Case study

Full scale POMETHANE® plant for the largest Crude Palm Oil Producer in Malaysia

Client

FELDA one of Malaysia's largest diversified agro-based enterprises with a turnover of RM 11.8 billion in 2009 fiscal year.

Incorporated in July 1975, Felda Palm Industries Sdn Bhd (FPI) is the Malaysia's largest miller with 70 palm oil mills all over the country and 550,000 hectares of land. In 2009, FPI processes 3.11 million tonnes of Crude Palm Oil.

FPI is principally engaged in purchasing and processing of Fresh Fruit Bunches (FFB) from Felda schemes, estates owned by the Felda Group and external suppliers.

Client needs

Felda has chosen Veolia to deliver a turnkey installation consisting of a biogas plant to treat the effluents of the Serting Hilir palm oil mill. The project involves study, design, construction, hand-over, testing & commissioning. Veolia is also servicing the installation.

Due to the acidic nature and very high Chemical Oxygen Demand (COD) of the POME, a tailor made treatment solution was put in place following International Clean Development Mechanism (CDM).
The main challenge was to design an efficient system capturing the gas emitted from the treatment process.

Veolia's solution

A complete waste to energy treatment plant was built to provide a constant energy supply to the mill towards a more sustainable manufacturing environment.

The waste from the existing palm oil mill represents a valuable resource in terms of biomass as energy can be generated and the remaining sludge can be reused as fertiliser.

This project is a first full scale Palm Oil Mills Effluents (POME) anaerobic demonstration plant in Asia. The plant is designed to treat 770m³/day of palm oil mills effluents, operating with a capacity of 60 tonnes per hour of FFB.

The use of anaerobic thermophilic digestion offers an attractive alternative for the treatment of high strengths and hot wastewater streams.This technology offers an increased loading rate and the elimination of cooling before treatment.

Performance

  • The biogas plant generates about 1.2MW electricity per hour
  • The electricity generated is supplying the mills' production and is also connected to the grid of the local energy provider (Tenaga Nasional Berhad)
  • Highly efficient treatment system with a COD removal above 85%.

Specifications anaerobic effluent

Data

Flow (m3/h

38

pH

7

COD (mg/l)

4,000

BOD (mg/l)

2,000

TSS (mg/l)

500

VS (mg/l)

-

O&G (mg/l)

50

Viscosity

-

Temperature (°C)

52-55

Specifications biogas

Data

Flow (m3/h)

900

Methane

55 - 65 %

Co2

30 - 35%

O2

-

H2

1%

H2S

0,2%

Other gasses

2 - 7 %

Tar

0,15 kg/Nm3

H₂5 after purification

< 200 ppm