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Journal ofofOil
OilPalm
PalmResearch
ResearchVol.
22 (december 2010)2010 p. 904-912
22 December
ABSTRACT
The present reality is that we have to deal with environmental deterioration. Mitigation using the life cycle
assessment (LCA) concept must be viewed as an investment for our future generations, if not for ourselves,
because efforts in mitigation of environmental degradation will translate into a concerted effort to combat the
many environmental impacts resulting from mismanagement of natural resources and energy. The oil palm
fresh fruit bunches (FFB) are a unique crop product. Two types of oil can be obtained from this raw material.
Crude palm oil (CPO) is obtained from the mesocarp while palm kernel oil is obtained from the kernel within
the nut. CPO is processed at palm oil mills, and the kernels which are removed from the cracked nuts is a
by-product at the palm oil mills as has been discussed in the Part 3 article. These kernels are then transported
by trucks to kernel-crushing plants that process the kernels into crude palm kernel oil (CPKO). The objective
of this study is to identify the potential environmental impacts associated with the production of CPKO, and
to evaluate opportunities to overcome the potential impacts. This study has a cradle-to-gate system boundary.
This resulting article is part of LCA of the whole palm oil supply chain which is linked to the upstream LCA
for nursery (Part 1), plantation (Part 2) and palm oil mill (Part 3). The article examines the life cycle impact
assessment (LCIA) of the production of 1 t of CPKO at the kernel-crushing plant. For this study, six kernel-
crushing plants were chosen for their locations which were well-distributed all over Peninsular Malaysia.
Five kernel-crushing plants were located near the ports, while the remaining plant was located right beside a
palm oil mill. This selection strategy was carried out to examine the different scenarios that exist in Malaysia,
and also to ensure that they were representative of the scenarios of all kernel-crushing plants in Malaysia.
Inventory data collection consisted of inputs and outputs of materials and energy. LCIA was carried out using
the Simapro software version 7.1, and the Eco-indicator 99 methodology was selected.
Based on the results, the main impacts from upstream activities were from fertilizer production and
application, and biogas emissions. The impacts directly associated with the production of CPKO were mainly
from the transportation of palm kernels from the palm oil mills to the kernel-crushing plants and from the
electricity consumption from the grid for the processing of the CPKO. The best scenario for the production of
CPKO with the least environmental impact was when the kernel-crushing plant was integrated with a palm
oil mill which captured the biogas.
Keywords: life cycle assessment, life cycle impact assessment, kernel-crushing plant, palm kernel oil, palm kernel.
Date received: 6 October 2010; Sent for revision: 10 October 2010; Received in final form: 22 October 2010; Accepted: 25 October 2010.
904
LIFE CYCLE ASSESSMENT OF THE PRODUCTION OF CRUDE PALM KERNEL OIL (part 3a)
SCOPE/SYSTEM BOUNDARY
905
Journal of Oil Palm Research 22 (december 2010)
Collection of
PK from the Transportation
Diesel
mill of PK to kernel-
crushing plant Legend:
CPKO: crude palm kernel oil
PK: palm kernel
PK
Electricity
from grid
Cleaning
CPKO
Screw pressing
1st pressing Filter press
Palm kernel
cake or palm
Screw pressing kernel meal
2nd pressing Coarse screen filter
Figure 2. Flow chart for processing of crude palm kernel oil (CPKO).
Figure 3. System boundary of life cycle inventory (LCI) for crude palm kernel oil (CPKO).
906
LIFE CYCLE ASSESSMENT OF THE PRODUCTION OF CRUDE PALM KERNEL OIL (part 3a)
oil palm seedling production (Part 1), LCA of FFB was done to examine the different scenarios that
production (Part 2) and LCA of CPO production exist in Malaysia and also to ensure that they were
(Part 3). The functional unit for this study is 1 t of representative of the various scenarios of kernel-
CPKO produced at the kernel-crushing plant. crushing plants in Malaysia.
In this study, all processes were considered
relevant unless excluded based on the exclusion
METHODOLOGY criteria shown in Table 1. In general, processes are
excluded if they are judged to have an insignificant
Inventory Data contribution (< 3%) to the overall environmental
load; if representative data for the processes are
Kernel-crushing plants are normally located near extremely difficult or impractical to gather; and if
the ports to enable easy access to export facilities for the processes are clearly part of a separate product
both CPKO and the palm kernel cake. Inventory system.
data were collected directly from the kernel- Data on all capital goods were collected from
crushing plants through questionnaires which the kernel-crushing plants through actual visits
were developed specifically for data collection, and information from the kernel-crushing plants
and also through actual on-site measurements except where stated. The use of capital goods was
and quantification. Compliance with geographical obtained by estimating the total stock of capital
coverage for data collection was adhered to by goods divided by the amount of CPKO produced in
collecting data from different regions in Malaysia. the year 2008, followed by multiplying the estimate
The data validation procedure was carried out by with a replacement factor expressing the fraction
on-site visits, on-site measurements, communication of the goods replaced each year. Based on the data
and discussions via e-mail and telephone, and collected from the six kernel-crushing plants with
interviews to verify the reliability of collected data. CPKO processing capacities ranging from small
For this study, six kernel-crushing plants to large, the average total palm kernel processed
were chosen for their locations which were well- was assumed to be 21 600 t yr-1. The capital goods
distributed all over Peninsular Malaysia. Five of involved in the production of CPKO are shown in
the kernel-crushing plants were located near the Table 4.
ports, namely, the Klang Port in the mid region, the
Pasir Gudang Port in the south and the Kuantan Allocation of Co-products
Port in Pahang on the east coast of Peninsular
Malaysia. The remaining kernel-crushing plant was More often than not, a system will yield more
located right beside a palm oil mill. This selection than one product. In such cases, allocation must be
Excluded
Difficult to Not directly
Insignificant Part of a
Processing category Included environmental obtain relevant to
different
representative scope and
impact system
data goals of study
Production, maintenance - - - -
and replacement of capital
equipment
Transportation of capital goods - -
Extraction of crude palm - - - -
kernel oil (CPKO) from palm
kernels
Electricity generation - - - -
Transportation of palm kernels - - - -
to the kernel-crushing plants
Capital goods - - - -
Exporting of palm kernel cake - - - -
as animal feed
Refining of CPKO - - - -
907
Journal of Oil Palm Research 22 (december 2010)
made for input and output flows of each product. TABLE 2. LIFE CYCLE INVENTORY FOR THE
Allocation was carried out upstream at the palm PRODUCTION OF 1 t CRUDE PALM KERNEL OIL (CPKO)
FOR FIVE KERNEL-CRUSHING PLANTS LOCATED NEAR
oil mill where the palm kernels were produced. PORTS (allocated)
In view of this, the LCI data for the production
of palm kernels shared the inputs and outputs Parameter Amount
of the production of CPO at the palm oil mill. In
the kernel-crushing plants for the production of Palm kernels (t) 1.07
CPKO, the by-product is palm kernel cake or palm Electricity from grid (MJ) 448.6
kernel meal. Weight allocation was carried out at Transportation of kernels (tkm) 149.40
the kernel-crushing plant between CPKO and palm Palm kernel cake (t) 1.12
kernel cake. The allocation between CPKO and
palm kernel cake was 47:53.
TABLE 3. LIFE CYCLE INVENTORY FOR THE
Life Cycle Impact Assessment (LCIA) PRODUCTION OF 1 t CRUDE PALM KERNEL OIL (CPKO)
FOR ONE KERNEL-CRUSHING PLANT LOCATED BESIDE
A PALM OIL MILL FAR FROM THE PORTS (allocated)
LCIA was conducted using the SimaPro software
version 7.1 and the Eco-indicator 99 methodology. Parameter Amount
LCIA was conducted for two scenarios as follows:
Palm kernels (t) 1.07
Scenario 1: a kernel-crushing plant located
near a port; uses electricity from the grid for Electricity from grid (MJ) 44.0
processing; with biogas emissions at the palm Electricity generated at palm oil 421.30
oil mill. mill (MJ)
Scenario 2: a kernel-crushing plant located Transportation of kernels (tkm) 2.24
beside a palm oil mill; uses the renewable Palm kernel cake (t) 1.12
energy from the mill for processing; with biogas
capture at the palm oil mill.
TABLE 4. TOTAL CAPITAL GOODS AT
KERNEL-CRUSHING PLANT (average of six plants,
no allocation)
RESULTS AND DISCUSSION
Use of capital
Life Cycle Inventory Weight
goods (kg t-1
(t)
CPKO)
As discussed in the Part 3 article, CPKO is not
the only product produced at the kernel-crushing Buildings, steel 490 2.57
plant. The by-product of the crushing process is Buildings, concrete 1 370 7.19
palm kernel cake. In view of this, weight allocation Kernel plant machinery 505 5.30
was conducted to allocate part of the inputs and Tractors 6 0.08
outputs to palm kernel cake.
Lorries 2 0.03
Table 2 shows the LCI data for 1 t CPKO produced
at the kernel-crushing plants located nearer to the
ports, while Table 3 shows the LCI data for 1 t CPKO crushing plants, but it had one big difference which
from a kernel-crushing plant that was located just was the source of energy. The other five kernel-
beside a palm oil mill but far away from the ports. crushing plants used only one energy source for
The selected crushing plants all had identical processing, which was electricity from the national
processing methods and conditions. These crushing grid supply. However, the kernel-crushing plant
plants were typical of the majority of the crushing located beside the palm oil mill used the electricity
plants in Malaysia. All the kernel-crushing plants supply from the neighbouring mill. In other words,
used the double squeezing method to press out as the palm oil mill generated electricity for its own
much CPKO as possible. milling process as well as for the kernel-crushing
Based on Tables 2 and 3, one of the environmental plant nearby.
inputs was the energy consumption for the whole
system for processing of palm kernels into CPKO. Life Cycle Impact Assessment
The energy source was the electricity supply from
the national grid. On average, about 448.6 MJ The characterization and weighted results for
electricity was consumed for every tonne of CPKO both the scenarios were for the system boundary
produced. which started from the nursery right up to the
The kernel-crushing plant (Table 3) which was production of CPKO at the kernel-crushing plant.
located beside the palm oil mill also practiced Land occupation by the kernel-crushing plant was
processing methods identical with the other not included in LCIA for both scenarios.
908
LIFE CYCLE ASSESSMENT OF THE PRODUCTION OF CRUDE PALM KERNEL OIL (part 3a)
0120
0100
080
% 060
040
020
00
Carcinogens Resp. organics Resp. inorganics Climate Radiation Ozone layer Ecotoxicity Acidification/ Land use Minerals Fossil fuels
change eutrophication
Analyzing 1 t CPKO (No LUC with biogas near ports) allocated Sept 2010, Method: Eco-indicator 99 (H) V2.03 /
Europe EI 99 H/A/ characterization.
CPKO
CPKO(No
(NoLUC withBiogas
LUC with Biogas near
near ports)
ports) allocated
allocated Sept 2010
Sept 2010 Palm(No
Palm kernel kernel
LUC(No
with LUC with
biogas) biogas)
Sept 2010 Sept 2010
Electricity Malaysia Electricity Malaysia
Truck 16t B250 Truck 16t B250
Figure 4. Characterization for life cycle impact assessment (LCIA) of 1 t crude palm kernel oil (CPKO) – continued
land use, biogas, plant located near port.
025
020
015
Pt
010
05
00
Carcinogens Resp. organics Resp. inorganics Climate Radiation Ozone layer Ecotoxicity Acidification/ Land use Minerals Fossil fuels
change eutrophication
Analyzing 1 t CPKO (No LUC with biogas near ports) allocated Sept 2010, Method: Eco-indicator 99 (H) V2.03 /
Europe EI 99 H/A/ weighting.
CPKO
CPKO(No
(NoLUC
LUCwith
with Biogas nearports)
Biogas near ports)allocated
allocated Sept
Sept 2010
2010 Palm kernel
Palm (No
kernel LUC
(No LUCwith
withbiogas)
biogas) Sept 2010
Sept 2010 Electricity
Electricity Malaysia
Malaysia Truck
Truck 16t 16t B250
B250
Figure 5. Weighting for life cycle impact assessment (LCIA) of 1 t crude palm kernel oil (CPKO) – continued land
use, biogas, plant located near port.
909
Journal of Oil Palm Research 22 (december 2010)
from the grid for processing under the fossil fuels, Scenario 2
respiratory inorganics and climate change impact
categories. The impact from transportation was LCIA was conducted for 1 t CPKO produced at
mainly from the diesel consumption by the trucks the kernel-crushing plant. The system boundary
or lorries. Due to the distance between the palm oil included:
mill and the kernel-crushing plant, transporting the
• nursery;
kernels which used fossil fuel caused the potential
• plantation (continued land use);
impact under fossil fuels. The kernel-crushing
• palm oil mill (with allocation to palm kernels
plants in Malaysia are situated nearer to the ports
and shells, with biogas captured); and
for easier access to facilities for exporting their
• kernel-crushing plant (located near a palm oil
CPKO and palm kernel cake. This is the reason
mill with allocation to palm kernel cake).
for the distance between the palm oil mills and
the kernel-crushing plants. The palm oil mills, on The characterization weighted results are shown
the other hand, are normally located nearer the in Figures 6 and 7, respectively.
oil palm plantations. The other parameter causing The weighted results show that when the kernel-
the impact was the electricity consumption from crushing plant was located either within the palm
the national grid. Again being a fossil fuel-based oil mill compound or nearby, the impact from diesel
energy source, this also contributed as an impact consumption was almost negligible. The potential
under the fossil fuels impact category. impact from electricity consumption from the grid
Most kernel-crushing plants in Malaysia use also became very small. As the kernel-crushing
predominantly electricity from the national grid for plant used electricity which was generated at the
their processing. However, there are some kernel- palm oil mill, the use of fossil-based energy was
crushing plants that use alternative energy sources. displaced. As discussed in the Part 3 article, in the
Although this is quite rare, there are crushing plants palm oil mills, pressed mesocarp fibre and shells are
that are located right beside the palm oil mills. This used as fuel in the boiler and are burnt to produce
type of kernel-crushing plant uses the electricity heat to convert water into steam. This steam is then
generated at the palm oil mill for its processing. used to run a turbine which generates electricity for
When there is a shortage of generated electricity or the milling process and the whole mill compound.
shut-down of the palm oil mill, then the crushing The pressed mesocarp fibre and shells are actually
plant uses the grid supply as back-up. In order to wastes from FFB which are recycled as boiler fuel.
compare the differences between a kernel-crushing The pressed mesocarp fibre is the waste after oil
plant which uses electricity from the grid and is has been pressed out of the mesocarp of the fruit.
located near a port with a kernel-crushing plant The shell is the outer layer of the nut which when
which uses electricity from the neighbouring palm cracked produces the kernel and shell. However,
oil mill and is located near the mill, LCIA for the the kernel-crushing plant still has to consume some
latter type of kernel-crushing plant was conducted, electricity from the national grid supply when the
and the results are shown as Scenario 2. palm oil mill is not processing. It should be noted
0120
0100
080
% 060
040
020
00
Carcinogens Resp. organics Resp. inorganics Climate Radiation Ozone layer Ecotoxicity Acidification/ Land use Minerals Fossil fuels
change eutrophication
Analyzing 1 t CPKO (No LUC with Biogas capture near mill) allocated Sept 2010, Method: Eco-indicator 99 (H) V2.03 /
Europe EI 99 H/A/ characterization.
CPKOCPKO(No LUC withwith
(No LUC biogas capture
biogas capturenear mill)allocated
near mill) allocated Sept
Sept 20102010 Palm kernel (No LUC
Palmwith
kernel (No
biogas LUC Sept
capture) with 2010
biogas capture) Sept 2010
Electricity generated
Electricity at POM
generated at POM Electricity Malaysia
Electricity Malaysia
Truck
Truck 16t 16t B250
B250
Figure 6. Characterization for life cycle impact assessment (LCIA) of 1 t crude palm kernel oil (CPKO) – continued
land use, biogas, plant located near mill.
910
LIFE CYCLE ASSESSMENT OF THE PRODUCTION OF CRUDE PALM KERNEL OIL (part 3a)
018
016
014
012
010
Pt
08
06
04
02
00
Carcinogens Resp. organics Resp. inorganics Climate Radiation Ozone layer Ecotoxicity Acidification/ Land use Minerals Fossil fuels
change eutrophication
Analyzing 1 t CPKO (No LUC with biogas capture near mill) allocated Sept 2010, Method: Eco-indicator 99 (H) V2.03 /
Europe EI 99 H/A/ weighting.
CPKO
CPKO(No (NoLUC
LUCwith
withbiogas
biogas capture near mill)
capture near mill) allocated
allocatedSept
Sept2010
2010 Palm kernel (No Palm
LUCkernel
biogas(No LUC with
capture) Septbiogas
2010 capture) Sept 2010
Electricity
Electricitygenerated
generatedat
atPOM
POM Electricity Malaysia
Electricity Malaysia
Truck
Truck16t
16tB250
B250
Figure 7. Weighting for life cycle impact assessment (LCIA) of 1 t crude palm kernel oil (CPKO) – continued land
use, biogas, plant located near mill.
that the amount in such a situation is very low. The has been cultivating oil palm for 50 years or more,
impact under climate change was also reduced due i.e. practicing continued land use from oil palm to
to the capture of biogas at the palm oil mill. What oil palm with no change.
was left were only the impacts from upstream
activities in the plantation. This result shows the
best scenario for the production of CPKO, i.e. a ACKNOWLEDGEMENT
kernel-crushing plant should be integrated with a
palm oil mill which captures its biogas, and at the The authors would like to thank the palm oil
same time gets FFB from a plantation that has been millers for allowing them to conduct the study at
cultivating oil palm for 50 years or more so that the mills.
there is no land use change or continued land use
change. Again the impacts from capital goods were
negligible in both scenarios. REFERENCES
911
Journal of Oil Palm Research 22 (december 2010)
MA, A N (1994). Extraction of crude palm oil and STALMANS, M H; BERENBOLD, J; BERNA,
palm kernel oil. Selected Readings on Palm Oil and its L; CAVALI, A; DILLARSTONE, M; FRANKE,
Uses. PORIM, Bangi. p. 30-31. F; HIRSINGER, D; JANZEN, K; KOSSWIG, D;
POSTLETHWAITE, T H; RAPPERT, C; RENTA, D;
SETAC (1993). Guidelines for Life-Cycle Assessment: SCHARER, K P; SCHICK, W; SCHUL, H and VAN
A Code of Practice. SETAC Publications, Brussels. 2 SLOTEN, T R (1995). European life-cycle inventory
pp. for detergent surfactants production. Tenside Surf.
Det., (32): 84-85.
Announcement
In response to the numerous requests from the scientific community, academicians, students
and readers, MPOB is pleased to announce that the Journal of Oil Palm Research (JOPR) will be
published THREE times a year beginning 2010.
Beginning 2010, JOPR is published in April, August and December. The Journal will continue to
publish full-length original research papers and scientific review papers on various aspects of oil
palm, palm oil and other palms.
As part of our continuous effort to improve the quality and to offer value-added benefits to our
valued readers, two new columns have been introduced in JOPR, i.e. Letters to Editor and Short
Communications.
Beginning JOPR December 2009, photos that are unique or related to the articles published in
JOPR will be used for the cover.
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