1 b7 - Imam Paryanto Bppt - Ebtke-conex - English - Rev 0_2

8/13/2019 1 b7 - Imam Paryanto Bppt - Ebtke-conex - English - Rev 0_2

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EBTKE-CONEX Jakarta, 21-23 August 2013

Imam Paryanto , Ag us K ism anto, Maharani Dewi S., Hariana

( Engineering Center BPPT )

TECHNOLOGY FOR BIOFUELS

1

Development of Biodiesel Plant Design

Integrated with Palm Oil Mill for Diesel FuelSubstitution in Oil Palm Industry


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TECHNOLOGY FOR BIOFUEL

2

Outline

Background

Objective

Methodology

Result & Discussion

Conclusion



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3

Background

Availability of raw material : CPO, CPO Off-spek and CPO recoveredfrom POME (POM Effluent) in Palm Oil Mill (POM).

(Note : Availability of CPO from POME ranging 1.53 TPD depending

on POM capacity)

Availability of spare : electricity, water and steam from POM.

Availability of other facilities and infrastructures : road, workshop, etc.

in POM.

Palm Plantation and POM need diesel fuel substitution for genset and

transportation (cost reduction).


Objective To assess and develop the design of biodiesel plant integrated with

POM to utilize some of the oil raw material so that biodiesel product

can be used for diesel fuel substitution in oil palm industry.


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4

Methodology


No Assumptions Scenario 1 Scenario 2 Scenario 3

1 Raw material of oil CPO CPOOff-grade CPO

from POME

2 Cost of oil (raw material),IDR/kg

6,500 6,000 3,500

3 LocationNot integrated

with palm oil mill

Integrated with

palm oil mill

Integrated with

palm oil mill

4 Heat source

Steam supplied

from purchased

boiler

Steam supplied

from palm oil mill

Steam supplied

from palm oil mill

5 ElectricitySupplied from

genset

Supplied from

palm oil mill

Supplied from

palm oil mill

Comparison of three scenarios was based on the assumptions ofutilization of different raw materials :

Then, the biodiesel production technology and estimated

calculation of investment and production costs were compared.


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5

PALM OIL MILL


FRESH FRUIT BUNCH CPO MILL

CPO PALM KERNEL PALM SHELLEMPTY FRUIT

BUNCHPALM OIL MILL

EFFLUENT

PALM KERNEL

OIL

PALM KERNEL

MEAL


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6

BIODIESEL PLANT INTEGRATED

WITH OIL PALM INDUSTRY



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7

Raw Material


No Handling Activities CPO Off-Grade CPO

1 Oil transportation tank without installed heater with installed heater

2 Unloading with heated piping system

to transfer/ unloading

with heated piping system to

transfer/ unloading

3 Storage Storage tanks installed withheater and piping is heated

for transfer

Storage tanks installed withheater and piping is heated

for transfer

4 Pretreatment Usually not required Required to remove solid and

water impurities as well as

gum content

No Test Parameter

Sample

CPOa

Sample

CPO Paritb

Sample

CPO Parita

1 FFA Content, %w/w 4.2 50 60-64

2 Water Content, %w/w 0.39 4.2 1.1-3.8

3 Solid Impurity Content, %w/w 0.2 0.4 0.9-2.6

aLab Test BRDST-BPPT bLab Test by PTPN V


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Principle of Biodiesel Production

from Oil Based on FFA Content


Acid CatalystC-OOC-R + ROH R-COO-R + H-OH

Fatty AcidAlcohol

(methanol)

Alkil Ester

(Methyl Ester) Water

Trans-esterification

Esterification

Glycerin

Base CatalystC-OOC-R1

C-OOC-R2

C-OOC-R3

R1-COO-R

R2-COO-R

R3-COO-R

3ROH

C-OH

C-OH

C-OH

Triglyceride

Alcohol

(methanol) Fatty Acid Ester

Contoh R

+ +


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9

Biodiesel Production Technology


MIXING

CPO or olein

POME

ESTERIFICATION

MIXING

TREATMENT

Off -Grade CPO

TREATMENT

TRANSESTERIFICATION

METHANOL

Acid

Catalyst

Base

Catalyst

SEPARATION AND

PURIFICATIONRECOVERY

Crude

Glycerol

BIODIESEL

PFAD


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10

Step of Engineering Design for

Biodiesel Production Plant


Valid Data from

Laboratory

(Optimized Process)

Process Block Diagram

&

Process Flow Diagram

Material & Heat Balances

Piping & Instrumentation

Diagram (P&ID)

Detail Design I(Equipment List & Data Sheet, Material

Selection, Pumps, Instruments,Utilities, SOP/Process Manual)

Detail Design II(Electrical, Structure, Piping, Plant Layout,

Waste Treatment)

Detail Design III(Civil Works & Building)

BQ & Cost Estimation

I


II


III

TOTAL COST

Complete

Biodiesel Plant Design


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11EBTKE-CONEX Jakarta, 21-23 August 2013

Complete Plant Design Procurement

Fabrication & Instalation

(Construction)

Testing & Commissioning

Training for Operators

Target :

-Raw material used-Spesification of product

-Process specification: pretreatment,

batch/kontinu, wet/dry washing,

catalyst used, etc

-Production capacity

-Utilities used

-By-product handling

-Waste treatment

Project Execution of Biodiesel Plant


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ResearchDevelopment Engineering Operation

SETTLING

TANK

POMPA

TRANSFER 1

DRY

PURIFI-

CATION

MEOH

EVAPORATOR

SETTLING

TANKMEOH

EVAPORATOR

LIC

Glycerol

SETTLING

TANKPOMPA

TRANSFER 1

MLIC

POMPA

TRANSFER 1

FRESH

ACYD CLAY


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13

Layout Biodiesel Plant in Palm Oil Mill


Palm Oil

Mill

BiodieselPlant

Fat-Pit Pond


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14

Estimated Investement Cost

Biodiesel Plant : 1 TPD


No Item

Estimated Investment Cost of 1 TPD Biodiesel Plant, IDRScenario 1

(Not integrated with

palm oil mill & CPO as

raw material)

Scenario 2

(Integrated with palm

oil mill & CPO as raw

material)

Scenario 3

(Integrated with palm oil

mill & off-grade CPO

from POME as raw

material)

1 Building & civil works 400,000,000 400,000,000 400,000,000

2 Equipment (including accessories & structures) 650,000,000 650,000,000 745,000,000

3 Storage tanks (raw material & product) 160,000,000 70,000,000 90,000,000

4 Pumps & motors 195,000,000 130,000,000 170,000,000

5 Utilities (steam, electricity/genset, water) 415,000,000 100,000,000 100,000,000

6 Electrical & Instrumentation 165,000,000 100,000,000 125,000,000

7 Piping (including support & insulation) 335,000,000 185,000,000 270,000,000

8 Feasibility study (internal) & engineering 250,000,000 250,000,000 250,000,000

9 Commissioning & training 100,000,000 100,000,000 110,000,000

10 Overhead 125,000,000 125,000,000 125,000,000

Total 2,795,000,000 2,110,000,000 2,385,000,000

Estimated Reduction of Investment Cost - 25% 15%


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Estimated Production Cost

Biodiesel Plant : 1 TPD


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CONCLUSION

Biodiesel plant integrated with palm oil mill using

CPO off-grade from POME as raw material was one

of the strategies to produce biodiesel fuel with lower

investment and production costs, and the biodieselproduct could be used for substituting diesel fuel for

internal use in the oil palm industry.

Development of biodiesel plant with appropriate

capacity will ensure the supply of biodiesel fuel fordiesel fuel substitution in oil palm industry.


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17EBTKE-CONEX Jakarta 21-23 August 2013

1 b7 - Imam Paryanto Bppt - Ebtke-conex - English - Rev 0_2

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