JOINT RESEARCH & DEVELOPMENT BETWEEN

UNIVERSITI PUTRA MALAYSIA

FELDA PALM INDUSTRIES SDN. BHD.
KYUSHU INSTITUTE OF TECHNOLOGY

BIOMETHANE PRODUCTION FROM PALM OIL MILL EFFLUENT (POME) IN

A SEMI-COMMERCIAL CLOSED ANAEROBIC DIGESTER
Presenters: Alawi Sulaiman, Zainuri Busu, Shahrakbah Yacob
Environmental Biotechnology Group, Department of Bioprocess Technology
Faculty of Biotechnology and Biomolecular Sciences
Universiti Putra Malaysia (UPM)
Japan Society on Promotion of Science (JSPS)
Seminar on Sustainable Palm Biomass Initiatives
29th November 2007

Project Leaders
Professor Dr. Mohd Ali Hassan
Faculty of Biotechnology& Biomolecular
Sciences
Universiti Putra Malaysia
43400 UPM Serdang, Selangor, Malaysia
Tel: +603 89467591
alihas@bioteach.upm.edu.my
www.biotech.upm.edu.my

Professor Dr. Yoshihito Shirai

Graduate School of Life Science &
Systems Engineering
Kyushu Institute of Technology
2-4, Hibikino, Wakamtsu-ku,
Kitakyushu,808-0196 Japan
Tel: +8193 6956070
shirai@life.kyutech.ac.jp

Mr. Zainuri B. Busu

FELDA Palm Industries Sdn. Bhd.
4th Floor, Balai FELDA,
Jalan Gurney Satu
54000 Kuala Lumpur
Malaysia
Tel: +603 26916980
zainuri.b@felda.net.my

Preamble
Biomass existing in nature represents a storehouse of solar energy and is
continuously reprocessed in a biological cycle (renewable).
The majority of biological decomposition processes in nature takes place
involving the consumption of oxygen and, at the same time, the production
of CO2.
A smaller proportion undergoes anaerobic conversion which gives rise to
biogas containing a high percentage of methane representing a
significant energy source.
Without human interruption the
release of methane could be
easily absorbed by the eco-system
BUT with industrialization and
human activities, the emission of
methane has increased which
partly contributed to the global
warming phenomena

Global Methane Budget (TG Methane/Yr) (Ehhalt and Prather, 2001)

Natural
release
36%

Anthropogenic
sources
64%

Energy Requirement
Global scenario :
Rising of oil price
Depletion of reserves
Political uncertainties oil producers

Depletion of fossil fuels reserves

Energy Balance Report 2003

Malaysia scenario :
Growing demand - developed nation
by 2020
Limited fossil fuel reserves
Net oil importer soon

Rising of crude oil price

The climate change

The greenhouse effect and global warming are

two major factors contributed to the catastrophic
implications of the global climate change.

Uncontrolled industrialization/human activities has

increased the GHG content which increase in heat
trapped in the atmosphere (1.4-5.8oC in the 21st
century), resulted in increase of the sea level and
changing weather pattern and water supplies and
eventually affect the WORLD FOOD Supply and
natural ecosystem

Kyoto Protocol (1997) - objective is to achieve

sustainable development via quantification of
emission limitation and reduction of GHG

Clean Development Mechanism (CDM)

reduction of GHG emission by facilitating cooperative projects between developing
countries and developed countries with the
opportunity for additional financial and
technological investments in GHG reduction
projects.
http://en.wikipedia.org/wiki/Global_warming_potential

Greenhouse Gases under Kyoto Protocol

For example, the GWP for methane is 21 means that

emissions of 1 million metric tonnes of methane is
equivalent to emissions of 21 million metric tonnes of
carbon dioxide.

The GWP is defined as the ratio of the

time-integrated radioactive forcing from
the instantaneous release of 1 kg of a trace
substance relative to that of 1 kg of a reference gas
(IPCC, l990):

Methane
Methane
GWP: 21
GWP: 21
Carbon
Carbon
dioxide
dioxide
GWP: 1
GWP: 1

Nitrous
Nitrous
oxide
oxide
GWP: 310
GWP: 310

http://en.wikipedia.org/wiki/Global_warming_potential
GHGs
GWP
Sulphur
Sulphur
hexafluoride
hexafluoride
GWP: 23,900
GWP: 23,900

Perfluorocarbons
Perfluorocarbons
GWP: 9,200
GWP: 9,200

Hydrofluorocarbon
Hydrofluorocarbon
s
s
GWP: 11,700
GWP: 11,700

Biomass resources: Agricultural residues

Most abundant in Malaysia - (> 70 million tones annually)
Main contributor of biomass
palm oil industry
EFB (solid)
POME (liquid)
Fiber (solid)
Shells (solid)

1% 1%

4%

Mainly ligno-cellulosic materials

Structure:

94%

Palm Oil

Rice

Sugarcane

Wood Industry

Biomass output from the palm oil mill

Shell
(19,200 t/yr)
Fiber
(38,400 t/yr)
60 t/hr Mill
Fresh
Fruit
Bunch

EFB
(70,400 t/yr)
POME
(160,000 m3/yr)
Treated &
discharged
Maintenance Cost
RM 40,000/yr

From estimation of 28m3 * 0.65 / m3 POME

For 47 million m3 POME would produce
855 million m3 of CH4.

47% shell
100% fiber

Incineration
60% EFB

Excess shell
(12,288 t/yr)
Steam generation
(192,000 t/yr) to generate
1.3 MW power
Soil mulching
/Disposal 40% EFB

POME Sources and characteristics

POME
sources

80000

C O D F e e d (m g L -1 )

70000

60000

50000

40000

30000
1

10

19

28

37

46

55

64

73

82

91

Operation days
Sludge recycling period COD Feed
Non sludge recycling period COD Feed
Start-up period COD Feed
Common
COD Strength
fluctuations
for 100 days
of study

Palm Oil Industry - POME

Algae ponds

POME treatment facility

anaerobic, facultative and aerobic
Open tanks system
Discharge limit 100 mg/L
> 70% of total mill area i.e 20 hectares for 60t/hr mill

Facultative ponds
Open digester system

Open tanks system

Biogas emission - 28m3/m3
POME,with 65% methane
content
Untapped renewable energy

Closed digester system

Biogas
Polishing
stage

Biogas
Engine

Mill usage OR
grid
connection

Research Project Motivation

Better management of palm oil mill effluent
(POME)

Sustainable palm oil industry

Replacement for open lagoon system

(improvement)
Reduction of land use for treatment
Prevention of bad odor emission (H2S gas)
Reduction of greenhouse gas emission (i.e CH4)
Recovery of methane gas for renewable energy
Carbon credit through Certified Emission
Reduction (CER) for CDM programs
Technology transfer for closed anaerobic
digester

Technology
transfer

The biogas plant location

Distribution of palm oil plantations in Malaysia.

Plantation areas are shown in red
Source: MPOB homepage on
www.mpob.gov.my

Malaysia

The biochemistry
Anaerobic
Anaerobic digestion
digestion is
is a
a biological
biological process
process that
that produces
produces a
a gas
gas principally
principally composed
composed of
of methane
methane
(CH
(CH44)) and
and carbon
carbon dioxide
dioxide (CO
(CO22..
Anaerobic
Anaerobic processes
processes could
could either
either occur
occur naturally
naturally or
or in
in a
a controlled
controlled environment
environment such
such as
as a
a biogas
biogas
plant.
plant. Organic
Organic waste
waste such
such as
as livestock
livestock manure
manure and
and various
various types
types of
of bacteria
bacteria are
are put
put in
in a
a digester
digester so
so
the
process
could
occur.
Depending
on
the
waste
feedstock
and
the
system
design,
biogas
is
the process could occur. Depending on the waste feedstock and the system design, biogas is
typically
typically 55
55 to
to 75
75 percent
percent pure
pure methane.
methane.
Hydrolysis: complex organic matter is decomposed into
simple soluble organic molecules using water to split the
chemical bonds between the substances.

Acidogenesis: the chemical decomposition

of carbohydrates by enzymes, bacteria, yeasts, or molds
in the absence of oxygen.
Acetogenesis: the fermentation products are converted
into acetate, hydrogen and carbon dioxide by so-called
acetogenic bacteria.

Methanogenesis: methane (CH4) is formed from acetate

and hydrogen/carbon dioxide by methanogenic bacteria...

Process Flow Scheme

Process flow diagram of the semi-commercial 500m3 single stage closed anaerobic digester;
1-Fresh Raw POME from the mill; 2-Centrifugal pump; 3-Sampling ports; 4-Gas collection chamber;
5-Biogas safety relief system; 6-Settling tank; 7- Sludge recycling pump; 8- pH probe;
9- Temperature probe; 10- pH probe for scrubbing liquid (NaOH Solution).
5

Recycling line to
holding tank

Gas
Scrubber
System

Palm Oil Mill

Effluent (POME)
Holding Tank
3

500 m3
Closed Anaerobic
Digester

10

7
1

Purified
Methane
To storage

Treated
Effluent

Process Flow Scheme

HOLDING TANK
Continuous feeding

GAS SCRUBBER
Biogas polishing

Sludge recycle
DIGESTER
Methane fermentation

SETTLING TANK
Sludge separation

GAS UTILIZATION

GAS STORAGE
Methane storage

Performance Comparison
Parameters

Open digester
system

Closed anaerobic
digester

81%

97%

20

10

Methane utilization

Released to
atmosphere

Recoverable

Methane yield
(kgCH4/kgCODrem
oved)

0.11

0.20 (target)

Methane content
(%)

36

55

Biogas production
(m3/tone POME)

28

20

Solid discharge
(g/L)

20

COD removal
efficiency (%)
HRT (days)

Biogas flare (night and day)

Start-up of the digester

The V Feed was increased from

10m3/d, 20m3/d, 30m3/d, 40m3/d
and 50m3/d.

8.00
7.00

50

6.00
HRT, V Feed

The start-up was completed

within a month after
acclimatization phase.

60

40

5.00

30

4.00
3.00

20

2.00
10

The HRT was reduced from 50 days

down to 10 days.

1.00

0.00
1

The OLR was automatically increased

from 1.0 kgCOD/m3/day to
6.0 kgCOD/m3/day.

13

17

21

25

29

33

Operation days
HRT (days)

V Feed

OLR

The relationship between HRT, V.Feed and

organic loading rate (OLR) during start-up operation.

O rg a n ic lo a d in g ra t e (O L R )

Seeding used sludge from the

Similar waste (open digester)
and diluted to 5% TS.

The digester performance

during the start-up period
High COD Feed fluctuation, yet
the system still stable

70000
10.00

60000
50000

1.00

40000
1

13

17

21

25

29

33

0.10

20000
10000

Operation days

VFA increased with OLR

but the VFA/Alkalinity ratio
was within the optimum
range (0.1-0.3)

30000

C O D F ee d

COD Rem. Eff. = COD Feed COD Treated X 100%

COD Feed

80000
COD measures the organic strength of the raw POME

C O D R em E ff , V F A :A lk

High COD removal efficiency

of higher than 90%

100.00

0.01

0
VFA:Alk

COD Rem. Eff. (%)

COD Feed

The COD Rem. Eff. (%), VFA to alkalinity ratio and

COD Feed fluctuation during the start-up period.

The effect of increasing

organic loading rate
OLR was increased by increasing
the V Feed to the digester; thus
HRT was reduced
HRT=500m3
VFeedm3/day

VFA/Alkalinity increased but still

within acceptable limit (0.1-0.3)
Methane yield reduced from 0.17
to 0.10 kg CH4/kgCOD removed

VFA
maintained

1000

Steady increased

0.35
0.30

100
0.25
0.20
10
0.15
0.10

1
1

10

19

28

37

0.1

46

0.05
0.00

Operation days

OLR

V.Feed

VFA

COD

Methane Yield

The effect of increasing OLR on VFA, COD removal

efficiency and methane yield.

M e th a n e y i e l d

Alkalinity reduced as more

alkaline needed in order to
maintain neutral pH condition
(pH 6.8-7.2)

0.40
O L R , V .F e e d , V F A , C O D R e m . E f f

VFA increased
(steadily after OLR 1.5) but still
below 1000 mg/L (critical limit)

0.45

10000

The effect of sludge recycling

on the digester performance
Comparison of the digester performance
The effects of sludge recycling
parameters for the sludge recycling and non
are clear:
recycling modes
The operating OLR was higher
Mean SD
Mean SD
Mean SD
Organic
COD Rem.Eff. (%)
Methane yield
VFA (mgL )
(6.0 kgCOD/m3/day) than
loading
(kgCH kgCODremoved
without case (4.0 kgCOD/m3/day) rate
-1

The VFA accumulation was

restricted to below 500 mg/L as
compared to 1300 mg/L at OLR of
only 4.0 kgCOD/m3/day
COD removal efficiency was
higher even at higher OLR

-1)

(OLR)

Sludge
recycling

Non-sludge
recycling

Sludge
recycling

Non-sludge
recycling

Sludge
recycling

Non-sludge
recycling

1.0

23822

961.0

0.170.02

1.5

24320

961.7

0.140.14

2.0

284122

41277

971.6

940.9

0.160.15

2.5

26832

46742

960.7

950.2

3.0

29367

709138

952.1

941.0

3.5

25576

98794

960.8

911.9

4.0

22489

1300262

943.5

911.2

962.8

951.6

941.2

962.0

0.170.0
4
0.170.0
1
0.140.0
1
0.150.0
1
0.140.0
1
0.140.0
1
0.130.0
1
0.120.0
1
0.100.0
1

Methane yield was higher

5.0
33685
i.e at OLR 4.0 kgCOD/m3/day
43283
yield was 0.14 kgCH4/kgCODremoved5.5
6.0
500109
as compared to
SD-Standard deviation
0.07 kgCH4/kgCOD removed
4.5

34388

0.120.12
0.120.12
0.100.09
0.070.07
-

Conclusion
The pilot plant design was appropriate for treatment and biomethanation of POME
The biomethanation of POME in a semi-commercial scale was successfully demonstrated.
The biogas plant was start-up and operated within a month after acclimatization period.
Despite high fluctuation of COD the plant was still able to be operated due to its simple
and effective design for POME.
The biogas plant was started-up without sludge recycling and received its peak load at 50
m3/day indicating suitable seeding from the existing open digester tank.
The sludge recycling mode was found to be an effective technique to enhance methane
yield.
Moreover, the technique also ensured higher OLR (up to 6.0 kgCOD/m3/day) to be
operated while restricting VFA accumulation (only to 500 mgL-1) within the system.
The methane yield was improved to 0.14 kgCH4/kgCODremoved
at OLR of 4.0 kgCOD/m3/day while maintaining good COD removal efficiency at higher
than 90%

Special acknowledgements
1. Environmental Biotechnology Group Universiti Putra Malaysia
(Technical and research-MSc. And PhD)
2. Kyushu Institute of Technology (KIT) Japan and
Japan Society for Promotion of Science (JSPS)
(Technical and funding)
3. FELDA Palm Industries (M) Sdn. Bhd.
(Site and engineering works)
4. Universiti Teknologi MARA (UiTM) (PhD scholarship)