43400 Serdang, Selangor, Malaysia. * e-mail: chinnl@eng.upm.edu.my Abstract Co-composting is one of the important bio-waste treatments in the palm oil industry for achieving sustainable process and zero waste. However, improper conditions of composting may cause several problems such as gas emission, bad odour, low quality product, production delay and high handling cost. Enhancing the efficiency of waste composting becomes a vital issue to overcome these problems. This review provides information on the practices and developments related to co-composting of the palm oil mill waste. The description on a typical palm oil mill process and the wastes generated, i.e. empty fruit bunch and palm oil mill effluent, as composting substrates are given. The common windrow composting system is described. The recent venture of using microorganisms in composting processes are also covered under the pretext of several researchers interpretation that composting can be accelerated by the introduction of microorganism to the process through its influence on the physical, dynamic and biological behaviours of organic material. The criteria of choosing functional microbes for fast composting are discussed. Key words: Co-composting, palm oil mill waste, empty fruit bunch, functional microbe, windrow composting. Introduction At present, composting is a waste treatment method performed by palm oil industry as an approach to zero waste process. The two main palm oil mill wastes, which are the empty fruit bunch (EFB) and palm oil mill effluent (POME), are suitable substrates for co-composting. Both wastes are of plant origin and do not create harmful effect as the chemical waste does. In the past, factories dumped the wastes to the nearby land without pre- treatment. By treating this waste as trash, the nutrients in these organic materials are being thrown away. Furthermore, this land filling option has detrimental effects on the environment. The disposed organic wastes would simply rot quickly and this produces toxic effect on soil, stream water and air, and increases global temperature. In achieving a sustainable process of palm oil, composting becomes the alternative of its bio-waste treatment. By converting these bio-wastes into compost, the nutrients in waste can be harnessed and potentially utilized as a valuable soil amendment, hence creating a zero waste process. Composting, being a biological decomposition process has many advantages as well as disadvantages like any biological systems. Composting systems have the advantages of using lower technology equipment, simple operation outlay, and less undesirable impacts upon the quality of environment. However, the limitations of systems are often attributed to the slow rate of processing and its unpredictability. The understanding of composting process through the transformation of organic matter and the evaluation of compost maturity are essential in achieving an effective compost production. With many analytical methods being determined, the increase of composting efficiency is still the main issue to be developed and researched 36 . The efficiency of composting refers to a shorter production time and better compost quality. Both are the current motives of fulfilling large feedstock of the palm oil mill waste. Fig. 1 shows that the number of researches conducted on waste composting and palm oil waste independently have increased through the years but specific research on palm oil waste composting is rather scarce. Palm Oil Mill Waste Understanding the quantity and quality of waste is the first step in designing a manageable composting process. The EFB and POME are by-products from palm oil extraction. The extraction method has not changed from the past, only the equipment used has become more sophisticated and particularly different from one factory to another. The extraction process is performed within few hours after harvesting of oil palm fruit bunches. Fig.2 shows a simplified diagram of palm oil extraction steps and its by- products. Firstly, the fresh fruit bunches undergo sterilization. The fruit bunches are steamed under high pressure to sterilize, loosen and soften the fruits from the bunch stalks. The fruits are stripped from the bunch stalks in a large rotating cage. Then, the fruits are digested and pressed to obtain crude palm oil. One ton of fresh fruit bunches usually produce about 0.45-0.50 ton of crude palm oil 13 . The solid waste including the empty fruit bunches (EFB) and mesocarp fibres are conveyed for shredding. Around 0.23-0.25 ton of EFB per ton of fresh fruit bunch is produced 24 . Approximately 0.65 ton of POME per ton of fresh fruit bunches is generated from various process points such as clarification sludge, sterilization condensates, fruit washing water, hydro cyclone drain- off, various tank and decanters drain 13 . The pros are no chemical or solvents are needed in the extraction of palm oil making its by- products safe from undesired matters. Journal of Food, Agriculture & Environment, Vol.9 (3&4), July-October 2011 881 Empty Fruit Bunches (EFB) The empty fruit bunches (EFB) is the main solid waste from palm oil extraction. Together with other solid waste such as the mesocarp fibres (from pressed fruits) and kernel shells (from fruit kernels), they are usually used as boiler fuels for the steam turbines to produce steam for sterilization of fruit and for generation of electricity. The EFB, as a lignocellulosic rich crop residue is suitable for many kinds of applications. EFB can be converted to bio-plastic, pulp, source of enzymes, hydrogen and animal feed 22 . Sumathi et al. 22 reported that the EFB were re-used in the industry to produce bio-oil, biodiesel, chemical compounds, and microorganisms. However, the demand of EFB re-use by these industrial processes is still limited. Nevertheless, these processes will again create another type of waste and introduce release of greenhouse gas during the transportation of the biomass. Composting, being not the only choice, however, offers the advantage of zero waste as the EFB can be used as a nutrient source for the nearby plantation soils. EFB is a preferred source as composting materials. EFB has high porosity, water holding capacity and consequently high nutrient holding capacity; these characteristics are suitable features for aerobic microbial composting. Tables 1 and 2 list the properties of EFB and POME from most recent researches. Although the element values of EFB may vary slightly among researchers reports due to its dependence on the plant growth condition and factory handling procedure, they remain to be in appropriate ranges. The researchers and practitioners, therefore, should anticipate some difference in the quality of composting feedstock when obtained from different sources. Palm Oil Mill Effluent (POME) Palm oil mill effluent (POME) is the colloidal slurry of water, oil and suspended solids that comprised mainly cellulose from the fruits. The amount of POME estimated is three times more than the production amount of crude palm oil. POME has a high content of organic matter with levels of biological oxygen demand (BOD) from 2,500 to 35,000 mg/l and chemical oxygen demand (COD) between 1,460 and 38,840 mg/l on average 13, 37 . Due to its hygienic instability and immaturity of organic matter, fresh POME should not be introduced directly into the soil environment. If POME is applied to agricultural soil, it will soon cause nitrogen and oxygen deficiency in the soil and turn out to be phytotoxic to plants. Most palm oil mills in Malaysia have adapted the ponding system for the treatment of their POME effluents. POME is biologically treated using the effluent ponds before being discharged into watercourses. Such ponding system consists of a number of ponds for anaerobic, aerobic and facultative digestion of POME. This system is capable of producing a final discharge with a BOD of less than 100 mg/l 13 . This treatment process, however, could be effective and acceptable for countries or states
POME Crude Palm Oil Fresh Fruit Bunches Sterilization Extraction Digestion POME Solid Waste (EFB) Figure 2. A simple diagram simulating the by-production of EFB and POME in a palm oil extraction process. Year R e c o r d
c o u n t
( n u m b e r o f
a r t i c l e s )
(a) R e c o r d
c o u n t
( n u m b e r o f
a r t i c l e s )
R e c o r d
c o u n t
( n u m b e r o f
a r t i c l e s )
Year Year Figure 1. The number of research articles increases from recent years searched through ISI web of knowledge by Thomson Reuters (a) on waste composting (b) on palm oil waste, and (c) palm oil waste composting. (b) (a) (c) Element (% wt/wt) Source 1 2 3 4 Cellulose 38.3 59.7 52.56.5 Hemicellulose 35.3 22.1 28.81.1 Lignin 22.1 18.1 17.13.6 Carbon 49.07 46.64 53.01.5 Hydrogen 6.48 5.66 Nitrogen 0.7 1.73 0.90.1 Sulphur <0.10 0.10 1.10.3 Oxygen 38.29 39.46 Moisture 7.95 245.8 Volatiles 87.3 73.7 Ash 1.6 3.02 6.6 Table 1. Key properties of EFB (readings taken from literature). Note:1 Yong et al. 42 , 2 Abdullah and Gerhauser 2 , 3 Luangkiattikhun et al. 17 , 4 Baharuddin et al. 3
Source Element 1 2 3 4 Moisture (% w/w) 95 94 95 93 Total solid (% w/w) 4 5.2 3.2-6.2 7.8 Oil (mg/l) 104050 4000-6000 20-34 pH 4.0 7.5 4.7 BOD (mg/l) 2500-35000 25000 1000-2600 COD (mg/l) 1460-38840 50000 26000-37000 Nitrogen (% w/w) 1.03 2.3 1.9 Carbon (% w/w) 19.0 46.37 Note: 1 Igwe and Onyegbado 13 , 2 Sumathi et al. 26 , 3 Baharuddin et al. 3 , 4 Yeoh et al. 41 . Table 2. Key properties of POME (readings taken from the literature). 882 Journal of Food, Agriculture & Environment, Vol.9 (3&4), July-October 2011 which have great system to treat their watercourses and provisions of pipe water to the citizens. For people who rely on river water, this effluent discards from the POME ponding system will not only lead to watercourse pollution but risk their citizens health. The handling of POME in treatment ponds needs careful attention. Fresh POME is very rich in nitrogen and in the early stage of treatment, the nitrogen in POME in the anaerobic pond will be rapidly mineralized into proteins. This leads to the production of ammonia and methane at which, if without a proper gas collection system, the emission of methane gas will cause global warming and the ammonia gas (NH 3 ) will give odor problem. Loss of nitrogen diminishes POMEs value as a fertilizer. As such, fresh POME is recommended and often suggested for use in developing new bio-products. Through biotechnological advances, fresh POME can be reused as a fermentation substrate in the production of various metabolites, fertilizers and animal feeds 13 . The sourcing and adoption of sustainable organic inputs and resources are essential in establishing a composting project in the oil palm industry. The fresh POME produced simultaneously with the EFB can be mixed together and further degraded into compost. Thambirajah et al. 30 have added animal manure to palm press fibres to produce a good quality compost. Although, animal manure can be a better source of nutrients and microorganisms, the manure resource could not be enough for the large amounts of EFB produced each year. Likewise, transporting either EFB or manure causes the emission of greenhouse gases. Thus, POME becomes the easier moisture and nutrient source for sustainable EFB composting. Windrow Composting System for Palm Oil Mill Waste The windrow composting is the simplest way of composting system, i.e. by piling the materials placed in a long row and then aerating regularly. The windrowing site consists of not only the large plot of compost row; there is a large concrete floor to facilitate maintenance, movement of equipment, and to control leaching 4 . The area where composting takes place is commonly referred as the compost pad. The size of the pad depends on the volume of material and the windrow shape. The dimensions of windrow are determined by the type of equipment used for ventilation. Open site windrows composting is adopted in regions where relatively milder climates prevail. The windrow enclosed with plastic film is satisfactory in the absence of unusual circumstances such as storm, snow, hot and dry weather. In Indonesia and Malaysia (main palm oil producers), the compost plant design has to consider the prevention of tropical rain and extreme hot sun. The windrow compost has to be protected under roof, cement floor and wall. Enclosed system is more effective for control purposes 33 . An example of windrow semi-open composting plant is presented in Fig. 3. Window aeration is performed by mechanical turning or static air injection. Using a turner or mixer has more advantages than using static air injection as it allows separation of EFB lumps and the windrow is homogenized. Warm air rises in the pile and cold air slots in through the turning process. With a porous structure allowing air passing through freely in the EFB, piping for aeration is not necessary 25 . The turning mechanism also advances in maintaining a porous structure in windrow for the replenishment of oxygen used by the microbes compared to static air blow. Apart from the constructed windrow site and its mechanical aerator, the overall compost production needs some other machinery support. The EFB or substrate for composting needs a shredding and sorting machine. Reducing the substrate size to 2-3 cm could help to optimize the decomposition rate 32, 41 . Tractor is used to collect the shredded EFB and to form EFB windrow. The spraying of POME onto EFB row needs a piping system. In the review of a composting process, a complete process usually undergoes three stages: the mesophilic, thermophilic and curing stages. During the mesophilic stage, the temperature of EFB row rises gradually. Upon reaching above 45 o C, it will maintain for a period of time and this is considered the thermophilic phase 8 . Turning is scheduled to release the heat and to provide air in the EFB row. The compost will then cool down to its curing stage, whereby turning or addition of POME is stopped 3 . The compost is stored until mechanical screening and drying. After screening, the compost is ready for application on plantation soil or packed for sales. Any compost which did not pass through the screener will be returned to the windrow for further decomposition. Fig. 4 shows a simple diagram of EFB windrow composting procedure. The manufacturers who adopt composting instead of other waste management alternatives must understand that this technique also has some significant drawbacks. When utilizing composting strategies involving minimum technology, the production time for making finished compost can be extensive thus requiring large tracts of secluded land. Furthermore, the feedstock characteristics, processing equipment and the overall throughput are all directly correlated to the amount of land required, initial capital outlay, product quality and continual operational costs. Lack of advanced understanding on the requirements can lead to throughput restrictions, process bottlenecks, cash flow problems and pollution. To overcome unexpected results of the EFB composting process, researchers have studied various methods to improve it 3, 20, 21, 30, 40 . Baharuddin et al. 3 investigated the quality of co- composting of EFB with partially treated POME on a pilot scale. Vermicomposting of EFB was evaluated by Sabrina et al. 20 . Static aerated reactor was used by Yaser et al. 40 to compost palm oil mill sludge with sawdust. Salates et al. 21 added ripe compost to the
Figure 3. Semi-open windrow composting system (taken during trial 1, July 2008, Sedenak Composting Plant, Malaysia). Journal of Food, Agriculture & Environment, Vol.9 (3&4), July-October 2011 883 mass of EFB and found that it gave a significant effect on the degradation speed. These researches, however, did not show that composting of EFB could be shorten to below 60 days. Further researches were conducted by trying different methods or treatments to achieve a shorter composting period. In other type of waste composting, usage of additives has been a popular method to achieve fast composting. Wei et al. 36 reported that compost or biofertilizer could be produced with the inoculation of appropriate functional microbes which increase the decomposition rate, shorten the maturity period and improve the compost (or biofertilizer) quality. Xi et al. 38 found that the degradation rate of municipal solid waste was highest at 15.671 g/ kg.h after seeding with a mixture inoculum of A (Bacillus spp.) and B (cellulolytic strains, i.e. Trichoderma, Streptomyces and white-rot fungi). The efficiency of microbe inoculums on EFB composting therefore is a worthy subject to be explored. Besides on biological aspect, a more expensive investment for a speeded up composting process in terms of development on mechanical system can also be viable. For example, industrial in- vessel composting systems or plants can be constructed for composting the palm oil mill wastes. In-vessel composting is popularly used for food waste composting 1, 5, 15 . Role of Microorganisms in Composting Composting is an extraordinarily complex process which involves microbiological degradation, mass and energy transfer phenomena and coexistence of non-steady state conditions. Among the many parameters developed to measure the efficiency of composting processes are based on the survival of key degradation agents, the microorganisms. Considering that composting is an aerobic process, the amount of oxygen which is required by microorganism to stabilize the organic wastes must be kept at its optimum level. Other factors for microorganism survival are sufficient nutrient, space, water and air. These basic requirements have inspired researchers to create measurable parameters, for instance, water content, oxygen content, carbon and nitrogen ratio, other nutrient element contents, particle size of substrate, size of windrow, temperature, pH, electrical conductivity, humification ratio, etc. In co-composting, the key decomposers are the various types of microorganisms and insects. They are capable of converting material to a more digested, fine and ready nutrient to be absorbed by the root of plants. The primary decomposers first consume the easily decomposable substances and induce a rise of temperature. Then, the thermophilic decomposers propagate and use up the primary decomposers left over nutrient. After the thermophilic stage, the mesophilic decomposers will take over and give signs of decreasing temperature. The composting stops once the compost temperature reaches the ambient temperature. The organic matter is completely mineralized. The final products obtained including carbon dioxide, water, minerals and stabilized organic matter are beneficial to plant growth and other organisms. The organic substrates may also attract compost worms, mites, millipedes and other fauna to develop and act as catalysts. The EFB vermi-composting is an example of such approach 20 . In short, understanding factors that affect composting is essential in evaluating the performance of an overall composting process. The survival factors of key degradation agents are to be considered in the selection of a suitable composting process design. Ignorance or failure to select the right system satisfying the composting needs often lead to a sophisticated and unsatisfied process. The available composting researches are proves of good and well predicted progress in composting if conditions are known and the design factors of the system are not exceeded 14 . Functional Microorganisms as Inoculums for EFB Composting To date, the time required for EFB composting is simply too long and it is unable to satisfy the daily waste produced by the palm oil mill. Previous researchers have conducted different methods of EFB composting 21, 23, 29 , and these processes took at least two months. They also require large compost pad, high labour energy, high material handling and equipment cost. In shortening the time of composting, compost substrates could be added with some supplements to enhance the decomposition process. A shorter production time could minimize the space requirement in a mill, and make easy and efficient system to comply the daily input of palm oil mill wastes. The use of additive to speed up the composting process or to improve compost quality has been a controversial subject in this research field. At times, addition of improper chemical component may bring side effect to the biodegradability of compost. Yadav 39
reported that supplements with molasses had lead to a better protein gain but not a better biodegradation. Decomposers may referentially utilize the supplemental ingredient instead of the organic component in substrate causing low decomposition of organic component in substrate and increase the degradation of supplemental ingredient. However, some microorganisms have been discovered as useful cultures in composting process as they act as biocatalysts in the composting process in biological waste treatments. Through microbial metabolic, the pollutants waste is transformed into environmental friendly products. The microorganisms showed good performance when used as a starter culture in shortening the length of composting period 6, 11, 18, 27, 38 . Tiquia et al. 31 reports that compost or biofertilizer could be produced with the inoculation of appropriate microbes which increased the decomposition rate and shortened the maturity period. For example, the Bacillus sp. isolate improved the rate of composting through the decrease of Figure 4. A diagram simulating compost production. Mesophilic phase: temperatue of compost stable as the ambient Shredding and remove large sized EFB Compost packaging Window composting, record temperature Thermophilic phase: turn and add POME Unsatisfied compost Screening and drying 884 Journal of Food, Agriculture & Environment, Vol.9 (3&4), July-October 2011 the concentration of polymer cellulose, hemicellulose and lignin 35 . The produced composts increased the yields of tomato 16 . The form of inoculum could be a pure isolate or a mixed variety of microbes. In composting, the use of microbial consortia or mixed cultures is more effective compared to a pure culture 23 . As the microbial population evolves in response to changes of phases, nutrient source and environmental conditions during composting and other microorganisms may continually enter through air, and by human contact to the compost, a mixed inoculum is preferable for microbes survival in the different phases and in providing different degradation activities during the entire composting process. Specifically for the EFB and POME substrates, microorganisms that have the ability to degrade fat, lignin, cellulose and hemicelluloses are given priority in the inoculums cocktailing. The cocktail should be formulated to contain a wide range of organisms including bacteria, actinomycetes, fungi and yeasts. The co-composting process is expected to use natural organism and as such the microorganisms used are derived and isolated from different agricultural composts from a diverse natural community 16 . The selected microbes must able to live easily in soil and cellulolytic materials. Some of the common species which are discussed in the following text belong to genera of Agromonas, Aspergillus, Azotobacter, Bacillus, Cellulomonas, Chaetomium, Clostridium, Coprinus, Microbispora, Penicillium, Pseudomonas, Thermoactinomyces, Trichoderma and Trichurus. Complex organic compounds of EFB like lignin are mainly degraded by thermophilic microfungi and actinomycetes. The Thermomonaspora, Thermoactinonmyces 34 , Trichurus 11 and Chaetomium 27 are indicated as thermophilic cellulolytic degradation agents. Those thermophilic fungi have an optimum functioning temperature of around 40-50C, which is also the optimum temperature for lignin degradation in compost 34 . Some other microbes having cellulase and protease activities are Aspergillus, Cellulomonas 19 , Coprinus, Microbispora, Pseudomonas 34 , Penicillium and Trichoderma 10 . Inoculation of these facultative bacteria and fungus may shorten the composting time, improve the compost quality and inhibit the growth of some plant pathogens. Another factor of choosing inoculum for co-composting is the ability of microbes to reduce nitrogen loss. Nitrification can be regarded as the gatekeeper of nitrogen turnover during composting. During the first weeks of decomposition, readily available organic nitrogen is normally mineralized by microbial activity and released as ammonia. The mineralization rate become slower as the more labile organic nitrogen disappears. In contrast, nitrification performed by the microbes could reduce the likelihood of NH 3 emissions and control the subsequent rate of mineralized nitrogen. Therefore, Argomonas, Azotobacter 23 , and Clostridium 28 have been selected to be nitrogen-fixer in composting. Having an active stock culture for performing composting experiments is essential. Simple stock culture methods can be used to grow selected microorganisms. The most often used technique is inoculating a nutrient agar medium and allowing the microorganisms grow at the optimum growth temperature for one to two days. Common bacteria and fungi growth mediums can be purchased each time needed. There are selective mediums that References 1 Abdullah, N. and Chin, N. L. 2010. Simplex-centroid mixture formulation for optimised composting of kitchen waste. Bioresour. Technol. 101: 8205-8210. 2 Abdullah, N. and Gerhauser, H. 2008. Bio-oil derived from empty fruit can be used to isolate and culture specific microorganisms. For preservation, the microbe culture is usually placed in a refrigerator (4 o C) for a month storage. For longer-term storage, cultures can be frozen or freeze-dried. Microbes Assessment for Windrow Composting The microbes present in compost are tremendous diverse and their ecologies are extremely complex. The isolation of the microorganism species and communities cannot be fully accomplished through the simple isolation methods 12 . To investigate the microbial community succession in compost, methods that have been used include the selective plate-count methods. Total bacteria are enumerated on nutrient agar after 2 days incubation while the cellulolytic bacteria are enumerated on a medium containing cellulite 43 . The mesophilic microorganisms are treated at 30 o C while the thermophilics are treated at 55 o C. Generally, the thermophilic microorganisms will increase during the thermophilic stage and then decline to their initial values. The mesophilic microorganisms will be present during the entire process and at the mesophilic stage, their population will be significantly elevated. The cellulolytic microorganisms demonstrated a high count at the end of the thermophilic phase 7 . At this juncture, it is worth noticing that an unstable material which contains a high proportion of biodegradable matter may sustain high microbial count. At a more advanced level, Franke-Whittle et al. 9 has recommended some bacteria gene probes through specifying individual microorganism species involved in composting where they developed 369 different 16S rRNA bacteria gene probes using a microarray. Conclusions The composting process may not be as simple and easy as one thinks whether it is at small or large scale to address the management of waste produced. For example, the palm oil extraction factories have set up large-scale composting facilities and only to find that the composting activities and products are delayed because of various issues. The design of the composting facilities and control of the composting factors are their main challenges. 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