POME Biogas Project in Indonesia: EPC Contractor with GFS Tanks and USR Process
Indonesia's palm oil industry generates enormous volumes of wastewater every year, and converting this POME into clean energy through a well-designed Biogas Project has become a national priority. This article explains how the USR Process and GFS Tanks, delivered by an experienced EPC Contractor, turn palm oil wastewater into a valuable renewable resource.
Palm Oil Production and Wastewater Treatment Challenges in Indonesia
As the world's largest palm oil producer, Indonesia operates hundreds of palm oil mills that process fresh fruit bunches around the clock. Each ton of crude palm oil produced generates several tons of Palm Oil Mill Effluent (POME), a thick, high-strength organic wastewater with high chemical oxygen demand (COD) and biological oxygen demand (BOD). If discharged untreated, POME severely pollutes rivers and groundwater, harms aquaculture, and releases significant methane emissions into the atmosphere. Traditional open lagoon treatment is land-intensive, slow, and allows methane to escape freely, wasting a valuable energy resource. Mills across Sumatra, Kalimantan, and Sulawesi increasingly need efficient, enclosed treatment systems that both meet environmental regulations and capture energy value from this abundant organic waste stream.
Converting POME into Biogas
Rather than treating POME as pure waste, forward-thinking mills now view it as a Biogas Project feedstock. The process begins with mechanical screening and oil separation to remove fibrous solids and residual oil, followed by a regulating tank that balances flow and temperature fluctuations. The pretreated wastewater then enters an anaerobic digester, where naturally occurring microorganisms break down organic matter in an oxygen-free environment, producing biogas rich in methane. The resulting biogas can be dehydrated, desulfurized, and used to fuel boilers, generate electricity through biogas generators, or be upgraded into compressed natural gas (CNG) for vehicle fuel. The remaining digestate separates into liquid fertilizer, suitable for direct land application, and fibrous solids that can be composted into organic fertilizer, closing the resource loop for palm oil estates.
The USR Process Explained
At the heart of many Indonesian POME-to-energy systems is the USR Process, or Upflow Solids Reactor. This anaerobic digestion technology is specifically suited to organic wastewater with total solids content between 3% and 6%, making it an excellent match for palm oil effluent. Wastewater flows upward through the reactor, passing through a solid bed where active microbial communities degrade organic pollutants while biogas rises to a built-in gas holder above. The tank body is vertical and cylindrical with an air-tight roof, and its volume is calculated based on volumetric loading rate, medium type, temperature, and required removal efficiency — typically 3 to 5 kg COD per cubic meter per day under mesophilic conditions. A water collection and recycling system further improves treatment stability and efficiency.
Center Enamel's Professional Design Solutions for Biogas Projects
Delivering a reliable Biogas Project requires more than just tanks — it requires engineering expertise tailored to each site's wastewater characteristics. Center Enamel, operating from a 150,000 square meter research and production base with production capacity of 250,000 sheets per year, supports Indonesian palm oil mills with complete process design covering pretreatment, anaerobic digestion, and gas utilization systems. Backed by internationally recognized certifications including CE/EN1090, ISO 9001, NSF61, WRAS, and EN28765, and design standards such as AWWA D103, OSHA, EN28765, and EuroCode, the company's engineering team configures each digester system to match specific COD loads, flow rates, and site conditions, ensuring dependable long-term performance.
GFS Tanks and Double Membrane Roof
Two products form the core of Center Enamel's biogas infrastructure. GFS Tanks — Glass-Fused-to-Steel tanks — are manufactured by fusing molten glass onto steel plates at 820°C to 930°C, creating an inert, corrosion-resistant surface with a double coating layer structure (2C2F) protecting both interior and exterior faces. This makes GFS Tanks exceptionally durable for the acidic, high-strength environment of palm oil wastewater treatment, and the bolted, modular assembly method allows rapid on-site construction compared to conventional welded structures. Paired with a Double Membrane Roof, the system offers an air-tight, cost-effective covering solution: the design significantly reduces roof construction costs while cutting the footprint and foundation requirements compared with traditional ground-mounted gas holders — an ideal combination for anaerobic digestion and biogas collection.
Center Enamel's Range of Storage Tanks and Roof Solutions
Beyond the standard GFS Tanks, Center Enamel offers a full portfolio of storage tank and roof options to match different palm oil mill requirements:
Galvanized Steel Tanks — coated through a galvanizing process for a tough, wear-resistant, and durable protective finish.
Fusion Bonded Epoxy (FBE) Tanks — developed in cooperation with AkzoNobel, a global leader in paints and coatings, offering innovative epoxy coating protection.
Stainless Steel Tanks — available in AISI 304/316 grades, suited to demanding storage requirements including high-purity liquids.
Aluminum Geodesic Dome Roof — offering advanced corrosion resistance, expansive clear-span capability, and minimal maintenance.
Glass-Fused-to-Steel Roof — air-tight, cone-shaped, suitable for pressurized structures and odour control.
Single and Double Membrane Roof — the preferred air-tight cover for anaerobic digestion and biogas collection, cost-effective and integrated directly atop the tank.
Stainless Steel Roof — air-tight, corrosion-resistant, viable for pressurized and harsh environments.
Aluminum Alloy Trough Deck Roof and FRP Roof — economical, non-air-tight options suited to potable water, agricultural, and firewater storage.
Supporting Biogas Equipment
A complete Biogas Project also depends on well-matched auxiliary equipment. Center Enamel supplies:
Gas Holders for flexible biogas storage capacity
Lagoon/Black Membrane systems for economical anaerobic covering
Hot Water Boilers for utilizing recovered biogas as fuel
Emergency Torch Systems for safe excess gas combustion
Lifting Pumps for wastewater and sludge transfer
Dehydration and Desulfurization Tanks for biogas purification before use
Screw Sludge Dewatering Machines for efficient digestate solid-liquid separation
Efficient GFS Tank Installation Capability
Fast, high-quality installation is essential for palm oil mills that cannot afford extended construction downtime. Center Enamel's approach includes:
Modular, bolted panel assembly that eliminates the need for on-site welding
Standardized panel manufacturing at the company's production base, ensuring consistent quality before shipment
Experienced installation crews familiar with tropical climate and remote plantation site conditions across Indonesia
Streamlined logistics for shipping and on-site erection of GFS Tanks, reducing overall project timelines
Rigorous quality checks at every installation stage to guarantee long-term structural integrity
Center Enamel as a One-Stop EPC Contractor Solution Provider
As an established EPC Contractor, Center Enamel delivers full-scope services so palm oil mill owners do not need to coordinate multiple vendors:
EPC service covering engineering design, equipment procurement, and construction execution
Process Package solutions tailored to each mill's wastewater characteristics and biogas utilization goals
Equipment Supply spanning tanks, roofs, reactors, and auxiliary systems from a single manufacturer
Global certification compliance ensuring projects meet international design and safety standards
Extensive experience serving more than 100 countries with a workforce of over 500 employees
Case Studies
Biogas Project in Malaysia
Tank dimensions: φ22.93m x 12.325m (H) (1 unit)
Total volume: 5,087 m³ (1 unit)
Completion year: 2025
Thailand Palm Oil Wastewater Treatment Project
Tank Size: Ø29.79 * 13.8m, 9000m3
Tank Quantity: 2 nos. of CSTR GFS tanks
Installation Date：Under construction
Conclusion
Indonesia's palm oil sector has a clear opportunity to transform POME from an environmental liability into a renewable energy asset. Through the USR Process, GFS Tanks, and Double Membrane Roof systems, mills can capture biogas efficiently while meeting strict environmental standards. Partnering with an experienced EPC Contractor like Center Enamel ensures each Biogas Project is designed, engineered, and installed to deliver dependable performance for decades to come.
Frequently Asked Questions
Q1: What total solids range is suitable for the USR Process?
The USR Process is designed for organic wastewater with total solids content between 3% and 6%, making it well suited to palm oil mill effluent (POME) treatment.
Q2: Why are GFS Tanks preferred for POME treatment in Indonesia?
GFS Tanks resist the corrosive, high-strength nature of POME thanks to their fused glass coating, and their modular assembly allows faster installation in remote plantation locations.
Q3: What services does an EPC Contractor provide for a biogas project?
An EPC Contractor manages engineering design, equipment supply, and construction, delivering a complete, ready-to-operate biogas project from a single point of responsibility.