1

SAPI PLANTATIONS SDN BHD

TERUSAN PALM OIL MILL




















PROPOSAL OF BIOGAS PLANT PROJECT
DATE OF PREPARED: 28
TH
JUNE 2012

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TABLE OF CONTENTS
NO PAGE
1.0 INTRODUCTION. 4
1.1 PPB OIL PALM BERHAD Environment Policy. 5
1.2 Acknowledgement Letter 6

2.0 BIOGAS PLANT PROJECT7
2.1 Project Concept... 7
2.2 Background of Concept.. 7
2.3 Location of Terusan Palm Oil Mill in East Coast,
Sabah.......8
2.4 Location of Biogas Plant in Terusan Palm Oil
Mill........9

3.0 FLOW CHART OF NEW PROPOSED WASTEWATER
TREATMENT PLANT...10
3.1 Description of New Proposed Wastewater Treatment
Plant Flow..11

4.0 NEW PROPOSED BIOGAS PLANT FLOW DIAGRAM..12
4.1 Description of New Proposed Biogas Plant Diagram.................................13

5.0 METHODICAL TABULATION ...........16
5.1 Computation Biochemical Oxygen Demand for
Effluent Treatment Plant and New Proposed
Biogas Plant ....16
5.2 Calculation of BOD for New Proposed Biogas Plant .17
5.3 Calculation of BOD for Aerobic Ponds....................................18
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5.4 Calculation of BOD for Aerobic Ponds......... .19
5.5 Calculation of BOD for Polishing Pond.. .20

6.0 CONCLUSION.21

7.0 GLOSSARY OF TERMS....22

8.0 APPENDIX A
8.1 Rainfall Chart.... 23
8.2 Result of BOD for 2008 and 2009 ....................................24
8.3 Biogas Plant Layout Plant ...25
8.4 Arrangement of Biogas Plant System .................................26















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1.0 INTRODUCTION

As the Terusan Palm Oil Mill (60 mt/hrs) has started with combination of effluent treatment
ponding system and land irrigation from May 2009, the final effluent is considerable very well treated and
almost achieved the zero discharge to water course. The palm oil mill effluent (POME) is no longer
considered as a source of pollution of river and nowadays every single drops of POME was transferred
into field for improving the soil condition and subsequently, reducing the tonnage of non-organic fertilizer
application which is nightmare for every plantation company.
For further preserving the environment climate and eliminate any potential adverse global
warming impact on our planet, the management of Terusan Palm Oil Mill (PPB Oil Palms Berhad) has
decided to develop of Terusan Methane Recovery in Wastewater Treatment and Utilization for electricity
project at Terusan Palm Oil Mill. This project will register as part of the Clean Development Mechanisms
(CDM) under the United Nations Framework Convection on Climate Change (UNFCCC). The proposed
Palm Oil Mill Methane Recovery and Power Generation will apply innovation environment technology to
improve waste management at the mill and reduce the emission of methane to the atmosphere. This
project also contributes to Malaysias sustainable development policy on efficient waste management in
the palm oil industry and help to reduce the green house gas emissions (GHGs). To implement this
project, we do had surveyed every single corner of our area where is best suit to the project
implementation. The details will present on the following this proposal.








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1.1 PPB OIL PALMS BERHAD ENVIRONMENTAL POLICY:


ENVIRONMENTAL POLICY

PPB Oil Palms Berhad has assle, to minimize the environmental impacts of all our activities and we shall
achieve this through:-

Compliance with all relevant environmental laws and their requirements;

Developing oil palm plantations only on degraded and logged over land. Oil palm development
on pristine unlogged forest is totally prohibited;

Adherence by all concerned to the Good Agricultural and Manufacturing Code of Practices
which are based on principles of sustainability and these are documented in the Agricultural
and Milling Manuals;

Preserving unplantable areas (where applicable) as highly protected conservation areas to
enhance biodiversity in the plantation environment;

Employees (directly or indirectly employed) taking all reasonable measures to co-operate with
management and complying with the relevant laws, instructions and/ or measures instituted
concerning the environment;

Making all relevant information and instructions on minimizing environmental impacts in all
related agricultural and milling operations available to all concerned;

Regularly educating and updating all concerned on issues related to the environment and
adopting a concept of continuous improvement in minimizing their impact through all practical
means.

By Order of the Board of Directors
of PPB OIL PALMS BERHAD
Environmental Policy (16-5-06)
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5.0 METHODICAL TABULATION
5.1 COMPUTATION OF BIOCHEMICAL OXYGEN DEMAND ( BOD ) FOR EFFLUENT
TREATMENT PLANT AND NEW PROPOSED BIOGAS PLANT:
( I ) Based on assumption of POME,
Mill Rated Capacity = 60 mt FFB/ hr
Max. Operation Capacity = 60 mt FFB/ hr
Max. Operation Hrs/ day = 24 hrs
Max. FFB Processed/ day = 1440 mt FFB/ day
Max. BOD Influent POME = 25,000 mg/ltr
Requirement of Final Discharge BOD = 100 mg/ ltr

Most of the effluent be produced came from :-
a) Clarification & Steriliser Station = 51 mt/ hr
b) Hydrocyclone and washing = 9 mt/ hr
60 mt/ hr

Therefore, maximum volume of POME produced within 24 hours per day,
the effluent will be generated = 1440 mt per day
(1mt FFB processed = 1mt POME produced)

( II ) Estimated Composition of Raw POME
a) pH : 4.0 - 5.0
b) BOD5, mg/ 1tr : 25,000 - 30,000
c) COD, mg/ 1tr : 52,000 - 64,000
d) TS, mg/ 1tr : 35,000 - 45,000
e) SS, mg/ 1tr : 20,000 - 28,000
f) Total P , mg/ 1tr : 290
g) Total N, mg/ 1tr : 500
h) Temperature,
o
C : 70 - 80
o
C

( III ) Expected Composition of Treatment effluent
a) pH : 7.0 - 9.0
7
b) BOD
3
, mg/ 1tr : <50
c) COD, mg/ 1tr : <500
d) TS, mg/ 1tr : <300
e) SS, mg/ 1tr : <100
f) Total P , mg/ 1tr : <50
g) Total N, mg/ 1tr : <50
h) Temperature,
o
C : <35

( IV ) Formula of Model of Anaerobic / Aerobic Ponds

Le = Lo x 1
1 + KK
1

Where Le = Exit BOD mg / 1tr
Lo = Inlet BOD mg / 1tr
K = Cell Residence time, day
K
1
= BOD removal rate, mg/ 1tr/ day
= 0.4 mg/ 1tr (as per MPOB)

5.2 CALCULATION OF BOD FOR NEW PROPOSED BIOGAS TANKS :
According to drawing no: 20950/ DOE/1 [ REKAAN JURUTERA PERUNDING SDN.BHD. ]
(Biogas Plant Layout Plan) *refer to Appendix A-8.3
There are FOUR ( 4 ) new proposed Biogas Tanks will act as an anaerobic ponds in Terusan Palm Oil
Mill,
Anaerobic Tank A1 = 3909 mt
Anaerobic Tank A2 = 3909 mt
Anaerobic Tank A3 = 3909 mt
Clarifier Tank B = 1838 mt

Total volume of new proposed Biogas Tanks = [3909 + 3909 + 3909 + 1838]
= 13,565 m
3


Surface area of Mixing Pond = 30 x 17
= 510 m
2


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Based on previous year (2011) rainfall chart record in Terusan area,

*refer to Appendix A-8.1
Total rainfall for year 2011 = 5490.5 mm/ year
The maximum rainfall per day = 31.37 mm/ day
Therefore, total volume of rain water will collected in Mixing Ponds alone
= 510 x 31.37 x 1/ 1000
= 16 m
3
/ day
Hydraulic Retention Time (HRT) for Biogas Tanks (anaerobic), t
1

= 13,565/ (1,440 + 16)
= 9.32 days
BOD anticipated ex Biogas Tanks, Le
1
= 30,000/ 1 + (0.4 x 9.31)
= 6,351 mg/ 1tr

5.3 CALCULATION OF BOD FOR ANAEROBIC PONDS:
There are three (3) anaerobic ponds in Terusan Palm Oil Mill and their approximate size for
Anaerobic Pond 1 = 80m x 40m x 4m
Anaerobic Pond 2 = 80m x 40m x 4m
Anaerobic Pond 3 = 80m x 80m x 6m

Effective Volume of aerobic liquor at operating level of
3.5 m for Anaerobic Pond 1 = 80m x 40m x 3.5m
= 11,200 m
3
3.5 m for Anaerobic Pond 2 = 80m x 40m x 3.5m
= 11,200 m
3
5.5 m for Anaerobic Pond 3 = 80m x 80m x 5.5m
= 35,200 m
3


Total volume of Anaerobic Ponds = 11,200 + 11,200 + 35,200
= 57,600 m
3

Surface area of Anaerobic Pond 1, 2 and 3 = (80 x 40) + (80 x 40) + (80 x 80)
Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec
Rainfall (mm) 678 510 559 440 596 190 253 453.5 356 460 503 492
Raindays 22 18 23 16 19 16 11 19 16 18 23 19
Average rain per
day (mm)
30.82 28.33 24.30 27.50 31.37 11.88 23.00 23.87 22.25 25.56 21.87 25.89
Rainfall
Month
9
= 12,800 m
2

Based on previous year (yr 2011) rainfall in Terusan area,
the maximum rainfall per day = 31.37 mm

Therefore, total volume of rain water will collected in Anaerobic Ponds alone
= 12,800 x 31.37 x 1/ 1000
= 402 m
3
/ day
Hydraulic Retention Time (HRT) for Anaerobic Ponds, t
2
= 57,600/ (1,440 + 402)
= 31.27 days
BOD anticipated ex Anaerobic pond, Le
2
= 6,351/ 1 + (0.4 x 31.27)
= 470 mg/ 1tr

5.4 CALCULATION OF BOD FOR AEROBIC PONDS:
There are FOUR (4) aerobic ponds and their approximate size for
Aerobic Pond 1 = 80m x 80m x 6m
Aerobic Pond 2 = 80m x 30m x 6m
Aerobic Pond 3 = 80m x 80m x 6m
Aerobic Pond 4 = 80m x 80m x 6m

Effective Volume of aerobic ponds at operating level of
5.5m for Aerobic Pond 1 = 80m x 80m x 5.5m
= 35,200 m
3

5.5m for Aerobic Pond 2 = 80m x 30m x 5.5m
= 13,200 m
3
5.5m for Aerobic Pond 3 = 80m x 80m x 5.5m
= 35,200 m
3

5.5m for Aerobic Pond 4 = 80m x 80m x 5.5m
= 35,200 m
3

Total volume of Aerobic Ponds = 35,200 + 13,200 + 35,200 + 35,200
= 118,800 m
3

Surface area of Aerobic Pond 1, 2, 3 and 4 = (80 x 80) + (80 x 30) + (80 x 80) + (80 x
80)
= 21, 600 m
2

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Based on previous year (yr 2011) rainfall in Terusan area,
the maximum rainfall per day = 31.37 mm

Therefore, total volume of rain water will collected in Aerobic Ponds alone
= 21,600 x 31.37 x 1/ 1000
= 678 m
3
/ day
Hydraulic Retention Time (HRT) for Aerobic Ponds, t
3
= 118,800/ (1,440 + 678)
= 56.09 days
BOD anticipated ex Aerobic pond, Le
3
= 470/ 1 + (0.4 x 56.09)
= 20 mg/ 1tr


5.5 CALCULATION OF BOD FOR POLISHING POND:
There are THREE (3) polishing pond and approximate size for

4.5 m Polishing Pond 1 = 115m x 40m x 5m
4.5 m Polishing Pond 2 = 115m x 40m x 5m
3.5 m Polishing Pond 3 = 115m x 40m x 4m

Effective Volume of polishing ponds at operating level of
Polishing Pond 1 = 115m x 40m x 4.5m
= 20,700 m
3

Polishing Pond 2 = 115m x 40m x 4.5m
= 20,700 m
3

Polishing Pond 3 = 115m x 40m x 3.5m
= 16,100 m
3

Total volume of Polishing Pond = 20,700 m
3
+ 20,700 m
3
+ 16,100 m
3

= 57,500 m
3

Surface area of Polishing Pond 1, 2 & 3 = (115 x 40) + (115 x 40) + (115 x 40)
= 13,800 m
2




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Based on previous year (yr 2008) rainfall in Terusan area,
the maximum rainfall per day = 31.37 mm/ day

Therefore, total volume of rain water will collected in Polishing Pond alone
= 13,800 x 31.37 x 1/ 1000
= 185 m
3
/ day
Hydraulic Retention Time (HRT) for Polishing Ponds, t
4
= 57, 500/ (1,440 + 185)
= 35.38 days
BOD anticipated ex Polishing pond, Le
4
= 20/ 1 + (0.4 x 35.38)
= 1.3 mg/ 1tr
Hence, the final discharge effluent from polishing pond = 1.3 mg/ ltr
and total minimum of Hydraulic Retention Time ( HRT ) = 132.04 days

6.0 CONCLUSION

Theoretically, the biochemical oxygen demand (BOD) shall be 1.3 ppm and superb well below
minimum requirement of Department of Environment (DOE) based on the tabulation. Compared year
2011 and year 2012 (Jan June.) the average of BOD is 72 ppm and 50 ppm. By constructing new Biogas
Plant with holding capacity (13,565 mt) in wastewater treatment plant, not only significant reduction of
presently BOD but also can help to reduce the emission of greenhouse gasses (GHGs) in number of key
ways:
Replacement of fossil fuels
Reduction of methane emission
Reduction odor
Reduction of vehicle movements

A part of that, when biogas is produced especially in warm and tropical countries like
Malaysia where ambient temperature are ideal for year round optimum biogas production, more that
what is needed or excess biogas is usually produced. It is provides an in-expensive, abundant and eco-
friendly LPG-like fuel. Furthermore, it also qualifies as a Clean Development Mechanism (CDM) project
of the United Nations Framework Convention on Climate Change (UNFCCC) where carbon credits
known as Certified Emission Reduction (CER) can be earned to defray project costs and become financial
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rewards for helping to protect against climate change and global warming. This will definitely to promote
Malaysia palm oil industry as Green and sustainable industry.
































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7.0 GLOSSARY OF TERMS

DOE DEPARTMENT OF ENVIRONMENT
MPOB MALAYSIA PALM OIL BOARD
UNFCCC UNITED NATION FRAMEWORK CONVENTION ON CLIMATE CHANGE
CER CERTIFIED EMISSION REDUCTION
FFB FRESH FRUIT BUNCH
CDM CLEAN DEVELOPMENT MECHANISM
GHG GREEN HOUSE GASES
BOD BIOCHEMICAL OXYGEN DEMAND
HRT HYDRAULIC RETENTION TIME
COD CHEMICAL OXYGEN DEMAND
VFA VOLATILE FATTY ACID
POME PALM OIL MILL EFFLUENT
BTU BRITISH THERMAL UNIT
PPM PART PER MILLION
CH
4
METHANE GAS
CO
2
CARBON DIOXIDE
H
2
S HYDROGEN SULFIDE
H
2
O WATER
TS TOTAL SOLID
SS SUSPENDED SOLID
N NITROGEN
P PHOSPHORUS









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APPENDIX A-8.1

RAINFALL CHART






























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APPENDIX A-8.2

RESULT OF BOD FOR 2010 AND 2011













0
20
40
60
80
100
120
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Month
B
O
D

(
m
g
/
L
)

TERUSAN PALM OIL MILL
BOD FOR EFFLUENT POND 2011
BOD
Limit
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APPENDIX A-8.3

BIOGAS PLANT LAYOUT PLAN












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APPENDIX A-8.4

ARRANGEMENT OF BIOGAS PLANT SYSTEM