Identified Physical in Management Pamol Kluang Oil Mill Water abstraction for processing.

ssing. Water abstraction for domestic use. Water treatment for both processing (Boiler) and domestic use. Palm Oil Mill Effluent (POME) discharge. Washing of Marshalling Yard. Pollution prevention of rivers and streams through sewage, oil and sedimentation traps.

Pamol Timur, Barat, Mamor, Kluang (Kahang), Unijaya, Swee Lam Estates Natural streams and buffer zone restoration and maintenance. Water abstraction for drinking water for residents and its treatment. Empty Fruit Bunches for moisture conservation. Placement of pruned fronds for moisture conservation. Maintenance of ground vegetation. Terrace slopes to be maintained with ground vegetation. Road side water diversions drain to be constructed and maintained especially at hilly area. Pollution prevention of rivers and streams through sewage, oil and sedimentation traps, placement of fronds and solid POME near the bank of waterways and collection of bunches and loose fruits from the waterways, avoidance of throwing plastics and other domestic waste into tributaries. Terracing for all re-planting fields and maintenance of stop bund. Water supply for nursery (Pamol Barat Estate)

Water Management Plans for Pamol Kluang Oil Mill Abstraction of Water for Fresh Fruit Bunch (FFB) Milling and Domestic Use Theoretically, the amount of water needed for processing is 1mt of FFB needs 1.2-1.5 mt of water. Water is abstracted from Sg. Semberong. Two pumps are used and alternated every two days. The pumping rate of the water is approximately 100mt/hour. In case the river level has gone down, water can also be pumped from Field No.7 in Pamol Timur. The source of Field No.7 water is from the Mengkibol river. Raw water from the river is pumped directly into a 300 m3 vertical clarifier at the water treatment plant for treatment. It will then overflow into the holding tank and followed by a sand filter system. Then, the water is pumped up to a 114m3 overhead tank. From here, the water is diverted to both the boiler house and also domestic supply. A pump house that is electrically run is placed near the river bank of Sembrong river. License from SPAN is available with the oil mill management to abstract water from the Sembrong river. The water extracted from the Sembrong river is treated and used for milling and domestic purposes for the employees of oil mill and Pamol Timur Estate. The raw water quality of stream tributaries flows into

Sembrong river is included into the water quality monitoring programme and being monitored every 6 months. Water Storage and Use for FFB Processing and Domestic Purpose Oil mill has one water storage tank (located at the mills water treatment plant) to store water pumped from Sembrong river. The storage capacity is 300 m3, which only able to cater water supply for a short period if breakdown of water pump occurs. However, the oil mill has 2 pumps for water pumping in case of one of the pump failure. Water Treatment Raw Water Treatment Raw Water Treatment to remove the following items. a. b. c. d. Suspended solids Colour/organics Iron/Manganese Total Dissolved Solid (TDS) [it will not reduce but increased if Alum and Soda is used]

There are 5 basic steps involved in water clarification: a. pH adjustment (if pH>7 or <7) Human body ideally needs to consume water with neutral pH of 7. Raw water came with different level of pH. If pH<7, use Soda Ash to increase the alkalinity of water. If pH>7, use Hydrochloric Acid to bring it back to pH 7. b. Coagulation Addition of Alum in order to coagulate the solids in raw water. It requires mixing energy or mechanical turbulence to allow chemical bonding between alum and the solids. c. Flocculant (Clarification) It is a big flocs building process; a process where suspended solids merge to become bigger so that it can settle fast. Polymer is added to do this process. d. Sedimentation The flocculants that enter the clarifier will then settle down with sufficient retention time. The clarified water will then overflow to the holding tank. e. Filtration Using sand filter to filter out the carry over flocs and other foreign matters before distribute to the mill or domestic usage after chlorination process.

It is essential to do the coagulation and flocculation first before pH adjustment by using soda ash because organic matters are acidic. pH adjustment must be done correctly before chlorination because chlorine is not stable in acidic condition. Raw Water Treatment (Pamol Kluang Oil Mill) Due to the variation of water quality from Sembrong River, daily JAR Test is required to determine the chemical rates to be mixed for treatment. At the raw water treatment plant, there are three chemical injection points before the water enters the clarifier. Table below shows the calculation done for each chemical dosage. Alum/PAC (Coagulant) 1% Mixture; 99mL (distilled water) + 1mL (Alum)=20ppm in 0.5L (500mL) Raw water AL Soda Ash (pH Booster) 1% Mixture; 99mL (distilled water) + 1mL (Soda Ash) = 20ppm in 0.5L (500mL) Raw Water BL Polymer (Flocculant) 0.1% Mixture; 99mL (distilled water) + 0.1mL (Polymer) = 2ppm in 0.5L (500mL) Raw Water CL

Lab Preparation

Chemical Amount Mixed in 500mL Raw Water during Jar Test, L Flow Rate of Raw Water Pump, m3/hr Running Hours/Day, hrs/day Total Weight of Chemical Needed per, kg/L Chemical Preparation Tank Volume, L Dosage Pump Rate, L/min

100m3/hr=100,000L/hr T hours

100L

1000L

1000L

Domestic Water Treatment (Pamol Kluang Palm Oil Mill) The treated water is supplied to the Mill Camp and also Pamol operating units. The water from the overhead tank goes to a secondary sand filtering system. Backwash is done once a day for sand filters to remove all the unwanted sediments. After the filtering process, chlorine is injected into the treated water pipe line before it is used for domestic supply. The overhead storage tank is cleaned once every six months. Monitoring Water is pumped from Sembrong River daily for 24 hours. Water Consumption Monitoring

The Oil Mill has installed 10 units of flow meter to record the daily water usage from Pamol Timur, Pamol Barat, and mills domestic and processing purposes. Locations of flow meters are: i. ii. iii. iv. v. vi. vii. viii. ix. From storage tank to mill camp. From storage tank to Pamol Timur Estate. From pump house to Pamol Barat Estate. From storage tank to club house. From storage tank to research station. From storage tank to office compound. From storage tank to boiler. From storage tank to cleaning mill compound. From storage tank to mill processing.

Water consumption is recorded on daily basis and summarized on a monthly basis. Water pump and flow meter needs to be serviced and calibrated, respectively. Separate measurements are recorded for the water use of processing FFB and domestic purpose. The quality of the water for processing and for human consumption needs to be analysed for heavy metals and organic matter at 6 monthly intervals as per Malaysian drinking water standard. Waste Water Treatment and Discharge Management in Pamol Kluang Mill There are two sources of waste water from the oil mill. The first source is surface runoff of water from the oil mill premises mainly from ramps, boiler ash and fibre retention locations. The second source is a major one which is the effluent of FFB processed and has to be stored and treated naturally by simple retention process. Surface run-off of sediments from the oil mill Ramp and Marshalling Yard The main source of waste water arise during raining and washing especially the ramp surface ground, where the smashed fruits, leaked hydrocarbon from the tractors flows in to monsoon drain. The rainwater with smashed fruit sediments, scum, oil and grease if not contained will end up in natural waterways in pollution form. The outlets of the monsoon drains need to be controlled b sedimentation and oil traps. Similiarly, the marshalling yard also contains ample of oil from the sterilizer location and cage rails. The floors are washed and waste water with oil is flowed towards monsoon drains. Oil mill has established 6 sets of oil trap at the outlet of monsoon drains to contain sediments and oil from the workshop, ramp, CPO dispatch area, marshalling yard and sterilizer. All the sedimentation oil traps need to be cleaned regularly at weekly interval and sediments left at the base need to ne de-silted once in a

month or depends on necessity. The sediments, scum and oil collected from the trap will have to be treated as schedule waste and disposed through licensed agent. Waste Water Seepage from Boiler Ash, Shell and Fibre It is best that the oil mill maximize the use of fibre and shell as renewable energy and any excess of fibre and shell should be sent to the field as mulching in the following day. Mulching can be considered as part of the soil moisture conservation programme especially for the Pamol TImur and Pamol Barat Estates. Currently, the oil mill is using 100% of the fibre as fuel for boiler and starting-up of genset in engine room. As for the shell, 80% of it is used as fuel in the mill and the balance will be sent to the estates for mulching or sell to the external factory for enviro-carbon production. The balance is sent to estate as mulching. Heaping of unused fibre and shell should be avoided at all time in the oil mill premises or else the sediments, solids and leachates will end up in the monsoon drains and finally to the waterways. Similarly, boiler ash has to be evacuated on the same day from the oil mill with Empty Fruit Bunch (EFB), In case of sedimentation of fibre and bunch ash into monsoon drain, there should be sedimentation cum oil trap at the outlet of oil mill to contain them prior to release into water ways. If oil mill wish to store the fibre and shell in the event of low cropping, appropriate storage shed is essential with proper pollution prevention plan especially how to contain the leachate and oil from the fibre. Water Quality Index (WQI) of the River Passing Near Oil Mill The water flowing from oil mill into Sembrong River are analysed for WQI at quarterly intervals. The map of the rivers affected by oil mill operation is shown in Appendix 1. The inlet, midstream and outlet of the river is sampled and classify the analysis into several clauses as per interim national water quality standard (INWQS) 2005. Reports are available in the oil mill. The oil mill needs to monitor, study the report and take action on improvement of water quality of the rivers affected the oil mill operation. Palm Oil Mill Effluent (POME) POME is considered as one of the most highly polluntant that could create hazardous effect to the waterways and its organisms. Waste water treatment is essential prior to release it to the field or water ways. Pamol Kluang Oil Mill has license for land discharge of POME base on the Environmental Quality A ct 1974 (Act 127) with BOD specification 5000mg/l. Land application is done from Anaerobic Pond 3 and 4 to land application furrows at the estate. Two progressive cavity pumps (Mono pumps) are sued to pump the effluent fluids into the trenches. The number of effluent ponds in the Pamol Kluang Oil Mill is 14 and the function and retention time for each pind is given as table below: Pond Number 1 Pond Type Cooling Pond 1 Volume (m3) 10,353 HRT (days) est. 15 Remarks

2 3 4 5 6

Cooling Pond 2 Cooling Pond 3 Anaerobic 1 Anaerobic 2 Anaerobic 3

4,631 4,631 12,379 12,379 12,379

7 7 15 15 15

Anaerobic 4

6,369

15

Mono Pump 1 for land application (BOD < 5000ppm) Mono Pump 2 for land application (BOD < 5000ppm)

8 9 10

Aerobic 1 Aerobic 2 Facultative Pond

7,417 13,363.3 15,458

17 31 36

11 12 13 14

Buffer Pond 1 Buffer Pond 2 Buffer Pond 3 Buffer Pond 4

Cutter Pump used to recycle back fluid if BOD >100ppm For desilted scum from ponds For desilted scum from ponds For desilted scum from ponds For desilted scum from ponds

Effluent irrigation programme is in place. Approval has been obtained from the Department of Environment. Details of the irrigation approval plans are with the oil mill management. Water Management Plans for Pamol Kluang Region Estates All the estates are located in inland mineral soils. There are no special soils in the region that are affected by sea tides, acid sulphate, salinity, peat, coastal and sandy nature. Therefore, special development of tidal gate or drains to maintain water in the problematic soil is not necessary in inland mineral soils. Soil series such as Sogomana, Manik, and Local Alluvium are somewhat poorly drained and prone to seasonal flooding. Thus drainage and water control are essential in the flood-prone areas to flooed-prone areas to quickly channel out floodwater. Most of the soil management programmes are given in the soil information report. The water management plans in the estate is more towards soil water or moisture conservation, pollution prevention and to some extent domestic usage similar to the oil mill management plan. Soil Moisture Conservation Programmes Pruned Fronds

Each harvesting round some amount of fronds (about 6 10 mt dry matter per hectare) are pruned and brought down to ground. The pruned fronds are placed in between two palms in the interrow. The coverage of inter-row with pruned fronds is about 20-22% of the total land planted with oil palm. The placement of pruned fronds should not obstruct harvesting, evacuation of bunches (harvesting path) and loose fruit collections which are considered as primary operations in the oil palm plantation. The pruned frond placement is applicable for all the estates in the Pamol Kluang region. Empty Fruit Bunch (EFB) mulching EFB mulching is applicable for the estates near to palm oil mill such as Pamol Timur Estate, Pamol Barat Estate and Mamor Estate. The empty fruit bunch application is mainly focused on the supply palm and areas that are under replanting. The respective estate will have to collect the EFB from the oil mill and transport it to the estate replanting field for mulching around palm circles. It is important to bear in mind, Pamol Kluang Oil mill does double pressing of EFB hence the ratio of FFB to EFB is 1 ton FFb = 0.18 0.22 tons of EFB. Hence, the EFB produced cannot be served to all the estates as shown in the ratio. If the Pamol Kluang Oil mill processes estimated 219,836 tons of FFb per year, the estimated tonnage of EFB is around 39,570 ton which covers about 989 hecates per year at the rate of 40 mt per hectare per year. Theoretically, the EFB produced per year is just sufficient to cover one portion of the estate that surround the oil mill. EFB is applied to along palm rows which can cover about 23% of the land of Pamol Timur and Pamol Barat Estates if applied at 40mt per hectare per application. EFB should not be applied in heap which can result in Rhinoceros beetles damage. Care should be given not to over heaped the EFB so that the breeding ground for Rhinoceros beetles can be minimized. Required number of layers of spreading EFB is approximately not more than 2 layers. Fibre There would be an excess of fibre derived from the oil mill after burning in the boiler for renewable fuel. The oil mill will have to transfer the excess of fibre to the estate field as mulch. The ratio of 1 ton FFB to fibre is 0.07 tons. In a year, Pamol Kluang Oil mill processed about 219,836 tons of FFB can produce about 15,389 tons of fibre. Excess fibre after used as renewable energy for boiler should be applied to the field instead of stacking up in the ill compound. The rate application in the field is about 40mt per hectare per year which is equivalent to 385 hectares and should be covered within the Pamol Kluang estates. Shell There would be an excess of shell derived from the oil mill after burning in the boiler for renewable fuel. The oil mill will have to transfer the excess shell to the estate field as mulch. The ratio of 1 ton FFB to shell is 0.03 tons. In a year, Pamol Kluang Oil Mill Processed about 219,836 tons of FFB to shell is 0.03 tons. In a year, Pamol Kluang Oil Mill processed about 6595 tons of shell. The rate application in the field

is about 40mt per hectare per year which is equivalent to 198 hectares and should be covered withn the adjacent estates. Moisture Conservation of the Hill and Rolling Terrains Plantings The moisture conservation terraces in the rolling and hilly terrains for all the estates in the Pamol Kluang region. Inland mineral soil with hill terrain of more than 5o to 10o needs moisture conservation terraces. Prior to constructing terraces, the roads have to be made first and when terraces made, it should be connected to terraces as a conservation programme. The width of the conservation terraces must be 2.5m. The conservation terraces to be built with a back drop of 0.6 to 0.7m to hold water. The distance between 2 conservation terraces must be 30-40m apart, depending on the slopes of the hills. Stop bunds to be built at 20m interval in the conservation terrace. Details are prvided in Group Standard Operating Procedure. Oil Palm Planting Terraces Terraces were constructed whever necessary during replanting time. The moisture conservation terraces in the hill covers for all the replanting fields in the Pamol Kluang Region. Terraces should be constructed on lsopes of more than 10o. Terracing should be constructed only after road construction in order to allow the water flow from roads to the terraces and to ensure that all terraces are connected to the roads i.e. there should be no hanging terraces. The terraces should be 3.6 4.2 m wide with a backward slope of 60cm to allow consolidation of soil spoil and to serve as catchment for water run-off. After constructing the terraces run the bulldozer at least twice to and fro over the terrace for consolidation. Stop bunds to be constructed at 20 m intervals within the terrace. The size of the bund to be 1 m or 3 wide and these should be level from the lip of the terrace to the backdrop. Flat Alluvial Land Flat alluvial land is not much covered in many of the estates. It is not more than 5% of the total land. The alluvial plain is generally a catchment area of the land whereby the water from the hills to undulating terrain is flowed to and from the alluvial land to the streams and rivers. Here the water is taken out, or will be end up in swampy condition and drains are cut towards lowest point i.e. towards river. Buffer Zone of the Streams and Rivers All the estates in the Pamol Kluang region are required to maintain buffer zones for the streams and rivers passing through the estate. All the rivers in the estate are considered as HCV 4 or HCV 5. The benefit of maintaining buffer zone is not only meant for the estates only but also to the main rivers, the neighbouring smallholders and plantations who depend on the main river. One to two river from each estate are selected for Water Quality Index (WQI) study for the purpose of ensuring the natural water quality is maintained. Pruned fronds should be stacked at least 10m away from streams or waterways. Workers are to be trained not to leave the fronds in waterways. Leaving fronds in the waterways will obstruct the free flow of water.

Empty fertilizer bags are placed in the field for loose fruit collection. The empty fertilizer is likely to wash down to river if it is not taken care well or use for loose fruit collection. Once the empty fertilizer is in the river considered as pollutant. Water for Domestic Use Water for domestic use in the operating units for this region is from different sources. Pamol Barat, Pamol Timur Estates and mill gets water from Sembrong river and treated in Pamol Kluang Oil Mill. Detailed water treatment process for the mill is explained in Section 2.1.1.2b. As for Mamor, Swee Lam and Unijaya Estates, domestic water source is extracted from the river water. Domestic water source from Kahang Estate was extracted from tube well. Chemical treatment is required for all the domestic water treatment. Domestic water quality analysis for chemical and biological contamination shall be conducted every 6 months interval to ensure the quality of water is up to the mark and in accordance with National Drinking Water Quality Standard (NDWQS). The extracted water is treated with Soda, Alum, and Clacium Hypochlorite. All the estates need to clean the main water storage tank and overhead storage tank at least once in every six months to clean-up all the sediment matters. Sewage and Septic Tank Houses are provided for the workers, staff and executives in the estate and oil mill. The houses are provided with kitchen and toilets. The toilets are equipped with septic tanks. Contractors are to be contacted in case of such incidences to clean up the septic tank. Nursery Seedlings should receive water equivalent to 12.5mm of rainfall every 2 days (135,000 liters of water per hectare). Only one (1) estate has main nursery. The main nursery is in Pamol Barat Estate. The nursery is meant for long term. Ensure water source, where the water is pumped for nursery has continuous running water to reduce the usage of pesticide. The irrigated water should not be returned to the water source where the pump is located. The excess nursery water should be diverted to different parts of the water course. For irrigation use perforated lay-flat polythene tube Sumisansui piping system or over head sprinkler system. Length of spray lines will depend on the length of the bed. If there is rain of more than 8mm in a day, the artificial irrigation should be avoided. Workshop, Lubricant Store Oil traps to be built at the outlet of lubricant and workshops so that the oil spilled on floor or drain can be washed and trapped in the oil trap before it is released to the streams and rivers. Details are provided in the individual estate environmental impact assessment and management plans. Conclusion The Pamol Kluang region oil mill and estates are to be guided by this water management plan. Should there be any improvement made due to new technology, the water management plan will have to be changed and updated accordingly.