COMPONENT AND PROCESS FLOW OF PALM OIL MILL

CHE RAHMAT CHE MAT
UNIT PENGILANGAN & PEMPROSESAN BAHAGIAN KEJURUTERAAN & PEMPROSESAN

PALM OIL MILL

RAW MATERIAL FRESH FRUIT BUNCH (1 Tonne) MAIN PRODUCTS

CRUDE PALM OIL (20 – 22 %) BY-PRODUCTS

PALM KERNEL (5 -6 %)

EMPTY FRUIT BUNCH (20 – 22 %)

FIBRE (12 – 14 %)

SHELL (5 – 6 %)

POME (60 – 65 %)

BOILER ASH

Process Flow Palm Oil Mill
FFB LORRY FRESH FRUIT BUNCH (FFB) STRIPPER EMPTY BUNCH HOPPER CAGE STERILISER TIPPER FFB HOPPER

Fruitlets
FRUIT ELEVATOR

Fibre
DIGESTER

FIBRE CYCLONE

SCREW PRESS

Press Cake
SLUDGE TANK 1

DEPERICATER

NUT POLISHING DRUM CLARIFIER

BOILER

Press Liqour
SAND TRAP TANK NUT SILO

DESANDER

Standby usage

SAND SLUDGE TANK 2 PUMP PUMP CRUDE OIL TUNK VIBRATING SCREEN MESH

DESTONER WET KERNEL BANKER

STONES

Recycle Oil
SLUDGE SEPARATOR PRODUCTION OIL TANK (CPO) ROLEK NUT CRACKER

ROTARY BRUSH STRAINER

FATS OIL TANK WINNOWING COLUMNS PURE OIL TANK PUMP VACUUM DRYER

CLAY BATH

Wet Shells
DISPOSAL

Wet Kernel
KERNEL TRAY DRYER KERNEL SILO

SAND SLUDGE PIT EFFLUENT TANK PURIFIER HOLDING TANK PUMP

Project Planning

3 yrs before commissioning..
Submit all applications to the relevant authorities. Some of them are:  MPOB - license  DOE – effluent disposal  PWD – access road  Drainage & Irrigation Dept - river water  Health dept – housing/ sanitation  TNB – for power generation

Mill Construction
• Simple guide line  5,000 hectare will need a 30 tph mill. •     Major Activities Crop Projection Mill site selection and verification Liaison with regulatory bodies Mill design

Crop
 Decide whether the mill need to process crop from 1. Own estate or 2. Own crop + outside crop  Try to get a mill utilization factor not less than 90%. This will bring down the unit operating cost. After all the fixed cost will not alter much.

Basic Information
 Location plan of the mill  Expected crop projection for 20 years  Topographic map of the selected mill site  Un-interrupted availability of water for processing & distance of the water source from the mill  Commissioning date and  Distance to the nearest national grid (NEW)

Location
 Reasonably central – transportation cost  3 km away from the nearest settlement - DOE  Close to water source  Access to main road – dispatch  Gentle sloppy terrain 10 m high – loading ramp  Effluent ponds – gravity feed facility

Planning Stage
 Select a large area eg. 60 ha - mill infra structure & a RE power plant.  Prepare the mill layout- leave out effluent ponds  Prepare 0.5 metre interval contour of the site  Superimpose the mill layout on this  Locate the mill entrance  Check the shape of of the remaining land & draw the layout of the effluent ponds OR  Consider tank digestion, gas collection for RE

Average Mill cost
Cost Centres Rough % 40 45 10 20 tph 8.8 9.9 2.2 30 tph 9.6 10.8 2.4 30>60 tph 10.4 11.7 2.6 60 tph 14.4 16.2 3.6

Mech. Works
Civil works Electrical Consultants/ others TOTAL (RM Million)

5
100

1.1
22

1.2
24

1.3
26

1.8
36

Propriety Equipment (branded machines)
       Boilers Diesel generators Steam generators Screw presses Oil purifiers Sludge separators Vacuum dryers        Cranes/ tippers Weighbridges Pumps Nut crackers Water softeners De-aerators Sterilizer automation

Mill sizing
       Planted area Predicted yield Annual crop Monthly crop Peak month 113% Daily crop (peak) Hourly capacity = 8,000 ha = 25 t/ha/yr = 200,000 t = 16,667 t = 18,833 t = 724 t (26day/mth) = 36 t (20 hrs/day)

 The mill size should be 45 tph capable of delivering 36 tph (80%) as the monthly average.

Mill rated capacity vs actual
No. Rated capacity 1 2 3 4 10 tph 30 tph 60 tph in 2 lines 45 tph Actual monthly avg. 10 tph 27 tph 48 tph 36 tph Factor 100% 90% 80% 80%

5

90 tph in 2 lines Law of Diminishing

72 tph Returns ?

80%

Plant Sizing (Basis)

Plant Sizing - Basis
1.Loading Ramps The hoppers must be able to keep at least 8 hours crop. i.e Mill t/put x 8hrs excluding cages. For a 30 tph mill 30 x 8 = 240 tonnes. Must not dump crop on hopper

Plant Sizing - Basis
2. Sterilizers Fix the cage weight preferred : say 5 kg Number of cages per sterilizer: say 6 numbers Sterilization time : say 80 minutes per charge Number of sterilizers : 2 units double doors Weight per charge = 6 x 5 = 30 tonnes Throughput for this set up = 30 x 2 x 60 = 45 t /hr 80 There is sample surplus capacity to give 30 tph Mill is expandable to 45 tph

Plant Sizing - Basis
3. Presses • Install 3 presses, capacity: 15 tph each OR • Install 2 presses, capacity : 20 tph each. This is capable of 26 tph OR • Install 4 presses 10 tph each

Plant Sizing - Basis
4. Nut Station The most comfortable throughput for the nut station on a single line is 30 tph (FFB). It is always better to overdesign the nut station so that there is no bottleneck when the fruit composition changes and there is more fibre than expected. Cater for a 45 tph capacity. This is an usual problem in most problem.

Plant Sizing - Basis
5. Power Requirement Energy requirement = 15 to 18 kwh/ t FFB For 30 tph = 540 kwh (using 18 kwh) Power requirement = 540 kW Domestic electrical load = eg: 30 kW Total 590 kW It is advisable to provide excess capacity of say 20% to cater for the rise in demand. Power plant size = 700 kW

Plant Sizing - Basis
6. Boiler sizing Base on 45 tph in case of mill expansion Steam requirement = 0.65 t/ t FFB = 30 tph For flexibility of operation, Consider 2 x 20 tph boilers at 21 barg. A single boiler is sufficient to operate the mill. During machinery inspection the mill can still process.

Milling Processing

FFB Loading Ramp

FFB Ramp

Marshalling Yard

FFB Grading Unripe Bunch Under-ripe Bunch Ripe Bunch Empty Bunch Rotten Bunch Long Stalk Bunch

FFB Hopper
 A sliding platform made of mild steel where the vehicles unload the fresh fruit bunches.  Ensure Hopper and cages can handle the crop delivered during peak hour.  Avoid provision to dump crop on hopper apron during peak crop period.  Loose fruits contain maximum oil. Do not allow their destruction by tractor wheels

FFB Transfer Carriage

To transport the fruit bunches from the hopper to sterilizer.

Sterilizer

Sterilizer
 To prevent any further rise in FFA due to enzym action by inactivtion of these lipolytic enzymes.  To further weaken the attachment of the fruit to the stalk. Exposure of a bunch to dry heat does not loosen any fruit by moist heat in the form of steam is very effective.  To conditioning the mesocarp for good oil recovery. Mesocarp is softened during this process. Mesocarp will be separated from the nut during digestion and processes. If the nuts are not well polished, the nut silos will be clogged with fibre and nut drying, nut cracking and kernel separation process will be seriously affected.  Nut conditioning for better cracking. To achieve good nut cracking efficiency in the nut cracker or ripple mills, the nuts must be dried to a given temperature for a given time.

Sterilizer Design Consideration
Conventional (Horizontal) Sterilizer

Sterilizer Design Consideration
Vertical Sterilizer

Sterilizer Design Consideration
Continuous Sterilizer Single Deck Continuous Sterilizer

Double Deck Continuous Sterilizer

Sterilizer Design Consideration
Spherical Sterilizer

Tipper

Rotating device that tips the FFB cage at 180 degrees to transfer the sterilised bunches to the stripper

Thresher / Stripper
 Rotary drum in which the lifting bars pick up the bunches and throw a few times to detach the fruits from the bunch and then pass through the perforations of the stripper to a bottom conveyor

Digester
Steam heated vertical tank with a motorized central shaft fitted with 5 pairs of stirring arms, which causes the fruitlets to rupture the oil bearing and conditions the fruits for subsequent pressing operation

Digester

Screw Press
Two screws revolving in opposite to compress the digested mash to squeeze out the oil with maximum oil content and minimum nut breakage.

Vibrating Screen

To remove all fibres materials from crude oil and recycle them to the digester

Crude Oil Tank
To collect the crude oil after screening as a buffer tank, with provision for steam heating

Desander
To remove sand from the oil

Vertical Clarifier Tank
Separates the pure oil and sludge (underflow) from the diluted crude oil, using specific gravity for separation

Purifier
Pure oil is purified further to remove dirt, suspended sediments and moisture

Vacuum Dryer
 Pure oil moisture evaporates at low pressure in this vacuum chamber  To reduce CPO moisture content through vacuum drying process

Sludge Centrifuges / Decanter
To recover oil from sludge by centrifugal separation

Storage Tank
Crude palm oil is stored in this tank before dispatch to buyers

Press Cake Conveyor

De-pericarper
Separates the fibre and nut from the press cake, using pneumatic separation principle

Nut Polishing Drum
 Rotary drum which receives the nuts from depericarper column.  The mutual rubbing action removes the fibre attached on the nut before cracking

Fibre Cyclone
The separates fibre is discharged through this cyclone to boiler fuel conveyor

Nut Silo

Vertical steam heating tank that holds the polished nuts before going to nut cracker

Nut Crackers
To cracks the nut to shell and kernel

Winnower

 Separate light shell from kernel pneumatically  Shells and dust are drawn to the boiler as a boiler fuel.

Claybath

 To separate heavy shell from kernel through wet separation.  Kaolin solution having a specific gravity of 1.185 causes the shell to separate from kernel.

Kernel Silo
A vertical tank that stores the dried kernel before dispatch to the buyers

Boiler

Turbo Alternator / Turbine

Back Pressure Receiver

Workshop

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