Bio 3 Revised Assignmet 1

UNIVERSITAS INDONESIA
BIOMETHANE PRODUCTION FROM RICE STRAW BIOMASS AND

ORGANIC MUNICIPAL SOLID WASTE
Revised Assignment 1
GROUP 03
GROUP PERSONNEL:
AJENG INAS SETYORINI (1606828066)
ANINDITO AWINDYA (1606879161)
ANANDA BAGUS RICKI DIGDAYA (1606887812)
DAMAI KASIH LINTANGHATI (1606890126)
NURUL HIKMAH RAMADHANI (1606838262)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
OCTOBER 2019
EXECUTIVE SUMMARY
According to The Jakarta Post (2017), the waste to energy concept is a

recognizable concept in Indonesia, however it has not seen widespread utilization.
In waste to energy, municipal solid waste (MSW) can produce biogas that can be
used for several power, heat or combined heat and power systems. Such method of
treating waste can not only reduce the increasing amount of waste produced but can
also fulfill the countries increasing demand for power.
Lignocellulosic biomass, another component for biofuel, is an abundant
organic material that can be used for sustainable production of bioenergy such as
biogas (about 50-75% CH4 and 25-50% CO2). Out of all bioconversion
technologies bioenergy production, anaerobic digestion (AD) is the most cost-
effective bioconversion technology that has been implemented worldwide for
commercial production of electricity, heat, and compressed natural gas (CNG) from
organic materials. Lignocellulosic content is one of the most considerable
components to produce as many biogas as possible.
Biogas is a combustible mixture of gases. It consists mainly of methane
(CH4) and carbon dioxide (CO2) and is formed from the anaerobic bacterial
decomposition of organic compounds, i.e. without oxygen. Biomethane can be
obtained by biogas purification, which produces gas with nearly perfect methane
content. Biomethane in principal can be used for exactly the same applications as
natural gas. Therefore, it can be used as a substitute for liquid transport fuels, to
produce combined heat and power (CHP), heat alone and serve as feedstock for the
chemical sector.
Based on many considerations, the plant will be located in Karawang
Industrial Area specifically in Wancimekar, Kota Baru, Karawang District, West
Java. There are some advantages in this area such as being near to MSW and rice
straw source, being in same district with PLTGU Karawang as a customer target
and having a high population density of worker in Indonesia.
The plant’s purpose is to produce biomethane from lignocellulosic biomass
which is in this case is Rice Straw with Municipal Solid Waste. Biomethane
production process begins by washed the rice straw to remove impurities and other
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foreign material. The production process in general that is going to run in the plant
includes washing, drying, grinding, pre-treatment biomass with hot water,
methanobacterium cultivation, anaerobic digestion, biogas upgrading with water
scrubbing and stripping and degasifying.
The mass balance explains about mass input and output of production of
biogas from organic municipal solid waste and biomass. Mass balance equation is
conducted to evaluate the production capacity with the supply of raw material.
Meanwhile, energy balance is calculated using mass balance that had been
calculated previously. Energy balance means the heat generated by every unit
operation in the whole production process. Mass and energy balance are calculated
with Intelligen Inc.’s SuperPro Designer V9.0 software. Overall mass balance is
13716.45222 kg in and 13431.32924 kg while the energy balance is 10562523575
KJ in and 10563374873 KJ out.
A plant produces heat transmission because of its process. A designed plant
that starts from reactor section to separation and recycle system requires heat
recovery system, so heat exchanger is necessary. To fix the material and energy
balances, heating and cooling major process is needed as a recovery for system.
The result will allow prediction to process changes for the reactor, separation
process and recycle system to support the result for the energy and capital cost of
the assessed heat exchanger network.
Heat exchanger network diagram proves to be the effective way to take the
advantage of the heat exchanger equipment. In this case, the hot fluid and the cold
fluid complete each other in order to reach the designated temperature. This result
adding more two heat exchangers leads to more integrated heating and cooling
system of the plant.
Utility is one of the most important factors in factory. Utility is divided into
water, air, electricity, and water treatment. Components such as water and air must
undergo treatment process in order for them to be usable. Electricity is used to
power up factory’s equipment. HEN integration into the utility makes the electricity
of the plant becoming more efficient. Lastly, wastewater treatment is required to
remove contaminant from used water, and the treated useable water are recycled
for process.
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LIST OF CONTENT
EXECUTIVE SUMMARY ................................................................................ii

LIST OF CONTENT ........................................................................................ iv
LIST OF FIGURES .......................................................................................... vi
LIST OF TABLES ........................................................................................... vii
CHAPTER 1 INTRODUCTION .................................................................. 1
1.1. Backgrounds ................................................................................................ 1
1.2. Basic Theory ................................................................................................ 2
1.2.1. Municipal Solid Waste .............................................................................. 2
1.2.2. Biomass .................................................................................................... 4
1.2.3. Biogas ....................................................................................................... 6
1.2.4. Properties of Biogas .................................................................................. 6
1.2.5. Biomethane ............................................................................................... 7
1.3. Raw Material Analysis ................................................................................ 8
1.3.1 Municipal Solid Waste .............................................................................. 8
1.3.2 Biomass .................................................................................................... 9
1.3.3 Bacteria ....................................................................................................13
1.4. Market and Capacity Analysis ...................................................................15
1.5. Plant Location Analysis ..............................................................................17
1.5.1 Raw Material Distribution and Availibility ...............................................17
1.5.2 Government Policy...................................................................................17
1.5.3 Human Resource ......................................................................................17
1.5.4 Product Distribution .................................................................................17
1.5.5 Water Accessibility ..................................................................................18
1.5.6 Infrastructure............................................................................................18
1.5.7 Land and Wage Price ...............................................................................19
1.5.8 Final Consideration and Plant Location ....................................................19
CHAPTER 2 PROCESS SYNTHESIS AND SELECTION ..................... 21
2.1. Process Synthesis ........................................................................................21
2.2. Alternative Process .....................................................................................21
2.2.1 Pre-Treatment ..........................................................................................21
2.2.2 Digester Types .........................................................................................30
2.2.3 Biogas Upgrading Technology .................................................................31
2.3. Process Selection .........................................................................................35
2.3.1. Size Reduction Process Selection .............................................................35
2.3.2. Pre-Treatment Process Selection...............................................................37
2.3.3. Digester Types Selection ..........................................................................41
2.3.4. Biogas Upgrading Technology .................................................................42
2.4. Process Description ....................................................................................44
2.4.1. Raw Material Process ...............................................................................44
2.4.2. Washing ...................................................................................................44
2.4.3. Drying......................................................................................................45
2.4.4. Grinding...................................................................................................46
2.4.5. Biomass Pretreatment ...............................................................................47
2.4.6. Bacteria Cultivation Inoculum ..................................................................48
2.4.7. Anaerobic Digestion .................................................................................49
2.4.8. Water Scrubbing ......................................................................................54
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2.4.9. Stripping ..................................................................................................56
2.4.10. Condenser ................................................................................................58
2.5. Block Flow Diagram ...................................................................................59
2.6. Process Flow Diagram ................................................................................60
CHAPTER 3 MASS AND ENERGY BALANCE ..................................... 61
3.1. Mass Balance ..............................................................................................61
3.1.1. Mass Balance per Unit Operation .............................................................61
3.1.2. Overall Mass Balance...............................................................................70
3.2. Energy Balance ...........................................................................................71
3.2.1 Energy Balance per Unit Operation ..........................................................72
3.2.2 Overall Energy Balance ............................................................................82
3.3. Production Efficiency Efficiency ................................................................83
3.4. Process Simulation .....................................................................................84
CHAPTER 4 HEAT EXCHANGER NETWORKING ANALYSIS ........ 86
4.1. Stream Classification ..................................................................................86
4.2. Heat Recovery Pinch ..................................................................................87
4.2.1 Problem Table Cascade Method ...............................................................87
4.2.2 Pinch Design Method ...............................................................................88
4.3. Process Flow Diagram After HEN .............................................................91
CHAPTER 5 UTILITY .............................................................................. 93
Water Utility ...............................................................................................93
5.1.1 Main Process ............................................................................................93
5.1.2 Cooling Process .......................................................................................95
5.1.3 Heating Process ........................................................................................99
5.1.3 Water Treatment ......................................................................................99
Air Utility .................................................................................................. 103
Electricity.................................................................................................. 105
5.4.1 Electricity Before HEN .......................................................................... 105
5.4.2 Electricity After HEN............................................................................. 107
5.5. Fuel Waste ................................................................................................ 109
5.5.1. Fuel Utility............................................................................................. 109
5.5.2. Off-gas Flare .......................................................................................... 110
5.5.3. Boiler ..................................................................................................... 110
5.6. Water Treatment .............................................. Error! Bookmark not defined.
5.4.3 Waste Water Treatment .............................. Error! Bookmark not defined.
CHAPTER 6 CONCLUSION .................................................................. 113
REFERENCES .............................................................................................. 115
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LIST OF FIGURES
Figure 1.1 Municipal Solid Waste Composition .................................................. 3

Figure 1.2 Type of Biomass ................................................................................ 5
Figure 1.3 Distributed Energy Production and Utilisation based on Biomass ....... 5
Figure 1.4 Rice Straw........................................................................................ 13
Figure 1.5 Plant Location .................................................................................. 20
Figure 2.1 Black Box Diagram .......................................................................... 21
Figure 2.2 Pre-Treatment Method ..................................................................... 22
Figure 2.3 Biomass Washer ............................................................................... 45
Figure 2.4 Rotary Dryer Machine ...................................................................... 46
Figure 2.5 Grinding Machine ............................................................................ 47
Figure 2.6 Anaerobic Digestion System Separation Phase ................................. 50
Figure 2.7 Anaerobic Digestion ......................................................................... 54
Figure 2.8 Water Scrubbing Machine ................................................................ 56
Figure 2.9 Stripping Machine ............................................................................ 57
Figure 2.10 Block Flow Diagram ...................................................................... 59
Figure 2.11 Process Flow Diagram .................................................................... 60
Figure 4.1 Cascade Diagram of Biomethane Plant from Rice Straw and MSW .. 89
Figure 4.2 Heat Exchanger Network Design for Biomethane Plant .................... 90
Figure 4.3 Process Flow Diagram After HEN ................................................... 92
Figure 5.1 Plant Location for Seawater.............................................................. 93
Figure 5.2 A Water Pump from Taizhou BLUESEA Pump Co. ......................... 94
Figure 5.3 A Water Pump from Zhejiang Chenjie Pump Industry Co., Ltd ........ 95
Figure 5.4 Water Utility Process Flow Diagram Before HEN .......................... 101
Figure 5.5 Water Utility Process Flow Diagram After HEN ............................ 102
Figure 5.6 Two Air Blowers, Left is Used for Drying, and Right is Used for
Stripping .......................................................................................................... 103
Figure 5.7 Air Utility Flow Diagram ............................................................... 104
Figure 5.8 Fuel Boiler ..................................................................................... 110
Figure 5.9 Fuel Utility Flow Diagram ............................................................. 112
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LIST OF TABLES
Table 1.1 The Composition of Biogas ................................................................. 7

Table 1.2 Scoring Value Biomass ........................................................................ 9
Table 1.3 Biomass Selection .............................................................................. 10
Table 1.4 Rice Straw Composition .................................................................... 11
Table 1.5 Scoring Value of Bacteria .................................................................. 13
Table 1.6 Bacteria Selection .............................................................................. 14
Table 1.7 Gas Consumption .............................................................................. 15
Table 1.8 The Amount of Electricity Production................................................ 15
Table 2.1 Alternative Pre-Treatment .................................................................. 28
Table 2.2 Types of Digester............................................................................... 30
Table 2.3 Criteria Selection of Physical Pre-Treatment ...................................... 36
Table 2.4 Comparison Alternatives of Physical Pre-Treatment .......................... 36
Table 2.5 Scoring Parameter of Physical Pre-Treatment .................................... 36
Table 2.6 Criteria Scoring of Pre-Treatment ...................................................... 38
Table 2.7 Comparisan of Pre-Treatments Methods ............................................ 38
Table 2.8 Pre-Treatment Process Scoring .......................................................... 40
Table 2.9 Parameter Comparison of Digester Types .......................................... 41
Table 2.10 Temperature Comparison of Digester Types .................................... 42
Table 2.11 Scoring of Purification Gas .............................................................. 44
Table 2.12 Operation Condition of Washing Machine ....................................... 45
Table 2.13 Operation Conditions of Drying ....................................................... 45
Table 2.14 Operation Conditions of Grinding .................................................... 46
Table 2.15 Operation Conditions of LHW ......................................................... 47
Table 2.16 Kinetic Parameter Values of Methanogen ........................................ 49
Table 2.17 Chemical Reactions Involved in the Anaerobic Digestion ................ 52
Table 2.18 Operation Conditions of Water Scrubbing ........................................ 55
Table 2.19 Operation Conditions of Stripping.................................................... 57
Table 2.20 Operation Conditions of Condenser ................................................. 58
Table 3.1 Mass Balance in Washing Process ..................................................... 61
Table 3.2 Mass Balance in Rotary Drying ......................................................... 62
Table 3.3 Mass Balance in Belt Conveyor 1 ...................................................... 62
Table 3.4 Mass Balance in Grinding .................................................................. 62
Table 3.5 Mass Balance in Pre Treatment .......................................................... 63
Table 3.6 Mass Balance in Heating.................................................................... 63
Table 3.7 Mass Balance in Cooling ................................................................... 63
Table 3.8 Mass Balance in Anaerobic Digestion ................................................ 64
Table 3.9 Mass Balance in Gas Compressor ...................................................... 64
Table 3.10 Mass Balance in Belt Conveyor 2 .................................................... 65
Table 3.11 Mass Balance in Seed Fermentor ..................................................... 65
Table 3.12 Mass Balance in Cooling 2............................................................... 66
Table 3.13 Mass Balance in Gas Compression................................................... 66
Table 3.14 Mass Balance in Gas Compression................................................... 67
Table 3.15 Mass Balance in Cooling 2............................................................... 67
Table 3.16 Mass Balance in Absorption ............................................................ 68
Table 3.17 Mass Balance in Condensation ......................................................... 68
Table 3.18 Mass Balance in Stripping ............................................................... 69
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Table 3.19 Mass Balance in Degasification ....................................................... 69
Table 3.20 Mass Balance in Compressor ........................................................... 69
Table 3.21 Mass Balance in Gas Compressor .................................................... 70
Table 3.22 Mass Balance in Heat Exchanger ..................................................... 70
Table 3.23 Overall Mass Balance ...................................................................... 71
Table 3.24 Heat Specific of Each Component .................................................... 72
Table 3.25 Energy Balance in Washing Process ................................................ 72
Table 3.26 Energy Balance in Rotary Drying .................................................... 73
Table 3.27 Energy Balance in Belt Conveyor .................................................... 73
Table 3.28 Energy Balance in Grinding ............................................................. 73
Table 3.29 Energy Balance in Pretreatment ....................................................... 74
Table 3.30 Energy Balance in Heating ............................................................... 74
Table 3.31 Energy Balance in Cooling Process .................................................. 75
Table 3.32 Energy Balance in Anaerobic Digestion ........................................... 76
Table 3.33 Energy Balance in Gas Compressor ................................................. 77
Table 3.34 Energy Balance in Belt Conveyor .................................................... 77
Table 3.35 Energy Balance in Seed Fermentor .................................................. 78
Table 3.36 Energy Balance in Cooling .............................................................. 78
Table 3.37 Energy Balance in Gas Compression................................................ 79
Table 3.38 Energy Balance in Gas Compression................................................ 79
Table 3.39 Energy Balance in Cooling .............................................................. 80
Table 3.40 Energy Balance in Absorption.......................................................... 80
Table 3.41 Energy Balance in Condensation ...................................................... 81
Table 3.42 Energy Balance in Stripping ............................................................ 81
Table 3.43 Energy Balance in Heat Exchanger .................................................. 81
Table 3.44 Energy Balance in Gas Compressor ................................................. 82
Table 3.45 Mass Balance in Heat Exchanger ..................................................... 82
Table 3.46 Overall Energy Balance ................................................................... 83
Table 4.1 Stream Classification ......................................................................... 86
Table 4.2 Shifted Temperature Data from Table 4.1 ......................................... 87
Table 4.3 Shifted Temperature Area .................................................................. 88
Table 4.4 Temperature Interval Balance ............................................................ 88
Table 5.1 Water Used in Main Process .............................................................. 94
Table 5.2 Cooling Water Requirement Before HEN .......................................... 96
Table 5.3 Calculation of Makeup Cooling Water Before HEN ........................... 96
Table 5.4 Calculation of Makeup Cooling Water Before HEN (cont’d) ............. 97
Table 5.5 Cooling Water Requirement After HEN............................................. 97
Table 5.6 Calculation of Makeup Cooling Water After HEN ............................. 98
Table 5.7 Heating Requirement in Plant Before HEN ........................................ 99
Table 5.8 Air used in the process ..................................................................... 103
Table 5.9 Electricity used in the process .......................................................... 105
Table 5.10 Electricity used in the process ........................................................ 107
Table 5.11 Specification of Boiler ................................................................... 111
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CHAPTER 1
INTRODUCTION
1.1. Backgrounds
Currently, a quarter of Indonesia’s population lacks access to electricity
(World Bank, 2013). As a developing country, Indonesia is expecting a growth in
economic development and urban population. This results in an increasing amount
of MSW and a rising energy demand. In order to keep up with such development,
waste management systems must be considered as a means to make use of this
growing amount of waste. The waste to energy concept is a recognizable concept
in Indonesia, however it has not seen widespread utilization (The Jakarta Post,
2017). In waste to energy, municipal solid waste can produce biogas that can be
used for several power, heat or combined heat and power systems. Such method of
treating waste can not only reduce the increasing amount of waste produced but can
also fulfill the countries increasing demand for power.
Municipal Solid Waste (MSW) is a waste type that consists of everyday items
that are discarded by the public. These wastes are composed by organic materials,
papers, plastics, glass, metals and other wastes and come from sources such as
households, markets, streets, public facilities, offices and industries.
In most major cities in Indonesia, population increase has created poor
environmental living conditions that significantly affect sanitary conditions. Of all
these problems, the commonest in urban areas is currently the improper
management of municipal solid waste (MSW), which is also a growing concern
within those cities. Meanwhile, it was nationally estimated that only 60%–70% of
all generated MSW is transported to the final disposal sites by the institutions in
charge of waste and sanitation affairs. Most of the waste not handled by the city is
usually burned or dumped in open spaces or in rivers and streams. Moreover, only
small amounts of the unhandled waste are recovered by scavengers for their benefit.
Karawang is known as one of the busiest industrial district in West Java. It has
produce municipal solid waste in average 255 kg/m3, with average accumulation
1.75 liter of municipal solid waste per day per one person or equal to 0,45 kg
municipal solid waste per day per one person. So that the total accumulation of
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2
municipal solid waste generated every day in Karawang in 2010 with a population
of 2,125,234 people is 3,750.41 m3 MSW/day or equal to 956.3 ton per day. The
highest composition of municipal solid waste in Karawang District is in form of
food scraps and leaves is reached up to 67.67%, plastics 23.49%, paper 2.91%,
fabric 0.43%, metals 0.22%, glass of 0.32% and others 4.96 %. Not only known in
industrial sector, Karawang is also known in agricultural sector with an area 95,906
hectare including irrigation and non irrigation rice field. Data from Badan Pusat
Statistik Karawang shown that in 2016 the accumulation of rice straw in Karawang
District is reaching 709,704.4 ton.
Several technologies exist to treat such organic fractions of wastes, among
them include anaerobic digestion, landfill gas recovery, pyrolysis and gasification.
Several studies have been conducted that compare these different technologies of
waste to energy. For example, Kumar and Samadder (2017) reviewed the
technological options for effective management of MSW in terms of energy
recovery potential, cost and environmental and health impacts.
1.2. Basic Theory
Biogas from biomass is a promising for fulfill energy demand. Biogas has
been drawing wide attention for its ability to replace fossil fuels which are likely
to get exhausted in the expected future. The basic of converting biomass to
produce biogas will be explained below.
1.2.1. Municipal Solid Waste
Municipal solid waste (MSW) also called trash consists of everyday items
such as product packaging, yard trimmings, furniture, clothing, bottles and cans,
food, newspapers, appliances, electronics and batteries. Sources of MSW include
residential waste (including waste from multi-family housing) and waste from
commercial and institutional locations, such as businesses, schools and hospitals.
The Environmental Protection Agency’s (EPA) definition of MSW does not include
industrial, hazardous or construction and demolition (C&D) waste. Once generated,
MSW must be collected and managed. Common management methods include
recycling, composting, combustion with energy recovery and landfilling. Many
wastes that are landfilled represent a loss of materials that could be reused, recycled
or converted to energy to displace the use of virgin materials.
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Before the 1970s, MSW management generally consisted of depositing

wastes in open dumps, accompanied by open burning to reduce waste volumes.
Often industrial hazardous wastes were co-disposed with municipal garbage and
refuse in open dumps or landfills. Historically, environmental problems associated
with these older landfills have included ground water contamination, emissions of
toxic fumes and greenhouse gases, land contamination and increases in pest and
disease vector populations, such as rodents, flies and mosquitos. Landfills are now
subject to federal or state requirements to minimize these environmental impacts.
As a society consumes more materials, it demands more resources like water,
energy, minerals and land and generates more pollutants and waste. Sustainable
materials management (SMM) refers to the use and reuse of materials in the most
productive and sustainable way across their lifecycle, while minimizing the impact
on the environment. An important goal of SMM is a reduction in material use
without a reduction in economic prosperity. Measuring and understanding the data
on MSW generation, recycling, composting, combustion with energy recovery and
landfilling is an important foundation for knowing where these valuable materials
are going and as well as a good starting point to figure out trends to use resources
more efficiently. By employing SMM principles, households, businesses and
society can achieve cost savings and reduce the effects on the environment.
Figure 1.1 Municipal Solid Waste Composition

(Source: http://techalive.mtu.edu)
4
Karawang is known as one of the busiest industrial district in West Java. It

has produce municipal solid waste in average 255 kg/m3, with average
accumulation 1.75 liter of municipal solid waste per day per one person or equal to
0,45 kg municipal solid waste per day per one person. So that the total accumulation
of municipal solid waste generated every day in Karawang in 2010 with a
population of 2,125,234 people is 3,750.41 m3 MSW/day or equal to 956.3 ton per
day. The highest composition of municipal solid waste in Karawang District is in
form of food scraps and leaves is reached up to 67.67%, plastics 23.49%, paper
2.91%, fabric 0.43%, metals 0.22%, glass of 0.32% and others 4.96 %.
1.2.2. Biomass
Biomass contributes as the world’s fourth largest energy source today up
to 14% of the world’s primary energy demand. In developing countries, it can be
as high as 35% of the primary energy supply. Biomass is a versatile source of
energy in that it can be readily stored and transformed into electricity and heat.
It has also the potential that it is used as a raw material for production of fuel and
chemical feedstock. Production units range from small scale up to multi-
megawatt sizes (Veringa, 2010).
Biomass is organic material that comes from plants and animals, and it is a
renewable source of energy. Biomass contains stored energy from the sun. Plants
absorb the sun's energy in a process called photosynthesis. When biomass is
burned, the chemical energy in biomass is released as heat. Biomass can be
burned directly or converted to liquid biofuels or biogas that can be burned as
fuels. Examples of biomass and their uses for energy.
 Wood and wood processing wastes - burned to heat buildings, to produce
process heat in industry, and to generate electricity
 Agricultural crops and waste materials - burned as a fuel or converted to liquid
biofuels
 Food, yard, and wood waste in garbage - burned to generate electricity in
power plants or converted to biogas in landfills
 Animal manure and human sewage - converted to biogas, which can be
burned as a fuel
5
Figure 1.2 Type of Biomass

(Source: The National Energy Education Project)
The current status of biomass technology from biomass crops, conversion

technologies to end products, technologies available and end products of the
conversion process. Figure below gives an overview of the different routes from
biomass to end products. This system focuses on distributed production, which
is the area where nowadays the very challenging developments are underway.
Figure 1.3 Distributed Energy Production and Utilisation based on Biomass

(Source: Veringa, 2010).
6
1.2.3. Biogas
Biogas is a combustible mixture of gases. It consists mainly of methane
(CH4) and carbon dioxide (CO2) and is formed from the anaerobic bacterial
decomposition of organic compounds, i.e. without oxygen. The gases formed are
the waste products of the respiration of these decomposer microorganisms and
the composition of the gases depends on the substance that is being decomposed.
If the material consists of mainly carbohydrates, such as glucose and other simple
sugars and high-molecular compounds (polymers) such as cellulose and
hemicellulose, the methane production is low. However, if the fat content is high,
the methane production is likewise high. Methane and whatever additional
hydrogen there may be makes up the combustible part of biogas. Methane is a
colourless and odourless gas with a boiling point of -162°C and it burns with a
blue flame. Methane is also the main constituent (77-90%) of natural gas
(Jorgensen, 2009).
Chemically, methane belongs to the alkanes and is the simplest possible
form of these. At normal temperature and pressure, methane has a density of
approximately 0.75 kg/m. Due to carbon dioxide being somewhat heavier, biogas
has a slightly higher density of 1.15 kg/m. Pure methane has an upper calorific
value of 39.8 MJ/m, which corresponds to 11.06 kWh/. If biogas is mixed with
10-20% air, you get explosive air, which – as the name indicates – is explosive
(Jorgensen, 2009).
1.2.4. Properties of Biogas
In fact, gas emitting from fermented animal, plant, and human waste in
anaerobic conditions (the absence of oxygen) is called biogas. Biogas is also
known as marsh gas and its main active gas is methane (CH4). In addition to
methane, biogas includes carbon dioxide (CO2), hydrogen sulfide (H2S), and
other gases such as hydrogen (H2), oxygen (O2), and nitrogen (N2). CO2 and
contaminant concentration profiles can be used as a measure of biofilter
performance. The composition of gases in biogas and their percentages are
shown in Table 1.1 Methane (CH4). In addition to methane, biogas includes
carbon dioxide (CO2), hydrogen sulfide (H2S), and other gases such as hydrogen
(H2), oxygen (O2), and nitrogen (N2). CO2 and contaminant concentration
7
profiles can be used as a measure of biofilter performance. The composition of

gases in and their percentages are shown in table below.
Biogas combustion temperature is about 700 and the flame temperature
is 870 like other gases, is combustible and it is mixed with air at a ratio of 1 to
20 with high combustion speed. Its heating value is about 6 kWh /m3 (i.e. equal
to heating value of half a liter of diesel fuel). The suitable pressure for cooking
with biogas is between 5 and 20 cm of water column. Heating value of 1 m3 of

biogas is equal to 0.4 liter of diesel, 0.6 liter of kerosene, 0.8 kg of coal, 1.46 kg
of charcoal, 3.47 kg of firewood, and 0.43 kg of LPG. Generally, garbage, rural
and urban waste, and human and animal waste are biogas production resources
(Rajati, 2014).
Table 1.1 The Composition of Biogas

Material Unit Percenta
s ge
Methane (CH4) % 60-70
Carbon Dioxide % 30-40
(CO2)
Water (H2O) % 1-5
Nitrogen (N2) % 0-0.5
Ammonia (NH3) ppm 100
Hidrogen Sulphide Ppm 0-4000
(H2S)
(Source:anserobic-digestion.com)
1.2.5. Biomethane
Biogas is acknowledged worldwide as one of the foremost technologies for
producing valuable fertilizer and renewable energy from all kinds of digestible
biomass. After undergoing a cleaning and upgrading process, biogas can be used
in the form of biomethane as a renewable substitute for natural gas.
The biogas process is a natural process, which takes place, for example, in
moors and swamps as well as in the digestive tracts of some animals, such as cows.
During the process, organic material is decomposed by microbial organisms in the
absence of oxygen and turned predominantly into methane (CH ). The methane
4
content of the biogas generated varies from 50 vol % to 70 vol%, depending on the
feedstock. The remaining part of the gas consists largely of CO2, of which 30 vol%
8
to 45 vol% is contained in the biogas. In addition, raw biogas contains small

amounts of water (H2O), oxygen (O2), hydrogen sulphide (H2S), ammonia (NH3)
and other trace gases.

The decomposition of the organic material can be divided into four different
phases. During hydrolysis, complex long-chain structures such as carbohydrates,
proteins or fats are broken down into smaller molecules such as amino acids, sugars
and fatty acids. During the subsequent acidogenesis, the intermediate products
formed in the rst step are further degraded to form lower fatty acids and other
carboxylic acids, such as butric and propionic acid. In addition, hydrogen, carbon
dioxide and acetic acid are produced, which are the basic elements for the
subsequent production of methane. During the third phase of the decomposition
process, referred to as acetogenesis, the lower fatty acids are broken down into
acetic acid by acetogenic microorganisms. Thus, the starting products are avail-
able for methanogenesis, the fourth step of the biogas process. During this phase,
archaea – the oldest forms of life on earth – convert acetic acid or hydrogen and
carbon into methane.
Biomethane in principal can be used for exactly the same applications as
natural gas, if the final composition is in line with the different natural gas qualities
on the market Therefore, it can be used as a substitute for liquid transport fuels, to
produce combined heat and power (CHP), heat alone and serve as feedstock for the
chemical sector. In contrast to liquid biofuels such as biodiesel and bioethanol,
biomethane and natural gas are fully interchangeable from an end-user perspective.
Biomethane can also play a significant role in future power-to-gas concepts by
combination of renewable methane from excess electrical energy, e.g. by providing
the renewable carbon source (separated CO2), so that hydrogen from excess energy
conversion can be used to increase the methane output of biogas process.
1.3. Raw Material Analysis
1.3.1 Municipal Solid Waste
MSW is generally composed of three groups of materials: organic waste
(kitchen waste, garden waste, etc), non-recyclable inorganic waste (coal ash, cinder,
dust, etc), and recyclable waste (paper, plastics, glass, metal, etc.). At present, MSW
9
is collected in a mixed state, but residents can volunteer to participate in the source-
separated collection.
The recyclable materials from daily use are often collected at the source by
scavengers. Selection of recyclable waste will only leave organic waste and
inorganic waste, but inorganic waste can be reduced by washing. Drying is needed
to reduce water content in organic waste with the purpose to minimize the risk of
spoilage. The process after organic waste selection until selling the customized
organic solid waste is done by non-governmental organization.
1.3.2 Biomass
Lignocellulosic biomass is an abundant organic material that can be used
for sustainable production of bioenergy such as biogas (about 50-75% CH4 and 25-
50% CO2). Out of all bioconversion technologies bioenergy production, anaerobic
digestion (AD) is a most cost-effective bioconversion technology that has been
implemented worldwide for commercial production of electricity, heat, and
compressed natural gas (CNG) from organic materials. So that lignocellulosic
content is one of the most considerable component to produce as many biogas as
possible. Another consideration are include availability, cost, water content in
biomass and also the easiness during the process.
Table 1.2 Scoring Value Biomass

Criteria 1 2 3 4
Availability Less than 1.000.000 - 25.000.000- More than
1.000.000 ton 24.999.999 50.000.000 ton 50.000.000
ton ton
Cost Rp. Rp. Rp.250.000/ton Equal or
350.000/ton – 300.000/ton – Rp less then
Rp/300.001/ton – Rp 200.001/ton Rp.200.000/
250.001/ton ton
Lignocellulosic 0-19.99% 20– 39.99% 40 – 59.99 % 60 – 80%
Content
Water Content 25-30% 20-24.99% 15-19.99% Less than
15%
10
Table 1.3 Biomass Selection
Parameter
Raw
Material Availibility (25%) Cost Lignocellulosic Content Water Content Total Rank
Value Rating Score Value Rating Score Value Rating Score Value Rating Score
Corn 8.128.734 Rp
2 0.5 2 0.5 79.60% 4 1.2 10.3% 4 0.4 2.3 2
Stalk ton 250.000/ton
Rice 67.310.000 Rp
4 1 4 1 79.75% 4 1.2 15% 3 0.3 3.5 1
Straw ton 200.000/ton
Oil Palm
Empty 12.400.000 Rp
2 0.5 3 0.75 76.66% 4 1.2 30% 2 0.2 2.3 3
Fruit ton 350.000/ton
Bunch
11
Rice is primarily grown in tropical and sub-tropical climates, however some

rice production occurs in Mediterranean climates. The biochemical composition of
rice straw is characterized by a typical composition of an agricultural-based
lignocellulosic residue: it contains on average 30 – 45% cellulose, 20 – 25%
hemicellulose, 15 – 20 % lignin, as well as a number of minor organic compounds.
Rice straw is poor in nitrogen, but relatively high in inorganic compounds, often
referred to as ash. Table 1.4 presents an overview of characteristics of rice straw as
they occur in the Phyllis database.
Table 1.4 Rice Straw Composition
Rice Straw
Mean Min Max
Component
Value Value Value
Water Content wt% wet 23.9 6.8 88
Volatiles wt% daf 83.9 80.1 98.2
Ash wt% dry 18 9.6 24.4
HHV kJ/kg daf 18824 17673 19718
LHV calc kJ/kg daf 17511 16381 18440
C wt% daf 48.7 43.3 60
H wt% daf 5.92 4.94 7.01
O wt% daf 44.2 30.8 50.4
N wt% daf 1.05 0.57 2.11
S wt% daf 0.14 0.07 0.23
Cl wt% daf 0.489 0.013 0.909
Cellulose wt.% dry 44.675 41 48.35

Hemicellulose wt.% dry 24 21.5 26.5
Lignine wt.% dry 15.6 9.9 23.3
Lignine acid
wt.% dry - - -
insoluble (AIL)
Ligine acid soluble
wt.% dry - - -
(ASL)
Lipids wt.% dry - - -
Protein wt.% dry 0 0 0
(Source: researchgate.net)
There are two particular challenges of rice straw with regard to applications
for bioenergy purposes. The high carbon-to-nitrogen content (due to low amounts
of nitrogen) of rice straw leads to a very low biodegradability in comparison to
12
other agricultural residues. This is of particular interest when straw is used for
anaerobic digestion to produce biogas. It means that in many cases, straw needs to
be blended with other agricultural residues, in order to speed up the degradation of
organic constituents contained in straw.
Since rice is largely produced in developing countries, a lot of current uses of
rice straw are traditional, such as fuel for cooking (either directly or by producing
briquettes which are produced by compressing the material), animal feed, animal
bedding, anaerobic digestion to biogas and building materials such as roof
thatching. In many cases, straw is left in piles for composting and returned to the
field. In most of these cases, straw is used together with other agricultural residues
generated at village level. There are few official statistics on actual rice straw
utilization, and therefore quantitative estimates of current uses are difficult to make.
Following is an overview of traditional uses for rice straw.
Fuel for cooking: Mainly combustion of straw in stoves. In certain regions,
straw is briquetted to produced fuel briquettes. Compared to other agricultural
residues such as cotton stalks or rice husks, straw produces more smoke and is
therefore less desired as fuel for cooking Building materials: Straw is combined
with mud to produce simple building blocks. In addition, straw is used for thatching
of roofs. Animal production: Straw use in animal bedding. Rice straw and wheat
straw are used in animal feed. Rice straw is a very low quality roughage feed.
Composting: In combination with other agricultural residues including animal
manure, straw is composted and returned to the field Incorporation: Straw is
returned to the field, usually by tillage. Incorporation of large amounts of fresh
straw is either labor-intensive or requires suitable machinery for land preparation
and may result in the build-up of disease problems.
13
Figure 1.4 Rice Straw

(Source: Amazon.com)
1.3.3 Bacteria
Biogas is produced when organic matter is digested by certain
microorganisms in the absence of oxygen to become biogas which mainly consist
of methane, carbon dioxide and other inertly available gases. Microorganisms
release large quantities of gases that can be used to produce energy. The biogas
forming bacteria used are anaerobic bacteria such as Methanobacterium,
Methanobacillus, Methanococcus and Methanosarcina (Price and Cheremisinoff,
1981). The consideration to choose the bacteria that can produce methane are
include cost, yield and the growth rate. Methanobacterium and Methanosarcina is
the most common used bacteria to produce methane but with the result of table
below, Methanobacteium sp is chosen because it has bigger amount of the yield and
growth rate than methanosarcina but the price is lower than Methanosarcina.
Table 1.5 Scoring Value of Bacteria

Criteria 1 2 3 4
Rp. Less than
More than Rp. 4.500.000 – 4.000.000 Rp.
Cost
Rp.5.000.000 Rp. 4.999.999 – Rp. 4.000.000
4.499.999
0-0.249 0.25-0.499 0.5-0.749 0.75-1
Yield
(g/g) (g/g) (g/g) (g/g)
Less than 0.1 0.1 - 0.249 0.2 – 0.499 More than
Growth Rate
h-1 h-1 h-1 0.5 h-1
14
Table 1.6 Bacteria Selection
Parameter
Bacteria Cost Yield (g/g) Growth Rate (h-1)
Total Rank
Value Rating Score Value Rating Score Value Rating Score
Methanobacterium Rp. 4.340.000 3 0.9 1 4 1.4 0.69 4 1.4 3.7 1
Methanosarcina Rp 4.411.687 3 0.9 0.048 1 0.35 0.018 1 0.35 1.6 2
15
1.4. Market and Capacity Analysis

The technical analysis in this study uses data on the operation of the power
plant in 2015 at the Balai Pungut power station.
Table 1.7 Gas Consumption
Gas Consumption
Month Heat Value Working Hour
Scf
(kkal/Scf)
January 101050000 1042 606.5
February 101016000 1042 623.3
March 108910000 1042 712.9
April 103398000 1042 721.3
May 108910000 1042 560.2
June 108910000 1042 719.9
July 108910000 1042 560.2
August 98330000 1042 412.9
September 101120000 1042 719.9
October 103330000 1042 698.4
November 102660000 1042 698.4
December 96720000 1042 412.9
Total 1243264000 1042 7446.8
Average 103605333.3 620.5666667
(Source Novi, 2017)
Based on the table above, it can be seen the amount of gas fuel consumption
in Balai Pungut electricity center is 1243664 MMScf per year, while operating
hours are 6166.7 hours per year. From these data obtained electricity production as
follows:
Table 1.8 The Amount of Electricity Production
Total Energy Production

Month
(Kw)
January 7829730
February 7135761
March 9499257
April 8273114
May 6529904
June 8505020
July 7882734
16
Table 1.9 The Amount of Electricity Production (Cont’d)
Total Energy Production

Month
(Kw)
August 4868023
September 8396169
October 8478093
November 8427970
December 4327110
Total 90152885
Average 7512740.417
(Sumber: Novi, 2017)
The amount of electricity production at Balai Pungut power center is

90152.8 MW per year, with an average electricity production per month at
7,512,740 kW. The data is used to compered amount of electricity consumption and
electricity production on the big power generator with micro generator. PLTG
Sampean Baru with 1.8 MW is used as comparison to know amount of electricity
production and electricity consumption in micro power generator that can be used
to know the demand of biomethane production to electricity.
Gas consumption
Electricity Production
1243664 MMScf 𝑥
=
7512 MW 1.8 𝑀𝑊
𝑥 = 186,5 MMScf = 528023,7 m3 per year
528023,7 𝑚3 𝑚3
= 85,625 × 24 ℎ𝑜𝑢𝑟 = 2055 𝑚3 𝑝𝑒𝑟 𝑑𝑎𝑦
6166,7 ℎ𝑜𝑢𝑟𝑠 ℎ𝑜𝑢𝑟
𝑘𝑔 𝑘𝑔
2055 𝑚3 × 0,656 = 1348, 377
𝑚3 𝑏𝑎𝑡𝑐ℎ
17
So that amount of biomethane needed to produce 1.8 MW electricity is 2055

m3 or equal to 1348,377 kg/batch biomethane.
1.5. Plant Location Analysis
Plant location refers to the choice of the region where men, material, money,
machinery and equipment are brought together for setting up a business or factory.
Plant location is one of the most important factors that will affect the cost of the
nicotine production. The plant location should fulfill some crucial criteria such as
accessible for transportations and has good infrastructure. Plant location should be
consider carefully as it will affect the cost of nicotine distribution to consumer. The
decision maker must choose for facilities that will not only perform well, but also
it will be flexible enough to accommodate the necessary future changes. There are
several factors that determine the plant location.
1.5.1 Raw Material Distribution and Availibility
Raw material have a direct bearing on the location of a plant, but the effect
varies depending on the type of operation involved. It is generally true that if raw
material distribution and availability as a initial step by manufacturing process. Is
carried on close to the raw material source.
Source of municipal solid waste will be supplied by Jalupang Landfill and it is
located in the same sub-district and the supply of rice straw will be taken from the
agricultural area near the plant.
1.5.2 Government Policy
Karawang is an industrial area that are set by the government to driving the
economic growth. Industrial state that are set by the government will give great
assurance that the industrial area is safe. Industrial state that are set by government
will also has a clear policy about licensing, surrounding communities, and social
factors.
1.5.3 Human Resource
Karawang is a district which has a high population density in Indonesia.
There are 2,288,000 people in Karawang and 1,087,750 are still in their productive
age (20-50) (Badan Pusat Statistik,2015).
1.5.4 Product Distribution
Product characteristic of business which is chosing of manufacture were
18
production, collection, distribution and retail. Every business characteristic have

customer and suplier which different or same system. Because of that, decision and
and target customer and supplier it is very important to choice the business location
for the different spesification, indentification of customer and where to becoming
suplier, where is it and the great of potention.
The basic of product distribution is production system, the special supplier
depend of the source of environtment, the input (continity) and output (absorbtion
and continity) potention of product distribution. As depend on raw material,
transportation and output absorbtion had correlation with other business.
Product distribution is also considered in the determination of the plant.
Since the product is biomethane that will be used for sustainable energy such as an
electricity, the plant location need to be near electricity company which is
Perusahaan Listrik Negara (PLN). In Karawang there will be built PLTGU
Karawang which located in Desa Cilamaya, Karawang District, West Java.
1.5.5 Water Accessibility
Depending on the nature of the plant firm should give impotance to the
locations where the water is available. For example power plants where use water
to produce power should be located near the water accessibility have very important
thing. Industrial areas usually have water resource system that is integrated to each
plant. Wancimekar is an agricultural area with high demand of water, the source of
water is taken from river near the area.
1.5.6 Infrastructure
Infrastructure is also an important factor to determine the plant location.
Having a good infrastructure means that the plant will have easy access to either
distribute the product or receive the source and raw material supply. Plant location
that is selected must have proper infrastructure facilities. Without good
infrastructure facilities, it will be difficult to do business efficiently. The
infrastructure facilities are the backbone of all industries. Without it, business
cannot be done.
The basic infrastructure facilities like power, water and waste disposal, etc,
become prominem factors in deciding the location. Certainly types of industries are
power hungry, crucial infrastructure facilities that help industries to grow up are
19
communication, banking and insurance services, regular service material,

continuous supply of electricity and water, etc.
The other facilities of infrastructure is a decent social infrastructure. There
is a need for social infrastructure not only for employees but also for the
development of their families. The availibility of social infrastructure will increased
the employees well far. The social infrastructures that are important for any plants
are education institution, hospital and health centre, community centre like worship
place, garden, meditation centre, and recreation facilities like theaters, clubs,
communication facilities, etc.
1.5.7 Land and Wage Price
Minimum wages and land prices need to be consider as those factors will
affect the cost of plant construction and operation. Compare to Jakarta Industrial
Area which is Pulo Gadung, Karawang Industrial Area has higher cost of minimum
wages, but for land prices Karawang has lower cost of Jakarta Industrial Estate. In
Jakarta, minimum wages is Rp. 3.940.973 while in Karawang, West Java has Rp.
4.234.010,27. The cost of land in West Java is lower than in Jakarta, in Karawang
the land price has an average of Rp. 1.100.000/m2 while in Jakarta has an average
price of Rp. 10.000.000/ m2.
1.5.8 Final Consideration and Plant Location
Based on those categories, it can be concluded that the plant location will
be located in Karawang Industrial Area specifically in Wancimekar, Kota Baru,
Karawang District, West Java. There are some advantages in this area such as:
 Near to municipal solid waste source which is TPA Jalupang
 Near to agricultural area to provide rice straw stock
 Located in same district with PLTGU Karawang as a customer target.
 Has a high population density of worker in Indonesia
20
Figure 1.5 Plant Location
(Source: Google earth)
21
CHAPTER 2
PROCESS SYNTHESIS AND SELECTION
2.1. Process Synthesis

The renewable energy plant which produce biomethane for electricity raw
material is requires several process. The first process is pre-treating the biomass
which come from rice straw before converting it into biogas with municipal solid
waste. The second process is biogas production. The next process is converting
biogas into biomethane.
Raw Material Process Desired Product

Flowsheet
Biomass and Biomethane
Municipal Solid
Waste
Figure 2.1 Black Box Diagram
There are plenty of process alternative from each of the steps in the processing
this plant. The process selection is then will be analyzed by using heuristic approach
and the scoring method.
2.2. Alternative Process
2.2.1 Pre-Treatment
The pre-treatment process must ensure low lignin degradation while
cellulose is activated for hydrolysis. As the feedstock enters the bio refinery in chip,
pellet, or powder form, the initial stage in a lignocellulosic process is a pretreatment
process to disrupt lignin and activate cellulose, which may also solubilize
hemicellulose. The method of pre-treatment chosen can affect the properties of the
lignocellulose materials downstream, impacting the effectiveness of hydrolysis,
fermentation, and other conversion processes. There are several type of
pretreatment method; physical, chemical, physico-chemical and biological
pretreatment, but the last two ways are redundantly utilize in the biomethane
production processes. Some of the major pre-treatment methods developed for
biomethane production include size reduction process, alkaline pretreatment, steam
22
explosion, ammonia fiber expansion, and hot water extraction (Wakelyn et al,
2006).
Figure 2.2 Pre-Treatment Method
2.2.1.1 Physical Pre-Treatment

Physical pre-treatment happen in this process is size reduction process.
Size reduction process is seemingly a simple process in the overall production
processes, but a correct decision to choose the method is important since the size of
the raw materials will impact the election of other process methods afterwards.
Other than that, choosing the right way to reduce the size of the raw material could
possibly help production cost knowing that manufacturer does not need to purchase
any machines that not going to help any processes involved in the production line.
Basically, the materials and the size are to factors that needed to be considered in
size reduction process which is consisted of three kind of methods; shredding,
grinding, and milling (Jordan Reduction Solution, 2018).
a) Shredding
Shredding is normally carried out in a machine that has low speed and high
torque. A shredder is designed to take large components and shred them down to
23
random size, smaller components produced normally in the range of 1 to 2 inch and
the rest are bigger components. This machine, most often, is selected when the
following criteria is desired.
 Reduce a product down for compacting of space in haul off application
to a landfill
 Reduction of items such as tires to larger chips for fuel, drain fill, and
etc.
 The reduction of paper or confidential documents to pieces
unrecognizable in regard to their former condition
 Reduction of plastics for washing
 Destruction of product of liability issues
 Prepare the product for another application follow
b) Grinding
While interchanging the terms shredding and grinding is often happening,
the actual process and the end product yielded, could not be further apart. Grinding,
most simplistically stated is the chipping of small pieces until the original part is in
thousands of smaller consistent chips, usually less than ¼ and ½ inch. The product
characteristic yielded by this process is the consistent size between one and another
grinded material. It is best to be applied for these following reason:
 Grinding large rejected parts back to smaller chips that can then be
recycled into making more parts
 Reducing organic materials for biogas production
 Grinding carpet and other textiles for fiber reclamation
Essentially, this process is an application used to take any larger raw or
rejected material and process it in the grinder to obtain a small enough particle, chip
or fiber suitable for the manufacturing of other components parts or new products.
c) Granulating
Granulators, essentially, has the same thing as the other size redactor that is
takes larger components and make them smaller. But, granulators tend to have the
ability to reduce certain materials to a much smaller particle size than a grinder.
The reason for this is that a granulator differs in design significantly from a grinder
in the following ways:
24
 Most all granulators have an “open rotor” design. This means that there
is a great deal of air space around the rotor for product agitation and
cooling. The open rotor allows for better processing of lighter materials
that would not be well suited for a closed rotor design.
 Many Grinders on the other hand, especially the type of grinders offered
by Jordan Reduction Solutions, have closed rotor designs. Meaning the
rotor is closed, high speed and very tight tolerances. These type rotors
leave little room for the product being process to go anywhere other than
across the cutting edges.
There are advantages to both designs mentioned above, but simply put; each
design is more applicable to specific products.
 A granulator, with an open rotor type design, is normally more applicable
in taking small components in the ½” to 6” or 8” sizes and reducing them
to much smaller chips than a grinder would be used to do. Often in the
range of producing 5/16” flake to even powders.
 Granulators are often used as an after process for materials that have been
size reduced previously. Granulators are well suited for lighter materials
such as plastic bottles which do not grind well in a closed rotor design
unit.
2.2.1.2 Chemical Pre-Treatment
Chemical Pre-treatment is the perquisite step in the production of biogas
which essential to remove lignin and reduce the crystallinity of the substrate.
Methods included in this treatment are effortless and give good conversion yields
in less span of time. However, several factors need to be further examined before
finally decide one. The methods of this treatment are:
a) Dilute Acid Hydrolysis
Dilute acid hydrolysis, the most studied form of pretreatment,
commonly utilizes sulphuric acid or sulphur dioxide in conjunction with hot water
or steam, although hydrochloric, nitric, and phosphoric acids have also been
considered. Acid hydrolysis selectively attacks the hemicellulose fraction of
lignocellulose, thus increasing the surface area of cellulose available to enzymes. It
is reported that 80-90% of the hemicellulose sugars are solubilized using this
25
technique, but depending upon the acid concentration, temperature, and residence
time, monomer recovery may be much lower. Acid treatment does not tend to
solubilize a large fraction of lignin, meaning an additional pretreatment stage may
be needed to activate the cellulose or separate it from the remaining lignin. After
acid pretreatment, the soluble and solids fractions must be conditioned through
treatments such as overliming, to neutralize the acids and remove the inhibitory
degradation products formed under acidic conditions. The acidic conditions also
require special process equipment that can withstand the corrosive environment.
b) Alkaline Pre-Treatment
This treatment digests lignin and make holocellulose accessible for acid
or enzymatic degradation. In other words, alkaline conditions tend to solubilize
lignin. Basic compound such as sodium hydroxide or lime most directly affect
lignin via the degradation of glycosidic and ester side chains (Girio et al, 2012).
Generally hydroxides of sodium, potassium, calcium, and ammonium are employed
in this process. The net effect of alkaline pretreatment is the disruption of the
structure of lignin, partial hemicellulose solubilisation, and swelling and partial
decrystallization of cellulose, which activates cellulose for enzymatic hydrolysis
(Menon, V., Rao, M, 2012). Sodium hydroxide has received the most study for
alkaline pretreatment, which Sun reported 60% lignin and 80% hemicellulose
removal for a 144 hours treatment at 20°C with 1.5% sodium hydroxide. However
the relatively high costs of sodium hydroxide combined with longer residence times
compared to other pretreatment types are a barrier to large scale processing
(Wakelyn et al, 2006).
On a raw material basis, the most cost effective alkaline compound is
lime, which is also relatively safe for handling. Lime is recovered from the solid
cellulose fraction through a wash stage with water, which is saturated with CO2 gas
to precipitate lime into calcium carbonate; the precipitate is then heated in a kiln to
regenerate lime. The use of lime is more effective for biomass with a lower lignin
component and is slower than the use of other compounds such as ammonia or
sodium hydroxide, which leads to increased residence times and higher equipment
costs. The mild reaction conditions of alkaline treatment lead to longer treatment
times at low temperatures. Low hemicellulose removal limits the effectiveness of
26
alkaline treatment for a process that will produce separate hemicellulose and
cellulose-derived products as the hemicellulose would need to be isolated at a later
stage in the process (Gerbrandt, 2014).
Xu et al. (2007) studied the influence of equal concentrations of sodium
and potassium hydroxides in the recovery of hemicellulose from perennial ryegrass
leaves, and found sodium hydroxide was effectively remove hemicellulose whereas
use of potassium hydroxide resulted in higher purity of hemicellulose.
2.2.1.3 Physico-Chemical Pre-Treatment
This category includes the majority of pretreatment technologies such as
ultrasonication, microwave irradiation, steam explosion, twin screw extruder and
so on. These forms of pretreatment exploit the use of conditions and compounds
that affect the physical and chemical properties of biomass. The alternatives
including:
a) Steam Explosion
In steam explosion, biomass is initially exposed to saturated, high-
pressure steam (160-260°C, 0.69-4.83 MPa). The reaction vessel is suddenly
depressurized and as a result, the biomass decompress explosively. The sudden
pressure change causes the biomass to disintegrate into fibre or bundles of fibre. To
improve steam explosion results, the hydrolysis of hemicellulose may be catalyzed
with the addition of acid such as sulphuric acid or gaseous SO2. However, inhibitors
to downstream processes such as furfural may be formed in this reaction due to the
degradation of pentose sugars, lowering pentose sugar recoveries and potentially
impacting ethanol fermentation. This method is promising due to low capital costs
due to the low residence times required and minimal environmental and minimal
environmental impacts due to low chemical inputs, as well as the high pentose sugar
recovery achieved using this technique.
b) Liquid Hot Water
Water under high pressure can penetrate into the biomass, hydrate
cellulose, and remove hemicellulose and part of lignin. The major advantages are
no addition of chemicals and no requirement of corrosion-resistant materials for
hydrolysis reactors in this process. The feedstock size reduction is a highly energy-
demanding operation for the huge bulk of materials on a commercial scale; there
27
could be no need for size reduction in LHW pretreatment. In addition, the process
has a much lower need of chemicals for neutralization of the produced hydrolyzate,
and produces lower amounts of neutralization residues compared to many processes
such as dilute-acid pretreatment. Hemicelluloses’s carbohydrates are dissolved as
liquid-soluble oligosaccharides and can be separated from insoluble cellulosic and
lignin fractions. LHW can enlarge the accessible and susceptible surface area of the
cellulose and make it more accessible to hydrolytic enzymes.
Pretreatments with steam and LHW are both hydrothermal pretreatments.
Higher pentosan recovery and lower formation of inhibitory components are the
main advantages of LHW pretreatment compared to steam explosion. For instance,
treating of de-starched corn fiber with hot water at 160°C for 20 min dissolved 75%
of the xylan. At higher temperatures, e.g. 220°C, LHW can dissolve hemicelluloses
completely and remove lignin partially within 2 min with no chemicals used.
Xylan removal via percolation reactor, or by base addition (adjusting the
pH) during the process, has been suggested to reduce the formation of inhibitors
such as furfural and degradation of xylose. The pH, processing temperature, and
time should be controlled in order to optimize the enzymatic digestibility by LHW
pretreatment. An optimized condition for LHW pretreatment of corn stover was
reported to be 190 °C for 15 min, in which 90% of the cellulose conversion was
observed by subsequent enzymatic hydrolysis. LHW pretreatment at 160 °C and a
pH above 4.0 can dissolve 50% of the fibers from corn fibers in 20 min. The results
showed that the pretreatment enabled the subsequent complete enzymatic
hydrolysis of the remaining polysaccharides, mainly cellulose, to the corresponding
monomers. The LHW pretreatment resulted in 80% soluble oligosaccharides and
20% monosaccharides with less than 1% of the carbohydrates lost to degradation
products.
Laser et al. compared the performance of LHW and steam pretreatments
of sugarcane bagasse, which was subsequently used in ethanol production by SSF.
They performed the treatments in a 25-l reactor at 170–230 °C for 1–46 min with
1% to 8% solids concentration. The results showed that both methods can
significantly improve the hydrolysis; however, the LHW resulted in much better
xylan recovery compared to steam pretreatment. Under the optimum conditions, the
28
results of LHW pretreatment were comparable with dilute-acid pretreatment

processes, besides having no requirement for acid or production of neutralization
wastes. They also showed that the process favored high temperatures (above 220
°C), short residence times (less than 2 min) and low solid concentration (less than
5%).
The hot water processing removes mainly hemicellulose. A two-stage
process which combines the hot water for hemicellulose removal and a treatment
for delignification (e.g. ammonia treatment) was also suggested for further
improvement of enzymatic hydrolysis.
2.2.1.4 Biological Pre-Treatment
Biological pretreatment using either organism directly or its metabolite for
pretreatment of biomass is a promising ecofriendly technology as it has various
advantages and is economically viable strategy for enhancing the rate of enzymatic
saccharification. Microorganisms like brown, white and soft rot fungi were used for
degradation of lignin in biological pre-treatment.
The table below shows the sum up of the advantages, characteristic,
limitation, and disadvantages of the alternative processes that have mentioned
above.
Table 2.1 Alternative Pre-Treatment

Limitation and
Pre-Treatment Advantages
Disadvantages
Physical Pre-Treatment
Shredding Cut 0.01 to 0.03 inch; -
inconsistent size of
components
Grinding Cut 0.25 to 0.5 inch; -
consistent size of
components
Granulating Cut bigger than grinding -
Chemical Pre-Treatment
29
Table 2.1 Alternative Pre-Treatment (cont’d)

Limitation and
Pre-Treatment Advantages
Disadvantages
Acid Hydrolisis Hydrolyzes High cost; equipment
hemicellulose to xylose corrosion; formation of
and other sugars; alters toxic substances
lignin structure
Alkaline Pre-Treatment Removes hemicelluloses Long residence times
and lignin; increases required; irrecoverable
accessible surface area salts formed and
incorporated into biomass
Physico-Chemical Pre-Treatment
Steam Explosion Causes hemicellulose Destruction of a portion of
degradation and lignin the xylan fraction;
transformation; cost- incomplete disruption of
effective the lignincarbohydrate
matrix; generation of
compounds inhibitory to
microorganisms
Liquid Hot Water Low chemical demands; The hemicellulose must be
mild conditions; hydrolysed in a separate
specificity towards step in the xylitol pathway
hemicellulose
solubilisation with low
degradation
Biological Pre-Treatment
Biological Simple equipment Rate of hydrolysis is very
degrades lignin and low
hemicellulose; low
energy requirements
30
2.2.2 Digester Types

Anaerobic digestion (anaerobic digestion) is a technology of processing
waste into energy which involves biochemical processes in which organic waste
will be decomposed by anaerobic microorganisms in the absence of dissolved
oxygen (anaerobic conditions). Anaerobic microorganisms digest organic input
which is converted through anaerobic degradation to a more stable form so as to
produce a high-energy mix gas (biogas) whose main composition consists of
methane (CH4) and carbon dioxide (CO2).
Biogas is collected and used as a source of heat and electricity. The
anaerobic digestion process takes 28-30 days (Zhang, 2013). The types of digesters
commonly used for biogas production include:
Table 2.2 Types of Digester
Total Komponen
Tipe Digester Waktu Retensi Kondisi Suhu
Kering (%)
Ambien
Fixed-film <2 3-5
Termofilik
Mesofilik
Complete-mix 3-10 20-25
Termofilik
Plug flow 10-14 20-30 Mesofilik
Covered Lagoon <2 35-60 Ambien
There are two main types of anaerobic digestion used in Indonesia, which
are Fixed-film and Covered Lagoon.
Fixed-film is a well-stirred tank containing the immobilized biomass. The
substrate is constantly pumped into the reactor, and the product stream is removed
at the same time. The reactor is categorized by mixing the contents either
continously or periodically. A study was conducted for the usage of fixed-film, that
the COD removal efficiency reaches 83%, and the production of methane is 62.5%
(Ahmed, Yaakob, Akhtar, & Sopian, 2014).
Fixed-film are usually insulated and the digestion chamber is heated with
internal hot water piping and/or internal and external heat exchangers coupled to
heat sources such as combined heat and power electric generators. Fixed-film are
31
most often designed for operation in mesophilic or thermophilic temperature

ranges. The contents of these digesters generally range from 2 – 5 % solids by
voluume, although they are often used for both scraped and washed manure
management systems. Fixed-film are constantly mixed via pumps, electric
propellers, or pressurized biogas agitators in order to keep the solids portion of the
waste in suspension and prevent settling (Ahmed, Yaakob, Akhtar, & Sopian,
2014).
2.2.3 Biogas Upgrading Technology
The main process involved in the upgrading of biogas to biomethane quality
is the separation of CH4 and CO2. There are several upgrading technologies
available on the market that have been used and improved for many years.
Conventional biogas upgrading methods can be categorised as follows:
 Membrane separation;
 Scrubbing technologies (absorption methods);
 Water scrubbing;
 Physical scrubbing;
 Chemical scrubbing;
 Pressure swing adsorption (PSA);
The aim of all upgrading technologies is to achieve high methane purity and
low methane losses with low energy consumption.
2.2.3.1 Membrane Separation
Membrane separation methods are based on the principle that gases diffuse
through the membranes at different speeds. A variety of polymers can be used as
membranes. A good membrane is highly permeable to smaller molecules such as
CO2, and impermeable to larger molecules such as CH4. The aim is to achieve the
highest possible permeability with high selectivity. For membranes typically used,
the permeability of CO2 is about twenty times higher than CH4.
Membranes are usually formed into hollow-fibre polymers, which are
combined in a tube bundle to provide maximum surface area. When raw biogas is
blown into the tube, gas components such as CO2, O2, H2O and H2S that diffuse
well through the fibre wall are discharged outside the hollow fibre. CH4 and N2
remain inside. The membranes are very thin (about 0.1 – 0.2 micrometres) and are
32
thus unstable. The tube shell protects the membranes, prevents bending and thus
provides the optimum shape.
Membrane separation methods are available in very different designs.
Typical operating pressures are 7 to 20 bar. In order to achieve high methane
purities, the tube bundles are often connected in two-stage or three-stage cascades.
A two-stage cascade means that the biogas is separated in an initial column. The
exhaust gas is blown off. Subsequently, the methane-rich product gas – which still
contains CO2 – is passed into a second column in which CO2 is further diffused.
This results in higher CH4 concentrations in the product gas. CH4 also diffuses
through the membrane, causing methane losses into the exhaust gas which should
be converted to CO2.
The process of membrane separation has been substantially improved over
the past 10 years. Initial problems, such as high pressure loss with an excessive
power requirement, high methane loss or limited membrane service life, have
largely been resolved. In order to protect the membranes, fine desulphurisation and
drying are carried out before the gas enters the hollow fibre.
2.2.3.2 Scrubbing Technology
Scrubbing, also referred to as absorption, is based on the effect whereby
gas components are soluble in different fluids to varying degrees. For example,
CO2 dissolves much better in water than CH4.
The most important influential variables in scrubbing processes result from
the properties of the solvents used and the solubility of the gas components. In
general, the solubility of the gas improves with increasing pressure or decreasing
temperature.
In this section, the design principles involved in the scrubbing process are explained
in general terms using pressurised water scrubbing as an example. The subsequent
sections outline the properties of other solvents.
Physical scrubbing methods are based on the physical solubility of gas
components in a wash solution without chemical reaction.
Water is used as a solvent in the pressurised water scrubbing method. Since
much more CO2 is dissolved in the water when the system is pressurised, water
scrubbing usually takes place at a pressure of 4 to 10 bar.
33
A tall scrubbing column is used, in which water is sprayed from above,

similar to a shower. The biogas is directed upwards from the bottom of the
scrubbing column. As it rises, the gas is brought into contact with the falling liquid.
In order to ensure a greater transitional surface area, filling bodies are added to the
columns, in which the water runs down. In addition, multiple intermediate floors
are installed, in which the water is collected and sprayed again into the lower gas
space below. The purified biomethane, with small constituents of O2 and N2, is
suctioned off at the top of the scrubbing column. Depending on the design of the
column the methane purity is 90 to 99 vol%.
In physical scrubbing, it is also possible to use organic solvents instead of
water to upgrade the biogas. Polyethylene glycol dimethyl ether, which is marketed
commercially under the names Genosorb or Seloxol, is one example. The process
and the technical design are very similar to pressurised water scrubbing. The
advantage of these solvents is the higher solubility of CO2 and H2S compared to
water. The result is that less detergent is required and the height of the scrubber
column can be reduced. Technically speaking, a pressure of 4 to 8 bar is sufficient
inside the scrubber column. As a result, the energy required for compression is
reduced compared to pressurised water scrubbing. Since CO2 and H2S are more
strongly held in solution, the regeneration of the washing liquid is more complex.
In addition to pressure release and air stripping, the solvent must be heated to
between 40 and 80°C. In order to do this, heat must be provided. In most cases, heat
from the lean gas burner is sufficient. The heat requirement is 0.1 to 0.15 kWh per
m³ of biogas. Simultaneous desulphurisation is possible with this method. In reality,
however, fine desulphurisation is usually carried out before the scrubber.
In chemical scrubbing, some gases (e.g. CO2 and H2S) react reversibly with
the washing liquid. The binding agent/solution is therefore substantially stronger
than in the case of physical scrubbing. Mixtures of water with the additives
monoethanolamine (MEA), diethanolamine (DEA), methyldiethanolamine
(MDEA) and other amine compounds are usually used as detergent. The advantages
are the higher loading of the solution, higher selectivity of the gas separations, and
thus a higher purity of the product gas. A lean gas treatment is therefore not
necessary, but fine desulphurisation must be carried out upstream. The scrubbing
34
columns can be operated at almost ambient pressure. However, the higher binding
strength adversely affects the regeneration process for amine solution. It requires to
be heated to approximately 110–160°C for regeneration purposes, and must then be
cooled to 40°C in order to be able to absorb gases again, before being returned to
the scrubbing column. A portion of the heat can be recovered by heat exchangers
and used externally, for example to heat the digester.
2.2.3.3 Pressure Swing Adsorption
Adsorptive methods are based on the principle that different gas
components are attracted differently to specific surfaces (adsorbed) or penetrate to
varying degrees into the pores of the material.
In principle, adsorption is higher at higher pressures and lower
temperatures. Adsorptive biogas upgrading processes mainly use pressure
differences to carry out the separation. Pressure swing adsorption is a proven
method of separation and has been used for decades. It was previously used in the
gas industry, and has been adapted to meet the requirements of biogas processing.
The essential component for separating the gases is a column fi lled with
activated carbon, zeolitic molecular sieves or carbon molecular sieves. These
substances stand out for offering a large surface area and a certain pore size.
The gas separation is carried out in the following steps:
1. The pre-purified biogas is compressed to 2–7 bar. The compression
increases the temperature of the gas. To improve the adsorption, it is cooled
down to about 70°C and channelled into the adsorption column. CO2
molecules, which are smaller than methane molecules, accumulate to a
much greater degree on the surfaces or in the pores than CH4, while the
latter remains primarily in the gas phase.
2. A valve at the column head is opened, and the biomethane escapes from the
column (methanerich product gas).
3. After closing the valve, the pressure inside the column is released. The CO2
dissolves from the surfaces, returns into the gas phase and can be blown off
(CO2-rich exhaust gas).
4. The column can be fi lled with biogas again.
35
Since the pressure swing adsorption is a batch process, several columns

(typically 4 to 8) are operated and work in a slightly time-delayed manner to
equalise the gas production.
Fine-cleaning must be carried out to remove H2S before the biogas is
pumped into the adsorption column. The methane losses are heavily dependent on
the design of the system. The CH4 in the exhaust gas must be burnt because of its
greenhouse gas potential. Some system concepts are designed for low methane loss
with an RTO connected. Other methods allow a higher methane loss of up to 10
vol% in order to burn the exhaust gas in a gas burner and utilise the heat, for
example to heat the digester.
2.3. Process Selection
2.3.1. Size Reduction Process Selection
The three alternative process of size reduction will be scored by some
parameters. Score from each concept is evaluated by multiplying the score with a
percentage score. Percentage score is obtained by considering the most priority of
consumer needs. Concept scoring method is used to evaluate the suitable process
for the product making. Criteria used for this method including:
 Final Components Size
The final result of the raw material’s size becoming an important
consideration since it will affects the efficiency of the next procedures.
 Shape Consistency
Considering whether it is necessary to be consistence in size or not.
 Equipment Prize
The equipment prize is preferably low-cost in order to push the
production cost, but higher cost is preferred if the specification of the
equipment match the needs.
 Power Requirement
Low energy usage with high production efficiency is preferable.
After all the criteria have been determined, the next step is to construct the
matrix consist of the scoring value. This step aim to make the selection process
easier and easily meet the needs.
36
Table 2.3 Criteria Selection of Physical Pre-Treatment
Criteria 1 2 3 4 5
Final
0.01 in – 0.2 in – 0.5
Component > 1 in < 0.01 in 0.5 in – 1 in
0.1 in in
Size
Shape Slightly Slightly Very

Inconsistence Consistence
Consistency Inconsistence Consistence Consistence
Equipment > 100,000 60,000 - 5,000 - 50,000 - 4,000 -

Prize US$ 100,000 US$ 60,000 US$ 60,000 US$ 5,000 US$
Power
> 2 diesel 1-2 diesel 15 – 20 kW 5-15 kW < 5 kW
Requirement
After that, the method is being compare to each other so that the desire
method can be selected. The table below shows the comparison between the
alternatives.
Table 2.4 Comparison Alternatives of Physical Pre-Treatment
Criteria Shredding Grinding Granulating

Final
0.01 in- 0.03 0.25 in - 0.5 in -0.75
Component
in 0.5 in in
Size
Shape Very
Inconsistence Consistence
Consistency Consistence
Equipment 5,000 - 50,000 - 4,000 -

Prize 60,000 US$ 60,000 US$ 5,000 US$
Power
11,2 kW 2 diesel 18,5 kW
Requirement
Then, the next step is scoring each of the criteria for each alternative process.
The level of percentage written is based on the prior need that the manufacturer
wants to the tolerable criteria.
Table 2.5 Scoring Parameter of Physical Pre-Treatment
37
Shredding Grinding Granulating

Criteria Percentage
Rating Score Rating Score Rating Score
Final
Component
Size 35% 4 1,4 5 1,75 3 0,7
Shape
Consistency 25% 1 0,25 5 1,25 4 1
Equipment
Prize 20% 3 0,6 4 0,8 5 1
Power
Requirement 20% 4 0,8 2 0,4 3 0,6
Total 3,05 4,2 3,37
Rank 3 1 2
2.3.2. Pre-Treatment Process Selection

There are four alternatives for the pre-treatment process after the size
reduction is done, there are Alkaline Pre-Treatment, Steam Explosion, Liquid Hot
Water, and Biological Pre-Treatment. These alternatives will be scored by some
criteria. The method is still the same as the previous one that is scoring method.
Criteria used for this method including:
 Operating Condition Sustainability
Considering the optimum condition of the operating condition,
consisting temperature and pressure, whether they are energy-effective
or not, with the assumption their production yield is more or less the
same.
 Reaction Time
The reaction time needed for lignin and hemicellulose removal in raw
materials.
 Cost Effectivity
Cost incurred by the process for chemicals and other apparatus needed,
whether high or low consequences of operating conditions of the process
chosen.
 Availability
It describes the existence of the pre-treatment method, whether it is
usually used or not.
38
After all the criteria have been determined, then each of them being
parameterize by constructing scoring matrix to easily evaluate some qualify
concept.process
Table 2.6 Criteria Scoring of Pre-Treatment
Criteria 1 2 3 4 5
Operating
Very not Not Very
Condition Medium Effective
Effective Effective Effective
Sustainability
Very
Very Medium
Reaction Long (60- Short (10- Short
Long (21-60
Time 90 min) 20 min) (0.15-9.9
(>90 min) min)
min)
Cost Very Very

Expensive Moderate Affordable
Effectivity Expensive Affordable
Available,
Available,
Proven in
Have not proven in
Will be laboratory Available,
been large
Availability available scale or Proven in
proved scale,
soon not large scale
yet commonlu
commonly
use
use
Table 2.7 Comparisan of Pre-Treatments Methods
Alkaline Liquid Biological

Steam
Criteria Pre- Hot Pre-
Explosion
Treatment Extraction Treatment
T
Operating 55-120 160-230 120-240 23-30
(oC)
Condition
Sustainability P
1.034 6.9-48.3 1.013 1.013
(bar)
Reaction Time
90 2-10 3-15 Several Days
(minutes)
39
Table 2.7 Comparisan of Pre-Treatments Methods (cont’d)
Alkaline Liquid Biological

Steam
Criteria Pre- Hot Pre-
Explosion
Treatment Extraction Treatment
Low capital
cost due to Relatively Relatively
low residence low since Low (depend
300-400
Cost Effectivity time and its low on the
USS/MT
minimal chemical microorganism
environmental demands used)
impacts
Now Now Now

Availability 2-5 years later
Available Available Available
40
Table 2.8 Pre-Treatment Process Scoring
Alkaline Pre- Steam Liquid Hot Biological Pre-

Criteria Percentage Treatment Explosion Water Treatment
Rating Score Rating Score Rating Score Rating Score

Operating
Condition 25% 2 0.5 3 0.75 3 0.75 4 1
Sustainability
Reaction Time 20% 2 0.4 4 0.8 4 0.8 1 0.2
Cost Effectivity 20% 2 0.4 4 0.8 4 0.8 5 1
Availability 35% 4 1.4 2 0.7 3 1.05 3 1.05
Total 2.7 3.05 3.4 3.25
Rank 4 3 1 2
41
From the table above, it can be conclude that LHW is the most favourable
method to remove lignin and hemicellulose. This pre-treatment method is the most
commonly used in commercial biogas production in large scale and has been
successfully developed for pre-treatment of lignocellulosic material as then it is
being the major consideration for the method selection in order to minimize any
risk probabilities. Although the chemical used in this method is quite highly cost
rather than other non-chemical-based method, but actually the pre-treatment can
operate either under a high temperature and low acid concentration or under a low
temperature and high acid concentration (Taherzadeh, 2008). In recent years,
sulfuric acid has been the most interest in such studies and applications as it is
effectively treating lignocellulosic biomass as a means of hemicellulose hydrolysis
to produce biogas.
2.3.3. Digester Types Selection
There are several parameters to be considered, which are:
 Methane Yield
 Hydraulic Retention Time
 Cost
 Usage of Land
Table 2.9 Parameter Comparison of Digester Types
Parameter Fixed-film Covered Lagoon

Yield CH4 (L CH4/kg 0.21 0.109
COD)
HRT (days) 3 – 25 35 – 40
Cost ($) Higher Lower
Usage of Land (m3) Low High
With the scoring above, it could be determined that the reactor used for
anaerobic digestion is Fixed-film. There are two types of Fixed-film used in this
application, which are:
 HRT
 Max COD Reduction
 Temperature Fluctuation Tolerance
42
 Methane Gas Content of Biogas

 Reactor Volume
Table 2.10 Temperature Comparison of Digester Types

Parameter Mesophilic Thermophilic
HRT 15 – 25 3 – 10
Max COD Reduction 65 – 85 85 – 90
Temperature Fluctuation 3–5 1–2
Methane Gas Content 60 – 70 70 – 85
Reactor Volume Bigger Smaller
Hence, the reactor that is used is thermophilic Fixed-film.

2.3.4. Biogas Upgrading Technology
To determine which type of purification that will be used, the basic concepts
of purification itself must be understood. There are few criteria to be considered in
order to decide which type is the best Membrane Separation, Scrubbing
Technology, and Adsorption. The steps of process selection are determining the
parameters to compare some the alternatives, determining scoring parameter which
consists of weight and rank for each parameter, and doing scoring based on scoring
parameter where the process with the highest score will be chosen for purification
process in the plant.
One the proposed methods should be choosen first by scoring them to some
criteria. The score of each concept is evaluated by multiplying the score with the
score percentage. The score percentage is obtained by considering the most
prioritized need or how it effects the whole process. The criteria to score selected
technologies are:
1. Maturity
This parameter shows the maturity of the technology proposed. mature
technology is a technology that has been in use for long enough that most
of its initial faults and inherent problems have been removed or reduced by
further development. In some contexts, it may also refer to technology that
has not seen widespread use, but whose scientific background is well
understood. One of the key indicators of a mature technology is the ease of
43
use for both non-experts and professionals. Another indicator is a reduction

in the rate of new breakthrough advances related to it—whereas inventions
related to a (popular) immature technology are usually rapid and diverse,
and may change the whole use paradigm—advances to a mature technology
are usually incremental movements only.
2. Flexibility
This parameter shows the flexibility of proposed technology. technology
flexibility is the technology characteristic that allows or enables adjustments
and other changes to the business process. Technology flexibility has two
dimensions, structural and process flexibility, encompassing both the actual
technology application and the people and processes that support it. The
flexibility of technology that supports business processes can greatly
influence the organization's capacity for change. Existing technology can
present opportunities for or barriers to business process flexibility through
structural characteristics such as language, platform and design (K.M
Nelson, 1997)
3. Opperability
This parameter shows the complexity of the plant that will be design.
Operability ensures that the process has the capacity and flexibility to
achieve a range of operating conditions safely, reliably, profitably and with
good dynamic performance and product quality (Marlin, 2013).
4. CAPEX
This parameter shows the history data of existing equipment design which
calculated from capacity ratio. The design of cost estimation may be
influenced by factors, including equipments size, process requirements,
location, labor cost, and complexity level of process. All the important
parameters use in the guideline are explained in the definition section which
help the reader more understand the meaning of the parameters or the terms
utilized (KLM Group, 2014).
After determining the method parameter scoring, the proposed/ alternative
methods are scored with respective weight percentage between 0-100%. The
methods scoring matrix can be arranged with the value scoring as follow:
44
Table 2.11 Scoring of Purification Gas

Membrane
Percentage Water Scrubber PSA
Criteria Separation
(%)
Rating Scoring Rating Scoring Rating Scoring
Maturity 30 4 1.2 3 0.9 3 0.9
Flexibility 25 3 0.75 2 0.5 3 0.75
Operability 25 4 1 3 0.75 2 0.5
CAPEX 20 3 0.6 4 0.8 2 0.4
Total 100 3.55 2.95 2.55
Rank 1 3 2
2.4. Process Description

The plant’s purpose is to produce biomethane from lignocellulosic biomass
which is in this case is Rice Straw with Municipal Solid Waste. The production
process in general that is going to run in the plant includes washing, drying,
grinding, pre-treatment biomass with hot water, cultivation methanobacterium,
anaerobic digestion, biogas upgrading with water scrubbing and stripping and
degasifier.
2.4.1. Raw Material Process
The MSW is collected from suppliers in a dried conditions by trucks and
placed in plant’s storage at ambient temperature of 25 – 27C, before undergoing a
series of treatments to produce biomethane. Meanwhile, rice straw is collecterd
from supplier without pre-treatment.
2.4.2. Washing
Biomethane production process begins by washed the rice straw to remove
ash and other foreign material. Water washing pre-treatment is one of the methods
used to remove the ash content or other minerals from biomass. Ash varies in
different forms of biomass. The high ash content in biomass promotes secondary
reaction of the thermochemical process, thus producing non-homogenous liquids
(Davidson et al, 2002).
Simple water washing pre-treatment will remove a large amount of
minerals from the biomass surface. Some of these minerals are possibly due to their
contact with soil during the harvest season or during transportation of the biomass
itself. The water washing process used 5,4 L of distilled water for every 100 g of
rice straw at ambient temperature of 25°C-28°C. The feedstock is soaked in the
45
distilled water beforehand for to reduce 100% the ash content. The operation
condition will be describe in description bellow:
Table 2.12 Operation Condition of Washing Machine
Parameter Value
Washing Media Water
Temperature 25C
Impurities Removed 100%
Amount of Water/1kg feed 5,4 L
Process Time 30 Minutes
Figure 2.3 Biomass Washer

(Source: Alibaba.com)
2.4.3. Drying
The next steps is the drying process. The raw material should be dry first
for physical pre-treatment. In this case the last specification of rice straw must have
maximum 8,8% moisture to produce good quality of biogas from fermentation of
rice straw, so the authors try to find the suitable operating condition which 70°C
and 40 minutes drying time. This study can be complemented with an evaluation of
the industrial dryers energy cost, which could show the economic viability of high
temperature treatment for the drying process. (De Faria,2014).
Table 2.13 Operation Conditions of Drying
Parameter Value
Water Removed 91.2%
Temperature 70°C
46
Table 2.13 Operation Conditions of Drying (cont’d)
Parameter Value
40
Process Time Minutes
Figure 2.4 Rotary Dryer Machine

(Source: Alibaba.com)
2.4.4. Grinding
After drying process, the rice straw is proceed to another physical
pretreatment that is grinding. The treatment is aimed to reduce the particle size to
ease material handling and increase the surface volume/ratio. This process is being
carried out in grinder, reducing the size of rice straw to be in the range of ¼ to ½
inch (Cheng et al, 2009). Mechanical pretreatment can be done by cutting rice straw
into smaller sizes. Size reduction can break the cell wall. Furthermore, size
reduction reduces the degree of polymerization and increases the specific surface
area hence it can enrich the total hydrolysis yield.
Table 2.14 Operation Conditions of Grinding
Parameter Value
Total Power 434.3 KW
Operating Throughput per 4343.06
Unit kg/h
Process Time 60 Minutes
47
Figure 2.5 Grinding Machine
2.4.5. Biomass Pretreatment

The biogas production was simulated considering the LHW pretreatment
of the lignocellulosic raw material and the water scrubbing cleaning method. LHW
is a suitable process to produce xylose and glucose from biomass rice straw for
further processing to biogas and remove lignin. The LHW pretreatment was
simulated according to the conditions reported by Goh et al. [111] (i.e., 160°C, 10
bar, and a liquid-to-solid ratio of 8.0). The AD process was simulated considering
the yields.
Hydrolysis is the pre-treatment method to selectively solubilize
hemicellulose. In this process, the xylan, contained in the cellulose of rice straw, is
converted into xylose and hemicellulose converted into glucose. The process is
conducted in a reactor loaded with 1:8 solid to liquid ratio and 2000 kg water. The
reactions were carried out at the temperature of 160°C and 40 minutes of reaction
time (Rahman, 2006). The reaction will produce a solid and liquid fraction
consisting non-solubilized hemicellulose, cellulose, and lignin in the solid fraction
and the liquid fraction containing xylose and glucose.
Table 2.15 Operation Conditions of LHW
Parameter Value
Temperature 160 C
Pressure 101.325 kPa
Lignin Removed 60%
Water (Steam High
Heating Agent
Pressure)
48
Table 2.15 Operation Conditions of LHW (cont’d)

Parameter Value
Water Temperature 70°C
Pocess Time 40 Minutes
liquid-to-solid 1:8
2.4.6. Bacteria Cultivation Inoculum

Methanogens are unique obligate anaerobes that produce methane and are
grouped based on what compound they convert to methane: acetate fermenters,
obligate methylotrophs, and autotrophic hydrogen (H2) oxidizers. The bacteria
includes Methanobacterium. H2 is a key end product of organic fermentations and
can be used as an electron donor by microorganisms that utilize all terminal electron
acceptors. Therefore, competition for H2 is a common reality for the H2-oxidizing
methanogens. Thermodynamic and kinetic factors determine whether the
methanogens survive well.
Thermodynamically, the standard Gibbs free energies of reductive
dehalogenation (−135 kJ/mol-H2 for transformation of tetrachloroethene to ethane)
and sulfate reduction (−75 kJ/mol-H2) are greater than that of methane production
with H2 (−57 kJ/mol-H2); therefore, dehalogenators and sulfate reducers gain more
energy, synthesize more biomass, and grow faster than methanogens.
In terms of kinetics, Table 2.19 summarizes available Monod kinetic values
for methanogens, oxidize H2: μmax, the maximum specific growth rate
(1/day); qmax, the maximum specific rate of substrate (H2) utilization (mol
H2/gcells-day); and Ks, the half-maximum-rate concentration (μmol H2/L).
Equations 1 and 2 show how these parameters describe the growth of active biomass
(Xa in g-cells/L) and consumption of H2 (S in μmol H2/L) for a batch reaction.
𝑑𝑋𝑎 𝑆 𝑆
= [𝜇𝑚𝑎𝑥 ∗ ( ) − 𝑏] 𝑋𝑎 = [𝑦 ∗ 𝑞𝑚𝑎𝑥 ∗ ( ) − 𝑏] 𝑋𝑎 (1)
𝑑𝑡 𝐾𝑠𝐻2 + 𝑆 𝐾𝑠𝐻2 + 𝑆
𝑑𝑆 𝑆 (2)
= −𝑞𝑚𝑎𝑥 ∗ ( ) ∗ 𝑋𝑎
𝑑𝑡 𝐾𝑠𝐻2 + 𝑆
(sumber: Rittmann, B. E.; McCarty)
49
Also included in the mass balances are Y, the true yield (g-cells/mol-H2),
and b, the endogenous-decay coefficient (1/day).
Table 2.16 Kinetic Parameter Values of Methanogen
Microorganism μmax qmax Ks

Methanobacterium, 1.2−1.3 0.12 5.8−7.3
Methanobacillus,
- - 6.6
Methanococcus
Methanosarcina 1.4 - -
Methanogens (mixed
- - 1 ± 0.18
culture)
Methanogens
- - 0.08-13
(range)
Methanogens (mix) - - 5.8 – 13
(Source: Rittmann, B. E.; McCarty)
2.4.7. Anaerobic Digestion
Anaerobic digestion process is divided into 4 stages, namely:
 Hydrolysis
Hydrolysis is the process of decomposition of complex compounds into
simpler compounds. This reaction is catalyzed by enzymes that are excreted from
hydrolytic bacteria. Hydrolysis is the first step in the anaerobic digestion process
involving the transformation of enzymes mediated from insoluble organic
substances and large molecular weights such as lipids, polysaccharides, proteins,
fats, nucleic acids, etc. others become dissolved organic compounds, i.e.
compounds that are suitable for use as energy sources and cell carbon, such as
monosaccharides, amino acids and other simple organic compounds. The
hydrolysis process is carried out by anaerobic bacteria, such as Clostridia bacteria
and facultative bacteria, such as Streptococci (Merlin Christy, 2014).
The final product of this hydrolysis reaction is dissolved sugar, amino
acids, glycerol, and long chain carboxylic acids. This first stage is very important
because large organic molecules will be too large to be absorbed directly and used
by microorganisms as a food / media source. In the process of biodegradation,
certain microorganisms secrete various types of enzymes, called extracellular
50
enzymes. This enzyme which cuts larger molecules into smaller pieces so that
microorganisms can then enter the cell and be used as a source of energy and
nutrition (Ralph & Dong, 2010).
Figure 2.6 Anaerobic Digestion System Separation Phase

(Source : Schnurer, A. dan Jarvis, A., 2009)
The estimated chemical formula for organic solid waste is C6H10O4.

Therefore, the hydrolysis reaction that occurs in this case is as follows (Ostrem &
Themelis, 2004):
𝐶6 𝐻9,6 𝑂3,5 𝑁0,28 𝑆0,2 + 1,95 𝐻2 𝑂 → 3,275 𝐶𝐻4 + 2,725 𝐶𝑂2 + 0,2 𝐻2 𝑆 + 0,14 𝑁2
 Acidogenesis
Monomers produced in the hydrolytic phase are taken up by different
facultative and obligatory anaerobic bacteria and are further degraded to short chain
organic acids such as butyric acid, propanoic acid, acetic acid, alcohol, hydrogen
and carbon dioxide. The concentration of hydrogen formed as an intermediate
product at this stage affects the type of final product produced during the
fermentation process. For example, if the partial pressure of hydrogen is too high,
it will reduce the amount of compound that is reduced at this stage. In general,
during this phase, simple sugars, fatty acids and amino acids are converted to
organic acids and alcohols (Gerardi, M.H, 2003).
 Acetogenesis
In the third phase, products produced in the acidogenic phase are
consumed as substrates for other microorganisms (Aslanzadeh, 2014). Products that
cannot be directly converted to methane by methanogenic bacteria are converted to
methanogenic substrates. Volatile fatty acids (VFAs) are oxidized to methanogenic
substrates, such as acetate, hydrogen and carbon dioxide. Volatile fatty acids (VFA)
with carbon chains of more than one unit are oxidized to acetate and hydrogen (Al
Seadi, et al, 2008).
51
 Metanogenesis
In the methanogenesis phase, the production of methane and carbon
dioxide from intermediate products (intermediate products) is carried out by
methanogenic bacteria under anaerobic conditions. Methanogenesis is the most
critical stage of the overall anaerobic digestion process because at this stage
biochemical reactions occur at the latest compared to other stages in the anaerobic
digestion process (Al Seadi, et al., 2008).
The size of the biodigester volume is determined based on retention
time and the number of feeds entered which can be calculated by:
𝑉𝑑 = 𝑆𝑑 𝑥 𝑅𝑇 𝑥 𝑚𝑎𝑟𝑔𝑖𝑛
Where:
Vd: volume of biodigester
Sd: substrate input = biomass + water + medium (ratio of biomass: water = 1: 1.95)
RT: retention time (depending on the type of digester)
Margins usually range between 10-15% of the total volume of the digester.
Water is pumped to be mixed with garbage (the ratio of garbage to each water is 1:
1.95) in a stirred reactor (biodigester)
52
Table 2.17 Chemical Reactions Involved in the Anaerobic Digestion
Stage Type of Conversion Bacteria Involved

Clostridium, Proteus vulgaris, Vibrio,
Proteins to soluble peptides and amino acids
Bacillus, Peptococcus, Bacteriodes
Stage 1
Clostridium, Acetovibrio celluliticus,
Hydrolysis Carbohydrates to soluble sugars
Staphylococcus, Bacteriodes
(𝐶6 𝐻12 𝑂5 )𝑛 + 𝑛𝐻2 𝑂 → 𝑛(𝐶6 𝐻12 𝑂6 )
Clostridium, Micrococcus,
Lipids to fatty acids or alcohols
Staphylococcus
Stage 2 Lactobacillus, Escherichia, Bacillus,
Acidogenesis Amino acids to fatty acids, acetate, and NH3 Staphylococcus, Pseudomonas, Sarcina,
𝐶6 𝐻12 𝑂6 + 2𝐻2 𝑂 Desulfovibrio, Selenomonas
→ 2𝐶𝐻3 𝐶𝑂𝑂𝐻 + 4𝐻2 + 𝐶𝑂2
𝐶6 𝐻12 𝑂6 + 2𝐻2 → 2𝐶𝐻3 𝐶𝐻2 𝐶𝑂𝑂𝐻 + 2𝐻2 𝑂
𝐶6 𝐻12 𝑂6 → 𝐶𝐻3 𝐶𝐻2 𝐶𝐻2 𝐶𝑂𝑂𝐻 + 2𝐻2 Sugars to intermediary fermentation
Clostridium, Eubacterium, limosum,
+ 𝐶𝑂2 products
𝐶6 𝐻12 𝑂6 → 2𝐶𝐻3 𝐶𝐻2 𝑂𝐻 + 2𝐶𝑂2
𝐶6 𝐻12 𝑂6 → 2𝐶𝐻3 𝐶𝐻𝑂𝐻𝐶𝑂𝑂𝐻
53
Table 2.17 Chemical Reactions Involved in the Anaerobic Digestion (cont’d)
Stage Type of Conversion Bacteria Involved

Stage 3 Higher fatty acids or alcohols to hydrogen
Clostridium, Syntrophomonas, wolfeii
Acetogenesis and acetate
𝐶𝐻3 𝐶𝐻2 𝑂𝐻 + 𝐻2 𝑂 → 𝐶𝐻3 𝐶𝑂𝑂𝐻 + 2𝐻2
2𝐶𝐻3 𝐶𝐻2 𝑂𝐻 + 2𝐶𝑂2 → 𝐶𝐻4 + 2𝐶𝐻3 𝐶𝑂𝑂𝐻
𝐶𝐻3 𝐶𝐻2 𝐶𝑂𝑂𝐻 + 2𝐻2 𝑂
→ 𝐶𝐻3 𝐶𝑂𝑂𝐻 + 3𝐻2 + 𝐶𝑂2 Volatile fatty acids and alcohols to acetate Syntrophomonas wolfei, Syntrophomonas
𝐶𝐻3 𝐶𝐻2 𝐶𝐻2 𝐶𝑂𝑂𝐻 + 2𝐻2 𝑂 or hydrogen wolinii
→ 2𝐶𝐻3 𝐶𝑂𝑂𝐻 + 2𝐻2
𝐶𝐻3 𝐶𝐻𝑂𝐻𝐶𝑂𝑂𝐻 + 𝐻2 𝑂
→ 𝐶𝐻3 𝐶𝑂𝑂𝐻 + 𝐶𝑂2 + 2𝐻2
Stage 4 Acetate to methane and carbon dioxide Methanosaeta, Methanosarcina
Methanogenesis
Hydrogen and carbon dioxide to methane Methanosaeta, Methanosarcina
𝐶𝐻3 𝐶𝑂𝑂𝐻 → 𝐶𝐻4 + 𝐶𝑂2
(Source: Reproduced from B, V, & S, 2014)
54
Figure 2.7 Anaerobic Digestion

(Source: google.com)
2.4.8. Water Scrubbing

Water is used as a solvent in the pressurised water scrubbing method. Since
much more CO2 is dissolved in the water when the system is pressurised, water
scrubbing usually takes place at a pressure of 4 to 10 bar.
A tall scrubbing column is used, in which water is sprayed from above,
similar to a shower. The biogas is directed upwards from the bottom of the
scrubbing column. As it rises, the gas is brought into contact with the falling liquid.
In order to ensure a greater transitional surface area, filling bodies are added to the
columns, in which the water runs down. In addition, multiple intermediate floors
are installed, in which the water is collected and sprayed again into the lower gas
space below. The purified biomethane, with small constituents of O2 and N2, is
suctioned off at the top of the scrubbing column. Depending on the design of the
column the methane purity is 90 to 99 vol%.
The water is collected at the bottom of the column, charged with CO2 and
small amounts of other gas components (e.g. H2S or NH3). In order to regenerate
the liquid, it is first pumped into a vessel referred to as a flash column, where the
pressure is partially released. In this process, some dissolved gas components are
released. Since CH4 is discharged along with CO2 in this column, the flash gas is
fed back to the beginning of the process, which decreases methane losses.
Subsequently, the pressure in the stripping column is released to ambient pressure
55
and air is blown in. The principal removal of the carbon dioxide takes place at this
point – it is usually blown off into the environment as exhaust gas. The regenerated
water is now pumped back to the first process step inside the scrubber.
During compression, the temperature of the biogas increases. According to
thermodynamic principles, at higher temperatures less gas is dissolved in liquids.
The compressed biogas is therefore cooled. The temperature inside the scrubber is
about 15–20°C. This cooling makes it possible to recover surplus heat from the
scrubbing process, which can then be made available for external use such as
digester heating.
A proportion of less soluble gas components (e.g. CH4) will, however,
always dissolve in the washing liquid, just as some of the readily soluble gas
components will not dissolve. The separation can never be absolute. In terms of
emission regulation, it is therefore important to keep the methane loss as low as
possible. Biomethane plants based on simple technology may have methane losses
reaching several percent. Therefore, all pressurised water scrubbers must be
equipped for post-combustion of the exhaust gas.
Since hydrogen sulphide also dissolves very well in water, the product gas
contains very little H2S. For this reason, the treatment also functions as a
desulphurisation technique, which simplifies the pre-treatment of the sulphur. In
practice, however, an additional fine desulphurisation process is generally used for
biogas pre-treatment. One reason is that the H2S remains in the exhaust gas stream
and the amount of emissions should or must be reduced. Moreover, H2S is
converted into SOx in the RTO. The removal of the latter is technically more
complex than the removal of H2S.
Table 2.18 Operation Conditions of Water Scrubbing
Parameter Value
CO2 Removed 92%
CO Removed 90%
H2S Removed 85.7%
H2 Removed 87%
N2 Removed 88.9%
Liquid Surface Tension 30
dyn/cm
56
Table 2.18 Operation Conditions of Water Scrubbing (cont’d)
Parameter Value
Liquid Phase Viscosity 1 cP
Gaseous Phase Viscocity 0.018 cP
Pressure Drop/Length 0.004
bar/m
absorbent Water
Product Component Methane
Figure 2.8 Water Scrubbing Machine

2.4.9. Stripping
The equilibrium-stage approach in the gas–liquid system was used for
modeling the absorber and stripper units. The technological process flow is alike to
that described previously (Cozma et al. 2013a, b): the CO2-enriched water leaving
the scrubber is transferred to the flash column, where the pressure is reduced from
10 to 3 bar in order to minimize methane loss. The gas containing CO2, CH4, H2S,
N2, O2, and water released from the flash column is mixed with the raw biogas and
recirculated to the inlet of the compressor. After leaving the flash column, the rich
solution is sent to the desorption column (stripper), where it meets a counter flow
of air, into which carbon dioxide and hydrogen sulfide are released from water at
regular atmospheric pressure and at a temperature of 20 C. Subsequently, the water
is recirculated back to the top of the scrubber. Based on the initial process
conditions, it was calculated that the gas leaving the scrubber contains: 96.72 %
methane, 0.937 % CO2, 0.006 ppm H2S, 1.1 % N2, and 0.976 % O2. Methane loss
is very low, that is 0.313 %. It is assumed that the water stream is recycled
57
continuously (in a closed loop), so that only 2 m3/h, which means 2.4 % of
circulating water flow rate (i.e., 84.5 m3/h) is evaporated, or otherwise lost.
A large decrease of pressure (in this case from 10 to 3 bar) resulted in large
amount of recirculated gases and to a decrease of efficiency. The pressure in flash
was chosen to be 3 bar to avoid the presence of large amounts of methane in liquid
phase. In other words, the liquid phase from flash flows to stripper where desorption
takes place (methane is released from liquid phase and passes to gas phase).
Therefore, large quantities of methane can pass into gas outlet of desorber if initially
high amounts of methane exist in liquid phase.
Table 2.19 Operation Conditions of Stripping
Parameter Value
CO2 Removed 88.9%
CO Removed 90%
H2S Removed 85.3%
H2 Removed 86%
N2 Removed 85%
Product Carbon
Component Dioxide
Figure 2.9 Stripping Machine
58
2.4.10. Condenser
The last process in this plant is condenser. Condenser, is the removal of

dissolved liquid from gases, especially water or aqueous solutions. There are
numerous methods for removing liquids from gaseous. Water are removed for
purify the biomethane product to fulfill the desired gas sales conditions which is
0% water content. Several operation conditions in this process is adjust by superpro
program, except;
Table 2.20 Operation Conditions of Condenser
Parameter Value
Water
97.2%
Removed
Cooling
Cooling Agent
Water
59
2.5. Block Flow Diagram
Figure 2.10 Block Flow Diagram
60
2.6. Process Flow Diagram
Figure 2.11 Process Flow Diagram

61
CHAPTER 3
MASS AND ENERGY BALANCE
3.1. Mass Balance

The mass balance table below will explain about mass input and output of
production of biogas from organic municipal solid waste and biomass. Mass
balance equation conducted to evaluate the production capacity with the supply of
raw material. The input mass referred as raw material and other substances that used
on the production process, while mass output consists of waste or feed (semi-
finished product) that will be the input in another stream.
3.1.1. Mass Balance per Unit Operation
The calculation of the mass balance per unit operation is conducted using
process simulation program Intelligen Inc.’s SuperPro Designer V9.0. This process
modeling software is currently used in the biochemical, pharmaceutical, specialty
chemical, and food processing industries. The mass balance per unit operation can
be seen in the tables below.
Table 3.1 Mass Balance in Washing Process
Procedure P-1
Process Washing
Materials Input (kg/h) Output (kg/h)
From
To Next
Type New Input Previous Purge
Process
Process
Ash 616.7041591 0 0 616.704
Cellulose 1749.959286 0 1749.9593 0
Hemicellulose 1524.070296 0 1524.0703 0
Lignin 1069.02645 0 1069.0265 0
Water 583.3480082 0 483.34801 100
62
Table 3.2 Mass Balance in Rotary Drying
Procedure P-2
Process Rotary Drying
From
To Next
Process
Process
Cellulose 0 1749.9593 1749.9593 0
Hemicellulose 0 1524.0703 1524.0703 0
Lignin 0 1069.0265 1069.0265 0
Nitrogen 1853.924786 0 0 1853.92
Oxygen 562.815254 0 0 562.816
Water 0 483.34801 0 483.348
Table 3.3 Mass Balance in Belt Conveyor 1
Procedure P-3
Process Belt Conveying
From
To Next
Process
Process
Cellulose 0 1749.9593 1749.9593 0
Hemicellulose 0 1524.0703 1524.0703 0
Lignin 0 1069.0265 1069.0265 0
Yeast 0 0 0 0
Table 3.4 Mass Balance in Grinding
Procedure P-4
Process Grinding
From
To Next
Process
Process
Cellulose 0 1749.9593 1749.9593 0
Hemicellulose 0 1524.0703 1524.0703 0
Lignin 0 1069.0265 1069.0265 0
63
Table 3.5 Mass Balance in Pre Treatment
Procedure P-5
Process Blending/Storage
From
New To Next
Type Previous Purge
Input Process
Process
Cellulose 0 1749.9593 349.99186 0
Glucose 0 0 1218.9019 0
Hemicellulose 0 1524.0703 304.81406 0
Lignin 0 1069.0265 427.61058 641.416
Nitrogen 0 0 0 5.37796
Oxygen 0 0 0 1.63265
Water 0 1814.3694 0 1813
Xylose 0 0 1399.9709 0
Table 3.6 Mass Balance in Heating
Procedure P-6
Process Heating
From
To Next
Process
Process
Water 1814.3694 0 1814.3694 0
Table 3.7 Mass Balance in Cooling
Procedure P-7
Process Cooling
From
To Next
Process
Process
Cellulose 0 349.99186 349.99186 0
Glucose 0 1218.9019 1218.9019 0
Hemicellulose 0 304.81406 304.81406 0
Lignin 0 427.61058 427.61058 0
Xylose 0 1399.9709 1399.9709 0
64
Table 3.8 Mass Balance in Anaerobic Digestion
Procedure P-8
Process Vessel Procedure
From
New To Next
Type Previous Purge
Input Process
Process
Agar 0 0.09951 0 0.09951
Ash 0 87.08973 0 87.0897
Biomass 0 326.72083 0 223.097
Carbon Dioxide 0 0 621.24762 0
Carbon Monoxide 0 0 20.70825 0
Cellulose 0 894.30268 0 687.056
Glucose 0 1219.1009 0 182.865
Hemicellulose 0 449.96361 0 139.093
Hidrogen Sulfid 0 0 16.5666 0
Hydrogen 0 0 37.27486 0
Lignin 0 1180.3583 0 842.488
Methane 0 0 1346.0365 0
Methanobacterium 0 108.86216 0 112.411
Nitrogen 0 0 35.29432 0
Oxygen 0 0 1.9137 0
Water 0 1700.4634 0 1700.46
Xylose 0 1399.9709 0 1296.35
Yeast 0 0.04677 0 0.04677
Table 3.9 Mass Balance in Gas Compressor
Procedure P-9
Process Gas Compressor
From
To Next
Process
Process
Carbon Dioxide 0 621.24762 621.24762 0
Carbon Monoxide 0 20.70825 20.70825 0
Hidrogen Sulfid 0 16.5666 16.5666 0
Hydrogen 0 37.27486 37.27486 0
Methane 0 1346.0365 1346.0365 0
Nitrogen 0 35.29432 35.29432 0
Oxygen 0 1.9137 1.9137 0
65
Table 3.10 Mass Balance in Belt Conveyor 2
Procedure P-10
Process Belt Conveyor
From
To Next
Process
Process
Ash 87.0897312 0 87.089731 0
Biomass 326.586492 0 326.58649 0
Cellulose 544.31082 0 544.31082 0
Hemicellulose 145.149552 0 145.14955 0
Lignin 725.74776 0 725.74776 0
Methanobacterium 108.862164 0 108.86216 0
Water 1690.992281 0 1690.9923 0
Table 3.11 Mass Balance in Seed Fermentor
Procedure P-11
Process Seed Cell Culture
From
To Next
Process
Process
Agar 0.09551 0 0.09551 0
Biomass 0.13434 0 0.13434 0
Glucose 0.19902 0 0.19902 0
Methanobacterium 3.549 0 3.549 0
Water 9.47114 0 9.47114 0
Yeast 0.04677 0 0.04677 0
66
Table 3.12 Mass Balance in Cooling 2
Procedure P-12
Process Cooling
From
To Next
Process
Process
Carbon Dioxide 0 621.24762 621.24762 0
Carbon Monoxide 0 20.70825 20.70825 0
Hidrogen Sulfid 0 16.5666 16.5666 0
Hydrogen 0 37.27486 37.27486 0
Methane 0 1346.0365 1346.0365 0
Nitrogen 0 35.29432 35.29432 0
Oxygen 0 1.9137 1.9137 0
Table 3.13 Mass Balance in Gas Compression
Procedure P-13
Process Gas Compression
From
To Next
Process
Process
Carbon Dioxide 0 0.00006 0.00006 0
Methane 0 1346.0365 1346.0365 0
Oxygen 0 1.9137 1.9137 0
67
Table 3.14 Mass Balance in Gas Compression
Procedure P-14
From
To Next
Process
Process
Carbon Dioxide 0 3682702.8 3682702.8 0
Carbon Monoxide 0 86420.929 86420.929 0
Hidrogen Sulfid 0 39099.779 39099.779 0
Hydrogen 0 248165.69 248165.69 0
Methane 0 1346.0365 1346.0365 0
Nitrogen 0 201556.4 201556.4 0
Oxygen 0 1.9137 1.9137 0
Water 0 30238.194 30238.194 0
Table 3.15 Mass Balance in Cooling 2
Procedure P-15
Process Cooling
From
To Next
Process
Process
Carbon Dioxide 0 3682702.8 3682702.8 0
Carbon Monoxide 0 86420.929 86420.929 0
Hidrogen Sulfid 0 39099.779 39099.779 0
Hydrogen 0 248165.69 248165.69 0
Methane 0 1346.0365 1346.0365 0
Nitrogen 0 201556.4 201556.4 0
Oxygen 0 1.9137 1.9137 0
Water 0 30238.194 30238.194 0
68
Table 3.16 Mass Balance in Absorption
Procedure P-16
Process Absorption
From
To Next
Process
Process
Carbon Dioxide 0 3682702.8 3682702.8 0
Carbon Monoxide 0 86420.929 86420.929 0
Hidrogen Sulfid 0 39099.779 39099.779 0
Hydrogen 0 248165.69 248165.69 0
Methane 0 1346.0365 1346.0365 0
Nitrogen 0 201556.4 201556.4 0
Oxygen 0 1.9137 1.9137 0
Water 200 30238.194 30238.194 0
Table 3.17 Mass Balance in Condensation
Procedure P-17
Process Condensation
From
New To Next
Type Previous Purge
Input Process
Process
Carbon Dioxide 0 0.00006 0 0.00006
Methane 0 1346.0365 1346.0365 0
Oxygen 0 1.9137 1.9137 0
69
Table 3.18 Mass Balance in Stripping
Procedure P-18
Process Stripping
From
To Next
Process
Process
Carbon Dioxide 0.96 324.63001 0 324.732
Carbon Monoxide 0 37.20392 0 37.1068
Hidrogen Sulfid 0 51.63521 0 51.4995
Nitrogen 78.09 26.16262 0 104.186
Oxygen 20.95 0 0 20.95
Water 0 195.20407 0 195.204
Table 3.19 Mass Balance in Degasification
Procedure P-19
From
To Next
Process
Process
Methane 0 1346.0365 0 1346.04
Oxygen 0 1.9137 0 1.9137
Table 3.20 Mass Balance in Compressor
Procedure P-20
Process Heat Exchanger
From
To Next
Process
Process
Methane 0 1346.0365 0 1346.04
Oxygen 0 1.9137 0 1.9137
70
Table 3.21 Mass Balance in Gas Compressor
Procedure P-21
From
To Next
Process
Process
Methane 0 1346.0365 0 1346.04
Oxygen 0 1.9137 0 1.9137
Table 3.22 Mass Balance in Heat Exchanger
Procedure P-22
From
To Next
Process
Process
Methane 0 1346.0365 0 1346.04
Oxygen 0 1.9137 0 1.9137
3.1.2. Overall Mass Balance

After calculating the mass balance per unit operation, overall mass balance
can be determined. The overall mass balance shown in the table below.
71
Table 3.23 Overall Mass Balance
Material In Out
Agar 0.09551 0.09951
Ash 703.7938903 703.7938891
Biomass 326.720832 223.09725
Carbon Dioxide 0.96 325.10033
Carbon Monoxide 0 37.1154
Cellulose 2294.270106 687.05552
Glucose 0.19902 182.86514
Hemicellulose 1669.219848 139.09288
Hidrogen Sulfid 0 51.50344
Hydrogen 0 0.02481
Lignin 1794.77421 1483.90348
Methane 0 1346.03651
Methanobacterium 112.411164 112.41116
Nitrogen 1932.014786 1963.50901
Oxygen 583.765254 587.3119
Water 4298.180829 4292.01494
Xylose 0 1296.3473
Yeast 0.04677 0.04677
TOTAL 13716.45222 13431.32924
3.2. Energy Balance

Energy balance means the heat generated by every unit operation in the
whole production process. This calculation is used to evaluate the whole energy
used for production. The calculation will be executed in each of unit procedure or
process equipment. Each equipment will have their own energy balance, or in other
terms, energy in and energy out. The energy balance equation which will be used
is as follows:
𝐐 = 𝐦 . 𝐂𝐩 . ∆𝐓
Q = heat energy (KJ)
m = mass (Kg)
Cp = Specific heat (KJ/Kg ℃)
∆T = Change in Temperature (℃)
The data to specific heat of each component is shown in table below.
72
Table 3.24 Heat Specific of Each Component
Materials Cp (kJ/kg*K)
Agar 1.8
Ash 1.137
Biomass 1.63
Carbon Dioxide 0.843
Carbon Monoxide 1.04
Cellulose 1.4
Glucose 1.213
Hemicellulose 2.537
Hidrogen Sulfid 1.01
Hydrogen 14.32
Lignin 1.1
Methane 2.223
Methanobacterium 1.4
Nitrogen 1.04
Oxygen 0.919
Water 1.4
Xylose 2.5
Yeast 1.4
3.2.1 Energy Balance per Unit Operation

The energy balance for this plant is shown in table below. This table is
showing the energy balance for every unit operation in this plant.
Table 3.25 Energy Balance in Washing Process
Procedure P-1
Process Washing
Materials Energy Input (kJ) Energy Output (kJ) ΔH
Tin (K) Tout (K)
From (kJ)
New To Next
Type Previous Purge
Input Process
Process
Ash 298 298 208955.4 0 0 208955.4 0
Cellulose 298 298 730083.01 0 730083.01 0 0
Hemicellulose 298 298 1152236.8 0 1152236.8 0 0
Lignin 298 298 350426.87 0 350426.87 0 0
Water 298 298 243372.79 0 201652.79 41720 0
73
Table 3.26 Energy Balance in Rotary Drying
Procedure P-2
Process Rotary Drying
Materials Energy Input (kJ) Energy Output (kJ)
Tin (K) Tout (K) ΔH (kJ)
From
New To Next
Type Previous Purge
Input Process
Process
Cellulose 298 343 0 730083 840330.45 0 110247
Hemicellulose 298 343 0 1152237 1326232.3 0 173995
Lignin 298 343 0 350426.9 403343.68 0 52916.8
Nitrogen 298 343 574568.37 0 0 661331.94 86763.6
Oxygen 298 343 154133.71 0 0 177409.03 23275.3
Water 298 343 0 201652.8 0 232103.71 30450.9
Table 3.27 Energy Balance in Belt Conveyor
Procedure P-3
Process Belt Conveying
Energy Output
Materials Energy Input (kJ) ΔH
Tin (K) Tout (K) (kJ)
(kJ)
From
To Next
Process
Process
Cellulose 343 343 0 840330.5 840330.45 0 0
Hemicellulose 343 343 0 1326232 1326232.3 0 0
Lignin 343 343 0 403343.7 403343.68 0 0
Table 3.28 Energy Balance in Grinding
Procedure P-4
Process Grinding
Energy Output
(kJ)
From
To Next
Process
Process
Cellulose 343 343 0 840330.5 840330.45 0 0
Hemicellulose 343 343 0 1326232 1326232.3 0 0
Lignin 343 343 0 403343.7 403343.68 0 0
74
Table 3.29 Energy Balance in Pretreatment
Procedure P-5
Process Blending/Storage
From
New To Next
Type Previous Purge
Input Process
Process
Cellulose 343 433 0 840330.5 212165.07 0 -628165
Glucose 343 433 0 0 640202.63 0 640203
Hemicellulose 343 433 0 1326232 334844.65 0 -991388
Lignin 343 433 0 403343.7 203670.92 305506.38 105834
Nitrogen 343 433 0 0 0 2421.8029 2421.8
Oxygen 343 433 0 0 0 649.67552 649.676
Water 343 433 0 871260.2 0 1099038.6 227778
Xylose 343 433 0 0 1515468.5 0 1515468
Table 3.30 Energy Balance in Heating
Procedure P-6
Process Heating
Energy Output
(kJ)
From
To Next
Process
Process
Water 298 343 756954.91 0 871260.19 0 114305
75
Table 3.31 Energy Balance in Cooling Process
Procedure P-7
Process Cooling
Energy Output
(kJ)
From
To Next
Process
Process
Cellulose 433 309 0 212165.1 151406.48 0 -60759
-
Glucose 433 309 0 640202.6 456865.15 0
183337
Hemicellulose 433 309 0 334844.6 238953.8 0 -95891
Lignin 433 309 0 203670.9 145344.84 0 -58326
-
Xylose 433 309 0 1515468 1081477.5 0
433991
76
Table 3.32 Energy Balance in Anaerobic Digestion
Procedure P-8
Process Vessel Procedure
From
New To Next
Type Previous Purge
Input Process
Process
Agar 298 309 0 53.37716 0 55.347462 1.9703
Ash 298 309 0 29508.26 0 30597.496 1089.23
Biomass 298 309 0 158701.4 0 112367.39 -46334
Carbon Dioxide 0 309 0 0 161826.93 0 161827
Carbon Monoxide 0 309 0 0 6654.8032 0 6654.8
Cellulose 298 309 0 373103.1 0 297220.22 -75883
-
Glucose 309 309 0 456939.7 0 68540.963
388399
-
Hemicellulose 298 309 0 340184.2 0 109039.5
231145
Hidrogen Sulfid 0 309 0 0 5170.2702 0 5170.27
Hydrogen 0 309 0 0 164936.78 0 164937
-
Lignin 309 309 0 401203.8 0 286361.54
114842
Methane 0 309 0 0 924601.9 0 924602
Methanobacterium 298 309 0 45417.29 0 48629.068 3211.77
Nitrogen 0 309 0 0 11342.183 0 11342.2
Oxygen 0 309 0 0 543.4353 0 543.435
Water 298 309 0 709433.3 0 735620.4 26187.1
Xylose 309 309 0 1081478 0 1001428.3 -80049
Yeast 298 309 0 19.51244 0 20.232702 0.72026
77
Table 3.33 Energy Balance in Gas Compressor
Procedure P-9
Energy Output
Materials Energy Input (kJ)
Tin (K) Tout (K) (kJ) ΔH (kJ)
From
To Next
Process
Process
Carbon Dioxide 309 313 0 161826.9 163921.78 0 2094.85
Carbon Monoxide 309 313 0 6654.803 6740.9495 0 86.1463
Hidrogen Sulfid 309 313 0 5170.27 5237.1993 0 66.9291
Hydrogen 309 313 0 164936.8 167071.89 0 2135.1
Methane 309 313 0 924601.9 936570.86 0 11969
Nitrogen 309 313 0 11342.18 11489.007 0 146.824
Oxygen 309 313 0 543.4353 550.47006 0 7.03476
Table 3.34 Energy Balance in Belt Conveyor
Procedure P-10
Process Belt Conveyor
Energy Output
(kJ)
From
To Next
Process
Process
Ash 298 298 29508.265 0 29508.265 0 0
Biomass 298 298 158636.12 0 158636.12 0 0
Cellulose 298 298 227086.47 0 227086.47 0 0
Hemicellulose 298 298 109736.84 0 109736.84 0 0
Lignin 298 298 237900.12 0 237900.12 0 0
Methanobacterium 298 298 45417.295 0 45417.295 0 0
Water 298 298 705481.98 0 705481.98 0 0
78
Table 3.35 Energy Balance in Seed Fermentor
Procedure P-11
Process Seed Cell Culture
Energy Output
(kJ)
From
To Next
Process
Process
Agar 298 298 51.231564 0 51.231564 0 0
Biomass 298 298 65.254312 0 65.254312 0 0
Glucose 298 298 71.940555 0 71.940555 0 0
Methanobacterium 298 298 1480.6428 0 1480.6428 0 0
Water 298 298 3951.3596 0 3951.3596 0 0
Yeast 298 298 19.512444 0 19.512444 0 0
Table 3.36 Energy Balance in Cooling
Procedure P-12
Process Cooling
Energy Output
(kJ)
From
To Next
Process
Process
Carbon Dioxide 313 293 0 163921.8 153447.54 0 -10474
Carbon Monoxide 313 293 0 6740.95 6310.2179 0 -430.73
Hidrogen Sulfid 313 293 0 5237.199 4902.5539 0 -334.65
Hydrogen 313 293 0 167071.9 156396.37 0 -10676
Methane 313 293 0 936570.9 876726.07 0 -59845
Nitrogen 313 293 0 11489.01 10754.885 0 -734.12
Oxygen 313 293 0 550.4701 515.29626 0 -35.174
79
Table 3.37 Energy Balance in Gas Compression
Procedure P-13
Energy Output
Materials Tout Energy Input (kJ)
Tin (K) (kJ) ΔH (kJ)
(K)
From
To Next
Process
Process
Carbon Dioxide 293 304.1 0 0.01482 0.0153814 0 0.00056
Methane 293 304.1 0 876726.1 909939.93 0 33213.9
Oxygen 293 304.1 0 515.2963 534.81772 0 19.5215
Table 3.38 Energy Balance in Gas Compression
Procedure P-14
Energy Output
Materials Energy Input (kJ)
Tin (K) Tout (K) (kJ) ΔH (kJ)
From
To Next
Process
Process
Carbon Dioxide 304.1 313 0 9.44E+08 971714277 0 2.8E+07
Carbon Monoxide 304.1 313 0 27331829 28131741 0 799912
Hidrogen Sulfid 304.1 313 0 12009145 12360613 0 351468
Hydrogen 304.1 313 0 1.08E+09 1.112E+09 0 3.2E+07
Methane 304.1 313 0 909939.9 936570.86 0 26630.9
Nitrogen 304.1 313 0 63745033 65610639 0 1865606
Oxygen 304.1 313 0 534.8177 550.47006 0 15.6523
Water 304.1 313 0 12873609 13250377 0 376768
80
Table 3.39 Energy Balance in Cooling
Procedure P-15
Process Cooling
Energy Output
(kJ)
From
To Next
Process
Process
Carbon Dioxide 313 293 0 9.72E+08 909623908 0 -6E+07
Carbon Monoxide 313 293 0 28131741 26334185 0 -2E+06
-
Hidrogen Sulfid 313 293 0 12360613 11570798 0
789816
Hydrogen 313 293 0 1.11E+09 1.041E+09 0 -7E+07
Methane 313 293 0 936570.9 876726.07 0 -59845
Nitrogen 313 293 0 65610639 61418266 0 -4E+06
Oxygen 313 293 0 550.4701 515.29626 0 -35.174
-
Water 313 293 0 13250377 12403707 0
846669
Table 3.40 Energy Balance in Absorption
Procedure P-16
Process Absorption
Energy Output
(kJ)
From
To Next
Process
Process
Carbon Dioxide 293 293 0 9.1E+08 909623908 0 0
Carbon Monoxide 293 293 0 26334185 26334185 0 0
Hidrogen Sulfid 293 293 0 11570798 11570798 0 0
Hydrogen 293 293 0 1.04E+09 1.041E+09 0 0
Methane 293 293 0 876726.1 876726.07 0 0
Nitrogen 293 293 0 61418266 61418266 0 0
Oxygen 293 293 0 515.2963 515.29626 0 0
Water 293 293 82040 12403707 12403707 0 -82040
81
Table 3.41 Energy Balance in Condensation
Procedure P-17
Process Condensation
Materials Tout Energy Input (kJ) Energy Output (kJ) ΔH
Tin (K)
(K) From (kJ)
New To Next
Type Previous Purge
Input Process
Process
Carbon Dioxide 293 293 0 0.01482 0 0.0148199 0
Methane 293 293 0 876726.1 876726.07 0 0
Oxygen 293 293 0 515.2963 515.29626 0 0
Table 3.42 Energy Balance in Stripping
Procedure P-18
Process Stripping
From
New To Next
Type Previous Purge
Input Process
Process
Carbon Dioxide 298 293.4 241.16544 81551.6 0 80318.001 -1474.8
Carbon Monoxide 293 293.4 0 11336.78 0 11322.608 -14.17
Hidrogen Sulfid 293 293.4 0 15280.41 0 15261.062 -19.346
Nitrogen 298 293.4 24201.653 8108.319 0 31791.024 -518.95
Oxygen 298 293.4 5737.4089 0 0 5648.8449 -88.564
Water 293 293.4 0 80072.71 0 80181.958 109.249
Table 3.43 Energy Balance in Heat Exchanger
Procedure P-20
Tin (K)
(K) From (kJ)
New To Next
Type Previous Purge
Input Process
Process
Methane 304.1 293 0 909939.9 0 876726.07 -33214
Oxygen 304.1 293 0 534.8177 0 515.29626 -19.521
82
Table 3.44 Energy Balance in Gas Compressor
Procedure P-21
Materials Tout Energy Input (kJ) Energy Output (kJ)
Tin (K) ΔH (kJ)
(K) From
New To Next
Type Previous Purge
Input Process
Process
Methane 293 319 0 876726.1 0 954524.29 77798.2
Oxygen 293 319 0 515.2963 0 561.02221 45.7259
Table 3.45 Mass Balance in Heat Exchanger
Procedure P-22
Tin (K)
(K) From (kJ)
New To Next
Type Previous Purge
Input Process
Process
Methane 319 293 0 954524.3 0 876726.07 -77798
Oxygen 319 293 0 561.0222 0 515.29626 -45.726
3.2.2 Overall Energy Balance

After calculating every unit operation in the process, overall energy balance
can be calculated. The overall energy balance will be shown in the table below.
83
Table 3.46 Overall Energy Balance

Entalpy ΔH
Material Energy In (kJ) Energy Out (kJ)
(kJ)
Agar 104.608728 106.579026 1.970298
Ash 267971.9335 269061.1648 1089.231253
Biomass 317402.7529 271068.7688 -46333.98406
Carbon Dioxide 958686.0421 1103670.144 144984.1019
Carbon Monoxide 39306.41216 45386.18869 6079.776534
Cellulose 4793512.001 4138952.604 -654559.3973
Glucose 1097214.316 1165680.683 68466.3671
Hemicellulose 7067935.987 5923508.325 -1144427.662
Hidrogen Sulfid 30538.05868 35261.57737 4723.518692
Hydrogen 974194.5269 1124879.49 150684.9634
Lignin 2753659.614 2739241.698 -14417.91641
Methane 9955778.139 9877979.921 -77798.2182
Methanobacterium 92315.23077 95527.00544 3211.774664
Nitrogen 665946.1497 741108.4691 75162.31934
Oxygen 165722.6344 183864.4932 18141.8588
Water 3656187.356 4055021.062 398833.7057
Xylose 2596946.004 3598374.287 1001428.283
Yeast 39.024888 39.745146 0.720258
TOTAL 35433460.79 35368732.21 -64728.58671
3.3. Production Efficiency Efficiency

Based on the mass and energy balance calculations, the mass and energy
efficiency which represents plant efficiency can be determined. The output is a total
of product that sold to the customer, which are biogas and digestate from the
anaerobic digestion procedure. The input is the total mass of rice straw and organic
municipal solid waste. The production efficiency is calculated with the formula
below. Production efficiency is the same as the yield of production.
𝑀𝑎𝑠𝑠 𝑂𝑢𝑡𝑝𝑢𝑡
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 𝑥 100%
𝑀𝑎𝑠𝑠 𝐼𝑛𝑝𝑢𝑡
6617.0911
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 𝑥 100%
9071.847
= 72.94%
𝐸𝑛𝑒𝑟𝑔𝑦 𝑂𝑢𝑡𝑝𝑢𝑡
𝐸𝑛𝑒𝑟𝑔𝑦 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 𝑥 100%
𝐸𝑛𝑒𝑟𝑔𝑦 𝐼𝑛𝑝𝑢𝑡
84
2689880.441
𝐸𝑛𝑒𝑟𝑔𝑦 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 𝑥 100%
35368732.21
= 76.05%
3.4. Process Simulation

Process simulation is done in simulation program Intelligen Inc.’s SuperPro
Designer V9.0. from the previous process flow diagram. The usage of SuperPro
simulator itself is because the lack of UniSim simulator which cannot defines
biomass as material stream and proceed solid material. SuperPro allow modelling
batch production, estimate cost, and evaluate the environmental impact of each
stage of the process. The result of the plant simulation in SuperPro is as shown
below.
85
Figure 2. 1 Process Simulation
86
CHAPTER 4
HEAT EXCHANGER NETWORKING ANALYSIS
A plant must be produced heat transmission because of its process. A

designed plant that starts from reactor section to separation and recycle system,
required heat recovery system, so heat exchanger is necessary. To fix the material
and energy balances, heating and cooling major process is needed to recovery the
system. Fixing the design of heat exchanger network is not necessary at this
assignment. The aim can be set for the heat exchanger network to get the
performance of the finished design without mentioning the actual network design.
The result will show both the energy and capital cost for the operating heat
exchanger network. The result will also allow the designer to predict process
changes for the reactor, separation process and recycle system to support the result
for the energy and capital cost of the assessed heat exchanger network.
The network of heat exchanger is a general knowledge and technology, based
on the principle of thermodynamics which exchange two different temperature of
two or more substances, to reduce the overall energy consumption of a process.
According to the principle of thermodynamics, a heat exchanger network is
developed by arranging the hot flow and the cold flow.
4.1. Stream Classification
This section is done to determine cold stream and hot stream temperature
changes in the plant. Hot stream means fluid that is decreased by its temperature
and its enthalpy that it has a negative value of heat duty. Otherwise, cold stream
means fluid that is increased by its temperature and its enthalpy that it has a positive
value of heat duty.
Table 4.1 Stream Classification
Stream Stream Tin Tout

No Type ∆H (kW) CP (kw/⁰C)
In Out (oC) (oC)
1 12 13 32 70 Cold 15720.6 413.7
2 18 19 31.1 20 Hot 4592.07 -413.7
3 24 25 32 20 Hot 49454.7259 -4121.22716
4 26 27 46 20 Hot 294130.72 -11312.72
5 17 18 38 20 Hot 53954.0773 -2997.44874
87
4.2. Heat Recovery Pinch

Heat exchanger network is the application of pinch technology, a method
87
based on the principles of thermodynamics to reduce the overall energy
consumption of a process. This technology issued to design and develop a network
of heat exchangers, by integrating the hot flow (as a heat source) with cold flow (as
a heat sink). It guarantees minimum energy levels in design of heat exchanger
networks.
4.2.1 Problem Table Cascade Method
Calculate the energy targets directly without graphical construction can be
developed and it is an efficient method rather than using composite curves to set
the energy targets. The first step is to determine the shifted temperature by shifting
existing temperature into 0.5 x ΔTmin. The minimum approach temperature chosen
is ΔTmin=5oC. It follows the heuristic rules from Seider et al., 2003, which stated
near-optimal minimum temperature approaches in heat exchangers depend on the
temperature level, which is 20oF for temperature above ambient up to 300oF, and
50oF for high temperature. Since the whole process involving ambient temperature
to higher than 300oF, the near-optimal minimum temperature approaches taken was
41oF (5oC). The shifted temperature is shown in table 4.2.
Table 4.2 Shifted Temperature Data from Table 4.1
Stream Stream
No Tin Tout Type T*in T*out
In Out
1 12 13 32 70 Cold 34.5 72.5
2 18 19 31.1 20 Hot 28.6 17.5
3 24 25 32 20 Hot 43.5 17.5
4 26 27 46 20 Hot 29.5 17.5
5 17 18 38 20 Hot 35.5 17.5
The next step is to set the shifted temperature ordering from its highest
temperature to the lowest. These are used to create a cascade of temperature
intervals within which energy balance are carried out. Any excess heat available
(surplus) from hot streams in an interval should be able to supply the deficit in cold
stream of the next interval down. This graph below represents the visual
information of relative temperature change from one fluid to another.
88
Table 4.3 Shifted Temperature Area
Meanwhile, the temperature interval balance is shown in the following table.

Each interval shows enthalpy difference between removal energy from hot streams
to be taken up to the cold stream in the interval.
Table 4.4 Temperature Interval Balance
Shift
T(i+1)- Cpnet
Temperature Interval ΔH (kW) Deficit/Surplus
Ti (°C) (kW/°C)
°C
72.5
1 29 -413.7 -11997.3 deficit
43.5
2 8 10899.02 87192.16 surplus
35.5
3 1 13896.4687 13896.4687 surplus
34.5
4 5 14310.1687 71550.8437 surplus
29.5
5 0.9 18431.3959 16588.2563 surplus
28.6
4.2.2 Pinch Design Method

After creating cascade table, the next step is designing pinch method. This is
necessary because there is a parameter called pinch temperature which is the core
of pinch designing method. Results from cascade diagram made before are pinch
temperature and the minimum hot and cold utilities requirements.
89
Tempe-
Infeasible Feasible
rature
Cascade Cascade
(°C)
Hot Utility
72.5 ▼ 0 ▼ 11997.3
-11997.3 -11997.3
43.5 ▼ -11997.3 ▼ 0 PINCH
87192.16 87192.16
35.5 ▼ 75194.86 ▼ 87192.16
13896.469 13896.46874
34.5 ▼ 89091.3287 ▼ 101088.6287
71550.844 71550.8437
29.5 ▼ 160642.172 ▼ 172639.4724
16588.256 16588.25631
28.6 ▼ 177230.429 ▼ 189227.7288
209180.56 209180.5645
17.5 ▼ 386410.993 ▼ 398408.2932
Figure 4.1 Cascade Diagram of Biomethane Plant from Rice Straw and MSW
The yellow color marks the pinch temperature, with hot pinch temperature is 46oC
dan cold pinch temperature is 41oC. From the cascade diagram, it is also known that
the minimum hot utility requirement is 11997.3 kW, while the minimum cold utility
is 398408.29 kW.
The design of heat exchanger network is made afterwards. It is mean to design
heat transfer among fluids to achieve the minimum hot and cold utility requirement
set before. The design follows rules, which the networking stream can be created
between hot and cold stream if 𝐶𝐶 ≥ 𝐶h and when HEN is designed on the cold side
of the pinch, the networking stream can be created between hot and cold stream if
𝐶𝐶 ≤ 𝐶h. The result of the HEN design is listed in the figure bellow.
90
Figure 4.2 Heat Exchanger Network Design for Biomethane Plant
Above shown the heat exchanger network diagram. Heat exchanger network
diagram shows the effective way to take the advantage of the heat exchanger
equipment. In this case, the hot fluid and the cold fluid complete each other in order
to reach the designated temperature. In this case, there are only two possible line to
be connected. The first one is second from below, inlet water temperature of 43.5
degree Celcius and needed to be cooled as in the outlet water temperature of 17.5
degree Celcius. The second one with inlet water temperature of 34.5 degree Celcius
and used to cool fluid as the outlet temperature of 72.5 degree Celcius. Keep in
mind that the third line is on the right side of the pinch temperature area which
means the law of Ch>Cc is applied.
Before the HEN method is applied, the heat exchanger has to retrieve its own
specific coolant in order to reduce the hot temperature inlet. So the heat exchanger
can work with its own capacity but need more cost and heat/cold capacity. To
maximize the efficiency of the designed heat exchanger, heat exchanger network is
used to reduce cost and heat/cold capacitance. According to the law of Cc>Ch (left
side of the pinch temperature) and Ch>Cc (right side of the pinch temperatre), line
number one and number three is connected in order to exchange the heat/cold
power. For example in the left side, there are cold water line and in the right side
hot water line and has Cp value of 413,7 kW/oC and 11312,72 kW/oC each. It shows
that Cp of cold water lower than the CP of hot water and fulfil the law Ch>Cc. That
means both of the line can be connected each other. Through calculation, the heat
power has 294130,72 kW/oC and the cooling power has 3723,3 kW/oC. It means
that the connection has to be balanced in order to get the required temperature.
Further explanation below. According to the schematic above, there are three
cooling power and one heat power. The purpose is to balance the heat and cold
91
capacitance so the power value can cover up the designated fluid temperature.
Taking the first line explanation to guide the rest of the line. The first line need to
raise the temperature from 34.5 degree Celcius to 72.5 degree Celcius. The process
need to consider cooling capacitance from the cold water line (the upper one). To
cool down from 43.5 degree Celcius to 17.5 degree Celcius, it needs cooling
capacitance of 294130,72 kW/ oC and that value cannot be handled by the cold water
line (if the process continue, the cold water will rise far beyond the desginated
temperature). To keep the system sustainable, maximizing the cooling capacitance
to reduce the hot temperature is necessary. So with the cooling capacitance of
3723,3 kW/oC, the hot fluid temperature only can be reduced to 42,15 degree
Celcius. So the remain temperature will be reduce with 2778 kW/oC cooler to reach
the final temperature, 17.5 degree Celcius.
4.3. Process Flow Diagram After HEN
This figure below shows the adjusted whole process after doing HEN
analysis.
92
Figure 4.3 Process Flow Diagram After HEN

93
CHAPTER 5
UTILITY
Water Utility
Water is one of the most important components in this factory. Water usage
is divided depending on the application, with each application having its own
properties, such as temperature.
Water requirement per day must be calculated to determine the amount of
water which have to provide for the plant. The plant needs water as requirements
for cooling water, hot water and steam. The water sources is taken from the river,
near the agricultural area which is near the plant. Water from river is full of
impurities, so the level of impurities must be removed before used.
Figure 5.1 Plant Location for Seawater

(Source: Google earth)
5.1.1 Main Process

Water for main process makes up the majority in this factory. It is used for
many purposes, such as washing, biomass pretreatment, culture medium, and
absorption. Some process uses more water than other. For example, pretreatment
has the most water used compared to other process. This is because of the equally
many biomass that needs to be processed.
94
Table 5.1 Water Used in Main Process

No Process Flowrate (kg/batch)
1 Washing 100
2 Pretreatment 2000
3 Medium 9.46
4 Absorption 200
5 Total 2309.46
Table above shows water used for one batch. Based on the process, one
batch equals 59 hours. Therefore, water used per hour is:
2309.46 kg
= 40.48
57.04 batch
In order to distribute water into the process, a water pump is needed. For
this process, 2 water pumps from Taizhou BLUESEA Pump Co., Ltd and Zhejiang
Chenjie Pump Industry Co., Ltd will be used. The former is capable of pumping 60
L/min water and used for washing, bacteria medium, and absorption, while the latter
is capable of puming 360 L/min water and used for pretreatment.
Figure 5.2 A Water Pump from Taizhou BLUESEA Pump Co.
95
Figure 5.3 A Water Pump from Zhejiang Chenjie Pump Industry Co., Ltd
5.1.2 Cooling Process

Cooling water is assumed that Tin of cooling water is 35oC and Tout 30oC
when it pass cooling tower and when it pass chiller T in is 30oC and Tout 2oC.These
temperatures are chosen based on literature and average temperature used in many
plants.
Cooling water is used for heat exchange between cooling water stream and
hot process streams. Therefore, the water loss from evaporation, drift loss, and blow
down could exist. The numbers of calculating them is the number of makeup water
that is needed by this plant.
The water loss from evaporation is calculated by
We = 0.00085𝑊𝑐 (∆T)
where,
Wc = inlet water to cooling tower
We = water loss from evaporation
∆T = temperature difference between inlet and outlet water
The water loss from drift loss is usually 0.1-0.2% from the total inlet cooling
water. This plant assumes 0.2% drift loss.
Wd = % drift loss × We
Water losses from blow down depend on the amount of cooling water cycle,
usually between 3-5 cycles. This plant assumes 4 cycles. Then, it is calculated by
We
Wb =
C−1
where,
Wb = water losses from blow down
96
C = number of cycle
The total make up cooling water required can then be calculated
Makeup Cooling Water = We + Wd + Wb
The calculation of cooling water requirement before the implementation of
heat exchanger network as well as the makeup cooling water are tabulated in the
following tables.
Table 5.2 Cooling Water Requirement Before HEN
Cp
T in T out Mass
Equipme Stream Stream Q Water
Flow
nt In Out (∘C) (∘C) (kj/h) (kj/kg.K
(kg/h)
)
CT-201 24 25 35 23 30096 4.18 600
CH-201 25 26 23 16 8778 4.18 300
CH-201 25 27 23 16 8778 4.18 300
Total 1200
Table 5.3 Calculation of Makeup Cooling Water Before HEN
Amount
Losses Number
(kg/h)
Water Loss
from
12 6.12
Evaporation
(We1)
Water Loss
from
7 1.785
Evaporation
(We2)
Water Loss
from
7 1.785
Evaporation
(We3)
Drift Loss
(0.1-0.2%) 0.20% 0.01224
(Wd1)
Drift Loss
(0.1-0.2%) 0.20% 0.00357
(Wd2)
97
Table 5.4 Calculation of Makeup Cooling Water Before HEN (cont’d)
Amount
Losses Number
(kg/h)
Drift Loss
(0.1-0.2%) 0.20% 0.00357
(Wd3)
Blowdown
(Cycle 3-5
4 2.04
cooling
water)
Blowdown
(Cycle 3-5
4 0.595
cooling
water)
Blowdown
(Cycle 3-5
4 0.595
cooling
water)
Total 12.93938
Table 5.5 Cooling Water Requirement After HEN
Cp
T in T out Mass
Equipme Stream Stream Q Water
Flow
nt In Out (∘C) (∘C) (kj/h) (kj/kg.K
(kg/h)
)
CT-201 24 25 35 23 30096 4.18 600
CH-201 25 26 23 16 8778 4.18 300
CH-201 25 27 23 16 8778 4.18 300
Total 1200
98
Table 5.6 Calculation of Makeup Cooling Water After HEN

Amount
Losses Number
(kg/h)
Water Loss
from
12 6.12
Evaporation
(We1)
Water Loss
from
7 1.785
Evaporation
(We2)
Table 5.6 Calculation of Makeup Cooling Water After HEN (cont’d)
Amount
Losses Number
(kg/h)
Water Loss
from
7 1.785
Evaporation
(We3)
Drift Loss
(0.1-0.2%) 0.20% 0.01224
(Wd1)
Drift Loss
(0.1-0.2%) 0.20% 0.00357
(Wd2)
Drift Loss
(0.1-0.2%) 0.20% 0.00357
(Wd3)
Blowdown
(Cycle 3-5
4 2.04
cooling
water)
Blowdown
(Cycle 3-5
4 0.595
cooling
water)
Blowdown
(Cycle 3-5
4 0.595
cooling
water)
Total 12.93938
99
The amount of cooling water needs before and after has the same amount which is
1212.93938 kg/h.
5.1.3 Heating Process

In this plant. there are some heating system which uses steams as the hot
fluids for heating systems. The steam will be heated by boiler before supplied to
the equipment. Steam requirement calculation needs to be done before selecting
what kind of boiler or steam generator to use for the plant. Basically, the steam is
needed as heating medium for heater and reboiler in distillation column. For the
calculation, it is assumed that the system uses Low Pressure Steam and High
Pressure Steam
Table 5.7 Heating Requirement in Plant Before HEN
Spesific
Stream Stream T in T out Q Latent M Steam
Equipment
in out (°C) (°C) (MJ/hr) Heat (kg/h)
(MJ/kg)
BO-201 22 23 35 189 1074 1.79 600
C-201 25 26 189 201.37 977.34 1.79 546
Total 1146
The steam generated in BO-201 used for C-201. Steam selection is based
on temperature difference of cold stream that would be heated. Steam requirement
per hour is 123372.16 kg or 123 ton/h. By assuming that 90% of steam condensate
can be reused, the total addition of water per hour can be calculated as follow.
Make-up water for boiler = 0,1 x 1146 kg/h = 114.6 kg/h
After conducting HEN analysis, the steam generation is not necessary. It is
because for heating the water for LHW process is using hot water from the E-104.
After implementation of HEN, the hot streas which heat are exchanged with some
cold streams. Therefore, the before HEN and after HEN calculation is different. The
steam is not used. The consideration is based on the minimum temperature approach
provided by the process fluid in heat exchangers. It means that HEN makes steam
usage is more effective and efficient in this plant.
5.1.3 Water Treatment
The water is supplied from the river, which contain alot of impurities
Therefore, this plant needs to do the water treatment before using river water. The
100
method to treat the river water are sand filtration, ion exchange, lime softening and
demineralization. To ensure a continuous supply of water, it was built on the
location of the water intake which is also a pre-treatment of river water. Moreover,
water is pumped to the plant to be processed and used as needed.
The purified water is then supplied as the makeup cooling water and steam,
while the impurities are treated in waste water treatment area. The process flow
diagram of water treatment process is illustrated in the following figure.
101
Figure 5.4 Water Utility Process Flow Diagram Before HEN Universitas Indonesia
102
Figure 5.5 Water Utility Process Flow Diagram After HEN

103
Air Utility
Air is used for various processes, such as drying and stripping. Air is taken
from the surrounding environment using a blower, then flowed into the equipment
through a filter.
Table 5.8 Air used in the process
Code Process Rate (kg/batch)

D-101 Drying 2416.74004
T-102 Stripping 100
Total 2516.74004
Table above shows water used for one batch. Based on the process, one
batch equals 57.04 hours. Therefore, total air used per hour is:
2516.74004
= 44.12 kg/batch
57.04
To obtain air from the surrounding, 2 air blowers from Air Control Industry
will be used. One is capable of 212000 m3/h flow rate and used for drying, and the
other is capable of 850 m3/h flow rate and used for stripping.
Figure 5.6 Two Air Blowers, Left is Used for Drying, and Right is Used for Stripping
104
Figure 5.7 Air Utility Flow Diagram
105
Electricity
Electricity is used to power up factory’s equipment, obtained from PT PLN.
Operation for this process is 24 hours long and lasts for 335 days per year. The
electricity price per kW from PT PLN is IDR 1457. These electricity usages are for
this factory process and does not count any electricity used in other places, like
office and security area.
Based on process equipment, the energy needed is 249470.1436 MWh per
year before heat exchanger network. Meanwhile, the electricity after heat exchanger
network is 248651.2156MWh per year. The energy difference between these two
is 1,845.851 MWh
5.4.1 Electricity Before HEN
The calculation of electricity requirement before implementation of heat
exchanger network is tabulated as follow.
Table 5.9 Electricity used in the process
Usage Power Power

Equipment Amount Code
Time (kW) (kWh/day)
Process
Biomass WSH-
1 24 20.5 492
Washer 101
Biomass
1 D-101 24 30 720
Dryer
Biomass
1 G-101 24 506.689 12160.536
Grinder
Wet Belt
1 B-101 24 20.2676 486.4224
Conveyor
B-102
Dry Belt
2 24 13.6078 653.1744
Conveyor
B-103
P-101
Water Pump 3 P-103 24.00 6.45 464.4
P-105
106
Table 5.9 Electricity used in the process (cont’d)
Usage Power Power

Time (kW) (kWh/day)
LHW
Pretreatment 1 R-101 24.00 0.5938 14.2512
Reactor
Seed
1 BR-101 24.00 0.2355 5.652
Bioreactor
Anaerobic
1 R-102 24.00 0.844 20.256
Digester
Condensate 1 CO-101 24 0.3 7.2
C-101
Biogas
3 C-102 24.00 68.3623 4922.0856
Compressor
C-103
Biogas Heat E-102
Exchanger 2 24 18 864
(Cooling) E-103
Biomethane E-101
Heat
2 24 18 864
Exchanger E-104
(Cooling)
Degasifier 1 DE-101 24.00 5.445 130.68
Flare 1 FL-101 24 3.5 84
Biomethane
1 C-104 24.00 29602.3241 710455.7784
Compressor
Water Utility
River Water
1 P-202 24.00 12.35 296.4
Pump
Transfer
11 P-202 24.00 1.5 396
Pump
Mixing Tank 1 M-201 24 4 96
Compressor 1 C-201 24.00 212.72 5105.28
Chiller 1 CH-201 24 4.609 110.616
Cooling
1 CT-201 24.00 212.72 5105.28
Tower
Air Utility
Blower 1 SA-401 24.00 10.696 256.704
Compressor 1 C-401 24 176.22 4229.28
Cooling Heat
1 E-401 24.00 18 432
Exchanger
107
Usage Power Power

Time (kW) (kWh/day)
AHU-
AHU 1 24 17.5 420
401
Dehuminifier 1 DH-401 24 0.019 0.456
Compressor 1 C-401 24 176.22 4229.28
Waste Water
Sludge
Recycle 1 P-301 24.00 2.55 61.2
Pump
Total 31284.5231 755970.132
249470143
Total electricity needed/year kWh
.6
249470.143
Total electricity needed/year MWh
6
Total electricity cost/year 363,477,99 IDR

9,167
5.4.2 Electricity After HEN

The electricity requirement after the implementation of heat exchanger
network will not be any different for the main process. However, there is a
significant change of electricity requirement in the water utility process because
after HEN the main process doesn’t need cooler anymore. The calculation of
electricity requirement after HEN is tabulated as follow.
Table 5.10 Electricity used in the process
Usage Power
Equipment Amount Code Time Power (kW) (kWh/
(h) day)
Process
WSH-
Biomass Washer 1 24 20.5 492
101
Biomass Dryer 1 D-101 24 30 720
Biomass Grinder 1 G-101 24 506.689 12160.5
Wet Belt Conveyor 1 B-101 24 20.2676 486.422
108
Usage Power
(h) day)
B-102
Dry Belt Conveyor 2 24 13.6078 653.174
B-103
P-101
Water Pump 3 P-103 24.00 6.45 464.4
P-105
LHW Pretreatment
1 R-101 24.00 0.5938 14.2512
Reactor
Seed Bioreactor 1 BR-101 24.00 0.2355 5.652
Anaerobic Digester 1 R-102 24.00 0.844 20.256
Condensate 1 CO-101 24 0.3 7.2
Biogas Compressor 3 C-101 24.00 68.3623 4922.09
C-102
C-103
Biogas Heat Exchanger
2 E-102 24 18 864
(Cooling)
E-103
Biomethane Heat
2 E-101 24 18 864
Exchanger (Cooling)
E-104
Condensate Pump 1 P-105 24 6.45 154.8

Pretreated Biomass
1 P-102 24.00 6.45 154.8
Pump
109
Usage Power
(h) day)
Degasifier 1 DE-101 24.00 5.445 130.68
Flare 1 FL-101 24 3.5 84
Biomethane Compressor 1 C-104 24.00 29602.3241 710456
Water Utility
River Water Pump 1 P-202 24.00 12.35 296.4
Transfer Pump 11 P-202 24.00 1.5 396
Compressor 1 C-201 24.00 212.72 5105.28
Chiller 1 CH-201 24 4.609 110.616
Cooling Tower 1 CT-201 24.00 212.72 5105.28
Air Utility
Blower 1 SA-401 24.00 10.696 256.704
Compressor 1 C-401 24 176.22 4229.28
Cooling Heat Exchanger 1 E-401 24.00 18 432
AHU-
AHU 1 24 17.5 420
401
DH-
Dehuminifier 1 24 0.019 0.456
401
Compressor 1 C-401 24 176.22 4229.28
Waste Water
Sludge Recycle Pump 1 P-301 24.00 2.55 61.2
Total 31181,1231 753109,032
Total electricity needed/year 248525980,6 kWh
Total electricity needed/year 248525,9806 MWh
Total electricity cost/year 362.102.353.676 IDR
5.5. Fuel Waste

5.5.1. Fuel Utility
The Biomethane production plant requires fuel to run specific unit
operations. The units that need specific fuel are off gas flare, boiler LHW reactor
thermic oil heater. For all required fuel in this plant calculated about 204.728
kL/year.
110
5.5.2. Off-gas Flare

Biomethane Production plant for the fuel of the furnace on off gas flare.
Flaring is the way to allow the gas to escape into the environment. This is not the
preferable option for two reasons. The first is environmental: burning gas is far
more environmentally friendly than allowing gas to escape. The second is clearly
safety. When large volumes of gas escape the wind can blow these in unusual
directions and this is potentially threatening to safety. The total requirement of fuel
needed in off gas flare is 8.33 L/hour. Therefore, for the assumption price of the
fuel per litre is Rp8500,- then the cost for the off gas flare fuel for a year is
Rp.538.758.333,-.
5.5.3. Boiler
Boiler is required in this plant for heating the thermic oil for LHW reactor.
LHW reactor needs to be heated up to 160oC. Thus, it’s cheaper to use thermic oil
since it can be regenerated for couple times and has a faster heating rate than steam.
To heat the thermic oil, it is required to furnace the boiler using furnace. Figure and
table below shows the specification for boiler.
Figure 5.8 Fuel Boiler

(Source: alibaba.com)
111
Table 5.11 Specification of Boiler

Characteristic Specification
Model YY(Q)W type 2000kw
Weight 1-20 ton
Heat Supplied 12000 kW
Thermal Efficiency 88.73-92.67%
Circulating Oil 600 m3/h
Amount of fuel needed in boiler is 8.33 L/hour. Therefore, for the

assumption price of the fuel per litre is Rp8500,- then the cost for the boiler for a
year is Rp.538.758.333,-.
5.5.4. LHW Reactor Thermic Oil Heater

The LHW Reactor is one of the equipment in the process that need an extra
high temperature. That’s why the usage of steam will be non-economical. The LHW
reactor is heated using the thermic oil boiled in the fuel system for 969,7 L/year. It
keeps circulating for straight 6 months (referred to thermic oil system in Unilever).
The cost of fuel for LHW Reactor heating for a year is only about Rp.8.242.450,-
112
Figure 5.9 Fuel Utility Flow Diagram
CHAPTER 6
CONCLUSION
Based on the entire report that has been made, some conclusions could be
taken as below:
 Rice straw and organic municipal solid waste are chosen to be the biomass raw
material to produce biomethane
 The plant will be built in Wanci Mekar, Kota Baru, Karawang, because it is
located near the raw material supply, near water source and also the targe market
which is PLTGU Karawang
 Based on the result of production capacity, the plant will produce 2055 m3/day
biomethane by using 5443.108 kg rice straw and 3628.739 msw.
 The number of production capacity is the result of benchmarking with PLTG
Sampean Baru with 1.8 mw electricity production
 The production process of Biomethane from rice straw biomass and Municipas
Solid Waste in this plant is comprises of biomass washing, drying, grinding,
physico-chemical pre-treatment by LHW, biogas production using anaerobic
digestion, purification biogas to biomethane using water scrubber and multistage
compressor, followed by xylitol production using chemical hydrogenation
process
 Based on the mass balance, the total mass produced in the production of
biomethane is 1346.03651 kg
 Based on the energy balance, the total energy needed in the production of
biomethane is 64728,58671 kJ
 Based on mass balance, the production efficiency is 72.94%
 Based on energy balance, the energy efficiency of the plant is 76.05%
 Reducing heat exchanger by creating HEN (Heat Exchanger Network) is
possible
 The possible stream to be crossed is streamline number 12 & 13, and streamline
number 26 & 27
 The heat from stream number 26 is enough to heat up the streamline number 12
 Stream number 12 need to be heat up with heat power of 3374 kW/°C.

118
 Cooling water before and after HEN have the same value because there is no
reduction of cooling unit, and the amout of cooling water is 1212.94 kg/h
 The steam needed before HEN is 1146 kg/h, after HEN boiler is reduced from
the steam utility so that the amount of steam needed after HEN is 0 kg/h
 The air needed for the plant is 44.12 kg/batch. Air is used for Drying process
and Stripping process
 The electricity needed is 249470.1436 MWh per year before heat exchanger
network. Meanwhile, the electricity after heat exchanger network is
248651.2156MWh per year
 The Biomethane production plant requires fuel to run specific unit operations.
The units that need specific fuel are off gas flare, boiler LHW reactor thermic
oil heater. For all required fuel in this plant calculated about 204.728 kL/year.

115
REFERENCES
Beil, M. and Beyrich, W. (2013). Biogas upgrading to biomethane. The Biogas

Handbook, pp.342-377.
Cotana, F., Cavalaglio, G., Petrozzi, A. and Coccia, V. (2015). Lignocellulosic
Biomass Feeding in Biogas Pathway: State of the Art and Plant
Layouts. Energy Procedia, 81, pp.1231-1237.
Cozma, P., Wukovits, W., Mămăligă, I., Friedl, A. and Gavrilescu, M. (2014).
Modeling and simulation of high pressure water scrubbing technology
applied for biogas upgrading. Clean Technologies and Environmental
Policy, 17(2), pp.373-391.
Dehghani, M., Karimi, K. and Sadeghi, M. (2015). Pretreatment of Rice Straw for
the Improvement of Biogas Production. Energy & Fuels, 29(6), pp.3770-
3775.
Deublein, D. and Steinhauser, A. (2011). Biogas from waste and renewable
resources. Weinheim [Allemagne]: Wiley-VCH Verlag GmbH & Co.
Momayez, F., Karimi, K. and Horváth, I. (2018). Enhancing ethanol and methane
production from rice straw by pretreatment with liquid waste from biogas
plant. Energy Conversion and Management, 178, pp.290-298.
Mondal, P., Dang, G. and Garg, M. (2011). Syngas production through
gasification and cleanup for downstream applications — Recent
developments. Fuel Processing Technology, 92(8), pp.1395-1410.
Niu, M., Huang, Y., Jin, B. and Wang, X. (2013). Simulation of Syngas
Production from Municipal Solid Waste Gasification in a Bubbling
Fluidized Bed Using Aspen Plus. Industrial & Engineering Chemistry
Research, 52(42), pp.14768-14775.
Raposo, F., De la Rubia, M., Fernández-Cegrí, V. and Borja, R. (2012). Anaerobic
digestion of solid organic substrates in batch mode: An overview relating to
methane yields and experimental procedures. Renewable and Sustainable
Energy Reviews, 16(1), pp.861-877.

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Rollinson, A. and Williams, O. (2016). Experiments on torrefied wood pellet:

study by gasification and characterization for waste biomass to energy
applications. Royal Society Open Science, 3(5), p.150578.
Sari, F. and Budiyono, B. (2014). Enhanced Biogas Production From Rice Straw
With Various Pretreatment : A Review. Waste Technology, 2(1).
Solarte-Toro, J., Chacón-Pérez, Y. and Cardona-Alzate, C. (2018). Evaluation of
biogas and syngas as energy vectors for heat and power generation using
lignocellulosic biomass as raw material. Electronic Journal of
Biotechnology, 33, pp.52-62.
Tinaut, F., Melgar, A., Pérez, J. and Horrillo, A. (2008). Effect of biomass particle
size and air superficial velocity on the gasification process in a downdraft
fixed bed gasifier. An experimental and modelling study. Fuel Processing
Technology, 89(11), pp.1076-1089.
Veringa. 2010. Distribution Energy Production and Utilization. Oklahoma
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Zhu, J., Wan, C. and Li, Y. (2010). Enhanced solid-state anaerobic digestion of
corn stover by alkaline pretreatment. Bioresource Technology, 101(19),
pp.7523-7528.

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UNIVERSITAS INDONESIA

BIOMETHANE PRODUCTION FROM RICE STRAW BIOMASS AND

CHEMICAL ENGINEERING DEPARTMENT

According to The Jakarta Post (2017), the waste to energy concept is a

iii Universitas Indonesia

EXECUTIVE SUMMARY ................................................................................ii

Figure 1.1 Municipal Solid Waste Composition .................................................. 3

Table 1.1 The Composition of Biogas ................................................................. 7

viii Universitas Indonesia

Before the 1970s, MSW management generally consisted of depositing

Figure 1.1 Municipal Solid Waste Composition

Karawang is known as one of the busiest industrial district in West Java. It

Figure 1.2 Type of Biomass

The current status of biomass technology from biomass crops, conversion

Figure 1.3 Distributed Energy Production and Utilisation based on Biomass

profiles can be used as a measure of biofilter performance. The composition of

with biogas is between 5 and 20 cm of water column. Heating value of 1 m3 of

Table 1.1 The Composition of Biogas

to 45 vol% is contained in the biogas. In addition, raw biogas contains small

and other trace gases.

Table 1.2 Scoring Value Biomass

Table 1.3 Biomass Selection

Rice is primarily grown in tropical and sub-tropical climates, however some

Table 1.4 Rice Straw Composition

Cellulose wt.% dry 44.675 41 48.35

Figure 1.4 Rice Straw

Table 1.5 Scoring Value of Bacteria

Table 1.6 Bacteria Selection

1.4. Market and Capacity Analysis

Table 1.7 Gas Consumption

Table 1.8 The Amount of Electricity Production

Total Energy Production

Table 1.9 The Amount of Electricity Production (Cont’d)

Total Energy Production

The amount of electricity production at Balai Pungut power center is

𝑥 = 186,5 MMScf = 528023,7 m3 per year

So that amount of biomethane needed to produce 1.8 MW electricity is 2055

production, collection, distribution and retail. Every business characteristic have

communication, banking and insurance services, regular service material,

Figure 1.5 Plant Location

(Source: Google earth)

2.1. Process Synthesis

Raw Material Process Desired Product

Figure 2.1 Black Box Diagram

Figure 2.2 Pre-Treatment Method

2.2.1.1 Physical Pre-Treatment

results of LHW pretreatment were comparable with dilute-acid pretreatment

Table 2.1 Alternative Pre-Treatment

Table 2.1 Alternative Pre-Treatment (cont’d)

2.2.2 Digester Types

Table 2.2 Types of Digester

most often designed for operation in mesophilic or thermophilic temperature

A tall scrubbing column is used, in which water is sprayed from above,

Since the pressure swing adsorption is a batch process, several columns

Table 2.3 Criteria Selection of Physical Pre-Treatment

Shape Slightly Slightly Very

Equipment > 100,000 60,000 - 5,000 - 50,000 - 4,000 -

Table 2.4 Comparison Alternatives of Physical Pre-Treatment

Criteria Shredding Grinding Granulating

Equipment 5,000 - 50,000 - 4,000 -

Table 2.5 Scoring Parameter of Physical Pre-Treatment

Shredding Grinding Granulating

2.3.2. Pre-Treatment Process Selection

Table 2.6 Criteria Scoring of Pre-Treatment