Biodiesel-Presentasi Pasir

INTEGRATED BIODIESEL PLANT & PALM OIL MILL

Samarinda, 8 September 2006Dr. Agus Sulistyo Budi Kepala Pusat UMKM dan Wirausaha LPPM Ritson PurbaKepala PPKS Gedung Lembaga Penelitian Universitas Mulawarman Jl. Krayan No. 1 Telp : 0541 - 747432Fax : 0541- 747432

Kerjasama Lembaga Pengabdian Kepada Masyarakat (LPPM) dan Pusat Penelitian Kelapa Sawit (PPKS) Universitas Mulawarman

OUTLINE

• Pabrik Biodiesel• Potensi Kelapa Sawit

Integrasi • Kesimpulan


BIODIESEL PLANT

Biodiesel Pilot Plant, cap. 8 tons/day, 2004, Riau, in cooperation with Balitbang Prov. Riau


BIODIESEL PLANT KAP. 100 RIBU TON/TAHUN


DIAGRAM BIODIESEL PLANT

KatalisKatalis MeOHMeOH STEAMSTEAM WATERWATER ELECTRICITYELECTRICITY16.516.5 KGKG 110 KG110 KG 415 KG415 KG 25 M^325 M^3 1212 KwHKwH

Penyiapan

GliserinGliserin

Trans-esterifikasi

Pencucian Pengeringan

DistilasiPemurnian

BiodieselBiodiesel970 KG970 KG

CPOCPO1000 KG1000 KG

MODALMODAL

LABORLABOR

100 KG100 KG AIR LIMBAHAIR LIMBAH


SOLAR VS BIODIESEL

4050 MOPS

810

4300

SOLAR SOLAR

3240 CPO BELI

810

450 300

INDUSTRI SUBSIDI RP.4800/L RP.5400/L RP.4300/L HPP BIODIESEL


540

-----------------------------------------------------------

------------------------------------------------------------

KEEKONOMIAN :� Harga Produksi Biodiesel sudah kompetitif

Harga Bahan baku + Biaya Produksi + Pajak + Transport = Solar Industri (a) (b) (c) (d) (e)

Asumsi : Bahan baku CPO a) Biaya Produksi CPO Rp. 3600/kg b) Biaya Produksi Biodiesel (avg.) Rp. 900/kg

Harga net produk biodiesel Rp. 4.500/kgAtau Rp. 4050/liter (1 kg CPO => 1.1 liter biodiesel)

c) PPN 10% dari produk biodiesel Rp. 450/kg

Biodiesel + pajak : Rp. 4500/kg

d) Transport darat (asumsi 240 km) Rp. 300/liter tergantung jarak (Rp. 50/40 km/liter) -------------------------------------------------------------+ Harga net biodiesel di tempat : Rp. Rp. 4800/liter

e) Solar industri Rp. 5400/liter (harga depo)

Rp 4800/liter = Rp 5400 /liter===============================


HPP BIODIESEL� PERKIRAAN HARGA POKOK PRODUKSI BIODIESEL

- Chemicals : - MeOH Rp. 300,-- H2SO4 Rp. 100,-- KOH Rp. 30,-- Steam Rp. 100,-- Listrik, Air Rp. 30,-- Nitrogen Rp. 5,-

- Tenaga Kerja Rp 15,-- Pemeliharaan Rp. 60,-- Pengembalian Modal Rp. 260,- *)

TOTAL = 900,-*) Kapasitas 100 ribu ton/tahun, 6 tahun pay-back period


PROFITABILIAS PABRIK BIODIESEL

CONDITIONS : CPO = Rp.3600/KG; DIESEL FUEL Rp.5400/L(INDUSTRY) AND Rp.4300/L(TRANSPORT)

.

• BIG SCALE BD PLANT INTGR’D W/ COOKING OIL REFINERY, ENERGY FROM COAL, BD SOLD FOR TRANSPORTATION

• BIG SCALE BD PLANT, CPO FROM OTHERS, BD SOLD FOR INDUSTRY

• COAL, BD SOLD FOR INDUSTRY

• • BIG SCALE BD PLANT INTGR’D W/ PLANTATION, BD SOLD FOR INDUSTRY • SMALL SCALE BD

• SMALL SCALE, STAND ALONE BIODIESEL PLANT, ANY RAW MATERIAL • BIG SCALE BD PLANT, CPO FROM OTHERS, BD SOLD FOR TRANSPORTATION

BIG SCALE BIODIESEL PLANT INTGR’D W/ COOKING OIL REFINERY, ENERGY FROM

BIG SCALE BD PLANT INTGR’D W/ PLANTATION, BD SOLD FOR TRANSPORTATION

PLANT INTEGRATED WITH CPO MILL, BD FOR INTERNAL USE


BIODIESEL PLANT DI MASA DEPAN

TANTANGAN : � BERSAING DENGAN BBM BERBASIS ENERGI FOSIL YANG TELAH TERUJI

DAN SKALANYA BESAR � HARGA BBM KONVENSIONAL SEWAKTU – WAKTU JATUH KEMBALI � HARGA BAHAN PENDUKUNG YANG CENDERUNG NAIK � GLYCEROL AKAN MERUPAKAN LIMBAH

MAKA BIODIESEL PLANT DI MASA DEPAN HARUS :

� SKALANYA BESAR ( > 150 000 TON/TAHUN) � TERINTEGRASI DENGAN PERKEBUNAN DAN PKS � MEMPUNYAI MANAJEMEN ENERGI YANG EFISIEN � MAMPU MENYEDIAKAN METHANOL SENDIRI � MEMPUNYAI KATALIS RECOVERY PLANT ATAU PABRIK KATALIS

SENDIRI


INTEGRATED BIODIESEL PLANT

PALM OIL MILL BIODIESEL PLANT

BIOMASS POWER PLANT

TBS OIL

GLYCERINE PURIFICATION

BIOGAS PLANT

METHANOL PLANT

BIOMASS GASIFICATION

APR PROCESS

KATALIS RECOVERY

BIOMASS

PLANTATION BIODIESEL


BAHAN BAKU POTENSIALNo Deskripsi Sawit Jarak Pagar

1. Produktivitas lahan 20 t tbs/ha/th, 3.5 t minyak/ha/th (terbukti)

0.4 – 12 t biji/ha/th (belum ada data pasti)

2. Perkebunan siap 5 jt ha ( 2010 : 17.5 juta ton CPO)

Baru mulai dikembangkan

(potensi lahan kritis 20 jt ha) 3. Kontinuitas pasokan Terbukti stabil Belum terbukti

4. Harga $350 - $400/ton minyak Harga masih sangat berfluktuasi

5. Komoditi makanan edible Non edible

6. Sensitivitas harga pasar

Rentan terhadap fluktuasi pasar minyak nabati dunia

Tidak tergantung harga pasar dunia

7. CFPP relatif tinggi (12oC) lumayan rendah (-1oC)


MINYAK SAWIT (CPO)

Data Produksi dan Harga di Dunia (Rotterdam) (2004 : Oil World Annual): � Minyak Kedelai 30.9 juta ton (150% th.1995) 616 USD/ton � Minyak Sawit 30.0 (200%) 471 � Rapeseed 14.8 (150%) 685 � Sunflower 9.5 669 � Groundnut 4.7 � Cottonseed 4.4 � PKO 3.4 648 � Coconut 3.0 661 � Olive Oil 2.9 � Corn Oil 2.0 � Lain-lain < 2.0

CPO => Paling Murah

=> Paling Cepat Pertumbuhannya


PRODUKSI CPO INDONESIAData of CPO Production from Dept. of Agriculture, 2003

Riau 3.3 million tons

East Kalimantan 167,000 tons

North Sumatera 2.5 million tons

South Sumatera

Central Kalimantan

317,000 tons Papua

95,000 tons

West Java 31,425 tons

West Kalimantan 518,000 tons

1 milliontons

Tahun 2004 : 5.291 juta HA, Produksi 11.6 juta Ton,


POHON SAWIT

CPO PKO


PABRIK KELAPA SAWITDIAGRAM ALIR PROSES PENGOLAHAN MINYAK KELAPA SAWIT

TRANSPORTASI TBS

UNIT PENERIMAAN

UNIT PERONTOKAN

UNIT STERILISASI

UNIT EKSTRAKSI

UNIT PURIFIKASI

STASIUN KERNEL

CPO

KERNEL

PEMBANGKIT UAP

PEMBANGKIT LISTRIK (STEAM TURBINE)

SERABUT

CANGKANG

STEAM

PKS MEDIUM

PKS MEDIUM

LISTRIK

PLTU BIOMASA


MASA OLAH TBS

8 jam

Busuk

Kerjasaman Lembaga Pengabdian Kepada Masyarakat (LPPM) dan Pusat Penelitian Kelapa Sawit (PPKS) Universitas Mulawarman

3 hari

RELASI PERKEBUNAN DAN PKS

Perkebunan Rakyat

6000 ha (

PKS 30 Ton/jam

Buang Buang

Buang

Buang

Support PKS

? ?

?

?

?

milik PKS)


PABRIK KELAPA SAWITKAPASITAS 2 TON TBS/JAM


PABRIK KELAPA SAWIT

JEMBATAN TIMBANG

PENERIMAAN TBS


PABRIK KELAPA SAWIT

UNIT STERILISASI UNIT PERONTOK VERTICAL CONVEYOR DIGESTER SCREW PRESS


PABRIK KELAPA SAWIT

OIL TANK SCREW PRESS


-

PABRIK KELAPA SAWIT

OIL PURIFIER OIL DRYER


PABRIK KELAPA SAWIT CPO TANK KERNEL STATION


PABRIK KELAPA SAWITKAPASITAS 5 TON TBS/JAM


PABRIK KELAPA SAWITKAPASITAS 30TON TBS/JAM


HEAT & MASS BALANCE DI PABRIK KELAPA SAWIT

Kebutuhan energi untuk proses produksi : - 20-25 kWh/t - 0.73 ton uap panas (steam)

Pabrik Kelapa Sawit

~ 3 biogas

1 ton TBS

Limbah: 140- 200 kg CPO

600-700 kg POME (limbah cair) 20 m

190 kg serat dan cangkang

230 kg TKKS 120 kWh

(dimodifikasi dari Lacrosse, 2004)



TANDAN BUAH SEGAR DI LOADING RAMP

BIOMASS BOILER



CANGKANG (SHELL)

SERABUT (FIBRE)



TANDAN KOSONG

KOLAM LIMBAH


BIOMASS POWER PLANT (Serawak Malaysia) Fuel : Shell, Fibre & EFB


(SUMBER : Federal Emergency Management Agrncy

GASIFIKASI BIOMASA

, US:1989)


BIOGAS DARI LIMBAH CAIR PROSES ANAEROBIK

1 TON TBS

Organic Residue

Hydrolytic and Fermentative Bacteria

and Neutral Compounds

Acid-forming Bacteria

Methane-forming Bacteria

CH4, CO2, H2S

Acetate

Acetate

Acetate

H and

H

Soulble Acids, Alcohols,

20 M^3 BIOGAS


KECEPATAN PRODUKSI BIOGAS PROSES ANAEROBIK

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0 B

aiog

as p

rodu

ctio

n(m

l/ L/

day

)

midle temperature

high temperature

20 30 40 50Temperature(? )


60

PEMANFAATAN LIMBAH CAIR DI PABRIK KELAPA SAWIT

Parameter Rata-rata Baku mutu KLH

pH 4.2 6-9

BOD (mg/l) 25.000 100

COD (mg/l) 50.000 350

TS (mg/l) 40.000 250

SS (mg/l) 18.000 25

Lemak (mg/l) 6.000 ?

(SUMBER : DIDIEK GOENADI, LRPI:2005)


PEMANFAATAN LIMBAH CAIR DI PABRIK KELAPA SAWIT

BIOGAS PLANT DI MALAYSIA

(SUMBER : DIDIEK GOENADI, LRPI:2005)


GASIFIKASI BIOMASA

TRAKTOR BERBAHAN BAKAR KAYU

(SUMBER : Federal Emergency Management Agrncy, US:1989)


GASIFIKASI BIOMASA

GASIFIER

KOMPOSISI GAS

CO 23.41 vol-% CO2 9.90 vol-% H2 20.71 vol-% H20 3.32 vol-% CH4 0.93 vol-% N2 41.72 vol-% Sisa <0.10 vol-%

GAS HEATING VALUE

5.5 MJ/NM^3

(SUMBER : Carbona :2004)


Carbona(SUMBER : :2004)

GASIFIKASI BIOMASA


GASIFIKASI BIOMASA

FINLANDIA UTAH, USA


GLISEROL SEBAGAI BAHAN BAKU METHANOLAPR Glycerol conversion

C3H8O3 + 3H2O � 3CO2 + 7H2 � Reactor temperature: 200 – 250oC � Reactor pressure: 16 – 40 bar � Endothermic reaction � Produced H2 can be purified through PSA (pressure swing

adsorption) technology � PSA waste stream contains H2 ~20% of the feed, combustion of

this waste H2 can provide required energy for the aforementioned endothermic reaction


GLISEROL SEBAGAI BAHAN BAKU METHANOL Block diagram of H2 production from glycerol

catalyst 10wt%

water mixture

10wt% 90wt%

Nickel-based

of glycerol-


GLISEROL SEBAGAI BAHAN BAKU METHANOL

Virent Hydrogen Generator Prototype

• Integrated 300 cc/min system.

• Size of a small PC.

• 99.999% pure H2 with palladium filter.

• 300 gram/hour version under development.

• Can be significantly reduced in size.



Aqueous Phase ReformingAqueous Phase Reforming• Ultra Efficient, scalable, liquid

phase reactor design.

• Generates 200 cc/min of H2 from a small reactor volume and 2 grams of catalyst.

• Less than 240 °C operating temperature.

• Glycerol, Sorbitol, Ethylene Glycol and Glucose fuels


CuZn /


• The waste stream or final products from APR process can provide reactants to produce methanol via a catalyst of copper or zinc

C3H8O3 + 3H2O � 3CO2 + 7H2

Zn Cu� �� fi CH3OH + H2O3H2 + CO2 ‹ /

• The production of 1 mol methanol from glycerol leaves 0.3 mol of unused CO2


Pure methanol Purge gas

H2, CO2

Light ends

Wat

er

G H

C C

C

C CD

D D D

E

F

B A

A Pure methanol column

ICI’s low-pressure methanol process

B Light ends column Waste water

C HX E Separator G Compressor D Cooler F Reactor H Compressor recycle stage



� With 70% and 80% efficiency of APR process and H2+CO2 reaction to produce methanol respectively, 1 mol glycerol can be converted to approximately 1.25 mol methanol.

� But, we need 3 mol of methanol to produce 1 mol of glycerol.

� We must produce 1.75 mol methanol from other source : - biomass gasification - biogas


(Carbon neutral hydrogen from renewable sources)(Carbon neutral hydrogen from renewable sources)(Carbon neutral hydrogen from renewable sources)Total Cost of “Green” HydrogenTotal Cost ofTotal Cost of ““GreenGreen”” HydrogenHydrogen

10987

Hydrogen 6 Cost 5 ($/kg) 4

3210

Virent APR:C5 Sugars

Virent APR:Brazil

Sugar

Virent APR:US Sorbitol

Wind Solar Cell Natural Gas

Reforming

Source for wind & solar:

Low cost

bench -mark

National Academy of Sciences Report


KESIMPULAN� Integrasi antara Pabrik Kelapa Sawit dan Biodiesel akan dapat

memproduksi Biodiesel dengan harga yang paling kompetitif di dunia.

� Integrasi ini juga mengakibatkan keuntungan lain : - penggunaan energi yang lebih bertanggung jawab - mengurangi emisi gas metana - menimbulkan industri baru yang sehat dan kompetitif

� Namun begitu, masih perlu kerja keras dari para peneliti, dan keberanian mengambil resiko dari para investor, serta dukungan berbagai insentif dri Pemerintah.


Terima kasih ….


Documents

Biodiesel-Presentasi Pasir