Empty fruit bunches (EFB) are fibrous agricultural waste left over from palm oil extraction and can be processed into biomass fuel. The initial moisture content of palm fruit bunches is usually high (55-65%), and the moisture needs to be reduced to 15% before making biomass pellets. The EFB dryer is a specialized equipment used to dry empty palm fruit bunches. However, when palm oil plants/biomass pellet plants invest in palm fruit bunch dryers for drying empty palm fruit bunches, the total cost required does not equal the purchase price of the dryer. It also includes many other costs, and the actual expenditure should be calculated based on the service life. Next, I will explain in detail.

Five major costs of EFB drying

1. Machine procurement cost

A palm fruit bunch drying system comprises a rotary drum, a hot-air furnace, an inlet and outlet system, a fan, a dust removal system, and an electronic control system. In addition to equipment costs, procurement costs also include freight charges, installation, and commissioning expenses. The processing capacity of palm empty fruit bunch dryers ranges from 1 to 10 tons, and prices vary significantly depending on the processing capacity.

2. Energy consumption cost

This item represents the largest expenditure during equipment operation. It encompasses the consumption of fuels (biomass, coal, natural gas, steam) and the electricity bill generated by the electronic control system. Fuel costs are closely related to fuel type and the initial moisture content of the palm fruit bunches. Different fuels have different calorific values, and the higher the moisture content of the raw material, the more fuel is required, resulting in higher fuel costs. Additionally, factors such as equipment power, working hours, and local electricity prices must also be considered in terms of their impact on electricity bills.

3. Maintenance cost

The daily repair and maintenance costs of the palm fruit bunch dryer are also essential. After the machine has been in use for a period of time, the inner wall of the drum may wear out, parts may become loose, and the chain may rust. Timely maintenance, including rust removal, can reduce the likelihood of equipment malfunctions and extend its service life. Additionally, when the machine malfunctions, it needs to be shut down for maintenance. The time cost and production loss cost during the downtime should also be taken into account.

4. Labor cost

The operation personnel required for a palm empty fruit bunch drying production line include feed operators, parameter monitors, discharge and transportation personnel. It is necessary to calculate the number of operation personnel, shift arrangements, personnel salaries, and technical training expenses. A small EFB dryer requires 2-3 operators, while a large drying system may require 6-8 operators. Generally speaking, a highly automated production line can reduce the number of operation personnel, with high initial investment, but in the long run, it can reduce labor costs.

5. Environmental cost

EFB contains residual palm oil and fiber, which may generate dust and volatile gases during the drying process. In countries with strict industrial emission regulations, proper disposal of emissions is required, otherwise penalties will be imposed. Cyclone dust collectors, bag filters, and wet dust collectors are all used to filter the exhaust gas generated during the drying process. In use, the cost not only includes the purchase price of the dust collector, but also the replacement cost of consumables such as filter bags should be considered.

How to reduce the drying cost of EFB

1. Choose high thermal efficiency equipment

Choose equipment with stronger airtightness and better heat retention effect of the drum to prevent heat loss. A well-designed lifting plate can ensure the uniform spreading of EFB thin layers and improving heat exchange efficiency. Equipment equipped with a heat recovery system can preheat exhaust gases, thereby saving fuel costs.

2. Optimize heat source

Utilize locally common and low-cost fuels such as palm shells and wood chips to reduce fuel purchase costs and transportation expenses. Using a hot air furnace that is compatible with multiple fuels allows for fuel switching when fuel prices fluctuate to reduce energy risk. Precisely control air supply and combustion temperature to improve combustion efficiency.

3. Regular maintenance

Conducting routine inspections on the drum seal, calibrating temperature sensors, checking fan blades and belts, and removing dust can facilitate smoother heat exchange and reduce heat loss. Monthly in-depth maintenance can prolong the lifespan of the EFB dryer.

4. Automated control system

Choose equipment with PLC control system, which can monitor moisture content in real-time and control drying temperature, humidity, and air volume, preventing fuel waste due to too high temperature. Also, the automated control system can reduce the number of operators, thereby lowering labor costs.

Conclusion

Sometimes, equipment that appears to be cheap often has a higher cost, as the operational cost of the equipment is not solely determined by the purchase price. The purchase price may only account for 30% of the total cost. When selecting a palm fruit bunch dryer, it is important to choose high-quality equipment, as this will result in lower costs in the long run. If you wish to conduct a cost analysis for your palm fruit bunch drying project, you can contact us to help you develop the most feasible plan.