Task 3

The Concept of Zero Waste Industry (2 sks)

Lecturer : Dr. Ir. Arif Kusumawanto, M.T., I.A.I

Research Proposal

Processing Technology and Utilization of Manure as a Contribution to

the Development of Small and Medium Industries in Pandansimo

Baru

By :

Andik Irawan 11/ 322749/PTK/07426

Master Program of System Engineering

Faculty of Engineering Gadjah Mada University

Yogyakarta 2012

Research Proposal

Processing Technology and Utilization of Cow Manure as a Contribution to

the Development of Small and Medium Industries in Pandansimo Baru

Presented by :

Name : Andik Irawan

No. of Student : 11/32279/PTK/07426

Yogyakarta 03 October 2012

Student

Andik Irawan

1. Title

Processing Technology and Utilization of Cow Manure as a

Contribution to the Development of Small and Medium Industries in

Pandansimo Baru.

2. Background

a. Introduction

The concept of rural development in particular areas in Indonesia

was born of an interactive process that combines basic theoretical

understanding with practical experience as a form of dynamic

application. In other words, the concept of regional development in

Indonesia is an amalgamation of various theories and models that have

been tested constantly growing apply. Furthermore reformulated into

an approach that is tailored to the conditions and needs of development

in Indonesia.

In the history of its development, the development of the concept

of assembling parts of Indonesia there are several theoretical

foundation that also coloring existence. First is Walter Isard as a

pioneer who studied the regional science causality of the main factors

forming region of space, the physical factors, socio-economic, and

cultural. Both are Hirschmann (1950's era) that gave rise to the theory

of polarization effects and the trickling down effect by arguing that the

development of a region does not occur simultaneously (unbalanced

development). Third is Myrdal (1950's era) with a theory that explains

the relationship between the forward and rear areas of the term

backwash effect and spreadwash effect. Fourth is Freadmann (the

1960's) that places more emphasis on hierarchy formation in order to

facilitate the development of systems development that became known

as the theory of economic growth centers. Fifth is Douglass (70's era)

that introduces the birth model of rural-urban linkages (rural-urban

linkages) in the development of the region. The existence of the basic

theory and concept development in the region and then enriched with

ideas born of the sons of the nation's thinking. Among them are Sutami

(1970's era) with the idea that the intensive development of

infrastructure to support the use of natural resources will be able to

accelerate the development of the region. Poernomosidhi (transition

era) contributed to the birth of the concept of the cities and hikarki

hiriarki roads through kota.Selanjutnya order is Ruslan Diwiryo (the

1980's) who introduced the concept of pattern and structure of the

space that even a major inspiration for the birth of Law No. 24/1992 on

spatial planning . The concept of the development of the region began

to be directed to address regional disparities, between regions in the

island, as well as between urban and rural areas. Recent developments

in the early centuries and even millennia, directing regional

development concept as a means to realize the integration of the

unitary Republic of Indonesia.

Based on the understanding of the theoretical and empirical

experiences above, then the conceptual understanding of regional

development can be formulated as a series of attempts to bring

coherence in the use of various resources, glue and balancing national

development and national territorial integrity, increase harmony

between regions, through the integration between the development

sector on an understanding theoretical and empirical experiences

above, then the conceptual understanding of regional development can

be formulated as a series of attempts to bring coherence in the use of

various resources, glue and balancing national development and unity

of the national territory, increasing inter-regional harmony, integration

between the development sector through the process of spatial

planning role in the achievement of sustainable development goals in

the container Homeland.

Building on the above understanding of the development should

not only be held to meet sectoral objectives partial sufficient, but more

than that, construction was held to meet the objectives of regional

development is comprehensive and holistic approach by considering

compatibility between various resources as a key element forming

chamber (source natural, artificial, human and system activity), which

is supported by the legal and institutional system that surrounded him.

The development of energy related area is preferred to meet the

goals in the region's energy needs and the needs of the industry

tanggga. Since the oil crisis, the attention of the world, including

Indonesia, the development of renewable energy sources and

technologies of oil is increasing. Dependence only on fossil energy

sources and imports for energy, particularly oil, natural gas and coal as

well as increasing energy demand in Indonesia, should be anticipated

through the efforts of developing alternative energy sources available

and environmentally friendly. Development of rural areas have

considerable opportunity for berkontribisi in alternative energy

development program. Under the direction of the national team

developing alternative energy biofuels (BBN), in the area should be

linked poverty alleviation and job creation. In addition, the

development of biogas in rural areas also need to consider the benefits

and feasibility in order to take place on an ongoing basis. In relation to

the benefits, biogas is a renewable energy source that can address

energy needs and produce organic fertilizer in the form of solid and

liquid. The use of livestock manure into biogas by anaerobic

fermentation using bacteria and methanogens can support the

application of the concept of zero waste, so the practice of sustainable

agriculture and environmentally friendly can be achieved (Andreas

Wiji SP, 2010).

Enny Ariani, et al (2007), some of the advantages livestock waste

utilization in rural areas are: 1. reduce the cost of purchasing kerosene

or LPG gas, and energy-efficient in the search for firewood, 2.

environmentally friendly because livestock waste that had been

allowed to be utilized, 3. incidental produce organic sludge that can be

processed into compost, and 4. support the government's energy-saving

program.

b. Authenticity Research

Pandansimo a rural area in the district Poncosari Bantul.

Pandansimo trying to create an energy independent region with various

contributions in the development of rural areas. The development of

independent energy region associated with the use and processing of

livestock products in use and utilized as renewable energy and solid

waste treatment industry in livestock. Until now the results of animal

waste is used for small-scale biogas feedstock that is needed in the

development of clusters in the processing and utilization of biogas and

solid waste treatment biogas industry in the organic fertilizer industry.

The author tries to create industrial clusters in the processing and

utilization of biogas and biogas utilization of solid waste into organic

fertilizer industry in New Pandansimo.

c. Avail expected

Pandansimo is a region located in the southern coastal Poncosari

Bantul District with an area of ± 24ha, is an independent energy region

with wind turbines and solar panels. The author tries to develop new

Pandansimo region through the use of the concept of animal waste

produced in one hamlet of New Pandansimo region. Utilization and

processing are expected to provide added value to the local economy

as well as serve as a village industry in the processing and utilization

of animal waste into biogas and solid waste into organic fertilizer.

3. Research Objectives :

From the theoretical discussion on the selection of cases in New

Pandansimo aims to:

a. Designing design in the processing of animal waste

b. Providing industrial clusters in the processing and utilization of

solid waste into organic fertilizer

4. Planinng Mechanism

From the results of a case study in New Pandansimo draft plan with the

following machine models:

a. Biogas Cluster with Model Design Flow Rates in Small and

Medium Industries

b. Mechanisms Technology Fertilizer Organic with Cluster Model

5. Review of the literature

a. Potential Waste livestock (cattle) into compost

Dung and urine are the most animal waste generated in animal

husbandry in the form of residual waste other than food. In general,

every kilogram of beef produced cattle also produce 25 kg of solids.

The amount of solid waste generated from fattening beef cattle could

potentially be utilized as a source of compost and the potential to be a

source of fattening beef cattle. For example, for fattening with a target

daily weight gain (PBBH) of 0.5 kg will be produced as many as 12.5

kg dung per day. If the target is fattening weight gain of 90 kg in the

fattening period for 6 months will produce as much as 2.2 tons of dirt

from a cattle feedlot every single period. If livestock manure and feed

residue is processed into compost, then at least of any feedlot cattle

can produce 1.5 tons of compost per 6 months. Composting is the

process of biodegradation or decomposition of organic matter

decomposition by bacteria, yeast and decomposition of waste materials

additional income from the business to the fungus.

To speed up the composting process in which organic processes

into organic fertilizer that is ready to be used by plant decomposition

process is carried out artificially. Cattle dung can be used as the main

ingredient for making compost contains nitrogen, potassium and a high

fiber content. This manure need additional materials such as sawdust,

ash, lime and other materials that have a high fiber content to provide a

balanced supply of nutrients to the microbial decomposers that besides

the decomposition process can go faster also can produce high-quality

compost.

b. Potential Waste livestock (cattle) into Biogas

Biogas is a combustible gas produced from the fermentation of

organic matter by anaerobic bacteria (bacteria that live in air-tight

conditions). In general, any type of organic material can be processed

to produce biogas, organic material either solid, liquid and suitable for

biogas systems. In many areas of food processing industries such as

tofu, boiled fish or brem can unite channel Biogas waste into the

system, so that the industrial waste does not pollute the environment.

It's possible that the above-mentioned industrial waste originating from

organic material is homogeneous. Types of organic matter processed

greatly affects the productivity of the system in addition to other

parameters such as biogas digester temperature, pH, pressure and

humidity.

One way menentuka organic material that is suitable for input into

the system is to know the comparison Biogas Carbon (C) and nitrogen

(N) or called rasio C/N. Several experiments have been conducted by

the ISAT demonstrated that metabolic activity daribakteri

methanogenik be optimal in the value of the ratio C/N around 8-20.

Organic material incorporated into the airtight closed room (called

Digester) so that anaerobic bacteria will decompose the organic

material is then produced gas (called biogas). Biogas that has been

accumulated in the subsequent digester gas flow through pipelines into

gas storage tube or directly to localized use.

1. Process

In the processing and utilization of animal waste (cow) in Pandansimo

divided into :

a. Waste livestock (cattle) into compost

b. Waste livestock (cattle) into Biogas

Processing required in the processes and mechanisms that can be used

as a support treatment in the use of appropriate technology.

a. Procesing Waste livestock (cattle) into compost

The principle of decomposition in composting

Principles used in composting is the process of decomposition or

decomposition transform organic waste into organic fertilizer through

biological activity in controlled conditions. Decomposition in principle

is to reduce carbon and nitrogen (C/N) ratio of organic waste that

organic fertilizers can be readily utilized by plants. In the

decomposition process would be an increase of temperature can be

used to kill the weed seeds (weeds), pathogenic bacteria and form a

uniform product overhaul in the form of organic fertilizer. Some of the

essential elements needed for the decomposition process can run well,

namely: 1). Carbon (C) as an energy source for microbial decomposers

and. will be parsed through the oxidation process that produces heat,

2). Nitrogen (N) as a protein source for the bacteria to grow and

multiply, 3). Oxygen (O) as a material to oxidize elemental carbon

through decomposition and water (H2O) to ensure the decomposition

process is robust and does not cause an anaerobic atmosphere.

Table 1. Tolerance range of influential factors and elements in the

compost to ensure the composting process.

Source by: Center for Agricultural Technology

Influential factors that must be controlled in composting:

1. C/N ratio; microbes require carbon (C) 20 to 25 times more than

nitrogen (N) to remain active. Carbon source for composting can

come from small pieces of wood, sawdust, rice straw and other

materials that are high in fiber. Sources of N derived from manure.

C/N ratio> 25 will cause slow decomposition due to lack of N

instead of C/N ratio < 20 will result in the formation of ammonia

gas that cause odor.

2. Aeration air needed to prevent anaerobic conditions that cause

odor. Reversal regularly can improve aeration. Lack of air will

cause methane, microbial activity decreases and the temperature

dropped. Instead excess compost aeration causes dry and N

elements disappear.

3. Humidity is an important element in the metabolism of the

microbes. Good humidity is 50-60%, too wet (> 60%) can result in

unpleasant odors arise and microbial activity decreases, the

temperature also dropped and if it is too dry (<40%) also

decreased microbial activity.

Impact of Various composting gains from the effort to utilize

manure and food scraps for compost as fertilizer, among others:

a. Cage becomes more clear

b. Stools were collected to reduce environmental pollution

c. Reduce the population of flies around the cage

d. Reduce eye worm infection (Thelazia) which often attack livestock

e. Composting can be done naturally or using decomposers

f. Directly compost is used for agriculture or to be sold

Some of the conditions that need to be considered regarding the making of

compost are:

a. Higher than the surrounding floor to avoid a puddle

b. It has a roof to avoid direct sunlight or rain

How to compost

Materials needed:

● Cow dung 80-83%

● Sawdust 5%

● Abu husk 10%

● Calcite / Limestone 2%

● Decomposers 0.25%

Making Process

1. Cow dung is collected and drained for a week to reduce the water

content (± 60%)

2. Cow dung that has been drained and then mixed with organic materials

such as pulp saws, husk ash, lime and decomposers. All the materials

are mixed and stirred evenly.

3. After a week behind heaps / stir thoroughly to increase the supply of

oxygen and increase the homogeneity of the material. At this stage,

expect an increase in temperature up to 60 ° C, left behind again for a

week and every week

4. In the fourth week of ripe compost fertilizer blackish brown color with

a textured crumb odorless, to get a uniform shape and separate from

materials that are not expected (for example, stones, pieces of wood,

raffia) the fertilizer sieved / screened

5. Furthermore, the compost is ready to be applied to land or crops.

b. Waste livestock (cattle) into Biogas

Biogas and Application

Biogas is a mixture of gases produced by methanogenic bacteria

that occurs in materials that can decompose naturally in anaerobic

conditions. In general, biogas consisting of methane (CH4) by 50-70%,

carbon dioxide (CO2) emissions by 30-40%, Hydrogen 5-10% and other

gases in very small amounts. To make use of livestock manure into

biogas, required several requirements related to the technical aspects,

infrastructure, and human resource management. When these factors are

met, the use of livestock manure into biogas as an energy provider in

the country to run optimally. Figure 1. Illustration shows the functions

that used Cattle waste into biogas.

Figure 1. Illustration of the use of Biogas

There are ten factors that could affect the optimization of the use of

livestock manure into biogas, namely:

1. Availability of livestock

The type, amount and distribution of livestock in an area can be a

potential for the development of biogas. This is because it is run by

utilizing biogas manure. To run biogas individual or household scale

required manure from 2-4 adult cows.

2. Ownership of livestock

The number of livestock owned by farmers to base the selection of the

type and capacity of biogas that can be used. When adult cattle are

held for more than 4 tails, the biogas can be selected with a larger

capacity (made of fiber or cement) or some household scale biogas.

3. The pattern of animal husbandry

Availability of manure biogas needs to be maintained in order to

function optimally. Manure more easily obtained when cattle

maintained by grounded compared to the pasture.

4. Availability of land

Land necessary to build the biogas around cages luasannya depends on

the type and capacity of biogas. Land required to construct the smallest

scale biogas reactor (household level) is 14 m2 (7m x 2m).

5. Labor

To operate the biogas needed manpower from breeder / manager itself.

It is important to remember biogas can function optimally when filling

dirt into the reactor performed well and taken care equipment. Many

cases concerning the operation or not is not optimal due to biogas:

first, the lack of manpower to handle the unit, secondly, breeder /

managers do not have time to replenish the dirt because they have

other jobs in addition to raising livestock.

6. Waste Management

In connection with the determination of the composition of the solid-

liquid manure suitable for producing biogas, the frequency of intake of

dirt, and transporting manure or runoff into the reactor. The raw

material is animal manure biogas reactor and water in the ratio 1:3.

Frequency income dirt done every one or two days. Importation of

these impurities can be done by or transported through the channel.

7. Energy need

Energy from biogas can be utilized in a sustainable manner if the

availability of other energy sources are limited. If the other energy

sources available so farmers can be directed to process manure into

compost.

8. Distance (between the reactor and the home cage)

In order to optimal utilization of biogas should be between the cage,

and the reactor was not telampau far.

9. Management by product of biogas

Biogas by product management intended to use a liquid fertilizer and

solid fertilizer (compost).

10. Supporting Facilities

Means of support in the form of equipment used to facilitate work /

relief work / maintenance of biogas installations.

In addition to the above ten factors, willingness breeder / perpetrator, run

the installation and use of biogas and biogas care are the main assets in the

use of livestock manure into biogas.

The process of biogas production and utilization:

Figure 2. Diagram of biogas production process systems and utilization

6. Appropriate Use of Technology to Plan

a. Technology appropriate

Currently, the community empowerment and regional development

programs Border is one of the priority programs of the government is

very important. This will appear when everything that needs to be

reduced role of the government and the people in the border areas put

forward as an optimal driving force to the nation and the state. Forms

of empowerment border is the application and development of the

existing results in each layer continuously. This program gives more

confidence to the public area of the extent to accelerate the recovery

of the national economy, accelerate the progress of the village in the

face of global competition in the various fields to be able to use

appropriate technology. This is in accordance with Presidential

Instruction no. 3 year 2001 on the Application and Development of

Appropriate Technology.

The purpose of developing a technology is essentially to meet the

needs, both of which have real or perceived and desirable it is, and

even that is anticipated to be desired, then an effective technology

development efforts, first to be based on market demand, either There

was real or perceived presence that began to appear. Prerequisite is

indeed necessary, but not sufficient. That ability to be equipped with

the ability to translate the development needs of the market with the

ability to conceive how the spectrum of technologies that can respond

to the needs observed. Pattern approach described above requires the

institution, either stand alone or organized in the corporate systems or

society. Such systems need to have a clear thought sophisticated

resources, capable of integrating the needs of the potential wealth of

knowledge, vocabulary translation into technology packages,

evaluation of the technology that manages to pack to test the

appropriateness, both from the technical, economic, social and

environmental requirements. In addition, being able to communicate

to the scientific community and society, government and civil society

organizations to motivate or convince them to support the benefits of

what will be done, is being done, and that have been generated.

However, the success rate is determined by the use of technology

ketepat generated. The success rate will be higher when the elements

and the use of ketepat ketepat saatan met. Ketepat term use of a vague

term that means, if it is not followed by the use of statements against

what ketepat. The latter is highly contextual, depending on the

environment where the technology will be enabled. Discussion of

identifying efficiency, it will be linked to the context of the

developments in Indonesia.

Appropriate technology is a technology suited to the needs of the

community so that it can be used at a certain time frame. Usually used

as a term for the technologies associated with the local culture

appropriate technology as one of the important pathways to achieve

the fundamental purpose, which is to improve the welfare of society.

Most of the people of Indonesia to the diversity of science and

technology (science) can be positioned, not only as a supporter, but

also as a pioneer of the browser path towards peace with justice for all

people in Indonesia who are in different parts of the country with the

level of technological mastery and limited economic. Appropriate

Technology means the technology in accordance with the conditions

of cultural and economic conditions, and their use should be

environmentally friendly.

b. The draft plan on the use of Biogas

Preparation and determination of the location for the manufacture

biodegister be determined and adjusted to the needs of that efficiency

can be controlled. Figure 3. catch a glimpse of the beginning of

creation biodegister manure for fermentation.

Figure 3. Placement Digester

Figure 4. Front View and Top View Digester

Cluster usage and utilization Biogas

Figure 5. Cluster Usage Biogas

Individual House

Home Industri

Agriculture

Use stove for cooking

Use Diesel Engine

Use Oil Lamp

Use stove home industries

Use Engine Home Industries

Use Engine Pump

Use Engine Rice Mill

c. Become Fertilizer Livestock Waste Utilization and Industrial Fuel

Results from biogas waste can be processed into organic fertilizer

in the form of solid and granular form that can be used on agricultural

land. figure 6. Circulation shows the use of biogas into organic

fertilizer.

The circulation process is very beneficial if an appropriate technology

tools as well as the operator controls the highly profitable and provide

economic value to rural areas.

Figur 6. Circulation Of usage waste cow

Other than that required processing and technology that can be used to

process a unit system can run well. Figure 7. Addressing diagram solid

animal waste from the biogas into organic fertilizer. Figure 8. Shows a

flow diagram of granular organic fertilizer.

Figure 7. Diagram of solid waste biogas into organic fertilizer.

Figure 8. Organic Fertilizer Production Scheme

7. Conclusion

Spatial planning industry clusters in the processing or the use of

animal waste in the concept and need to be tested by simulating a

simple process that at the time of implementation failures can be

controlled. Additionally Appropriate technology are necessary in the

processing unit of a production of raw materials to form a new

product. Pandansimo is a fairly complex to be developed in terms of

sharing and the various types of products can be produced in

Pandansimo, one biogas and solid organic fertilizer.

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