ENERGY PRODUCTIVITY RATIO (EPR) IN PRODUCING

BIODIESEL FROM PALM OIL: A CASE STUDY IN NORTH

SUMATERA INDONESIA
Bode Haryanto* and Tatang H, Soerawidjaja
*Department Of Chemical Engineering, Faculty of Engineering,
University of Sumatera Utara
E-mail: haryanto_bode@ yahoo.com
Department Of Chemical Engineering, Faculty of Industrial Technology
Bandung Institute of Technology
Abstract
This paper reports the results of a study on energy productivity ratio (EPR) in producing
biodiesel from palm oil. This study was identified and evaluated the energy ratios of the input
energy from cultivation and harvest processing in comparing to output energy of biodiesel
product and side products. Calculations based on data obtained through field survey to palm
plantation and palm oil factories in North Sumatera province Indonesia, which are actually
intended for producing edible fat oils and supplemented by those from literatures. The major
output energy variations were based on the oil products used such as: a. CPO and PKO, b.
CPO only and c. stearin oil fraction. The EPR result of palm oil as biodiesels raw material
are > 3 for the use of CPO + PKO; and EPR > 4 for the use of CPO only, and very large value
of energy productivity for using of stearin fraction. The EPR results are an indication that the
production of biodiesel from palm oil is an energetically feasible venture. Palm oil stearin
fraction has the highest potential as raw material in producing biodiesel.
Key words: Energy, Productivity, Biodiesel, Palm oil

1. INTRODUCTION
Recently, Indonesian government has a project to increase the percentage biodiesel from
Palm Oil Methyl Ester (POME) from 20% to 30% mixed with fossil diesel (web paper road
show b 30). This concerning is on increasing trend of world energy demand and wh.ile
conventional energy resources such as: crude oil, gas 'and coal is limited and decreasing.
Moreover, people also know that the effect of high combustion of fossil fuel will harm
environment and human life. These are motivating people to End alternative energy
resources with low inherent risks. For example nuclear power is used to support 8% of the
world total energy supply 2009 as the information from Intemational Energy Agency Reports
(cited by Tukenmez and Demireli, 2012), but with the disposal of radioactive waste, it has
high inherent risks. Bioenergy from crops is possible to decrease environment risks
(McLaughlin and Walsh, 1998; Scltmer et.a1. 2008; F elten et al. 2013). Ethanol from switch
grass is possible to decrease 94% lower than greenhouse gas (GHG) emissions from gasoline
(Schmer et al. 2008),.
Trend to use the renewables energy power capacity is increasing. Some countries such as:
China, United State, Germany, Spain and India reported as the top live countries in the
world. (Renewable Energy Policy Network for the 21 Century, Renewables 2010 Global
Status Report, cited by Tiikenmez and Demireli, 2012). There are renewable energy
resources such as: running water, wind power, solar power, geothermal power and biomass
power (Peidong et al., 2009. cited by Tukenrnez and Demireli, 2012). Gissna et. al (2014)
was observed in comparing some crops for biogas production with result that sugar beet is
the highest biomass and biogas yield.
The prospective of crops as raw material for renewable bioenergy production can be
measured from the Energy Productivity Ratio (EPR) (Batchelor et al., 1995; Haryanto,
2000; Mandal et al. 2002; Schmer et al., 2008; Ren et al. 2012; Felten et al. 2013). Batchelor
et al.,(1995) in their study calculated the EPR on cultivating the winter oilseed rape
processed to rape methyl ester (RME) as shown in Table 1.

Table 1. Input and output energy in farming to produce winter oilseed rape and
processed become rape methyl ester (RME) (Batchelor et al., 1995)
(1)

INPUT: On-farm

(3)

OUTPUT: Product

Energy value of fuels and power

Fuel consumption for field operations

Bioenergy
RME

Fuel constunption for grain drying

Indirect on-farm inputs

Side Products

Farm machinery

Rape meal

Pesticide energy

Glycerin

Nitrogen fertilizer

Straw

P and K fertilizer
(2)

INPUT: Processing to RME

Transport energy
Crushing to oil
Refining
Esteritication:
Methanol, Heat, Capital Costs

The part activities were based on input energy in (1) cultivation part, (2) farm product
processing part and (3) the output energy of RME product part and side products part For
input energy was divided in two main parts such as on-farm and processing to RME. The
On-farm inputs were identified as requiring energy processes for oilseed rape production
such as: preparing the soil, fertilizer and pesticide application, swathing, combining the crop
and grain drying. Processing part, rapeseed to rapeseed methyl ester, the requiring energy
such as: crushing

seed, refining, esterification and plus energy consumed for transport.

Output energy of product was measured on energy RME equal content give a value in range
of

37.1-37.3 MJ/kg

as

reported by Culshaw and Butler (1992) and Studer and

Wolfensberger (1992). The each parts step in analyzing EPR are similar with the system

boundaries for the life cycle assessment of biodiesel fuel as reported by Krohn and Fripp
(2012). Schmer et al. (2008) was calculated the input and output energy of Switchgrass that
produced 540% more renewable than nonrenewable energy consumed.
Specific studies on cultivation part (1) were reported with related aspects. The some
example aspects are relate with orientation on greenhouse of tomato production (Hatirli et al.,
2006; Ozkan et al., 2011), economic analysis of tomato production base on energy
requirements and input costs (Cetin and Vardar, 2008), energy inputs of kiwifruit production
(Mohammadi et al., 2010), effects of different application farming technology for potato
(Zangeneh et al., 2010), commercial farming of sugar beet (Reineke, et al., 2013), energy
needed in farming olive orchards on land variants (Hemmati, et al, 2013), energy and
economic assessment prune (Tabatabaie, et al., 2013), in comparing two different crops wheat
and barley (Ziaei et al., 2015), etc. The energy input and energy output in cultivation of the
farming product is possible to extend with energy input on processing part in using the crops
product as raw material to produce bioenergy such as biodiesel, bioethanol or biogas as output
energy.
Energy analysis in producing a renewable energy resource from Crops has published
before by several authors. Thereafter, energy balance for ethyl alcohol producing from crops
published by Da Silva at all. (1978). Energy balance for biomass conversion systems was
published by Raphael Katzen (1983). Parisi (1984) was published a study the energy balance
of ethanol as a fuel. In making methyl ester (biodiesel) from crops, Batchelor, S.E. at all,
1995, published energy analysis of rape methyl ester production from winter oilseed rape.
Energy analysis study identifies the energy elements as input energy and output energy. The
input energy is energy-requiring on cultivation and post - harvest processing. Output energy is
energy contain from main product and side-product. Determining of energy productivity ratio
depend on utilization of energy side-product. Parisi (1984) calculated the EPR by add main
product and side-product (output energy) and divided by input energy. The assumption that
side product not utilization directly in this system, for example the straws as side product not
use as solid-fuel in post - harvest processing. In this paper reported EPR by divide main
product with input energy minus energy output from side-product (see equation 1). Batchelor
(1995) have calculated for both methods. According to result of calculation by Batchelor et
al for several condition in making biodiesel from rape seed the second method have higher
value of EPR.

2. METHOD
Determining EPR is used primary and secondary data. Primary data collected directly to
the plantation companies and any sources done in Sumatra Utara province and the secondary
data'collected by literature study. The data needed for calculating EPR are energy value of
fuels and power in field processing, farm machinery, and pesticide energy and fertilizer
energy equivalent. In processing to alkyl ester, data needed are transport energy, crushing to
oil, refining and esterification.
Conditions for proper technical-energetic is a principal based on consideration that
biodiesel comes from sources which are needed to be cultivated, and mainly stated: energy
contains in biodiesel must be bigger than total fossil energy which is accumulated by every
human activities, starts from biota source cultivation, oil extraction and conversion of
biodiesel. Further explanation for proper energetic will be discussed using Figure 1.
Two stages production activities needed to produce biodiesel are cultivation stage and
post-harvest processing stage. In cultivation stage, raw materials are CO2, H2O and solar
energy, which are obtained freely form the environment, are used by adding supplement
component such as palm seeds, agrochemical materials and fuel. Fuel is needed when using
farm and transportation equipment. Using fertilizers from decaying leaves and midrib or palm
waste it self and ashes irorn combustion in boiler are also supplement component in
cultivation stage. Several biologic processes occur in growing plantation to fomi product
taken when harvesting.
Yield of harvest is processed in post-harvest processing stage using supplement materials
such as catalysts and methanol, also energy is used to operate machinery of extraction and
refinery processes. Besides that, output energy from empty 'bunches, shells and fibers
combustion in boiler are energy sources contained and used directly in the processing stage,
yielding vegetable oil as product which is further processed using esteriticaticn process to
produce biodiesel.

Figure 1. Diagram of Conditions for Proper Technical-Energetic Energ Plantation

(Haryanto, 2000)

Proper technical-energetic concept mentioned above is quantified in a form of standard

parameter called Energy Productivity Ratio (EPR) and defined as comparison of output
energy and input netto energy. This definition means that EPR is energy contained in
biodiesel (Ep) divided by fossil energy used in cultivation and post-harvest processing stages
(El) which is first substracted by side product energy (E2). In equation:
E

EP R = E1PE2
Output renewable

(1)

energy is energy contained in energy plantation product

(lignocellulose, vegetable oil, sugar, or starch). In addition, fossil energy input is total fossil
energy contained and/or consumed in making and supplying supporting materials so that
cultivation and post-harvest processing activities run on the way they should be. Biodiesel or
other biofuel plantations are proper energetically if the output energy is bigger than input
netto. It means that Ep>(E1 - E2), or

EPR > l.

(2)

Cultivation begins from working in the land until post-harvest shipping to the processing
factory. This stage is summarized into block diagram Figure 2. UYP is Unyielding Periode (3
years), YP is Yielding Period (4-25 years), and PPF is processing in Palm Factory. Each
stages in Figure 2 need energy in the form of fertilizers andfor pesticides andfor fuel. Besides

that, it is also important to calculate energy consumed in using farm and transportation
equipments.

Figure 2. Block Diagram Cultivation Stage

Source: PTPN III

Post-harvest processing depends on raw materials used in making biodiesel. In this stage,
there are three options of raw materials using in making biodiesel; they are surnmariz/ed into
Figure3. PKOF (Palm Kemel Oil Factory) processes palm kemel yielding kernel oil. FRF
(Fractionation Refining Factory) processes CPO (Crude Palm Oil) yielding RBDPO (Refining
Bleaching Deodorizing Olein) and stearin fraction.

Figure 3. Post-harvest lirocessing Stage

Source: PTPN III

If the feed to biodiesel factory is Crude Palm Oil (CPO) and Palm Kernel Oil (PKO), the
post-harvest processing through (A) + (C) route, if only CPO through route (A) and if stearin
fraction only through route (B). The energy element needed is process heat fuel, motor
movement energy, specific chemicals such as methanol, and also transportation equivalent
energy and factory investment. The used energy from waste feed such as shell and fiber (nonfossil energy) is for generating electrical energy and process heat isnt calculated as input
energy.
Fuel energy element is needed to move agriculture tools, transportation tools, factory
tools and also heat of process. Standard data fossil fuel energy value in performance
evaluation of gasoline and diesel engines in Institut Teknologi Bandung (ITB) Mechanical
Engineering is 35.307 MJ/liter for diesel and 31.29 MJ/litter for gasoline (Anonymous, 1996),
it is the same with North American Combustion Hand Book, however Muller (1992) gives
37.7 MJ/litter value for diesel oil.
Energy value varies in fertilizer production. Batchelor (1995) used energy value for
various fertilizer as follows: urea feftiliz/er 83.5 MJ/kg N (Leach, 1975), NPK 87.5 MJ/kg N
(Tatchell, 1974; Leach, 1975), ammonium nitric 41.2 MJ/kg N (Bockman et. al., 1990). The
energy value for other fertilizer is 13.7 - 15.2 MJ/kg P and 7,9 - 9.0 MJ/kg K (Leach, 1975).
Using above energy value, Batchelor (1995) can calculate the fertilizer energy value in kanola
plantation. Muller (1992) used energy value 58.15 MJ/kg for Nitrogen (anhydrous ammonia)
fertilizer, phosphor 6.98 MJ/kg and Potassium 4.65 MJ/kg. In this essay, the fertilizer energy
value used is from Batchelor (1995). From the other fertilizer used in the field (Kieserite,
dolomite and boratc), the equivalent energy is determined from the purchase value in local
market. Chemical pesticide is used for preventing and wiping diseases, wiping grass and grass
chemical in palm plantation is used on schedule. The pesticide equivalent energy depends on
the active ingredient. In this calculation, the equivalent energy of chemicals is determined
from the purchase price in one area.
Production transportation is an important part of palm plantation as it may influence the
quality of the produced CPO. Transportation depends on the distance of land to palm
processing factory (PPF) that is always varies from the lowest 212 MJ/tons of fresh fruit
bunch (FFB) (PT. Socfrndo) to the highest 428.4 MJ/tons of FFB (PTPN II). Transportation
energy is also needed in delivery raw material from factory to the post-harvest processing
factory.

The important chemical, methanol, is used in methanolysis (esteritication). The energy

value of methanol is 33.4 Ml/litter (Batchelor, 1995). The indirect energy in land processing is
the energy value from the factor of manufacturing agriculture tools such as tractor, chain-sew,
etc. This value is related to the tool depreciation and caring. Batchelor (1995) reported that
Leach (1975) used a factor of 0.4 for the fuel needed in land processing, In this essay, this
energy value is directly calculated based on tools depreciation, repairing, and caring. The
equivalent of other indirect energy is the factory investment that is calculated from the tools
value and factory building multiplies the ratio of the total of palm production per ha per
period divided with the total ofthe operation capacity during the factory economic age. The
total of all above energy is then enlarged 5% for the other energy that is difiicult to detail
because of the variations. For example, light tools such as polybag, hoe, plant-germ sprayer,
road caring, fertilizer distribution and other chemicals for the post-harvest processing.
The factors influence pahn production is the land fertility, superior plant type, caring
(fertilizing), climate and the harvest method. Marihat center of research study for different
land classes shows the annual average production of 24, 22, 20, and 18 tons of FFB/ha yearly
(Risza, 1995). The tearns survey shows the annual average production of 22 and 20 tons
FFB/ha. Harvest products are FTB containing vegetable oil that is 21.7 % of crude palm oil
(CPO) and 2.15 % of palm kemel oil (PKO). Both these oil have the energy value and are the
biodiesel raw material. Bunting energy value of palm oil is 36.82 MJ/kgA(Anonymous,
1996). By-product such as bunch, fiber, shell, and kernel wastes also have burning energy
value. Bunch is usually bumed in iucinerator and the ash can be used as Potassium fertilizer;
fiber and shell are used as main fuel in palm processing factory; and kemel waste used as
cattle feed.
Post-harvest processing yields biodiesel as main product with 94 % to 99 % conversion
(Culshaw and Butler, 1992); this essay uses the 95 % conversion value. Biodiesel has energy
of 37,000 MJ/ton. By-product such as glycerol has the energy of 11,500.0 MJ/kg (Batchelor,
1995) with 16 - 20 % conversion (Bailey, 1996) Eom the main product result. The calculation
of cake buming energy gives the value of 13,625.0 MJ/ton.
Determination of the equivalent energy value from the obtained component is the price
value in rupiah such as pesticide, some fertilizers, tools and vehicles depreciation and
investment that is converted by dividing the rupiah value from the economic price of
diesel-fossil-fuel that is Rp 1780/liter (government/Pertamina cost) based on the crude oil

price $US 20/barrel and S 1 = Rp 8500; _ ( that is Rp 1780/liter (govemment/Pertamina cost)

based on the crude oil price $US 20/barrel and S l = Rp 8500; .

4.

DATA and CALCULATION

4.1. Cultivation
Survey data are obtained horn 3 large and 2 medium plantation; PTPN II and III, PT
Soclindo, Kacaribu and Seilepan tield, all in North Sumatra. Only two from the targets that
can be shown with complete data. The post-harvest processing step survey is in three palm
processing factories (PPF or palm oil mill (POM) ), two fractionation-refining factories (FRF)
and one Palm Kemel Oil Factory (PKOF). The different data'of energy, investment, and
transportation is obtained from the survey so calculation is using actual field condition.
Calculation of energy content value is done in the period of time and energy need
invplantation from year zero to the year 25th . Here is some data with re-planting land
processing condition.
Table 1 shows the energy input of palm plantation in replanting land. The survey targets
reported various energy needed in palm plantation and the calculation of the energy element
gives the energy input as above. Total output energy is the estimation of palm oil and palm
kemel energy in FFB. In this case PT. Socfmdo has the highest value, because of the relative
small input energy, and also the average production of FFB/ha yearly reaches 22 tons whereas
PTPN about 20 tons/ha yearly.
Table 1. Energy Input of Cultivation (Replanting Land)
Energy Element

Socfindo (MJ/ha)
Case A

PTPN II (MJ/ha)

Case B

Case C

Case D

N fertilizer

267891.08

267891.08

254,940.42

254,940.42

P fertilizer

19228.32

119228.32

14063.66

14063.66

K fertilizer

33314.78

33314.78

36088.95

36088.95

Mg fertilizer

10464.91

10464.91

209596.48

209596.48

B fertilizer

62698.49

54660.97

105.45

105.45

105.45

105.45

40314.55

71125.83

Seeding fertilizer
(A) TotaL chemicals

(B) wiping + seeding

40050.40

16294.28

Tools fuel

5244.49

3413.16

5244.49

3413.16

Chemical

13782.86

13782.86

13782.86

13782.86

6209.48

4132.30

6209.48

4132.30

Traxisportation

38399.85

38399.85

115508.60

115508.60

Others

24882.71

21539.16

39066.36

33396.31

Total

522536.99

452322.27

820393.56

701322.47

Agriculture tools inv.

Ganoderma sp. fungi can attack replanted land. If this happens, the land processing and
caring must be done more intensively, it means larger energy is needed, The Ganoderma
attacked replanted land as case A and the normal condition is case B, The calculation is
tabulated in Table 1.
Figure 4 and 5 are the flow of energy cultivation in PTPN II dan PT Socfindo.
Description of the figure show that at 3 first years, that only input energy is given to the
cultivation. After the fourth year, the cultivation starts giving output, although they are still
receiving input.

Figure 4. Flow Energy Cultivation in PTPN II

Output and input line show as the figure that PT Soctindo had achieved output energy
more than PTPN II this was cause by different energy input and product of FFB.

Figure 5. Flow Energy Cultivation in PT SOCFINDO

4.2. Post-Harvest Prbcessing

The values of input energy element in post-harvest processing are tabulated in Table 2.
This table also shows the energy needed in making biodiesel for three possibilities of feed
(CPO + PKO, CPO, and stearin). Methanol is the most input energy used because the buming
energy of methanol is large. Consequently, making biodiesel from stearin, the methanol need
is relative small, Which make the total input energy relative small. PT. Socfmdo has all
kindlof factories except biodiesel in an industrial zone so the transportation energy need is
small. Beside that, process heat energy for FRF and PKOF is obtained from the usage of shell,
fiber, and wood so it will be more eliicient.
Table 2. Total Input Energy in Post-Harvest Processing
Feed
Factory

POM
FRF
PKOF

CPO + PKO

CPO

Stearin

CPO +

CPO

PKO

Stearin

PT Socfindo

PTPN II

Energy consumption (MJ/ton)

Energy consumption (MJ/ton)

111813.00

111813.00

111813.00

101673.31

101673.31

101673.31

142219.26

184455.90

31714.49

31714.49

31714.49

32949.47

32949.47

32949.47

Biodiesel F.

148429.14

135155.28

31085.15

135042.04

122868.4

28259.23

Methanol

369070.00

336037.40

77292.44

335778.62

305509.27

70265.85

Others 5%

14597.83

13934.14

1584I1.60

30272.17

28150.02

20880.19

694077.96

645456.18

413830.54

635715.61

591150.51

4384833.95

Total

Table 3. Energy Data of Main Product and by-Product

Feed
Mainproduct
Biodiesel

CPO +

CPO

PKO

Stearin

Product (MJ) (22 ton/ha/year)

3711667.2

853673.0

CPO

Stearin

202496.4

184386. 0

42411.6

RBDO

PKO

Cake
Total

Side-prod
uct

4076227.2
CPO +

CPO

PKO

Stearin

Product (MJ) (20 ton/ha/year)

3708579.
6
CPO +

3374263. 2

7~76006.
4

CPO

Stearin

184232.7

167624.7

38552.9

2823005. 6

2566368.7

379798. 3

379798.3

348317.2

3483l7.2

l44455.8

l44455.8

l44455.8

13l323.5

131323.5

13l323.5

346952.2

708640.1

3389671. 0

315556.2

647265.4

30845623

PKO

Glycerol

CPO +

PKO

Feed variation in making biodiesel causes the different production step that gives
different output element value. Table 3 shows the variation of the output energy. The different
type of by-product can be obtained if the feed in making biodiesel is different (CPO + PKO,
CPO, or stearln).
Total energy need in plantation and post-harvst processing is tabulated in Table 4,
which also shows the variation of total energy need in the three survey targets. This total
energy value is needed to determine the net output energy value (El E2) which is tabulated
in Table 5. Net output is the total input energy minus the total by-products energy.

Table 4 Total Energy Needs (Plantation/Cultivation and Post-Harvest Processing)

Feed

CPO +

Variation

PKO

CPO

CPO +

Stearin

PKO

PT. Soefmdo (MJ/ha)

CPO

Stearin

PTPN II (MANAJEMEN/ha)

A.Plantation

522536.99

522536.99

5225369.99

820393.56

820393.56

820393.56

B. Plantation

452322.27

452322.27

452322.2

70l322.47

70l322.47

70l322.47

694077.96

645456.18

413830.54

6357l5.6

591150.51

4384833.95

A.Total

12166l4.9

l167993.1

l456l09.

1411544.0

Energy

17

B.Total

1146400.2

1097778.4

1337038.

1292472.9

1139806.

Energy

08

00

Postharvest

936367.53

866152.81

l258878. 00

Table 5. Determination of Net Input Energy (E1 E2)

Feed Variation

CPO +
PKO

CPO

CPO +

Stearin

PKO

PT. Soefmdo (MJ/ha)

A. Total input
Emgy (EO)
B.Tota1 input
Energy (El)

1216614

1167993

.95

.17

1146400

1097778

.23

.45

3469523

CPO

Stearin

PTPN II (MANAJEMEN/ha)
1411544.0

1258878.

1292472.9

1139806.

315556.20

647265.47

3084562

1140552.97

764278.67

1021481.88

645207.58

936367.53

1456109.17

866152.81

1337038.08

7086402

3389671.0

869662.

459352.

2453303.4

65

97

799447.

389138.

2523518.1

93

25

Total output
Energy
By-product (E2)
A. (E1 E2)
B. (E1 E2)

1825684.
0
1944756.
0

Table 6 gives the EPR value, which can be calculated by formula (1). Energy value
shown in case A and B for the CPO + PKO and CPO feed gives the satisfying value (3 - 5)

and even very satisfying (8 - 9). The negative EPR value in making biodiesel is obtained from
the stearin feed, because the denominator (E1 E2) in formula (1) in this case is negative (see
Table.5, because the energy contained in by-product is larger than the total input fossil
energy. It means energy productivity in making biodiesel that uses stearin as raw material, is
very large. Survey data studying and processing also shows the energy productivity actually
can be enlarged by increasing plantation quality and using shell and fiber as energy sources.

Table 6. Energy Productivity Ratio (EPR) Value

CPO + PKO

CPO

Stearin

EPR value from source data PT. Sociindo

Case A

4.687

8.080

-0.348

Case B

5.099

9.538

-0.338

EPR value from source data PTPN II

Case A

3.252

4.415

-0.425

Case B

3.631

5.230

-0.399

6. CONCLUSIONS
This paper reports the results of a study on energy productivity ratio (EPR) of producing
biodiesel through palm cultivation. Calculations based on data obtained through Held survey
to plantation and factories in North Sumatera.
"Energy plantation in making biodiesel from palm oil has positive EPR value (> 1). The
largest value for CPO + PKO feed in each case is from PT Socfindo (4.51 - 4.89), followed by
PTPN Il (3.06 - 3.46). For CPO feed, PT Socfindo is also the largest, followed by PTPN II.
Based on the feed type in making biodiesel, it is shovsm that the EPR for stearin feed > CPO
> CPO + PKO.
Increasing plantation quality and using waste material such as shell and fiber as energy
resources can increase the EPR value. Fertilizer is the largest input energy element in
plantation activity; methanol is the largest input energy element in post-harvest processing.
Based on the EPR value, biodiesel product from palm oil is technical-energetically
reasonable.

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