Design, Simulation, and Mapping of the Palm Fronds Composting Process in Saudi Arabia via the Combination of SuperPro-Designer and GIS Software

International Journal of Mechanical Engineering

© 2026 by SSRG - IJME Journal

Volume 13 Issue 1

Year of Publication : 2026

Authors : Salah Eldeen F.Hegazi, Mohamed Hassan, Mahmoud Abdelrahim Abdelgiom

10.14445/23488360/IJME-V13I1P102

How to Cite?

Salah Eldeen F.Hegazi, Mohamed Hassan, Mahmoud Abdelrahim Abdelgiom, "Design, Simulation, and Mapping of the Palm Fronds Composting Process in Saudi Arabia via the Combination of SuperPro-Designer and GIS Software," SSRG International Journal of Mechanical Engineering, vol. 13,  no. 1, pp. 14-37, 2026. Crossref, https://doi.org/10.14445/23488360/IJME-V13I1P102

Abstract:

Based on data from the Ministry of Agriculture’s Agricultural Statistical Yearbook from 1999 to 2013, the study uses Geographic Information Systems (GIS) methodologies to predict the expansion of palm tree agriculture and the shift in date production by the Saudi Arabia 2030 vision. In order to give an effective way to convert solid palm frond trash into organic fertilizer, SuperPro Designer is then utilized to model a palm frond composting process. Additionally, this paper uses SuperPro-Designer version 14 software to simulate, design, and do a cost analysis for palm frond composting for the first time in order to construct a batch-mode composting facility. The first stage in the design process was to choose the batch operation mode. The resulting analysis was then used to register the components in the software. The flow diagram was created with a dryer, a shredder, and two aerobic digestion reactors. All operational conditions related to the breakdown reaction of cellulose, hemicelluloses, lignin, and mummification were established, along with the temperature and pressure of the composting process. Moreover, batch mode was used to perform energy and material balances. Additionally, the finished composted product is compared to the literature for validation. Additionally, the plant’s Total Capital Investment (TCI), which comes to about $20,482,696, was calculated using the program. The complete cost estimate that was presented contained direct and indirect expenses, operational costs, revenues, a description of the fixed capital estimate, yearly Cost, materials cost, annual operating cost, and equipment specification.

Keywords:

GIS, ArcGIS 10.4, Geostatistical analysis, Palm fronds, Waste, Organic fertilizer, Environment, Simulation, SuperPro-Designer.

References:

[1] Ali Faiad et al., “Date Palm Tree Waste Recycling: Treatment and Processing for Potential Engineering Applications,” Sustainability, vol. 14, no. 3, pp. 1-21, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[2] Ahmad Hussai et al., “Pyrolysis Of Saudi Arabian Date Palm Waste: A Viable Option For Converting Waste Into Wealth,” Life Science Journal, vol. 11, no. 12, pp. 667-671, 2014.
[CrossRef] [Google Scholar] [Publisher Link]
[3] Lim Sheh Hong, Darah Ibrahim, and Ibrahim Che Oma, “Oil Palm Frond for the Production of Bioethanol,” International Journal of Biochemistry and Biotechnology, vol. 1, no. 1, pp. 7-11, 2012.
[Google Scholar] [Publisher Link]
[4] Kar Weng Kan et al., “Maximizing Biogas Yield from Palm Oil Mill Effluent (POME) through Advanced Simulation and Optimisation Techniques on an Industrial Scale,” Chemical Engineering Science, vol. 285, pp. 1-11, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[5] Maizirwan Mel et al., “Simulation Study for Economic Analysis of Biogas Production from Agricultural Biomass,” Energy Procedia, vol. 65, pp. 204-214, 2015.
[CrossRef] [Google Scholar] [Publisher Link]
[6] Marcos Ellacuriaga, Rubén González, and Xiomar Gómez, “Feasibility of Coupling Hydrogen and Methane Production in WWTP: Simulation of Sludge and Food Wastes Co-Digestion,” Energy Nexus, vol. 14, pp. 1-10, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[7] Monika Zajemska et al., “Numerical and Experimental Analysis of Pyrolysis Process of RDF Containing a High Percentage of Plastic Waste,” Fuel, vol. 320, pp. 1-13, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[8] Wai Lin Cheong et al., “Anaerobic Co-Digestion of Food Waste with Sewage Sludge: Simulation and Optimization for Maximum Biogas Production,” Water, vol. 14, no. 7, pp. 1-21, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[9] Licelly Canizales et al., “SuperPro Designer®, User-Oriented Software Used for Analyzing the Techno-Economic Feasibility of Electrical Energy Generation from Sugarcane Vinasse in Colombia,” Processes, vol. 8, no. 9, pp. 1-16, 2020.
[CrossRef] [Google Scholar] [Publisher Link]
[10] Adel R.A. Usman et al., “Biochar Production from Date Palm Waste: Charring Temperature Induced Changes in Composition and Surface Chemistry,” Journal of Analytical and Applied Pyrolysis, vol. 115, pp. 392-400, 2015.
[CrossRef] [Google Scholar] [Publisher Link]
[11] Saudi Ministry, “PIF Plan to Set up Palm Waste Recycling Firm,” Arggam, 2017.
[Publisher Link]
[12] Ghassan H. Mousa, “The Use of Date Palm Fronds Waste as Biomass in Saudi Arabia, Madina Region Case Study,” Key Engineering Materials, vol. 925, pp. 117-123, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[13] Arshid M. Ali et al., “Process Optimization and Economic Evaluation of Air Gasification of Saudi Arabian Date Palm Fronds for H2-Rich Syngas using Response Surface Methodology,” Fuel, vol. 316, pp. 1-28, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[14] Arshid Mahmood Ali et al., “Polygeneration Syngas and Power from Date Palm Waste Steam Gasification through an Aspen Plus Process Modelling,” Fuel, vol. 332, pp. 1-32, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[15] Ayed E. Alluqmani, and Abdelkader. T. Ahmed, “Date-Palm Waste Usage for Low-Cost Advanced Treatment for Domestic Wastewater in Arid Regions,” Islamic University Journal of Applied Sciences, vol. 5, no. 2, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[16] R. Mompó-Curell et al., “Characterization of HDPE Microparticles in Sludge Aerobic Digestion and their Influence on the Process,” Journal of Environmental Management, vol. 365, pp. 1-11, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[17] Mariana Fonseca et al., “Can a Functional Cheese Spread Incorporating Akkermansia Muciniphila Deliver Beneficial Physicochemical and Biological Properties While Enhancing Probiotic Stability and Viability during Aerobic Storage and in Vitro Digestion?,” Lwt, vol. 200, pp. 1-8, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[18] Agostina Chiavola et al., “Techno-Economic Evaluation of the Application of Ozone-Oxidation in a Full-Scale Aerobic Digestion Plant,” Chemosphere, vol. 91, no. 5, pp. 656-662, 2013.
[CrossRef] [Google Scholar] [Publisher Link]
[19] Vinay Kumar Tyagi, and Shang-Lien Lo, “Enhancement in Mesophilic Aerobic Digestion of Waste Activated Sludge by Chemically Assisted Thermal Pretreatment Method,” Bioresource Technology, vol. 119, pp. 105-113, 2012.
[CrossRef] [Google Scholar] [Publisher Link]
[20] C.G. Martínez-García, M.T. Olguín, and C. Fall, “Aerobic Stabilization of Biological Sludge Characterized by an Extremely Low Decay Rate: Modeling, Identifiability Analysis and Parameter Estimation,” Bioresource Technology, vol. 166, pp. 112-119, 2014.
[CrossRef] [Google Scholar] [Publisher Link]
[21] Ezio Ranieri et al., “Performance of Wastewater Treatment Plants in Emission of Greenhouse Gases,” Bioresource Technology, vol. 404, pp. 1-9, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[22] Katrin Vorkamp, Reimer Herrmann, and Thorkild Hvitved-Jacobsen, “Characterisation of Organic Matter from Anaerobic Digestion of Organic Waste by Aerobic Microbial Activity,” Bioresource Technology, vol. 78, no. 3, pp. 257-265, 2001.
[CrossRef] [Google Scholar] [Publisher Link]
[23] Liming Shao et al., “Comparison of Sludge Digestion under Aerobic and Anaerobic Conditions with a Focus on the Degradation of Proteins at Mesophilic Temperature,” Bioresource Technology, vol. 140, pp. 131-137, 2013.
[CrossRef] [Google Scholar] [Publisher Link]
[24] Ada Wojciula, Dariusz Boruszko, and Paweł Malinowski, “Removal of Polycyclic Aromatic Hydrocarbons from Leachates after Autothermal Thermophilic Aerobic Digestion using Effective Microorganisms,” Desalination and Water Treatment, vol. 305, pp. 43-51, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[25] Zhiyao Wang et al., “Quadrupling the Capacity of Post Aerobic Digestion Treating Anaerobically Digested Sludge using a Moving-bed Biofilm (MBBR) Configuration,” Water Research X, vol. 24, pp. 1-8, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[26] Yating Chen et al., “Short-time Aerobic Digestion Treatment of Waste Activated Sludge to Enhance EPS Production and Sludge Dewatering Performance by Changing Microbial Communities: The Impact of Temperature,” Water Cycle, vol. 5, pp. 146-155, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[27] F. Gary Shimp et al., “Anaerobic Digestion: Retooling an Old Process to Meet a 'Class A' Objective,” Water Environment & Technology, vol. 15, no. 5, pp. 45-49, 2003.
[Google Scholar]
[28] J. Tony Pembroke, and Michael P. Ryan, “Autothermal Thermophilic Aerobic Digestion (ATAD) for Heat, Gas, and Production of a Class A Biosolids with Fertilizer Potential,” Microorganisms, vol. 7, no. 8, pp. 1-14, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[29] Saloua Biyada et al., “Microbial Community Dynamics in the Mesophilic and Thermophilic Phases of Textile Waste Composting Identified through Next-Generation Sequencing,” Scientific Reports, vol. 11, pp. 1-11, 2021.
[CrossRef] [Google Scholar] [Publisher Link]
[30] Maria Papale et al., “Prokaryotic Diversity of the Composting Thermophilic Phase: The Case of Ground Coffee Compost,” Microorganisms, vol. 9, no. 2, pp. 1-19, 2021.
[CrossRef] [Google Scholar] [Publisher Link]
[31] Ilaria Finore et al., “Thermophilic Bacteria and their Thermozymes in Composting Processes: A Review,” Chemical and Biological Technologies in Agriculture, vol. 10, pp. 1-22, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[32] Xia-Yu Sun et al., “A First-Order Kinetic Model for Simulating the Aerobic Degradation of Municipal Solid Waste,” Journal of Environmental Management, vol. 329, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[33] Zhang Mengqi et al., “Comprehensive Review on Agricultural Waste Utilization and High-Temperature Fermentation and Composting,” Biomass Conversion and Biorefinery, vol. 13, pp. 5445-5468, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[34] Tom Richard, “The Effect of Lignin on Biodegradability,” Cornell Waste Management Institute, Cornell University, 1996.
[Google Scholar] [Publisher Link]
[35] M. Tuomela et al., “Biodegradation of Lignin in a Compost Environment: A Review,” Bioresource Technology, vol. 72, no. 2, pp. 169-183, 2000.
[CrossRef] [Google Scholar] [Publisher Link]
[36] Katharina Duran et al., “Microbial Lignin Degradation in an Industrial Composting Environment,” Bioresource Technology Reports, vol. 17, pp. 1-10, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[37] Dijana Grgas et al., “The Bacterial Degradation of Lignin—A Review,” Water, vol. 15, no. 7, pp. 1-17, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[38] M.J. Lopez, and S.S. Mohiuddin, Biochemistry, Essential Amino Acids, StatPearls, pp. 5-9, 2024.
[Google Scholar]
[39] Shu-Yuan Pan, Kung-Hui He, and Yu-Lun Liao, “Fertilization-Iinduced Reactive Nitrogen Gases and Carbon Dioxide Emissions: Insight to the Carbon-Nitrogen Cycles, Sustainable Environment Research, vol. 33, pp. 1-12, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[40] Highways Division, Highway Manual for Sustainable Landscape Maintenance, State of Hawaii, Department of Transportation, pp. 1-371, 2011.
[Publisher Link]
[41] Shuyan Li et al., “Effect of Different Organic Fertilizers Application on Growth and Environmental Risk of Nitrate under a Vegetable Field,” Scientific Reports, vol. 7, pp. 1-9, 2017.
[CrossRef] [Google Scholar] [Publisher Link]
[42] Patrick Heffer, and Michel Prud’homme, “Fertilizer Outlook 2014–2018, (IFA),” 82nd International Fertilizer Industry Association Annual Conference, Sydney (Australia), pp. 1-7, 2014.
[Google Scholar] [Publisher Link]
[43] Erik Bergman, “Evaluation of the Software SuperPro Designer through Simulation of a Biohydrogen Production Process,” Master Thesis, Division of Biotechnology, Lund University Libraries, pp. 1-31, 2016.
[Google Scholar] [Publisher Link]
[44] Vassilis Lyberatos, and Gerasimos Lyberatos, “Application of Machine Learning Algorithms to Predict Composting Process Performance,” Proceedings, vol. 121, no. 1, pp. 1-4, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[45] Li-ting Huang, Jia-yi Hou, and Hong-tao Liu, “Machine-Learning Intervention Progress in the Field of Organic Waste Composting: Simulation, Prediction, Optimization, and Challenges,” Waste Management, vol. 178, pp. 155-167, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[46] Christos Lytras et al., “Development of a Model Composting Process for Food Waste in an Island Community and Use of Machine Learning Models to Predict its Performance,” Waste and Biomass Valorization, vol. 16, pp. 683-700, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[47] Daniel Desalegn et al., “An Optimal Model for Municipal Solid Waste Management using a Hybrid GIS-MCDM Analysis in Hosaena Town, Southwest Ethiopia,” Environment, Development and Sustainability, pp. 1-27, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[48] Amelia Majid et al., “Mapping of solid waste generation and collection by using GIS: A case study in Depok City,” IOP Conference Series: Earth and Environmental Science: The 1st Journal of Environmental Science and Sustainable Development Symposium, Jakarta, Indonesia, vol. 716, pp. 1-13, 2021.
[CrossRef] [Google Scholar] [Publisher Link]
[49] U.S. Tim, “The Application of GIS in Environmental Health Sciences: Opportunities and Limitations,” Environmental Research, vol. 71, pp. 2, pp. 75-88, 1995.
[CrossRef] [Google Scholar] [Publisher Link]
[50] W.N.S. Wan-Mohamad, and A.N. Abdul-Ghani, “The Use of Geographic Information System (GIS) for Geotechnical Data Processing and Presentation,” Procedia Engineering, vol. 20, pp. 397-406, 2011.
[CrossRef] [Google Scholar] [Publisher Link]
[51] H. Murat Yilmaz, “The Effect of Interpolation Methods in Surface Definition: An Experimental Study,” Earth Surface Processes and Landforms, vol. 32, no. 9, pp. 1346-1361, 2007.
[CrossRef] [Google Scholar] [Publisher Link]
[52] G. Petrie, and T.J.M. Kennie, “Terrain Modelling in Surveying and Civil Engineering,” Computer-Aided Design, vol. 19, no. 4, pp. 171-187, 1987.
[CrossRef] [Google Scholar] [Publisher Link]
[53] M. Yanalak, “Effect of Gridding Method on Digital Terrain Model Profile Data Based on Scattered Data,” Journal of Computing in Civil Engineering, vol. 17, no. 1, 2003.
[CrossRef] [Google Scholar] [Publisher Link]
[54] Christopher W. Bater, and Nicholas C. Coops, “Evaluating Error Associated with Lidar-Derived DEM Interpolation,” Computers & Geosciences, vol. 35, no. 2, pp. 289-300, 2009.
[CrossRef] [Google Scholar] [Publisher Link]
[55] Mahmoud Abdelrahim Abdelgiom, and A.E. Hassaballa, “Applying GIS to Evaluate Five Interpolation Techniques and Prediction of Compressive Strength at 28 and 90 Days Based on 7 Days of Age for the Concrete Mixed with Gum Arabic,” International Journal of Energy, Environment, and Economics, vol. 32, no. 3, pp. 277-300, 2025.
[Google Scholar] [Publisher Link]
[56] Shawky Mansour, and Jeganathan Chockalingam, “Diagnostically Counting Palm Date Trees in Al-Ahssa Governorate of Saudi Arabia: An Integrated GIS and Remote Sensing Processing of IKONOS Imagery,” Spatial Information Research, vol. 28, pp. 579-588, 2020.
[CrossRef] [Google Scholar] [Publisher Link]
[57] Salah M. Aleid, Jameel M. Al-Khayri, and Abdulaziz M. Al-Bahrany, Date Palm Status and Perspective in Saudi Arabia, Date Palm Genetic Resources and Utilization, Springer, Dordrecht, pp. 49-95, 2015.
[CrossRef] [Google Scholar] [Publisher Link]
[58] Triana Karlina, and Wahyudi A'an Johan, “GIS Developments for Ecosystem-based Marine Spatial Planning and the Challenges Faced in Indonesia,” ASEAN Journal on Science and Technology for Development, vol. 36, no. 3, pp. 113-118, 2020.
[CrossRef] [Google Scholar] [Publisher Link]
[59] M.A. Oliver, and R. Webster, “A Tutorial Guide to Geostatistics: Computing and Modelling Variograms and Kriging, CATENA, vol. 113, pp. 56-69, 2014.
[CrossRef] [Google Scholar] [Publisher Link]
[60] Jin Li, and Andrew D. Heap, “A Review of Comparative Studies of Spatial Interpolation Methods in Environmental Sciences: Performance and Impact Factors,” Ecological Informatics, vol. 6, no. 3-4, pp. 228-241, 2011.
[CrossRef] [Google Scholar] [Publisher Link]
[61] Neil D. Bennett et al., “Characterising Performance of Environmental Models, Environmental Modelling & Software,” Environmental Modelling & Software, vol. 40, pp. 1-20, 2013.
[CrossRef] [Google Scholar] [Publisher Link]
[62] SuperPro ® Designer, User Guide, 2024.
[Publisher Link]
[63] Ruizhi Zhang et al., “Predicting the Spatial Distribution of Geological Hazards in Southern Sichuan, China, Using Machine Learning and ArcGIS,” Land, vol. 14, no. 3, pp. 1-23, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[64] P.O. Oviasogie, N.O. Aisueni, and G.E. Brown, “Oil Palm Composted Biomass: A Review of the Preparation, Utilization, Handling and Storage,” African Journal of Agricultural Research, vol. 5, no. 3, pp. 1553-1571, 2010.
[Google Scholar] [Publisher Link]
[65] K. Fadzilah, H.S. Saini, and M. Atong, “Physicochemical Characteristics of Oil Palm Frond (OPF) Composting with Fungal Inoculants,” Pertanika Journal Of Tropical Agricultural Science, vol. 40, no. 1, pp. 143-159, 2017.
[Google Scholar] [Publisher Link]
[66] Y. Yamada, and Y. Kawase, “Aerobic Composting of Waste Activated Sludge: Kinetic Analysis for Microbiological Reaction and Oxygen Consumption,” Waste Management, vol. 26, no. 1, pp. 49-61, 2006.
[CrossRef] [Google Scholar] [Publisher Link]