Simulation of Bioethanol Production Processes

From Oil Palm Empty Fruit Bunches

Hendra Susilo1, Taufiq Bin Nur1,2*, Indra Surya2,3

1Department of Mechanical Engineering, Faculty of Engineering, Universitas Sumatera Utara,
Padang Bulan, Medan 20155, Indonesia.
2Sustainable Energy and Biomaterial Center of Excellence, Universitas Sumatera Utara,

Padang Bulan, 20155 Medan, Indonesia

3Department of Chemical Engineering, Faculty of Engineering, Universitas Sumatera Utara,

Padang Bulan, Medan 20155, Indonesia.

*E-mail: taufiq.bin_nur@usu.ac.id

ABSTRACT
This study aims to analyze the possibility of Oil Palm Empty Fruit Bunch (EFB) used as raw material in Bioethanol
production using the Aspen Plus simulation. The process of making bioethanol from Oil Palm Empty Fruit Bunch (EFB) is
carried out in 3 stages: pretreatment, Simultaneous Saccharification Fermentation (SSF), and distillation. The first step is
pretreatment using NaOH and Enzymatic Hydrolysis for glucose release, followed by the SSF process. The saccharification
and fermentation process (SSF) was carried out using enzymes, while the fermentation process was carried out using
Saccharomyces cerevisiae as a nutrient in producing ethanol from lignocellulose. Fermented products were distilled from
different EFB’s sources, such as Bengkalis, Tandun, Dolok Ilir#2, and Adolina, which are available in huge sizes as waste
material on palm oil mills in the North Sumatera Province of Indonesia. The results showed that bioethanol produced from
Tandun, Dolok Ilir#2, Adolina, and Bengkalis were 0.0026 gr min-1, 0.003 gr min-1, 0.461 gr min-1, and 0.512 gr min-1,
respectively.

Keywords: Empty Fruit Bunch; Simultaneous Saccharification Fermentation (SSF); Bieothanol; Aspen Plus; Palm Oil Mill.

INTRODUCTION

Energy has a very important and strategic role in achieving social, industrial, economic and transportation goals in people's
lives. Energy requirements may continue to increase while fossil energy sources are currently depleting. Indonesia's fossil
energy supply 94.3% of the total energy needs of 1357 million SBM, the remaining 5.7% of renewable energy has not been Commented [t1]: Maksunya apaaa?? Kepanjangannya
fully developed according to the National Energy Council (DEN 2014). Current problems due to high use and demand for apaa??
fossil fuels have an impact on the energy crisis, as well as the threat of environmental pollution due to vehicle exhaust gases
such as CO2. Renewable energy sources needed to help to reduce the use of fossil energy. Global warming and energy
security are gaining attention from the government through government policies in the supply and utilization of renewable
energy sources of biodiesel (REN21 2018 and Anubhuti & Jay 2015).
Renewable energy sources are environmentally friendly energy sources that do not pollute the environment and do
not contribute to climate change and global warming. Based on data from the Ministry of Energy and Mineral Resources
ESDM (2015), the utilization of renewable energy in Indonesia is show in Fig. 1.

Minyak Bumi

Energy Baru
29% Terbarukan
43% Gas Bumi

Batu Bara
22%

6%
FIGURE 1. Renewable energy in Indonesia.

In general, biomass is a material that obtained from plants directly or indirectly, and used as energy or material in
large quantities (Yokoyama 2009). Biomass has the potential to become one of the main energies for the development of
sustainable energy in an effort to meet energy needs in each region (Welfle et al. 2014). The area of oil palm plantations
reaches 11,201.5 ha with a production of 31,731 tons per year in Indonesia. The conversion processes of FFB will produce
10-30% crude palm oil (CPO) with by product of fibers (12-15%), shells (5-7%), EFB (20-23%), and palm oil mill effluents
(60-70%) (Kramanandita et al. 2014). 22-24% of EFB could be obtained which will produce 23-26% of EFB as solid waste
(BPS 2018). Usually, 10% of the EFB will be used as fuel for boiler in the POM, and the remainder becomes waste and Commented [t2]: Ndra,
compost (Ngadi & Lani 2014 and Dian 2018). EFB can be used as a raw material to produce bioethanol which can reduce Kalimat ini sudah saya ubah dan sisanya “22-24% of EFB
dependence on fossil fuels, and at the same time reduce waste in the POM site. Biomass refers to organic materials derived could be obtained which will produce 23-26% of EFB as
from plants or animals A non-fossil and biodegradable organic material derived from plants, animals and micro-organisms solid waste (BPS 2018)” dihapus saja. Namun, pastikan
(Anne et al 2008 and Brown 2015). reference BPS 2018 dihapus juga kalau lah tidak ada yang
Bioethanol raw materials can divided into 3 parts may starch, sugar and cellulose. dipakai dalam manuscript ini.
Biomass can be is classified into several types such as may: biogas, biofuel, biodiesel and ethanol. Biofuel is energy Commented [t3]: Kalimat ini dihapus saja, dan pastikan
derived from vegetable materials, such as petroleum, jatropha, corn. This energy used as fuel, which called Biofuel (BBN). referencenya juga didelete jikalau tidak digunakan.
Biodiesel as an alternative energy substitute for fossil fuels. Energy derived from plants or animal fats used, either in pure
or mixed with other fuels (Sri 2006). Ethanol is also called ethyl alcohol, pure alcohol, absolute alcohol, or alcohol alone, is Commented [t4]: Ini saya tak paham maksudnya. Hapus
a type of volatile, flammable and colorless liquid. aja kalau tak nyambung dengan kalimat sebelumnya.
Biomass can be converted into bioethanol within two processes: biochemical and thermochemical (Basu 2010, and
Küҫük & Demirbas 1997). In biochemical conversion, biomass molecules are broken down into smaller molecules by
bacteria or enzymes. Biochemical conversion can be done in three main ways: digestion (anaerob and aerob), fermentation,
and enzymatic hydrolysis or thermochemical conversion acid. Thermochemical conversion can be done in 4 ways,
combustion, pyrolysis, gasification and liquefaction. The process of converting biomass to ethanol or bioethanol has been
widely developed from cellulose, hemicellulose and lignin in wood, which is one of the lignocellulose materials. The content
of the three main compounds of lignocellulose material varies based on the source as shown in Table. 1 David & Hon (2010).

TABLE 1. The content of cellulose, hemicellulose and lignin in some agricultural wastes and forest products.
Types of waste Cellulose (%) Hemicellulose (%) Lignin (%)
Borad stem leaves 40-55 24-40 18-25
Needle stem 45-50 25-35 25-35
Leaves 15-20 80-85 0
Corn Cob 45 35 15
Peanut shells 25-30 25-30 30-40
Wheat straw 30 50 15
Bagasse 50 25 25
Empty fruit bunches 41.30-46.50 25.30-33.80 27.60-32.50

Bioethanol can be classified in four different generations depending on their biomass feedstock as the raw material.
The composition of the raw material (first, second, third and fourth generation) and the structure of their monosaccharides /
polysaccharides is shown in Fig. 2 (Sonali 2019). Thus, this section is primarily focused on in-depth studies of the production
of bioethanol raw materials used in certain generations.

FIGURE 2. Different generation of bioethanol based on feedstocks and their cell wall compositions

Several studies have conducted research on the use of first generation, second generation, third generation ethanol
raw materials and even the fourth generation. First generation raw materials are mainly from food crops, which have high
sugar and starch levels such as grains, sugar cane, and tuber crops. Ethanol production from food crops has an effect on food
prices, while providing little reduction in greenhouse gas emissions (Balan et al 2013; Shikida et al. 2014). Bioethanol
production from corn in the European Union accounts for 67% of global bioethanol supply (Rulli et al. 2016). Second
generation raw materials which contain cellulose as the main ingredient in saccharide sources with lower amounts of pentose
sugar in the form of hemicellulose such as bagasse, straw, stover, stems, leaves and damaged seed residues, and grass
biomass have gained a lot of interest in the past two decades (Mohapatra et al. 2016, 2017). Third generation bioethanol
comes from algae, both micro algae and macro algae. Algae potential for bioethanol production processes due to faster
growth rates compared to land plants, high availability, and ability to survive in harsh conditions (Chia et al. 2017; Khan et
al. 2018; Silva and Bertucco 2016). Technology to make bioethanol from the third generation requires high technology and
the process of algae cultivation requires expensive financing so that bioethanol production developed on a laboratory scale.
Fourth generation bioethanol or advanced ethanol is bieoethanol which is produced through biomass that has undergone
genetic modification (GMO), wherein in the biomass matrix there are enzymes that will help destroy the biomass matrix
itself (autohydrolysis), thus facilitating the pretreatment process. Brazilian developed fourth generation bioethanol using
sugarcane plants which undergo genetic modification so that sugarcane stems are capable of autohydrolysis (Syahrul 2014).
In addition, the availability of EFB does not result in competition between energy needs and food needs. In this
study the has been developed to convert EFB into Bioethanol by biochemical method with the fermentation process. The
potential of EFB can used as raw material for making bioethanol which can reduce or replace fossil fuel, while demand
continues to increase. This study aims to propose the conversion processes in production bioethanol from obtain the design Commented [t5]: Jangan mengulang-ngulang kalimat
of Oil Palm Empty Fruit Bunch (EFB) reactors in bioethanol production using the Aspen Plus simulation process. This yang sudah disebutkan sebelumnya atau yang mempunyai
research study is expected to will make the possibility in reducinge the amount of EFB waste in the POM site by converting makna yang sama.
them into bioethanol and increase environmental pollution, add research insight, especially in the development of bioethanol
production technology from EFB, Reduce the use of fossil-based fuels and obtain as an alternative energy that is
environmentally friendly.

METHODOLOGY

The development of simulation for bioethanol production processes at Aspen Plus has been carried in 3 stages : pretreatment,
saccharification and distillation. The simulation development process based on the following assumptions in steady state.
EFB used in the Aspen Plus V.10 simulation obtained from the local palm oil industry in Sumatra, part of Bengkalis, Tandun,
Dolok Ilir # 2 and Adolina. The samples received were wet and intact bunches. The inputs used in the bioethanol production
process use a production simulation based on the sign of empty palm oil fruit. In running the simulation you must first Commented [t6]: Maksudnya apa??
determine the input flow of each block in the operating unit and introduce the id component used before the run process.
Aspen plus only knows chemical compounds, but solid and non conventional components can input by determining the
compounds contained in laboratory tests such as Prosimat analysis and ultimate analysis. The types of component IDs in
simulations such as TKKS (Nonconventional), H2O, ASH, H2, N2, S, O2, C(solid), NaOH, Glucose (C6H12O6), Ethanol
(C2H5OH), CO2, Sucrose (C6H12O6), Fructose (C6H12O6), Urea. Commented [t7]: Perbaiki kalimat ini. Masih kacau dan
The model used to calculate physical property in Aspen Plus is grouped into a property method called the SRK pembaca tidak mengerti dengan kalimat ini.
central model. Laboratory scale bioethanol production operation uses 1 kg / hour of empty fruit marks. The prosimat and
ultimate content of the analysis of the sign of empty fruit of oil palm was obtained from data from the system integration Commented [t8]: Perbaiki Hendra.
research group and optimization of North Sumatra University as shown in Table 2.

TABLE 1. Proximate analysis and ultimate analysis of EFB

EFB Source
Test Parameters
Tandun Dolok Ilir #2 Bengkalis Adolina
Proximate analysis (wt.%):
- Moisture 14.43 33,31 10 21.87
- Ash 5.02 3,20 2.97 6.23
- Volatile matter 68.26 53,44 8.6 9.03
- Fixed carbon 12.29 10,06 78.43 62.87
Ultimate Analysis (wt.%):
- Moiture 14.43 33,31 10 21.87
- Ash 5.02 3,20 2.97 6.23
- Carbon 45.94 35,18 55.52 54.37
- Hydrogen 5.64 4,80 7.83 6.94
- Sulphur 0.14 0,13 0.08 0.15
- Nitrogen 3.99 0,00 1.57 0.75
- Oxygen 24.84 23,39 31.73 31.56

The first stage is the pretreatment process in the production process of bioethanol based on lignocellulose biomass
before hydrolysis and fermentation is carried out. Pretreatment aims to break the polymer chain and separate portions of
lignin and hemicellulos in increasing the efficiency of the hydrolysis process by expanding the contact surface of the
substrate by enzyme (Mergner et all 20130). The pretreatment method using alkaline solution will increase the effectiveness
of the enzymatic hydrolysis process by increasing the accessibility of enzymes on the cellulose surface (Remli et al 2014).
The use of NaOH in agro-industrial waste can reduce lignin by more than 99% after immersion in 1 M NaOH solution at
room temperature for 48 hours or at 121C for 15 minutes (Sutikno et al 2010). According to Isroi et al (2011), pretreatment
methods have been carried out on different types of biomass and the results vary for the method and type of raw material.
The biomass is put into the decomp reactor with a flow mass of 1 kg / hour at a temperature of 27C for the proximate
content and ultimate analysis of empty fruit bunches. In the decomp reactor the empty fruit bunches are set to the mesh size
of the particle size dristribution accordingly. Pretreatment can be done physically, chemically, biologically or in a
combination that will affect the next process. The outflow from decomp to reactor tank is mixed with the addition of NaOH
solution as much as 0.5% of the kosog fruit bunches with a temperature of 120C for 30 minutes. The results of the
pretreatment process are two outlet channels in the form of cellulose and waste, each flow mass is 0.100222 kg / sec and
0.000055 kg / sec as in Fig. 3 stage 1. Commented [t9]: MASIH BINGUNG, MAKSUD
HENDRA APAA??
Stage 1

NaOH

Selulosa
Biomassa Process
Pretreatment

Waste

Heat

FIGURE 3. EFB pretreatment process

The second stage of the processes of is saccharide at temperature of 60C with addition composition of the enzyme
amylase 10% from the results cellulose flow pretreatment process. The hydrolysis process in bioconversion of empty fruit
bunches serves to break down carbohydrate polymer chains such as holocellulose (hemicellulose and cellulose) into reducing
sugar monomers. Perfect hydrolysis of cellulose produces glucose, whereas hemicellulose produces several pentose and
hexose sugar monomers based on differences in cellulose and hemicellulose compounds (Septiyani 2011 & Mergner et al
2013). The flow of results from the sacralication process is continued to the fermentation process. In the reactor fermtor
given the addition of yeast in the form of bread yeast as much as 5% of the amount of inflow. addition of bread yeast for the
development of bacteria in forming alcohol. Saccharification and fermentation reactors simplified for continuous operation.
the assumption was made to introduce enzymes and yeast to the water form in the simulation process such as Fig. 4. The
reactions that occur in bioethanol production from EFB have been simplified as follows (Nabgan Walid et al 2016). Commented [t10]: Masih bingung juga Hendra.
Saccaharification:
EFB + WATER  GLUCOSE
99% conversion of EFB (1)

Fermentation
GLUCOSE  1.9 Ethanol + 1.9 CO2 + 0.06 NFDS
100% conversion of glucose (2)
Stage 2

Yeast Nutrisi

Selulosa Beer/
Process Process Alcohol
Saccharafication Fermentation

Enzyme

FIGURE 4. The process of saccharafication and bioethanol fermentation

The third stage is the process of distillation or purification in the bioethanol production process. Distillation is a
method of separating chemicals based on differences in speed or ease of evaporation (volatility) of materials based on boiling
point differences. Destilator is a device that functions to separate ethanol from water so that ethanol obtained with a purity
of 95%. Bir-01 mass flow from the fermentation process obtained 0.100575 kg / second. The heater in the distillation process
works at a temperature of 80C with the amount of mass flow in the results of the fermentation flow from several types of
empty fruit bunches in Sumatera. The steam flow rate from the distillation process coded to obtain bioethanol as shown in
Fig. 5.
 Stage 3

Bioetanol Process Beer

95% Distillation

Heat

Figure 5. Process Distilation

RESULTS AND DISCUSSION

The first step in researching the bioethanol production process using Aspen Plus is look for journal literature on bioethanol. Commented [t11]: Ini nggak perlu.
The design of bioethanol reactors is made in 3 stages the process may pretreatment, saccharification and distillation. The
use NaOH as much as 0.5% of empty fruit bunches with a temperature at 120C for 30 minutes will increase the effectiveness Commented [t12]: Repetition. Jangan lakukan hal
tersebut. Sudah ada pada bagian lain di atas.
enzymatic hydrolysis process on the cellulose surface. The results of the pretreatment process are two outlet channels in the
form of cellulose and waste, the flow mass of each is 0.100222 kg sec-1 and 0.000055 kg sec-1.
The sakarafikasi process with temperature 60C with the addition composition 10% amylase enzyme with pH 6
produces a flow mass 0.10023 kg sec-1 in the form glucose. Glucose from the saccharification process continued to the
fermentation process in producing 10% alcohol by adding yeast to produce ethanol. During the fermentation process
nutrients needed as a bacterial growth intake in the form sugar, yeast, NPK and fermipan as much as 5 gr in liquid form.
Nutritional fluid is put into ethanol liquid when the air bubbles in fermentation process no longer exist. The fermentation
process produces glucose as much as 0,000575 kg sec-1, the fermentation results distilled to increase the ethanol level by
95%. The design results ethanol production process from empty fruit bunches using Aspen Plus simulations laboratory scale
such as Fig. 6.

FIGURE 6. The Aspen Plus simulation sheet of bioethanol production from EFB.

The results distillation process from palm oil mill effluents such as Tandun, Dolok Ilir # 2, Bengkalis, and Adolina
can be seen in Table 2. From the results distillation process at different temperatures the amount bioethanol is equally
influenced by the heatexhanger area.
TABLE 2. The results distillation process
Temp Tandun Area Dolok Ilir#2 Area Bengkalis Area Adolina Area
[°C] Inlet Outlet sqm Inlet Outlet sqm Inlet Outlet sqm Inlet Outlet sqm
70 0.0036 0.0031 0.2336 0.0032 0.0027 0.2332 0.5412 0.5118 0.2332 0.5322 0.4610 0.2332
80 0.0043 0.0031 0.3136 0.0038 0.0027 0.3128 0.5450 0.5118 0.3128 0.5505 0.4610 0.3128
90 0.0060 0.0031 0.3846 0.0052 0.0027 0.3827 0.5468 0.5118 0.3827 0.5562 0.4610 0.3827
100 0.0130 0.0031 0.4705 0.0114 0.0027 0.4646 0.5477 0.5118 0.4646 0.5586 0.4610 0.4646
110 0.2909 0.0031 1.7512 0.2897 0.0027 1.7467 0.5482 0.5118 1.7467 0.5598 0.4610 1.7467
 0.5412 0.5322 0.5450 0.5505
0.6000 0.6000
0.5118
0.4610 0.5000 0.4610
0.5000 0.5118
0.4000 0.4000
0.3000 0.3000
0.2000 0.2000
0.1000 0.0036 0.0031 0.0032 0.0043 0.0038
0.0027 0.1000
0.0000 0.0031 0.0027
Tandun Dolok Ilir#2 Bengkalis Adolina 0.0000
Tandun Dolok Ilir#2 Bengkalis Adolina
Temp 70°C Inlet Temp 70°C Outlet Temp 80°C Inlet Temp 80°C Outlet

0.5468 0.5562 0.5477 0.5586

0.6000 0.6000 0.5118
0.5118
0.4610 0.4610
0.5000 0.5000

0.4000 0.4000

0.3000 0.3000

0.2000 0.2000

0.1000 0.1000 0.0130 0.0114

0.0060 0.0031 0.0052 0.0027 0.0031 0.0027
0.0000 0.0000
Tandun Dolok Ilir#2 Bengkalis Adolina Tandun Dolok Ilir#2 Bengkalis Adolina
Temp 90°C Inlet Temp 90°C Outlet
Temp 100°C Inlet Temp 100°C Outlet

0.5482 0.5598
0.6000 0.5118
0.4610
0.5000

0.4000
0.2909 0.2897
0.3000

0.2000

0.1000
0.0031 0.0027
0.0000
Tandun Dolok Ilir#2 Bengkalis Adolina
Temp 110°C Inlet Temp 110°C Outlet
FIGURE 7. The result temperature variation process bioethanol distillation

Production Modeling results from palm oil mill effluent, using a difference in wet EFB at 1000 gr day-1, produces an
ethanol concentration of about 0.512 gr min-1. The estimation of ethanol production from difference EFB’s sources are
shown in figure 2. It shown that the EFB from Bengkalis palm oil mill can produce bioethanol higher than Adolona, Tandun,
Dolok Ilir#2 palm oil mill.

0.6
0.512
0.5 0.461

0.4
gr/min
Etanol

0.3

0.2

0.1
0.003 0.0026
0
Tandun Dolok Ilir#2 Bengkalis Adolina
etanol

FIGURE 8. Ethanol production from EFB.

 CONCLUSION
Fermented products are distilled from various EFB, produced by different palm oil mills in the North Sumatera Province of
Indonesia, such as Bengkalis, Tandun, Dolok Ilir#2, and Adolina. The results showed that bioethanol produced from Tandun,
Dolok Ilir#2, Adolina, and Bengkalis were 0.0026 gr min-1, 0.003 gr min-1, 0.461 gr min-1, and 0.512 gr min-1, respectively.
In this work, Aspen plus is used to model laboratory scale bioethanol production using palm oil mill effluents such as oil
palm empty fruit bunch. Several stages involve on producing the ethanol from EFB are initial treatment, saccharification,
fermentation, and distillation. The results show that 95% ethanol with a daily capacity of 0.512 gr min-1 of ethanol per day
can be produced from waste from oil palm empty fruit bunches.

ACKNOWLEDGEMENTS

The author would like to thank the University of North Sumatra. This research supported as a Masters Thesis Research
scheme through research funding at PTNBH

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