2/29/2012

Biocomposting

Biocompost
Faculty of Biotechnology and Biomolecular Sciences
Universiti Putra Malaysia

Fertilizer?
Chemical compounds containing essential
Learning Outcomes nutrients to promote plant growth
¾ Student will be able to explain the plant nutrients and
importance of biofertilizer (C3) 16 essential elements for plant growth and survival:
¾ Student will be able to identify and evaluate the substrates and ƒ Basic nutrients – carbon (C), hydrogen (H), oxygen (O)
raw materials of composting (C6)
ƒ Macronutrients – primary nutrient: nitrogen (N), phosphorus (P),
potassium (K)
¾ Student will be able to explain and analyze various type of
composting (C4, P5) ƒ Macronutrients: secondary nutrient: calcium (Ca), sulfur (S),
Magnesium (Mg)

ƒ Micronutrients: Boron (B), Chlorine (Cl), Manganese (Mn), Iron (Fe),

Zinc (Zn), Copper

1
 2/29/2012

ƒ Macronutrient required between 1 to 150 g per kg

plant dry matter. Biocompost
ƒ Micronutrients needed in very small quantity - 0.1 to ƒ Bio-compost is very rich in nutrients. It is mainly
100 mg per kg of plant dry matter. used in gardens, landscaping, horticulture,
and agriculture.
ƒ nutrient deficiencies - stunted growth, lack of new
growth, chlorosis, purplish-red coloring and necrosis ƒ It is usually done by shredding the plant matter,
adding of sufficient water and regularly turning
the mixture to provide better aeration.

ƒ Worms, fungi, bacteria helps in the process of

decomposition.

ƒ during the process lots of heat, CO2 and

ammonium is produced.

Compost Benefits
Raw Materials
Physical benefit
1) Agriculture and forestry - Improve structure-resist compaction in fine-textured
- Farm manure, crop residues, animal carcasses soil and increase water holding capacity and improve
- Logging and wood manufacture soil aggregation in sandy soil.
-Moisture management – humus improve soil ability to
2) Municipal
M i i l waste t hold moisture.
moisture
- Paper, cloth, yard refuse, leaves, garbage, landscape, refuse,
wood Chemical benefit
- Municipal sewage sludge - Modify and stabilize pH – addition of compost to soil may
- Domestic septic tank sludge modify the pH of the final mix. The addition of neutral to
slightly alkaline compost to an acidic soil would increase soil
pH.
3) Industrial by-products - Increase cation exchange capacity – the ability to hold
- Petroleum, paper, food processing waste, textile, nutrient and enable them to retain nutrients longer.
pharmaceutical - Contain considerable variety of macro and micro nutrient
- Hydrocarbon-contaminated soil, pesticide waste for plant uptake.

2
 2/29/2012

Cont.. Type of compost technology

Biological benefit

ƒ Provide soil organism – microorganism in compost provides many The most common composting methods are:
benefits to soil and plants.

ƒ Suppress plant disease – there are beneficial microorganisms such

ƒ Backyard or onsite composting
as pytium,
ti f
fusarium
i and
d nematodes
t d presentt in
i compostt to
t suppress
plant disease ƒ Vermicomposting
Additional benefits ƒ Aerated (turned) windrow composting
ƒ Bind contaminants – compost has ability to bind heavy metals and ƒ Aerated static pile composting
other contaminats, reducing leacheate and adsorption by plants.

ƒ Degrade compounds – microbes found in compost are also able ƒ In-vessel composting
to degrade some toxic organic compounds including
hydrocarbon.

Exercise

ƒ Discuss advantages and disadvantages

for each type of composting process
and prepare a report.
Scenario of palm oil industry
in Malaysia
&
Clean Development
Mechanism (CDM)

3
 2/29/2012

Cont..
Scenario of palm oil industry in
ƒ In recent years, co-composting of EFB and POME has gained
Malaysia popularity as an alternative approach to reduce the abundant of
biomass generated at palm oil mill.
ƒ Malaysia is the world’s leading producer and exporter of
crude palm oil and palm kernel oil. ƒ Composting is a biological process by which organic material
undergoes decomposition and transformation processes
ƒ Unfortunately, it also generates lignocellulosic residues and
organic waste such as empty fruit bunch (EFB) and palm oil ƒ With appropriate nutrients
nutrients, porosity,
porosity density and moisture content
mill effluent (POME), which are highly polluting to the during composting, the organic matter will be stabilized producing
environment. compost product.
ƒ One of the major sources of Green House Gases (GHG) in ƒ In Malaysia, there are several companies and semi-goverm. agencies
Malaysia is contributed from the incineration process of EFB involved in producing commercial compost products from different
and the POME treatment system at palm oil mill type of wastes such as FELDA Palm Industries (FPI) Sdn. Bhd., Malaysian
ƒ Thus, an innovative way to treat the EFB and POME coupled Palm Oil Board, Sime Darby Sdn Bhd., Asia Green Environmental Sdn.
with the production of valuable bio-product should be Bhd., Kulim (Malaysia) Bhd. and Organic Gro Sdn. Bhd.
developed

Cont..

ƒ However, the information about EFB-POME composting at field

scale operation in terms of process feasibility, microbial diversity
and composting operation are lacking.

ƒ It was found that the current composting treatment for EFB and
POME are facing the problems of ineffective composting
operation, inconsistent and low compost quality, leachate run
off, limited land area and high cost of microbial addition.

4
 2/29/2012

ƒ CDM allows emission-reduction projects in developing countries

ƒ The CDM allows emission-reduction projects in developing to earn certified emission reduction (CER) credits, each
countries to earn certified emission reduction (CER) credits, equivalent to one tone of CO2.
each equivalent to one tone of CO2.
ƒ These emission reduction (CER) credits, each equivalent to one
ƒ These CER can be traded and sold, and used by industrialized tone of CO2.
countries to meet a part of their emission reduction targets
under the Kyoto Protocol ƒ These CERs can be traded and used by industrialized countries
t meett a partt off their
to th i emission
i i reduction
d ti targets
t t under
d the
th
ƒ The Kyoto protocol was adopted in Kyoto, Japan, on 11 Kyoto Protocol.
December 1997 and entered into force on 16 February 2005.
ƒ In Malaysia, the main contributor of biomass and methane
ƒ 184 parties of the convention have ratified its protocol to date emission is the palm oil industry. In 2008, out of the 26 registered
CDM project in Malaysia, 19 involve GHG emission via palm oil
biomass waste.

Learning outcomes
Exercise
ƒ Student will be able to evaluate the process i) Each
student should write a short report
involved in palm oil industries in relation to zero on one example of CDM project.
discharge system (C6, A3)

ƒ Student will be able to explain about the Clean

ii) Each student should write a report on
Development Mechanism concept (C4) the project/activities involved in the
FELDA Serting Hilir.

5
 2/29/2012

Introduction
ƒ Windrow composting is suited to producing large volumes of
compost.

ƒ These rows are generally turned to improve porosity and

oxygen content, moisture, and redistribute temperature of the
“Windrow
Windrow System
System” pile.
il

ƒ The more advanced windrows are equipped with a ventilation

system underneath the windrow, which is either suction- or on
pressure-based.

ƒ Control of C02 or 02 have to be performed. In systems with

suction ventilation, this measurement is taken in the exhaust air.
The disadvantage is high air consumption.

ƒ A fast breakdown of easily degradable organic matter is

Process achieved by maintaining optimum temperature conditions for
the microbes.

ƒ A high temperature gradient from outside to inside called ƒ Sterilization of the material in the beginning of the process due
the "wall effect" prohibits an even degradation of the to the high temperatures means a long subsequent lag phase
material. and therefore an extended decomposition time.

ƒ The material therefore,

therefore has to be turned frequently to put ƒ Very frequent turnings are required to avoid overheating the
the outside material to the inside of the pile. While an in- pile.
vessel system can be insulated.
ƒ Achieving a high temperature for inactivating microbes and
ƒ Temperature is a critical point, because a unidirectional weed seeds is necessary for a safe product.
airflow will remove precious heat energy in the initial phase.
ƒ A temperature of 60 - 65 °C is considered sufficient for effective
elimination of pathogens. Higher that that is not suggested.

6
 2/29/2012

Learning outcomes Exercise

ƒ Student will be able to evaluate the composting in windrow i) Each student should write overall report of the visit to
system (C6, A4). FELDA Maokil Johor.
ii)) Each student should write a specific report on the
techniques of composting in windrow system and
discuss advantages the windrow system and
compare with other means of composting.

Justification
ƒ Why pellet form?

ƒ Justification

Compost in pellet form

7
 2/29/2012

Learning outcome Exercise

ƒ Students are required to write a report on the overall

ƒ The students will be able to evaluate and explain the
activities/project in the SIME Darby mill.
overall process of composting and pellet production (C6,
A4, P5) ƒ Students are required to prepare a report and explain in
details the overall composting process including the pellet
production.

ƒ Composting is the process to accelerate the

aerobic decomposition of organic material by
microorganisms under controlled condition into soil-
like substance called compost that is hygienic,
humus rich, and relatively stable.
Factors Affect Composting ƒ There
Th are severall variable
i bl essential
ti l for
f
microorganism to decompose efficiently which may
be ‘controlled’ during composting, including C:N
ratio of raw materials, Moisture content, Oxygen flow
(aeration), pH value, Temperature, Particle size

8
 2/29/2012

Brown material with relatively high C content include:

C:N ratio of raw materials ƒ Dry, straw-type material, such as cereal straws

ƒ Autumn Leaves

ƒ Sawdust and wood chips

ƒ Controlled decomposition requires a proper balance of
carbon ( C) and nitrogen (N) (C:N ratio) requirements. ƒ Paper and cardboard (corrugated cardboard or newsprint)

ƒ some materials contain high amounts of carbon (brown

material) in the form of cellulose which the bacteria need a Green material with relatively high N content include:
source of energy. ƒ Green plant material such as crops residue, hay, grass clippings, weeds

ƒ Other materials contain high amount of nitrogen (green ƒ Manure of poultry and herbivorous animals such as horse, cows
material) in the form of protein for building cell structures ƒ Fruit and vegetable trimmings.

The most efficient composting occurs by seeking to obtain an initial C:N ratio of
between 25:1 and 30:1; although ratios between 20:1 and 40:1 are also
acceptable.

Moisture content Oxygen flow (aeration)

ƒ Microorganism living in compost pile need an adequate ƒ The composting process consumes large amounts of O2
amount of moisture to survive. Water is the key element that particularly at the initial stage. Oxygen content of !6 to 18.5 %
helps transports substances within compost pile and makes is ideal. If the supply of O2 not sufficient, the growth of
the nutrients in organic
g material accessible to the microbes. microorganism
g is limited,, resulting
g a slower decomposition.
p
However, too much O2 can dry out the pile.
ƒ Moisture content of 50-60 %is generally recommended for
composting. If the pile is too dry, composting occurs more ƒ Turning the pile, placing the pile on a series of pipes, or
slowly, while moisture content in excess of 65 %develops including bulking agents such as woods chips and shredded
anaerobic conditions. newspaper assist in aerating the pile.

9
 2/29/2012

Temperature
pH value
ƒ Microorganism require a certain temperature range for optimal
activity.
ƒ The pH level is an indicator of the acidity or alkalinity of the
composting material. Composting can work effectively ƒ Certain temperature promote rapid composting and destroy
between 5.5 to 9 pathogens and weed seeds.

ƒ however, the process is most effective between 6.5 to 8.0. A ƒ Microbial activity can raise the temperature of the pile core to
pH level below 6 can slow decomposition. at least 140F.

ƒ Insufficient oxygen often cause of low pH during the active ƒ If the temperature does not increase, anaerobic conditions
composting stage. occur.

ƒ Temperatures within the pile or windrow will gradually drop to

190F as active composting slows and level out to ambient air
temperature.

Particle size Exercise

ƒ Each group should present the findings of the study about

ƒ Smaller particles of raw materials have more surface area, which factors affecting biocomposting process.
make nutrients and energy more available to microorganisms.

ƒ However too small partyicles can reduce the air space within the
composting mass; so a balance is necessary; particle size from
1/8 to 2 inches in diameter generally produce good results.

10
 2/29/2012

ƒ UPM in collaboration with Kyushu Institute of Technology, Japan

and Felda Palm Industries Sdn Bhd have constructed a
“Controlled Composting Pilot Plant” at UPM Agriculture Park for
the purpose of semi-commercial production of biocompost .

ƒ The raw material of biocompost are empty fruit bunches (EFB)

and POME anaerobic sludge.
Biocompost Pilot Plant UPM
ƒ The technology know-how was developed to provide a rapid
and controlled composting system for various
organic/agrowastes by combination of closed-controlled
composter and open pile windrow systems without the addition
of fresh microbes.

Cont..
Cont..
ƒ The technology developed in UPM compost plant enables all
the process parameters such as moisture, pH, temperature,
ƒ The raw materials are fermented for 7 days inside the 45m3 of aeration and mixing speed can be controlled.
cylindrical closed vessel and followed by curing stage in the
windrow pile. ƒ The POME anaerobic sludge from 500m3 closed anaerobic
digestion system could be used as an effective nitrogen
ƒ The breakdown of organic materials inside the vessel would source and microbial seeding for EFB composting by the
increase the temperature to the thermophilic range (60- minimum proportion of 1:1 (EFB:POME anaerobic sludge).
70°C), where breakdown of organic matter by
microorganisms is at the optimum rate. ƒ Changes in temperature, microbial community and SEM
micrograph indicated a high organic degradation rate
ƒ It was reported that the total composting process can be occurred inside the composter and windrow pile systems.
reduced from 100 days in the conventional windrow system
to only 40 days of treatment.

11
 2/29/2012

Cont…
Learning outcome
ƒ The EFB compost in the aerobic condition was completed
within 40 days of treatment.
ƒ Students will be able to sketch/draw the component of the
ƒ The important nutrients and nitrogen-phosphorous-potassium pilot plant and explain their functions (P4,C6)
(N-P-K) components of finished composting are approximately
2.8-0.7-2.8%
2.8 0.7 2.8% by dry weight and met the USEPA requirements.

ƒ The C/N ratio of 13 in the final compost product indicating that

the compost was matured and ready to be used as soil
amendment and fertilizer for palm oil plantation.

Schematic diagram of
Biocompost Pilot Plant UPM

Biocompost Pilot Plant

12
 2/29/2012

Exercise
Aims

ƒ UPM’s biocompost technology provides an environmental i) Each student is required to draw schematic diagram of the
friendly solution in managing waste from palm oil mills and UPM’s biocompost pilot plant, label its component and explain
palm plantation. their functions properly.

ƒ UPM’s biocompost technology enables organic wastes to be ii) Each group is required to assess facilities in the pilot plant.
turn into valuable product; biocompost product that is of Suggest the price of the facilities, supplier, etc.
comparable quality to other commercial compost in the
market.

Introduction

ƒ The palm oil cultivation process creates various organic wastes

comprising of biomass (solid) and wastewater (liquid effluent).

ƒ Palm oil biomass comprise solid waste resulting from milling

Organic waste from Palm Oil process i.e
i e empty fruit bunch (EFB),
(EFB) mesocarp,
mesocarp palm fibre and
palm kernel fruits. About 50 % of water results in POME (liquid
Cultivation waste).

13
 2/29/2012

Learning outcomes Empty fruit bunch

ƒ Students will be able to explain the composting process using

ƒ Empty fruit bunch is obtained from by product after oil palm fruit
raw materials from palm oil industry (A4,C5).
removed from the fresh fruit bunches during milling process.
ƒ Students will be able to access and evaluate suitable transport
ƒ In 2004,
2004 it was estimated that 26
26.7
7 million tones of solid biomass
and facilities to bring raw materials from the mill to the pilot
and an average of 30 million tones of palm oil mill effluent were
plant (C6, P5).
generated from 381 palm oil mills in Malaysia.

Cont.. Cont..
ƒ Traditionally, EFB is burned to produce ash, which is later used as
ƒ The biomass was made up of empty fruit bunch (53%), mesocarp
fertilizer.
(32%), fiber and palm kernel shell (15%).
ƒ Hovewer, due to environmental issues, incineration of EFB is
ƒ EFB in its raw form contain good source of organic matter and
discouraged and EFB nowsadays are recycled through
plant nutrients.
nutrients
composting process.
ƒ EFB forms 20-25 % of FFB.
ƒ The contents of nutrients N, P,K and Mg in EFB and POME.
ƒ In 2008, total FFB received by mills in Malaysia is 88.5 million tones,
ƒ The EFB constitute a large amount of K followed by N, Mg and P.
which results in approximately 18 million tones of EFB.
ƒ Baharuddin et al 2008 reported that shredded EFB contain 0.9%
N, 0.6% P, 2.4% K and 0.6% Mg. C:N ratio of EFB was 58.9.

14
 2/29/2012

Palm oil mill effluent (POME) Cont..

ƒ Although biodegradable, POME cannot be discharged without first
ƒ POME are liquid waste/effluent resulting during palm oil milling being treated because POME is acidic and has a very high
process. biochemical oxygen demand (BOD) and chemical oxygen demand
(COD).
ƒ POME consist of water soluble components of palm fruits as
well as suspended materials like palm fibre and oil which are ƒ BOD is a chemical procedure for determining how fast biological
g
biodegradable. organism use up oxygen in a body of water.
ƒ In 2006, it was estimated a total of 26.7 million tones of solid ƒ Traditionally, POME is treated in anaerobic ponds.
biomass created, of which an average of 30 million tones of
POME generated from 381 palm oil mills in Malaysia. ƒ However, significant pollution has been reported to arise from this
treatment, whereby methane was emitted from anaerobic pond
ƒ It is estimated that from 1 tonne of crude palm oil produces 5- system.
7.5 tonnes of water ends up as POME.
ƒ It is estimated that for every tone of POME treated, an average of 12.36
ƒ Furthermore, it was estimated that for every tone of POME kg of methane was emitted from anaerobic ponds system.
treated, an average of 12.36 kg CO2 was emitted from
anaerobic ponds.

Table: Characteristics of untreated POME

______________________________________________________

ƒ pH 3.4 – 5.2 Co-composting EFB and POME

ƒ Biological Oxygen Demand 10250 - 43750 ƒ Co-composting is defined as the composting of two or more
ƒ Chemical Oxygen Demand 15000 – 10000 feedstocks with different characteristics, for example, the co-
composting of biosolids in liquid/dewatered form with yard
ƒ Total solids 11500 – 79000 trimmings and leaves.
ƒ Suspended solids 5000 – 54000
ƒ Most of food waste compost mix other organic materials such as
ƒ Volatile solids 9000 – 72000 sawdust, wood chips, yard trimmings, or manure, with food waste
to produce high quality compost.
ƒ Oil and greese 130 – 18000
ƒ Ammonical nitrogen 4-80 ƒ There were many research in EFB composting showed that EFB itself
is insufficient to produce good quality compost because EFB
ƒ Total nitrogen 180 – 1400 content is low in nitrogen and moisture.
__________________________________________________
(Source: MPOB)

15
 2/29/2012

Cont.. Compost product

ƒ Therefore EFB composting need to be supplemented with other
organic materials. ƒ The temperature obtained in the pilot scale composting met
the sanitary requirement for pathogen-killing.
ƒ Various study shown that POME is favourable supplement to EFB
as POME contain high moisture and high nitrogen content. ƒ The compost product contained C/N ratio of 12 with
considerable amount of calcium
calcium, magnesium,
magnesium potassium,
potassium
ƒ Furthermore, as both EFB and POME come from the same phosphorus and other nutrients.
source, the combination of both materials is convenient and
economically beneficial.

ƒ Studies conducted at UPM has shown that co-composting of EFB

and partially treated POME using windrows composting pile can
produce compost that is suitable to be applied as fertilizer or soil
amendment.

Exercise
Part 2
ƒ Each group is required to read article related with co-
composting of palm oil biomass and present the findings in Collecting and transport system of raw
the class. material to the pilot plant

16
 2/29/2012

Introduction Exercise

ƒ Transport system is very essential to ensure the raw material ƒ Each group should identify the cost of transport from mill to
is ready and enough in capacity to be used for pilot plant.
composting. There are many choice of transport that
suitable for p
palm oil biomass such as: ƒ Identify the facilities of transport system such as tote tank.
How much the cost of the tank and how to order, which
ƒ Lorries –to transport empty fruit bunch company supply the facilities etc.

ƒ Tote tank – to contain palm oil mill effluent. The tote tank is
loaded into lorry.

Introduction
ƒ Oil palm production is a major agricultural industry in Malaysia. The oil
palm biomass (OPB) produces about 40 million tonnes per year.
ƒ This OPB can be categorized as a form of empty fruit bunches (EFB), oil
palm trunks (OPT) and oil palm fronds (OPF) and the rest are palm oil mill
effluent (POME).
Preparation of Raw Materials ƒ Composting has been considered to be one of the most suitable ways
for Composting of converting organic wastes into products that are beneficial for plant
growth.
ƒ Thus, the utilization of EFB and POME as substrate for the composting is
crucial to convert into value added product and treat the biomass
simultaneously.
ƒ Co-composting of EFB and partially treated POME can be used as an
alternative method for converting of these materials using a simple and
traditional windrow composting piles in pilot scale or combination with
composter system.

17
 2/29/2012

Empty fruit bunch

ƒ In this study, empty fruit bunch will be used as substrate for
composting.

ƒ However its bulky size is not feasible to be used in composting.

Various types of machines are required to reduce it into smaller
size.

ƒ Small particles of raw materials have more surface area, which

make nutrients and energy more available to microorganisms.

ƒ Particle size from 1/8 to 2 inches in diameter is acceptable to be

used in composting.

ƒ The size of shredded EFB is estimated about 15 to 20 cm length.

Figure : shredded EFB

POME Learning outcome

ƒ POME anaerobic sludge from the digester can also be used for ƒ Students will be able to hands on to various type of grinder for
EFB composting treatment. substrate preparation (P4)

ƒ The addition of thicken POME anaerobic sludge into EFB ƒ Students will be able to identify various type of grinder machine
compost might enrich the composting materials with high (A4 C4)
(A4,C4).
nutrient and microbial sources.
ƒ Student will be able to characterize and evaluate the raw
ƒ POME can be obtained from a 500 m3 closed anaerobic material of composting (P5, C6)
digester (CAD) developed at Felda Serting Hilir Palm Oil Mill,
Negeri Sembilan.

18
 2/29/2012

Exercise Analyses
ƒ Students will be exposed to hands on to various type of grinder for ƒ Chemical oxygen demand (COD),
substrate preparation.
ƒ Biological oxygen demand (BOD),
ƒ Students are required to write a report on the machine used and
ƒ Volatile suspended solid (VSS),
include information such as power uptake,
uptake capacity,
capacity price,
price
supplier, etc. ƒ Total solids (TS),
ƒ The students must characterize the raw material; EFB and POME. ƒ Total suspended solids (TSS),
ƒ Oil and grease and pH

- Measure according to American Public Health Association

(APHA) methods (1998).

Introduction

ƒ Composter is used to provide a conducive environment during

composting and therefore will speed up the composting process.

ƒ A 45m3 cylindrical vessel with vertical position was invented as a

composting apparatus for the decomposition of organic wastes
specifically oil palm biomass, organic and municipal wastes.
Empty fruit bunch (EFB) and
palm oil mill effluent (POME) ƒ The raw materials will be fermented for 7-10 days inside the cylindrical
closed vessel and followed by curing stage in the windrow pile.
in composter ƒ The feasibility of co-composting treatment between empty fruit bunch
(EFB) and POME anaerobic sludge through the combination of 45 m3
in-vessel closed-composter and windrow systems was carried out.

19
 2/29/2012

Cont. Cont..

ƒ Based on the start up of semi-commercial composting ƒ The composter used in this study was capable to utilize up to 10
treatment of empty fruit bunches and POME anaerobic tonnes of empty fruit bunches. It comprises screw type impeller
that contributes to the well mixing of the substrates.
sludge using combination of bioreactor and windrow
systems
y showed that the biocompost p product is a suitable
p ƒ The wall of composter was insulated to prevent the heat loss to
3-in-1 bioproduct for use in agriculture and horticulture as the surrounding area during thermophilic stage of composting
soil conditioner, soil humidifier and slow released fertilizer. treatment.

ƒ An appropriate composting method was successfully ƒ Besides, the staircase also has been installed around the
composter for the purpose of sampling and data collection.
developed either by using windrow system only or
combination of windrow and closed bioreactor. The ƒ Moreover, the load cell was installed at the bottom part of the
technology is ready for scaling up and commercialization. composter to determine the weight changes throughout the
treatment.

Cont.
ƒ The composter was designed with conical shape bottom vessel
and equipped with an axial mixing system, feeding and
discharge system, leachate collection system, aeration system
and CO2 removal system.

ƒ The important parameters for the composting in composter are

temperature (60-70oC), moisture content (55-65%).

ƒ Oxygen level should be controlled and monitored throughout

the thermophilic stage process.

ƒ After seven days of treatment in composter, then the pre-

matured compost will be introduced for the curing stage in
windrow system.
Composter system

20
 2/29/2012

Learning outcomes Exercise

ƒ Students will be able to design biocomposting treatment in ƒ Students are required to do experiments on co-
composting of EFB and POME in windrow system
composter (P7) followed by sample analysis. This is last for 7 days.
Technical preparation of the composting system will
ƒ Students will be able to evaluate and analyse the process be explained by the instructor.
occur during composting (A4, C6)

Students must compile all the data/profile

of composting and prepare a report. All
observation during composting process
should also be included.

ƒ Windrow composting systems were developed to handle the

decomposition of large amounts of material in a centralized
location.
ƒ Material to be composted is placed in a long pile approximately
5 feet wide. Typically, mechanical aeration and the addition of
water are used to speed up the decomposition process.

Empty fruit bunch (EFB) and ƒ Organic waste is formed into rows of long piles called
“windrows” and aerated by turning the pile periodically by
palm oil mill effluent (POME) either manual or mechanical means.

in windrow system ƒ The ideal pile height, which is between 4 and 8 feet, allows for a
pile large enough to generate sufficient heat and maintain
temperatures

21
 2/29/2012

ƒ The ideal pile width is between 14 and 16 feet. Leachate is liquid ƒ UPM in collaboration with Kyushu Institute of Technology, Japan
released during the composting process. and FELDA Palm Industries Sdn Bhd have undertaken a study
on co-composting of EFB and POME.
ƒ This can contaminate local ground-water and surface-water
ƒ The study was done in Maokil Palm Oil Mill site funded by FELDA
supplies and should be collected and treated.
Grant 67001 and Japan Society for Promotion of Science
(JSPS).
ƒ In addition, windrow composting is a large scale operation and
might be subject to regulatory enforcement.
enforcement ƒ A total
t t l off 202 windrow
i d were incubated
i b t d att the
th composting
ti site
it
which consists of two field area (13 hectares).
ƒ Samples of the compost should be tested in a laboratory for
bacterial and heavy metal content. ƒ Shredded EFB and partially treated POME were mixed at 40
tonnes and 120 tonnes respectively.
ƒ Thus, the study concludes that the treated POME can be used
as a main source of microbial seeding to EFB throughout the
composting process.

ƒ In this present study, the windrow pile system is conducted after

the raw material is treated from composter. Learning outcome
ƒ The pre-matured compost will be introduced for the curing
stage in windrow system with a pile size of 1.2m height, 3.0 m
wide and 15.0 m length. ƒ Students will be able to design biocomposting
ƒ The windrow pile is constructed under the transparent roof experiment in windrow system (P7)
building to facilitate for the drying process.
ƒ Students will be able to evaluate and analyse the
ƒ The windrow pile should be turned daily to provide sufficient process occur during composting (A4, C6)
aeration and reduce the moisture content of the composting
materials towards the end of treatment.
ƒ The mixing ratio of POME sludge added to enrich the EFB
materials throughout the composting process is one to one on
a weight basis.
ƒ The total composting process for each composting cycle is
completed within 40 days of treatment.

22
 2/29/2012

Analysis Exercise
ƒ The crucial parameters to be monitored are temperature,
oxygen level, moisture content, pH throughout composting Students are required to do experiments on co- composting of
process and metals/nutrients element, C:N ratio of the final EFB and POME in windrow system followed by sample analysis.
compost. This is last for 40 days. Technical preparation of the
ƒ The procedure/technique of measurements of those parameters composting
p g system
y will be explained
p by
y the instructor.
are based on the Standard Methods (APHA, 1989).
ƒ CNHS analyzer and Inductively Coupled Plasma (ICP) will be
used to measure carbon, nitrogen, nutrients and heavy metal Students must compile all the data/profile of composting and
elements. prepare a report. All observation during composting process
ƒ Plate count method will be used to obtain a viable bacterial should also be included.
count at different composting phase.

Introduction
ƒ The biocompost pilot plant has been developed in UPM to provide
the showcase of appropriate composting technology for organic,
municipal solid waste and oil palm biomass.
ƒ Applying the accelerated and controlled in-vessel composting
Preparation of Business system, the raw materials such as empty fruit bunches are
Model decomposed and transformed into a stable humus complex
within 5-6 weeks.

23
 2/29/2012

ƒ Initiated through the inoculants from treated POME sludge

ƒ This basic and consistent quality of compost product can be addition, the final compost contains millions of micro-
used as nutrient supplement to provide the plants with required organisms, a tightly knitted soil-food-web, creating a natural
nutrients and micro-elements. immune system for the plant, acting as natural predators
against most known soil born diseases and other pathogens.
ƒ Due to the special humus structure the water holding capacity of
the soils is increased up
p to 70% which is an important
p added ƒ This disease suppression is one of the outstanding unique selling
value for growers in arid and semi-arid areas. points
i t off UPM biocompost.
bi t

ƒ This disease suppression is one of the outstanding unique selling ƒ The proposed technology can offer a cooperation
points of UPM biocompost. model for the production and sales of high quality
compost but provides at the same time a
ƒ Besides the compost production and selling activity, one of the
main concerns is for greenhouse gas emission reduction at palm technology which qualifies as an emission reduction
oil mill that also offers alternative fund through Clean methodology under the regulations of the Kyoto
Development Mechanism (CDM) initiatives. protocol, generating an additional income stream
for the project, as the CO2 emissions reduced, can
be sold as carbon credits to offsetting companies
and in special cases to governments.

24
 2/29/2012

A. Introduction and overview

Learning outcome ƒ Type of technology
ƒ Type of raw materials
ƒ Students will be able to provide and evaluate a ƒ Composting site and pre-treatment
business model based on proposed compost project
(A4,C6) ƒ Climate/ environmental concerns
ƒ Final Compost product and value addition
ƒ Alternative fertilizer
ƒ Chemical fertilizer
ƒ Problem statement and recommendation

B. UPM Biocompost Technology C. Business strategy (6 hrs)

Overview
ƒ Market segmentation-key customer and compost quality
ƒ Technology map
ƒ Organic agriculture in Malaysia
ƒ IP and proposed appropriate composting technology
ƒ Operation analysis (manpower, machinery, method, material
ƒ Product readiness analysis etc)
ƒ Technology shelf life ƒ Commercialization model approach
ƒ Consumer demand ƒ Business model of UPM biocompost technology at palm oil mill
as example (integration)
ƒ Lower-cost alternative
ƒ Additional fund- eg; CDM
ƒ Integration system at palm oil mill

25
 2/29/2012

Exercise:
•The impact of CDM and without CDM on
biocompost production
•Project economic Students are required to draft a business model on
•Capital requirement (Financial/fund raising) proposed commercialization project and submit a report
within two weeks.
•Certification of compost product
•Market competition
•Pricing –NPK quality and value addition
•Product packaging and beneficial microbes

Introduction
ƒ There are several important factors that should be considered
to increase the profitability and economic viability of
composting business.
ƒ The quickest route to profitability is to enhance the value of the
Business Strategy and output product in order to obtain higher prices of compost.
Commercialization ƒ Proper site selection and careful planning for layout and
preparation can reduce that cost of operation, but it should
operate initially at small-medium scale for improvement.
ƒ Fuel prices are at the mercy of the market, thus the design of
the composting system must ensure the lower fuel consumption
for every tones of compost produced.

26
 2/29/2012

ƒ It is paramount to demonstrate cost effectiveness of

ƒ UPM’s biocompost technology has been tested at the technology in commercial demonstration scale.
field scale and currently under production scale-up
to 3 tons per day processing capacity at UPM ƒ With establish operation data and further processing
biorefinery complex. protocols, the technology can be marketed to
ƒ However the commercial scale at palm oil mill companies that are interested in process licensing or
requires at least 30 TPH processing capacity. production of the end p
p products.
ƒ Thus the economic viability and cost of operation ƒ The proposed deployement strategy is based on the
based on appropriate composting technology need
to be establish for the commercialization. building technology strength on commercial ground
prior further deployment into the process/product
ƒ The best commercialization mechanism is to market.
collaborate with mill owner either in form of
technology licensing or joint-venture or “built-
operate-transfer” (BOT).

Learning outcome Field work Task (Group):

ƒ Each group should identify the market potential (raw
ƒ Students will be able to evaluate the market potential of material), demand of compost, compost quality and
compost product (C6, P6) value addition.
ƒ Each group is required to analyse and discuss
internal/external market for rock mellon/mango
plantation.
ƒ Each group is required to present the proposed
business model for compost utilization in
mellon/mango plantation
ƒ The reports should be completed within two weeks.

27
 2/29/2012

ƒ Problem statement and discussion (field work)

ƒ Compost production and marketing strategy

Exercise:
ƒ Deployment approach-cost effectiveness, rapid and consistent
quality, high NPK etc Each student is required to prepare SWOT analysis on
ƒ Collaborating entity/strategic partnership proposed commercialization project and submit a
report within a week.
ƒ SWOT analysis on proposed Commercialization Project

ƒ Conclusion and recommendation

28