A pilot plant installed for the UKM-YSD Zero Waste Technology project at the Sime Darby’s Palm Oil Tennamaram mill, Bestari Jaya, Selangor features various technologies for sustainable development. It transforms a regular mill into a green technology factory. Seven strategic thrust areas were identified to address the sustainability challenges of palm oil processing, namely the discharge of a large amount of highly polluting effluent, emission of greenhouse gases (GHGs), and generation of a large amount of solid waste. The approaches adopted in this research programme generated renewable energy from palm oil mill effluent (POME) and pre-treated empty fruit bunches (EFB) hydrolysate in biohydrogen production. POME from biohydrogen and biomethane two-stage fermenter was then subjected to integrated algae wastewater treatment and CO2 sequestration and integrated membrane filtration treatment processes in recovering treated water for boiler feed application. On the other hand, EFB and POME, along with residual solids and algae biomass produced from these zero waste technologies, were used to produce organic fertiliser. The results of the pilot plant operation showed that POME and solid biomass could be used to generate additional 20% renewable energy compared to the technologies practised in existing mills at 1,020 t/d of POME discharge. Organic fertiliser was produced at a lower cost and in a shorter duration, as well as water being recovered to be used as boiler feed water. The UKM-YSD Zero Waste pilot plant serves as a pioneering technology with the possibility of changing perceptions, especially among foreign importers, that palm oil production can be environmentally friendly
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