Organics Bali Officially Launches Biogas Methane Capture Plant at Gunung Makmur Mill

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POME Conversion Process into Biogas

At this facility, POME liquid waste from the palm oil processing stage is not immediately discarded, but instead is processed into an energy source. The processing sequence begins with the conditioning of the POME. It is then channeled to the Closed Lagoon Bio-Reactor (CLBR) system. CLBR technology operates anaerobically within a closed system. Consequently, the methane gas formed can be optimally captured without being released into the atmosphere.

During the anaerobic process, the organic content within POME is broken down by microorganisms into biogas, which consists of a mixture of methane (CH₄) and carbon dioxide (CO₂). This resulting methane gas is then collected, channeled, and utilized as an energy source.

Utilization of Biogas for the Burner Process

Unlike some other biogas facilities that focus on utilizing biogas for electricity generation, this project implements a Co-Firing approach. The resulting biogas is channeled to the burner system to support the steam generation process within the palm oil mill. Through this technology, the consumption of conventional fuel can be significantly reduced. Simultaneously, it provides better energy efficiency in the production process.

Flow Process of the Methane Capture Biogas Plant at Gunung Makmur Mill

The methane capture process for Biogas Co-firing at PT Karya Makmur Bahagia – Gunung Makmur Mill converts palm oil mill effluent (POME wastewater) into biogas, a renewable energy source. The flow diagram of this process illustrates a series of efficient treatment stages, starting from the waste input to gas utilization and effluent management.

1. Pre-Treatment and Cooling

The treatment process starts with the input of POME Liquid Waste. This waste subsequently enters the WPS SCREEN (Screening Unit), which separates all coarse solid materials. Following the screening, the system channels the waste to the CTU COOLING TOWER (Cooling Tower Unit) to reduce its temperature. This temperature adjustment ensures the waste meets the operational requirements for the subsequent anaerobic fermentation process.

2. Treatment and Gas Preparation in the CSU

The CSU (Combined Structure Unit) receives the water cooled by the CTU. This integrated system incorporates several vital functions. Inside the CSU, the CO2 STRIPPER unit removes or reduces CO2 gas content from the waste stream.

Additionally, the CSU RECIRCULATION returns a portion of the process material to the PBR ANAEROBIC DIGESTER to maintain fermentation stability and efficiency. Finally, the treated water flows through the CSU OVERFLOW WATER. If the water level exceeds a specific threshold, the system releases it as TREATED DISCHARGE.

3. Core of the Process: PBR Anaerobic Digester

The system channels the prepared waste to the PBR ANAEROBIC DIGESTER (Pome Biogas Reactor), the core of the entire process. Here, anaerobic bacteria break down the organic matter within the POME to produce methane-rich biogas. Furthermore, the digester generates SLUDGE DISCHARGE as a byproduct, which the system disposes of following the dewatering process. Finally, this unit also manages runoff from the area as STORM WATER.

4. Biogas Utilization and Safety

The system distributes the biogas produced from the PBR through two main channels. First, the GDU (Gas Delivery Unit) channels the majority of the gas to the BOILER (steam boiler) for use as fuel. This setup employs a co-firing scheme, allowing the biogas to replace a portion of the fossil fuels previously used.

For safety, the system features a BGF FLARE (Biogas Flare) to manage excess biogas production. The flare burns any surplus gas, including during emergency conditions. Additionally, the safety system includes an EMERGENCY EXHAUST connected directly to the BGF FLARE, ensuring fast and safe gas disposal during operational disruptions.

Overall, this process flow demonstrates a strong commitment to responsible POME waste management. By converting waste into a source of clean energy, the system guarantees the controlled disposal of both liquid and solid waste.

Facility Data Output

In addition to being used for burners, this facility has the potential for further development toward biomethane and Compressed Biomethane (CBM) production, thereby supporting the low-carbon energy market in the future.

Perspective from BGA Group

How was your experience working with Organics?

“Collaboration & Improvement have been the core strengths in the development of the Biogas Co-Firing Methane Capture Plant (MCP) Project, yielding positive and satisfying results. This is demonstrated through Organics’ professionalism, which remained consistent and accountable alongside the BGA team in meticulously calculating every stage of the work, from planning to implementation.

We greatly appreciate Organics’ commitment to ensuring the project was completed on time with optimal quality, even exceeding our initial expectations.”

What are your expectations for the future sustainability of this facility?

“The operation of this Biogas Co-Firing Methane Capture Plant (MCP) strengthens BGA’s position as a pioneer in Indonesia’s sustainable palm oil industry, particularly in energy independence and greenhouse gas (GHG) emission reduction.

This MCP is equipped with an Enclosed Flare & Co-Firing system that meets the requirements for carbon credit application, allowing the facility to proceed into the carbon market phase in the future. This provides economic added value, enhances sustainability credibility, and serves as a contribution to global climate change mitigation.

Looking ahead, this technology is projected to serve as a pilot model for the implementation of green technology across BGA’s other operational units.”

— Rieza Rakhman
Project Planning and Development Department Head Bumitama Gunajaya Agro

With the operation of this Methane Capture Plant, Organics Bali and BGA Group reaffirm their commitment to the implementation of renewable energy and the reduction of carbon footprints within the Indonesian palm oil industry. This facility provides not only operational and environmental benefits but also serves as a strategic step in supporting an industry that is lower-emission, sustainable, and aligned with global green energy standards.