PALMEIRAS 200 T of Fruit per day- 10 T DQO/day Tumaco, Colombia

Palm oil mills generate an effluent highly contaminated with organic matter (COD around 50.000 mg/L)

The traditional system used for effluent treatment in these industries consists in a set of open anaerobic lagoons as it is the most extensive cost-efficient system as long as land is available and cheap. Usually these traditional systems are simple ponds and lack of pre-treatments, sludge removal and disposal systems.

However if these systems are well designed, operated and maintained they can reach removal efficiencies of 99% of the initial organic load. These “optimized” systems require a waterproof bottom liner in order avoid effluent seepage and groundwater contamination.

The main problems registered with the actual traditional systems in operation are:

• Extensive areas requirements 
• Uneasy oil recovery 
• Groundwater contamination 
• Lagoon clogging due to sludge accumulation 
• Frequent acidification

In addition, traditional uncovered ponds generate biogas (half of it being methane) which is discharged onto the atmosphere contributing to the enhancement of global warming. The methane released is classified as a powerful green house effect gas and its emissions are ruled by the Kyoto Protocol. Hence, this methane release can be defined as an energy resource loss and an atmospheric contamination.

PALMEIRAS Energectic plants adaptation (CAT 3408 - 300 kW) for biogas opration ( DUAL-FUEL sistem)

Nowadays, BIOTEC is a worldwide leader in palm oil mills effluent treatment and biogas use.
Through its system BIOTEC generates gas and electricity. The most relevant figures are:
- 15m³ of methane (CH4) per ton of fresh fruit
- 50 kWh per ton of fresh fruit
BIOTEC has also got experience in registering its projects as CDM in the UNFCCC. Methane capture and combustion is monitored and feeds specially designed reports ensuring to the UNFCCC verifiers the quality and reliability of the production (annual verifications).
The EECOPALSA project in Honduras (100.000 TFF/year, 1,2 MW, 25.000 TCO2/year) was validated in June 2006, registered in September (N° 492 in the UNFCCC registers) and its first verification took place in April 2007. It has already sold 12.800 CERs in its first 6 months of operation. The CDM process has been lead by the Dutch company ECOFYS (www.ecofys.nl).

EECOPALSA was the first “palm-biogas” project to be registered in the world.

In cases of small mills, difficult soil conditions or reduced areas BIOTEC builds it biodigesters in concrete or steel. In most cases biodigesters are optimized covered lagoons (check the “technologies” link). These biodigesters can be build based on existing lagoons or constructing new ones. These biodigesters are conceived and designed to comply with mixing and sludge purging requirements ensuring sustainable and efficient operation throughout the years.
Palm oil mills are ideal case studies for using sub-products of their effluent treatment system: 

• Biological sludge can be used directly on plantations as an organic fertilizer (liquid or after mechanical dehydration) 
• Treated effluent can be used as an organic liquid fertilizer. It can be distributed via ferti-irrigation systems. The cost of this system is approximately 1.000 US$/ha 
• Biogas can either be used as a combustible for boilers or for electricity production. The energy produced feeds the mill consumption and the excess (greater than the consumption) is sold to the national grid. BIOTEC handles biogas generator technology as well as dual-fuel generators.

Set of lagoons EECOPALSA, Honduras, 2006

References of operating plants (check the “applications and references” link)

PALMEIRAS, Tumaco, Colombia, 70.000 T/año (1999)
EECOPALSA, El Progreso, Honduras, 100.000 T/año (2006)
EL ESPINO, Perú, 200.000 T/año (Abril 2007)

Projects being currently implemented: Two mills of 250.000 and 160.000 TFF/year respectively.
Feasibility studies in process: 7 mills in 3 different countries

BIOTEC is currently setting up its new offices in Kuala-Lumpur (Malaysia) in order to attend the S-E Asian market and PNG. Office opening is set for the 15th of August.

PALM EVENTS: BIOTEC was in the EXPO-PALMA (Cartagena, Colombia) in September 2006 and will be at the PIPOC conference in Kuala Lumpur by the end of August 2007.