Cacao Processing Plant , South East Sulawesi, Indonesia

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This proposal provides recommendations towards the execution of a design for a cacao processing plant to produce cocoa liquor, powder, and butter from fermented cocoa beans in the North Kolaka district of South East Sulawesi province, Indonesia.
With rising demand globally for chocolate and chocolate derived products, the need is evident for increasing the output of cacao products across the entire supply value chain. Indonesia produces roughly 15% of the world’s cacao, trailing the leading producers, namely Côte d’Ivoire and Ghana
1.
The plant is intended to be located in close proximity to approximately 40,000 Ha of cacao farms.
Currently, cacao pods are transported approximately 200 km to Unahaa Town, the nearest warehousing facility, incurring a large financial and time cost. From Unahaa, the pods are transported to Makassar for processing, or exported to foreign processing plants in Europe, Britain or the United States.
Cacao plantations yield approximately 2 tonnes per Hectare (T/Ha)
2. By maximizing the utilisation of the local farms and lands, cacao plantations are estimated to double, with a predicted yield of up to 160,000 tonnes per annum. The processing plant will also provide a source of labour and may serve as a catalyst to unlock further foreign investment for the area.as been considered for an initial capacity of 120,000 tonnes/year. A total permanent investment of €16 M. The proposed cacao processing plant therefore is estimated. This price excludes other capital costs such as land acquisition, establishment of localised infrastructure and extending established infrastructure to the project site. Additional co the plant construction include :
a review of the existing infrastructure in the local area,
review of current market processes for the plantations in the area, and
identification of required and related infrastructure for the successful operation of the processing plant.

Section 1: Introduction and Background Information

1.1. Introduction

Indonesia is the world’s third largest cocoa producer with over 800,000 tonnes of raw cacao beans per year being produced. Interestingly, 70% of this production comes from the Sulawesi area, mostly from plantations privately owned by small-scale farmers. However, the plantation market is not at its optimal due to a lack of technological advances, agricultural techniques, harvest handling, pest and disease control and land management. It therefore follows that the current production is not at its maximum, required to realize higher profits. However, more importantly for this proposal, is that the current cocoa development initiatives are in three provinces, viz. West Sulawesi, South Sulawesi and Central Sulawesi. There are currently no processing plants in the South-East Sulawesi province, the closest plants being located in Makassar. The red place markers in Figure 1 below indicate Cacao producing areas.

The proposed plant will be located in North Kolaka, South-East Sulawesi and will be designed to initially process approximately 80,000 tonnes/year of cocoa beans, ramping up to 160,000 tonnes/year pending favourable conditions. This location was chosen due to its abundance in cacao bean plantations, which currently supply processing plants located out of the region. Furthermore, it is envisioned that the area of North Kolaka will be developed including a harbour.

1.2. Proposal Objective and Methodology

The main objective of this proposal is to prepare a preliminary task list and a road map of how to proceed with the development of a cacao processing plant for North Kolaka.
The methodology of the proposal is to:
Motivate for a cocoa processing plant in the South-East Sulawesi region,
Understand the workings of a cocoa processing plant and requirements,
Identify the key components and provide estimates of costs, to render a plant cost,
Identify utility requirements and related infrastructure,
Identify important considerations,
Provide recommendations and a project program for the design stage.

Section 2: Concept Stage

2.1. Market Analysis

To transform cacao beans into a consumer targeted product, the beans are processed into three main products: cocoa liquor, cocoa powder, and cocoa butter. Cocoa liquor is solid, unsweetened baking chocolate made from ground cacao nibs, which can be further transformed into cocoa powder and cocoa butter. Cocoa butter is the fat of the cacao nib, and may be used in lotions and pharmaceutical products. It is also the main ingredient in white chocolate. Cocoa powder is the solid product of the cacao nib and can be processed to have varying fat content. The powder is used in beverages, baking, and frequently as a dye. Chocolate is produced by combining both cocoa powder and butter with milk and sugar. With such diverse applications for cocoa liquor, butter, and powder, cacao bean processing is a worthwhile process to invest in.
The market for chocolate and cocoa derived products has grown strongly over the last few years. Demand is mainly driven by growing middle class populations in Brazil, India, China, amongs others, and domestically in Indonesia.
Indonesia processes roughly 30% of the worlds cacao. Although plantations in South-East Sulawesi are common, the province is not recorded to have cacao processing factories. However, the prevalence of plantations in the province does motivate for a further investigation and proposal towards establishing a local processing plant.
The location of the process plant proposed herewith for North Kolaka, is currently surrounded by cacao plantations in the region of 40,000 Ha with potential of reaching 80,000 Ha being predicted.
The plantations are owned and run privately, and the harvests are transported to processing plants outside the area; the nearest being in Makassar, approximately 800km away. Establishing a processing plant close to the farms shortens the value chain and potentially increases farmers’ profits and decreases losses.
Besides the cost of transportation, other challenges to transporting cacao beans over long distances include rain / wet bags, dirty sacks, oil stain sacks, torn/burst sacks and weight loss, which contribute to rejections upon delivery. These issues motivate the need for a local processing plant in the South-East Sulawesi area.

2.2.Competitive Analysis

Currently, cacao plantations in Indonesia cover a total area of 1.75 million hectares with production reaching 828,255 tonnes, spreading almost in all provinces with the main production centers being in the provinces of South Sulawesi, Southeast Sulawesi, Central Sulawesi, West Sulawesi, North Sumatra, East Kalimantan, NTT and Java East. Most (94%) of the cocoa plantations belong to smallholder plantation (Rosmawaty, 2015). Cacao processing facilities are found in the South, Western
and Central Sulawesi regions.
The absence of processing plants in the South-East Sulawesi province raises questions as to why it has
not been implemented to date. The reason for this disparity in supply versus local processing facilities is not fully understood, but may be attributed to low crop quality, low farming expertise or challenging accessibility. However, these issues can be addressed by supplementary development programs aimed at empowering farmers and increasing their output.
Rosmawaty et al (2015) studied the development potential of the cocoa industry in South-East Sulawesi. According to their research, the area has cacao as a priority commodity among estate crops
and contributed a 19.3% share of the total national production. The details of land area, production, productivity and the number of cocoa smallholder farmers in Southeast Sulawesi province during the period of 2009-2013 are presented in Table 1.


Table 1. Land Area, Production, Productivity and Number of Cocoa Smallholder Farmers in Southeast
Sulawesi Province for the Period 2009-2013 (Rosmawaty, 2015)

 

Credit :

1 World Consultants
Mohamed Peer B.Sc. (Elec) Pr. Eng.
mohamed@1wc.co.za
Fatima Peer B.Sc. (Hons) Pr.Sci.Nat., IAIAsa
fatima@1wc.co.za

 

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Sustainable Development in a Remote Area Kabupaten Mamasa

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Remote area in Mamasa Redgency are  300.588 ha with population of 125309 Peoples.

According The Government

According Own GIS Map

Land use Surface(km2) %    ha
Primary forest 306,35 10,8 30635
Secunairy forest 1260,47 44,5 126047
Pine forest 76,43 2,7 7643
Shrubbery 886,94 31,3 88694
Dry agriculture and shrubbery 204,30 7,2 20430
Sawah 53,93 1,9 5393
Marsh 1,93 0,1 193
Barren 39,22 1,4 3922
Total 2829,56 100 28295

 

 

Credit :

DR. Wouter Gotje

Categories: NEWS

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A PROMISING INDUSTRIAL PARK PLAN

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The new Industrial Park Plan with Pre – Owned 400 MW Coal Fired Power Plant in South Sulawesi Province, Indonesia

PT. RAJAWALI UTAMA NUSANTARA (RUN) was established in the year of 2014 in Makassar City, South Sulawesi Province, Indonesia and has been registered under the Indonesian Law. RUN is becomes an answer to the increasing pressure as a result of rapid development in all sectors, such as in the industrial sectors, commercial sectors, health sectors, education sectors, the tourism sectors, housings and so on. This rapid development is in direct need of an industrial park area.

RUN intend to establish an Industrial Park located in South Sulawesi with the mission to overcome the lack of industrial electricity supply, hence to build and operate a 400 MW coal – fired power plant.

Most of the power produced would be used within the Industrial Park by incumbent industries and the excess power would be sold to Perusahaan Listrik Negara (PLN), the Indonesian State-Owned Electricity Company.
The power sector in Indonesia is organized under the Ministry of Energy and Mineral Resources. PLN is responsible for the majority of Indonesia’s generation and is the monopoly provider of transmission, distribution and supply of electricity in Indonesia. This plant comprises one of the projects included in the 35,000 MW of the PLN Crash Program to cope with the electric power demand growth in Indonesia, particularly in Java island.

Sulawesi island has been allocated 10,000 MW of the program. PLN is promoting the development of the Power Plant as a private sector project and will award a Built Own Operated (“BOO”) concession to develop and operate the Plant to a private sponsor. A private sponsor with PLN through its subsidiary shall establish a project company (the Seller) that will finance, design, procure, construct, test, commission, operate and maintain the Plant and also will cover auxiliary equipment and supporting infrastructure to enable reliable base load of electricity generation for the system.

In Indonesia, especially Kalimantan Island, has a large reserve of coal resources. Approximately 60% of coal mined in Indonesia is used for power generation. While other forms of power generation are found in greater Indonesia (e.g. Geothermal, Hydro, Oil & gas), South Sulawesi depends on coal for base load generation.

RUN will be responsible for arranging and maintaining a reliable coal supply for the plant. Coal supply agreement might be negotiated on terms acceptable to local coal mine as ensure reliability of supply at market prices, and following procedures specified under the Power Purchase Agreement (“PPA”) Considering electricity situation as mentioned above in this time is critical, this project is expected to be in commercial operation in the middle of year 2020. Coal could be sourced from several mines located in East and South Kalimantan.  Indonesian coal typically has high calorific value and low ash content, resulting in lower input and processing costs, and lower environmental impacts respectively.
The power plant is intended to be located in close proximity to the new port and along the coastline in the South Sulawesi Province. This location is ideal for receiving coal shipments, access to cooling water from the ocean, and in close proximity to large electrical loads, thus reducing operational costs and electrical losses.

The proposed power plant shall have a maximum capability of 380 MW and will connect to PTN’s 150kV Transmission system. A permanent investment of € 266 million is estimated for the core generating plant. This price excludes other capital costs such as Balance of Plant (BoP) equipment, land acquisition and establishment of localized infrastructure (roads, water supply and processing infrastructure, electrical  distribution infrastructure and so on). Additional costs could run to an additional € 50 million, thus bringing the total investment to € 316 million.

The recommendations for design and execution of the plant construction include :

1 review of governmental policies pertaining to domestic power production using coal as a  resource,
2 assessment of new and soon to be established competitors,
3 a review of the existing electrical, water and logistics infrastructure in the local area, and
4 identification of required and related infrastructure for the successful operation of the processing plant.

 

Keywords: capacity, design, execution, yield, investment, operation, infrastructure.

Credit :
1 World Consultants
Mohamed Peer B.Sc. (Elec) Pr. Eng.
mohamed@1wc.co.za
Fatima Peer B.Sc. (Hons) Pr.Sci.Nat., IAIAsa
fatima@1wc.co.za

 

Categories: NEWS

A SOLUTION FOR MAKASSAR CITY’S BLACKOUT

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Coal Power Plant in South Sulawesi, Indonesia

In 15 November 2018 Makassar City experiencing the blackout for 12 hours because of the lack electricity from PLN, to overcome the less supply of industrial electricity, hence PT. Rajawali Utama Nusantara (RUN) and it’s partner DSD Power Technologies GmbH offer a 400 MW coal – fired power plant to establish in South Sulawesi Province.

The Pre-Owned Coal-Fired from DSD Power Technologies GmbH Germany has  Key Features :
Fuel : Hard Coal and Natural Gas
Boiler : Supercritical Once-Through (Benson type) boiler manufacturer SGP -Tangential firing System -4 burner levels
Flue Gas : Electrostatic precipitators – SCR DeNOx plant (Hitachi)
Treatment : -Spray dryer FGD plant (3 lines)
Steam Turbine : 3 stage Siemens Turbine
Condensing : Run of River cooled
Generator : 21 kV hydrogen cooled ELIN Generatorn
Grid Connection : 400 kV ODWF ELIN transformer
Control System : SPPA T3000 from Siemens

Performance Data :

Net Output (Base Load) :   387 Mwel
Net Efficiency :   41,9 %
Net Output (min Load) :    170 Mwel

Steam Parameters :

HP1 (1 Section) : 258 bar/ 540° C
IP (2 Sections) : 44 bar/ 535° C
LP (4 Sections) :  5,1 bar/ 244,5° C

Coal Fuel Parameters :

Lower Heating Value : 24,0- 28,5 MJ/kg
Volatile Content (dry ash free) : 28 – 32 %
Ash Content (as received) : 8 – 13 %
Water Content (as received) : 5 – 12 %

Operations Data :

Commercial Operation Date : March 1986
Accumulated Operating Hours :  113.000 OH
Number of Starts :  548
Steam Turbine Refurbishment 2012 : @100.000 OH
Control System Renewal : 2008
 Plant in dry preservation for long term layup since 30-04-2015

Benefits

  • Ø High Quality and State of the Art Austrian & German Standards, Machines & Components (SIEMENS, ELIN, ABB, AEG, ALSTOM, SGP,…)
    Ø Up to 40% Investment Cost Reduction
    Ø Shortened Construction Time (less then 5 years instead of 7 years)
    Ø Shortened Time to Profitability (less then 8 instead of 11 years)
    Ø Profen Performance and Availability
    Ø State of the Art Technology with less Operation Hours

Advantages

Plant Scheme

 

The Plant

Credit :
DSD Power Technologies GmbH

Categories: NEWS

INDUSTRIAL PARK PLAN with GREEN ENVIRONMENTAL MONITORING

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AIMS

Environmental and Natural Resources program for the Integrated Industrial Plan at South Sulawesi Province, Indonesia:

  • Establish risk-based remediation objectives to reduce the environmental impact of Industrial Plants
  • Encourage sustainable development and environmental awareness
  • Minimize the environmental impact of the operations, optimizing the natural and economic resources
  • Environmental services: Environmental Site Assessment, Site Characterization and Risk Assessment
  • Minimize the environmental impact of the operations, optimizing the natural and economic resources
  • Environmental services: Environmental Site Assessment, Site Characterization and Risk Assessment
    • Environmental management and the use of natural resources are crucial for achieving a sustainable development
    • Huge challenge for planner and policy makers
    • Prevention and Planning Vs Treatment Cost and Environmental Impact
    • We offer services and flexible solutions to resolve these critical issues

    Article 33 verse (4) of The 1945 Constitution of the Republic of Indonesia :

       

    • Industrial plans in tropical forest have adverse environmental impacts
    • Impacts may affect an area larger than the sites or facilities
    • Provide environmental tools and use natural resources for sustainable growth is a key issue

    Sustainable development

    Renewable energy

    • Desalination and fresh groundwater
    • Environmental management
    • Land management
    • Wastewater and industrial water
    • Waste energy plants

     

    Solar & Renewable Energy
    Land M
    anagement
    Environmental Management
    Wastewater 
    and Industrial Water System
    Waste Energy Plant
    Desalination & Groundwater

    Support the authorities to apply sustainable planning policies

    • Design economically realistic in site measurement methods
    • Modeling tools validated in pilot sites
    • Design surveillance systems and solutions
    • Assessment of different time-scales: from the very short term (immediate danger) to long term (probability of disturbances)
    • Literature review

    Environmental Communication

    • Public communication about environmental issues favoring the integration of the industrial Park Plan with the Society
    • Plans to promote the public participation : environmental events
    • Media and green marketing: promotional videos and activities

    Environmental Risk Assessment (ERA)

    • Integrated ERA : combined modeling and environmental monitoring
    • Biomarkers : provides an early indication of potential damage to an organism Biomarkers may close the gap between modeling and monitoring
    • Health, Safety and Environmental risk Assessment: make correct decisions in the optimization of an activity

    Vulnerability Assessment and Mapping

    • The vulnerability to pollution may or may not allow to resist pollution accidents
    • Water resources systems (both surface water and groundwater resources), soil and air are subject to different anthropogenic pollution impacts
    • The vulnerability assessment of soil, air and water resources systems to pollution is relevant for drawing pollution risk maps and models

    Integrated Quality Index for vulnerability, risk and pollution assessment

    • Risk and pollution assessment adapted to the local properties of the site
    • Index based on the 10 most prevailing parameters for each medium: pH, temperature, conductivity, CO2, TPH,
      Escherichia coli, Lead…
    • Scaled results: Measured parameters,Vulnerability, Pollution…
    • GIS mapping

    Natural geological risk and vulnerability assessment

    • Research and studies on geological risks : earthquakes, seepage, mass movements, collapses, volcanic eruptions, fire and flash flooding
    • Construction and management of databases
    • Cartographic and management approaches
    • Support to the State and Local Authorities
    • Delivery of data acquisition systems

    Environmental Monitoring

    • A solid implementation of a monitoring plan improves the response time and helps to reduce the damage of environmental incidents
    • Air, soil and groundwater monitoring
    • Use of monitoring data in assessing the consequences of natural resource management and pollution risks

    Environmental Monitoring

    • Civil works
    • Drilling
    • Installation of wells
    • Pumping systems
    • Geophysics
    • High pressure pipelines

    Soil and groundwater Remediation

    • Pump & treat
    • Bioremediation & Biopile
    • Dual-phase extraction (DPE)
    • Soil Vapor Extraction (SVE)
    • Sparging
    • Monitored Natural Attenuation

    RENEWABLE ENERGY

    Entire Design, Installation, Operation and Maintenance of renewable energy generation plants and parks :

    • Photovoltaic Solar Energy
    • Solar thermal energy systems
    • Electrical energy storage systems
    • Integrated Solar Combined Cycle (ISCC)
    • Biogas
    • Surface geothermal energy
    • Small hydropower plants

     

     Credit :

    UNEDO & EGGLOO

     

Categories: Uncategorized