OIL PALM MILL SYSTEMS & PROCESS

OIL PALM MILL, SYSTEMS AND PROCESS.

By Noe l Wambe ck ( Re vi sed June, 1999 )

&INTRODUCTION
The aim of the writer of this paper is to provide an overall brief description of the Oil Palm Mill flow process and its systems employed based on concept and collective experience of the firm. Any errors in intention are regrettable

The synopsis of the Malaysian Oil Palm Industry success is basically due to the following factors: Commercially sound investment with state encouragement. Practical Project Study Preparation. Good management of the plantation who will provide for and ensure good genetical planting material, soil conditioning, harvesting, collection standards, handling and transportation of FFB to the mill and let nature do the rest. Proper selection of the process system, machinery equipment and plant ( eg. Process matching with type of FFB ) for high extraction yield, quality palm oil and palm kernel. Efficient transportation of the finished production to the bulking station or refinery. Good shipping facilities for loading and discharge of the finished products for the export market. And last but not the least, a dedicated and loyal workforce whose ambition is filled with grit.

Malaysian engineers can to-day provide Oil Palm Mill and process systems designs to achieve lower production cost, train and organize a stable work force, which will maintain the oil palm mill effectively and produce the best quality product at maximum yield extraction for the minimum cost.

OIL PALM MILL SYSTEMS & PROCESS

&THE REQUIREMENT OF A MODERN OIL PALM MILL.

The requirements of a modern oil palm mill shall be with consideration for and incorporation of the latest technology available in the Industry and to include the following :
a) b) c) d) e) To be suitable in every respect for processing fruit from Tenera palms; To recovery with the minimum loss the palm oil and the kernels; To produce oil and kernels of the highest quality; To facilitate the disposal of the shell, fibre; and empty bunches; To incinerate the empty bunches for the recovery of the potash for fertilizer or to treat the empty bunch to recover 0.25% additional oil and used as fuel to produce steam for more valuable electrical power generation. The plant and process shall be Environmentally friendly and to dispose of waste water (sludge) in such as a way as not pollute local rivers and waters; To be reliable and suitable for local conditions of labour supervision and maintenance. Consideration and the incorporation of safety aspects that comply with Occupational Safety and Health act, such as to provide for good ventilation, working space, dust free and noise levels within permissible limits. The incorporation of operating procedures, equipment, plant and process systems to meet the ecological, hygienic and cleanliness of the plant on par with good food manufacturing industrial plant standards. Designed for cost effectiveness for operation and maintenance.

f)

g) h)

i)

j)

&THE PALM.
Practically all the oil palm planted in the Far East are directly related to one, two or four oil palms which were brought from Africa and planted in the Buiterzorg botanical gardens in Java in 1848. The material bred from these palms is referred to as Dura Deli. It is very stable and uniform in Oil and kernel content. An average content of the fresh fruit bunch ( FFB ) is 25% oil, 5.5% kernel, 6% shell, 9% fibre, 25% empty bunch ( EB ) and the balance is moisture. In recent years another parent has been introduced to produce the material referred to as Tenera. The same Dura Dali palm is used to produce the Tenera palm seed but it is pollinated with pollen from a selected Pisifera palm ( the selected Pisifera when self pollinated produce fruit with a small kernel and little shell ). The resultant Tenera material produces fruit with more oil than Dura material, the same kernels as Dura but less shell than Dura.

OIL PALM MILL SYSTEMS & PROCESS

For this reason, it is now always planted in preference to the straight Dura Deli and it is for Tenera material that all modern oil palm mill systems should be designed. The quality of the palm oil and kernels is at its highest just before harvesting, collection and milling. The extent to which the oil is degraded depends on the system used and the care with which is executed.

&TENERA BUNCH COMPOSITION.

The bunch composition will very from bunch to bunch and from tree to tree particularly in respect of shell thickness but the average bunch content for Tenara material (D x P) with an assumed average composition of Fresh Fruit Bunch ( FFB ) or now called Palm Fruit Bunch ( PFB ) from matured palms having a maximum 2.5 ffa for the extraction of Crude Palm Oil and Palm Kernel. TENERA MATERIAL COMPOSITION ( PORLA STD ) Empty bunch 25% = = = Nos 7% water 16% Oil 2% = ash 0.5%

Evaporation Fruitlets Total PFB

10% 65% = = nuts 15% pericarp 50% = = = = kernel 6% NOS 7.5% water 19.5% Oil 23%

100% ==== Total Oil Plus FFA =

25% to Palm Fruit Bunch

&HARVESTING.
Harvesting is normally a 6 to 8 day cycle. It is important that the fruit must not be harvested before it is ripe, that is until the process of photosynthesis, which converts the carbohydrates into fat, is well in advance. The oil content of unripe mesocarp may be in the order of 35% whereas the oil content of ripe mesocarp is usually between 50% and 55%. The harvesting of under ripe fruit can cause losses in the order of 8% of the possible yield.

OIL PALM MILL SYSTEMS & PROCESS

&FREE FATTY ACID ( FFA)

The FFA content of the oil in the bunch before harvesting may be in the order of 0.1% whilst the FFA of the oil in the same bunch when it is received at the mill will never be less than 1%, normally in the order of 3%, and is frequently above 3% under bad conditions. A low FFA content is the first characteristic to which edible oil refiners pay attention. A premium of 1% of the sale price is paid for every one percent, should the FFA content be below 5% and the Refining loss will be 1.25% to 1.80% per 1% of FFA. The rise in the FFA content from harvest to mill will make possible the harvesting of riper fruit with higher oil content and recovery of higher quality oil with a lower FFA. The riper the fruit the more vulnerable it is to damage during transport and handling. Of all different stages of processing, the harvesting of the palm tree and the transport of fruit to the edible oil refiner has the most effect on quality.

&FRUIT COLLECTION AND TRANSPORT.

There are two basic systems used for fruit transport. One is the collection of fruit directly into the sterilizer cages and the other is the collection of the fruit in trucks or trailers and then transferred into sterilizer cages at the oil palm mill. The transfer system is less costly but results in some loss of oil and a higher FFA content due to the extra handling and damage to the fruit. The other system requires that the sterilizer cages be taken to the field for direct loading from the collection points. At such points the harvesters place the fruit on nets which are lifted by crane to load gently into the sterilizer cages. At the time when the fruit is lifted in the nets it is convenient to weigh, using a weighing cell. This is particularly important for the collection of small holder crops.

OIL PALM MILL SYSTEMS & PROCESS

OIL PALM PROCESSING.

The flow diagram and matrix relating to the processing of fruit from T enera palms is shown in the appendix enclosed.

1.0

FFB Reception.

The FFB bunches loaded on trucks, cages or trailer are weighed on arrival at the mill and on departure when empty by weighbridge of 50 ton capacity and automatically recorded, that is computerised. After weighing-in process of the truck, cage or trailer, the PFB are dumped into the inclined hopper at the ramp that will hold 900 mt PFB ( 2 lines of 15 bays x 30 mt PFB ). Modern mills in Malaysia are equipped with the following in the reception area of the mill: A. Load cell ( pitless ) 50 tons weigh bridge of 3.3m W x 15m L and computerised. B. Larger loading ramp with double door hoppers of 30mt capacity per bay. C. FFB Cage and bogie with capacities of 5, 7 and 10 mt of wheel spanned of 800mm gauge. D. FFB loading into cages by conveyor system E. Straight line railway system with Cage transfer carriage located at both ends of the railtrack system to facilitate easier operation of the 2-door sterilizer and shunting of the cages can be handled easily with the capstan and Bollard.

On opening the hopper door ( 2 doors to a bay ) the bunches drop into the 7mt cages with bogies placed beneath it. The loaded PFB cages are then conveyed by the transfer carriage on the rail track and pushed into the sterilizer, by a winch and ballard system for sterilization.

2.0

Sterilization.

The sterilizer process is done in 5, 7 and today 10 tons capacity FFB cages which are pushed into long cylindrical steel vassel with special doors and subjected to steam at approximately 3 BAR. One of the effects of sterilisation is to inactivate the fruit enzyme. inactivated the rise of the FFA is virtually stopped. Once this enzyme has been

The objective after harvesting is to sterilize the fruit as quickly as possible with the minimum of handling and damage. In addition to arresting the development of the FFA content, the sterilizing of the fruit also facilitates: a. The purification of the palm oil by coagulating nitrogenous and mucilaginous matter and thus preventing the formation of emulsions during verification of the crude oil.

OIL PALM MILL SYSTEMS & PROCESS

b.

The extraction of the crude palm oil by freeing the fruits from the bunch stalks and by breaking the oil cells in the mesocarp.

Majority of mills today has programmable a utomatic control systems to cater for proper sterilization of 90-minute cycle. Sterilisation is a simple process but it is essential, for the proper operation of the mill so that it is done correctly. This operation is the largest user of steam in the mill.

A STERILISER STATION WITH SINGLE DOOR STERILISERS

3.0

Stripping.

After the sterilisation the sterilised fruit in 3.5 mt PFB Cages are then winched out of the steriliser vassal by the arrangement of Bollard & winch and then placed in position for the remote control overhead hoist, for the activity of emptying the FFB into the threshing machine which will separate the empty bunches from fruit. Or for larger capacity mill with 5 mt FFB cages and above, into the cage Tippler machine a ring structure for emptying the contents of FFB onto a scraper type conveyor and transported to the thresher machine for stripping of the fruitlets from bunch. The fruit is then conveyed by screw conveyors and bucket elevators to the Pressing or Extraction station. New mills have included in their design bunch crusher and secondary thresher system for recovery of fruitlets of large or poorly sterilised bunches which are difficult to strip.

OIL PALM MILL SYSTEMS & PROCESS

4.0

Empty Bunches.

Empty bunches from 25% of the total weight of the ffb. They are then returned to the field as fertilizer after incineration for the recovery of resultant potash, in conventional mills. They have no food value and have a high silica content. When properly incinerated they yield 0.3 to 0.5% of potash. Utilisation of empty bunche for field application as fertiliser supplement is found to be cost effective by some plantation groups and to the others justification of logistics, other constrains or practical experience? seems to be the objection for use of EFB in the field. In recent years a system has been introduced in Malaysia for the Treatment of Empty Bunches which recovers a further 0.25% of the oil on ffb from the empty bunches and at the same time reduces the moisture content to approximately 35% so that they can be used as additional solid waste fuel for steam and power generation, required for other down stream process.

5.0

Oil Extraction.

The efficient extraction of the crude oil from Tenera fruit has presented problems but these have been overcome by the development of the continuous screw press, which is now used in all modern factories. The fruit from the stripper passes to digesters, which complete the breaking of the oil cells with slow moving arms. Digesters have a capacity of above 3 cubic metres.

TYPICAL SIDE VIEW OF THE EXTRACTION STATION

OIL PALM MILL SYSTEMS & PROCESS

The fruit mash then passes to the screw presses (capacities of 1016Mt FFB per hour) which press the crude oil out through holes in the side of the press cage. The press cake, which is discharged from the end of the press, contains the fibre and the nuts. The three products separated in this section are : a) b) The crude oil which consists of water, dirt and palm oil. This is passed to the purification section; Nuts: 15% of the ffb. Is separated by the depericarper and kernel plant for the recovery of the kernels; Fibre: Approximately 15% of the ffb weight with moisture content of 37%. The residual oil content should be between 6% and 8% of oil to dry fibre. The fibre should also retain as far as possible the phophatides and other non-glycerides impurities. The fibre separated in the deparicarper winnowing system is conveyed to the boiler as fuel. The proper design of the extraction section is important. Unsatisfactory practices such as excessive drainage of the crude oil before the extraction press leads not only to purification problems and losses but also to the higher absorption of iron by the palm oil. The importance of reducing the absorption of heavy metal, copper and iron is indicated by the totox value. For the production of superior quality palm oil, stainless steel moving the wearing parts should be used for extraction units (such as the digester and screwpress).

c)

6.0

Kernel Recovery

The conditioning of the nuts starts in the sterilizer and the separation starts in the screw presses. After the screw press the nuts and the fibre traverse a heated breaker conveyor which further separates them and removes moisture from the fibre. The fibre and nuts then pass into a pneumatic separating column, called the winnowing column fitted with IC damper in operation, depending on the number of presses in operation. The fibre is blown into a cyclone close to the boiler and the nuts pass down a polishing drum, designed to handle a verity of nuts which removes any attached dirt or fibres and tramp iron.

OIL PALM MILL SYSTEMS & PROCESS

A. Press cake to winnowing B. Ejection of Nuts C. Fibre to cyclone D. Removal of dirt & tramp iron

A DEPARICARPER, WINNOWING COLUMN AND POLISHING DRUM STATION FOR FIBRE & NUTS SEPARATION

The nuts are conditioned in nut silos before being cracked in centrifugal nutcrackers or / and in present day Rippler mills. After cracking, the cracked mixture is separated in the double winnowing separating column for dry separating system or separated in hydrocyclones or clay baths. These processes are wet. A modern Hydroclay bath separator is more efficient than a hydrocyclone separator when processing more than 15% Dura material in the cracked mixture. A supply of suitable clay at the rate of approximately 450 kg to 100 tons of ffb is necessary for the clay separator system. Both systems depend upon the density of the shell being greater then the density of the kernels. The higher yield of PK compensates the addition cost of clay or kaolin required for the Hydro-clay bath separator process. The shell and kernels are washed and the kernels are passed to a kernel dryer to normalize the moisture content of 7% so as to minimize the development of FFA during storage and shipment. It is also advantages to sterilizer the kernels before shipment or storage with steam at atmospheric pressure. Kernel plants designed for Dura derived nuts are not suitable for the processing of Tenera derived nuts. There have been a number of experimental designs, which have proved failures. Caution and a wide experience are required in selecting the proper equipment and design for kernel recovery plant.

7.0

Palm Oil Purification

The modern purification or oil classification station is designed to recover and purify the crude oil as quickly as possible with the minimum heating and exposure to air. This is to minimize the damage by oxidation, which is caused by the exposure of crude oil to air at high temperature.

OIL PALM MILL SYSTEMS & PROCESS

10

The process begin at the crude oil tank of the extraction station and ends at oil cooler as finished CPO with dirt contents of 0.009% and moisture contents of 0.09%. The major effluent problem is eliminated by the decanter system, which removes the semi-solid sludge for treatment, by the sludge dryer, which reduces the moisture of the sludge from 45% to 10%. Adequate heat for drying of the sludge is obtained from the boiler exhaust flue gasses. The composition of the dryer decanter cake is shown in Appendix. The major contributor to poor quality oil is oxidation. Oxidation measured by the totox value, starts when the oil is above 60C and exposed to air During processing, storage and shipment.

8.0

Steam and Power Generation.

Utilization of existing energy resources is indispensable not only for large industrial processes but also for small production plant and in particular oil palm mills where the balance between heat and power are required for production process which are pre-condition for a combined heat and power ( CHP ) scheme. Or commonly referred to as C0-GENERATION SYSTEM. Solid waste fuel in the form of shell, fibre and empty bunches which are by-products of the process are utilized as fuel for the boiler. Steam is required for processing at the approximate rate of 500kg per hour per ton ffb. This steam can be easily raised in a reasonably efficient water tube boiler with fuel available from the Fibre, shell and empty bunch. Power is required at the approximate rate of 15 to 25 Kw per ton ffb. This can be easily be provided by placing a back-pressure single stage steam turbine between the boiler and the header of the mill processing system. Steam is generated from the boiler at a pressure of say 20 Bar.g and into the steam turbo alternator at 18.5 Bar.g at 260C with back pressure of 3.16 Bar.g for the mill process which is convenient and effective for process Heating. The additional power generated in this system is made possible by burning of the empty bunches as shown in the enclosed Fuel /Steam /Power balance and Steam Production from 1 Ton Solid Waste Fuel for a Oil Palm Mill. Every ton of FFB can produce 733 kg steam and 30kw power shown, in the diagram below : A system has been introduced for the treatment and disposal of empty bunches and recovery of palm oil and at the same instance reduces the moisture contents of the empty bunches to approx. 45 % so that they can be used as solid waste fuel for the boiler and production of additional steam and electrical power.

OIL PALM MILL SYSTEMS & PROCESS

11

Every ton of FFB can produce 733 kg steam and 30kw power shown, in the diagram below :

Steam is produced by water tube boilers at pressures and temperatures higher ( 20 bar.g 207 deg. C ) than required for the process. First it is expanded in steam turbines, and then led into the process where the latent heat contained in the exhaust steam ( 3.16 bar.g ) is utilized for sterilisation of FFB and heating systems in the process. The diagram below show a typical CHP scheme of a modern oil palm mill.

The energy released during the expansion of steam is converted by the turbine into mechanical power to drive an alternator.

OIL PALM MILL SYSTEMS & PROCESS

12

There is a direct relationship between the number of palms cultivated and the corresponding harvest yield of a given plantation area processed by the mill, the primary energy available in the by product fuel, and power / heat requirement of the mill A properly design Oil Palm Mill will not only provide sufficient steam and electrical power for its operation requirement but will provide an additional 17 to 33 % more power for other planned integrated down stream processes, domestic use or sold to other consumers of power.

9.0

Effluent Control.

SOURCE OF SOLID WASTE, EFFLUENT & POLLUTION

Effluent discharge quantities in Oil palm mills is dependent on the extent of design of the milling process systems, in -plant process control, equipment maintenance and good house-keeping. The solid waste or by-products in the oil palm milling process, consist of :

Empty bunches Shell and fibers Decanted solids Sludge centrifuge solids Boiler ash De-sludging of ponds.

Solid waste such as treated empty bunches ( de-water ) of approximately 25% to FFB and recovered dryed sludge of approximately 3% to FFB are by products that will be utilized in the plantation and sold as produces. The shell and fiber are sources of solid waste fuel for co-power generation in the oil palm mill. Waste water from the sterilizer condensate, clarificatio n effluent and hydro-cyclone or claybath discharges are sufficiently contaminated and require treatment. Some of the sources waste water discharged from the steam turbine condensate / cooling system and boiler blow down are relatively clean and can be put to good use in the process such as for the dilution system, screw press, oil gutter spraying and for the factory floor cleaning requirements. The liquid effluent total quantity of 0.6 to 1 mt per ton of FFB between the generating sources being as follows :

Sterilizer condensate Calrification station Hydrocyclone / Claybath. Other waste water

OIL PALM MILL SYSTEMS & PROCESS

13

The table below presents the typical physical and chemical properties of raw effluent from Oil palm milling process.
PARAMETER pH BOD COD Total Solids Suspended Solids Volatile Solids Ammoniacal Nitrogen Total Nitrogen Oil and Grease * All values except pH are in milligrams per liter ( mg / L) Source : PORIM MEAN 4.1 25,000 53,630 43,635 19,020 36,515 35 770 8,370

The total liquid effluent could well increase if mill process wash water is included. The effluent is not toxic but it has a biochemical oxygen demand of above 25,000 (BOD) which makes it objectionable to fish life when introduced in relatively large quantities in waterways and rivers. The objective is to treat the oil palm mill effluent discharge so as to comply with conditions imposed by the Department of Environment (DOE) for disposal in accordance to standards as follows: Standard A. - For discharge to rivers shall be less than Standard B For discharge to waterways shall be less than Standard C For discharge to land & field shall be less than BOD 20 mg / l - BOD 50 mg / l - BOD 500 mg / l

A system to treat affluent by ponding or Oxidation ponds is commonly adopted in Malaysia. The system of Anaerobic and Aerobic process in general conform to regulations which require a sizeable area of 65 to 75 days retention time for the ponds, proper monitoring, cost for power for circulation pumps and aerators, de-sludging of ponds, maintenance and supervision but at times are unstable as a result of a reduction of ponding volume due to silting with sludge, weather conditions and by contamination. Many systems are being tried but no generally accepted system has yet emerged. The systems tried including centrifuges, fitters, sun bed drying, air flotation / coagulation and mechanical extended aeration plants. Some pilot systems include Methane production units and Effluent free system or Zero discharge by means of a multi-Stage condensing unit and Thermal Oxidation plant to produce dry sludge in the finish product as POME which is sold as fertiliser and filler for animal feed. The search for new designs and systems continues..
q q q

Oil Palm Mill Schematic Process Flow Oil Palm Process Matrix Process Mass flow and losses during Production

Noel Wambeck / October. 1997 / Revised June 23, 1999.

ALTERNATIVE CAGE TIPPLER SYSTEM

EMPTY BUNCH DISPOSAL BY INCINERATION FIELD APPLICATION OR OIL RECOVERY

DECANTER FOR SOLIDS REMOVAL

CRUDE PALM OIL 0.09% moist. 0.009% dirt.

DRY KERNEL 7% moisture 4.6% dirt.

Designed by Noel Wambeck - 25th. July 1992

05b. Matrix OPM Process.xls

MATRIX OIL PALM MILL PROCESS.

POINT SAMPLE AT POINT
% / FFB OIL

BASED ON MALAYSIA TENERA MATERIAL WITH 25% OIL CONTENT

Mill Capacity: mt FFB / Hr >

WATER SOLID OTHER

1
Weight in kg.
1,000 250 83 5 660 20 640 260 380 257 120 137 125 55 70 80 5 532 250 423 239 215 1,000 700 120 180 430 120 80 5 225 660 600 540 120

3
3,000 750 249 15 1,980 60 1,920 780 1,140 771 360 411 375 165 210 240 15 1,596 750 1,269 717 645 3,000 2,100 360 540 1,290 360 240 15 675 1,980 1,800 1,620 360 3,000 1,650 450 240 360 300 75 60 6 9

5
5,000 1,250 415 25 3,300 100 3,200 1,300 1,900 1,285 600 685 625 275 350 400 25 2,660 1,250 2,115 1,195 1,075 5,000 3,500 600 900 2,150 600 400 25 1,125 3,300 3,000 2,700 600 5,000 2,750 750 400 600 500 125 100 10 15

10
10,000 2,500 830 50 6,600 200 6,400 2,600 3,800 2,570 1,200 1,370 1,250 550 700 800 50 5,320 2,500 4,230 2,390 2,150 10,000 7,000 1,200 1,800 4,300 1,200 800 50 2,250 6,600 6,000 5,400 1,200 10,000 5,500 1,500 800 1,200 1,000 250 200 20 30

20
20,000 5,000 1,660 100 13,200 400 12,800 5,200 7,600 5,140 2,400 2,740 2,500 1,100 1,400 1,600 100 10,640 5,000 8,460 4,780 4,300 20,000 14,000 2,400 3,600 8,600 2,400 1,600 100 4,500 13,200 12,000 10,800 2,400 20,000 11,000 3,000 1,600 2,400 2,000 500 400 40 60

30
30,000 7,500 2,490 150 19,800 600 19,200 7,800 11,400 7,710 3,600 4,110 3,750 1,650 2,100 2,400 150 15,960 7,500 12,690 7,170 6,450 30,000 21,000 3,600 5,400 12,900 3,600 2,400 150 6,750 19,800 18,000 16,200 3,600 30,000 16,500 4,500 2,400 3,600 3,000 750 600 60 90

45
45,000 11,250 3,735 225 29,700 900 28,800 11,700 17,100 11,565 5,400 6,165 5,625 2,475 3,150 3,600 225 23,940 11,250 19,035 10,755 9,675 45,000 31,500 5,400 8,100 19,350 5,400 3,600 225 10,125 29,700 27,000 24,300 5,400 45,000 24,750 6,750 3,600 5,400 4,500 1,125 900 90 135

60
60,000 15,000 4,980 300 39,600 1,200 38,400 15,600 22,800 15,420 7,200 8,220 7,500 3,300 4,200 4,800 300 31,920 15,000 25,380 14,340 12,900 60,000 42,000 7,200 10,800 25,800 7,200 4,800 300 13,500 39,600 36,000 32,400 7,200 60,000 33,000 9,000 4,800 7,200 6,000 1,500 1,200 120 180

90
90,000 22,500 7,470 450 59,400 1,800 57,600 23,400 34,200 23,130 10,800 12,330 11,250 4,950 6,300 7,200 450 47,880 22,500 38,070 21,510 19,350 90,000 63,000 10,800 16,200 38,700 10,800 7,200 450 20,250 59,400 54,000 48,600 10,800 90,000 49,500 13,500 7,200 10,800 9,000 2,250 1,800 180 270

120
120,000 30,000 9,960 600 79,200 2,400 76,800 31,200 45,600 30,840 14,400 16,440 15,000 6,600 8,400 9,600 600 63,840 30,000 50,760 28,680 25,800 120,000 84,000 14,400 21,600 51,600 14,400 9,600 600 27,000 79,200 72,000 64,800 14,400 120,000 66,000 18,000 9,600 14,400 12,000 3,000 2,400 240 360
5/10/00

A B B1 B2 C C1 D D1 D2 E E1 E2 F F1 F2 F3 F4 G G1 G2 H H1 J J1 J2 J3 K K1 K2 K3 K4 L L1 L2 L3 M M1 M2 M3 M4 M5 N N1 N2 N3

Fresh fruit bunches Empty bunches Liquid from EB Press Potash ( Bunch ash ) Fruitlets on bunch Fruitlets in Empty bunch loss Digested mash Press Cake Extraction CPO & water ex-press Wet Fibre & Nuts to depericarper Wet Fibre to boiler Wet Nut Ex- winnowing Cracked Mixture Kernel Shell Water for Hydrocyclone Clay for Claybath system Crude oil diluated with water Clarified crude oil to Purifier Sludge to Separator Clean oil to Oil dryer Clean & dry CPO to stoarge tank Raw water Boiler feed water Precess water Domestic water Solid waste fuel to boiler ( 30% moist.) Fibre Shell Light particals De-oiled empty bunches Boiler steam generation ( kg / ton FFB ) Turbine steam requirement Sterilisation steam requirement Process heating steam requirement Wast water Effluent ( kg / ton FFB ) From Clarification From Steriliser condensate From PK recovery plant Boiler blow down From OTHERS & cleaning Power generation ( kw / ton FFB / hr ) Process Mill lighting & grounds Domestic

100 25 8.3 0.5 66 2 64 26 38 25.75 12.0 13.75 12.5 5.5 7 80 5 53.2 25.00 42.31 23.91 21.52 1000 700 120 180 43 12 8 0.5 22.5 660 600 540 120 1000 550 150 80 120 100 25 20 2 3

25 0.75 0.249

48.5 18 7.387

26.5 6.25 0.664

kg 0 0 0.5 0 0 0 0 0 0 0 0 0 0 0 0 5kg

24.25 0.735 23.52 1.56 21.96 1.55 1.08 0.47

37 1.121 35.88 10.9 15.2 10.82 3.60 0.76

7 0.212 6.79 14.0 0.84 13.39 6.48 12.53

80kg

21.96 21.96 21.74 21.74 21.50

30.4 2.20 19.81 2.17 0.01 1000kg 700 kg 120kg 180kg

0.84 0.84 0.8

0 0 0 0 0 kg kg kg kg

0.009

0.01 0.016 0.008 0.0005 0.008

12.9 3.6 1.2 0.025 6.75 660kg 600kg 540 kg 120 kg 1000kg

30.09 8.384 6.792 0.4745 15.742

kg kg kg kg kg KW KW KW KW

1,000 550 150 80 120 100 25 20 2 3

Perunding AME / POMProMatrix / 16th November 1998 /nw.

PROCESS MASS FLOW AND LOSSES DURING PRODUCTION

Based on Tenera material FFB input in kg
STERILISER 100 kg Out Flow 12.3

Oil content FFA

24% 2.5% max

PRODUCT

WASTE

LOSS

kg

kg

kg

Evaporation Oil Loss

12 0.3

STRIPPING 87.7 kg

25

Empty bunches Oil Loss

24.5 0.5

EXTRACTION 62.7 kg

31.14 31.56

Solids Liquids

OIL CLARIFICATION 31.56 kg

Water Non-oily solids Oil Loss Oil 22.25

6.56 2 0.75

DEPERICARPER 31.14 kg

16.19

Evaporation Oil Loss Fibre Kernel Loss Evaporation Oil Loss Kernel Loss Shell Kernel

3.84 0.1 12 0.25 1.7 0.1 0.15 8 5

KERNEL RECOVERY 14.95 kg NUTS 5.4

TOTAL in kg CPO Yield Palm Kernel Yield 22.25 5

100 92.7% 92.6%

27.25

70.6

2.15 1.75 0.4

Total OIL loss in kg Total kernel loss in kg

( Including FFA as Oil )

QUALITY

Moisture % Dirt % FFA %

0.09 0.009 3.5

Moisture % Dirt % FFA %

7 5 2.5

Noel Wambeck Feb.1999

TYPICAL FLOW DIAGRAM OF AN EFFLUENT TREATMENT PONDING SYSTEM FOR A 30 MT FFB PER HOUR OIL PALM MILL.
RAW EFFLUENT INPUT 432 m3 /day BOD 25,000 ppm.

FAT PIT EFFLUENT OIL RECOVERY STATION WASTE WATER FROM : Steriliser Condensate, Clarification Station Kernel recovery station and wash water

Cooling Pond No 1 12 x 15 x 2.5

3 302 m each Pond 1 day HRT

Cooling Pond No 2
( 100%) 18m3 per hour

Recycle Activated Sludge

Acidification Pond No.1 12 x 15 x 2.5

302 m3 each Pond 1 day HRT

Acidification Pond No.2

Anaerobic Pond No.1 16 x 160 x 6

6629 m3 each Pond 61days HRT

Anaerobic Pond No.2

Anaerobic Pond No.3

Anaerobic Pond No.4

RECYCLE PIPE LINE

RECYCLE PUMP

Facultative Pond
932m3 2 days HRT 16 x 30 x 2.5

Aerobic Pond No.1 16 x 80 x 2.5

2,611 m3 each 12 days HRT

Aerobic Pond No.2

Pipeline / Tanker

FINAL DISCHARGE TO PLANTATION

FLOW RATE OF > 432 m3 / Day BOD REDUCTION = 99.6 % > LESS THAN 100 PPM BOD

Perunding AME/ ETP Flow Diagram

05g. MatrixPOMEffluent.xls

MATRIX OF AN OIL PALM MILL PROCESS & WASTE WATER EFFLUENT PONDING SYSTEM.
Item 1 2 Details Milling capacity Effluent Generation Rate a. FFB moisture b. Sterilizer condensiate c. Clarification station d. Kernel Plant e. Other & washwater Total per hour in kg. Flow rate of Effluent Per Hour Per Day ( 24 hours ) HRT of 75 days Suspended Solids at Fat / Sludge pit ( 22,000 mg/L ) at Final discharge ( 200 mg/L ) Rate of aerobic Biosolids produced Organic loading Rate ( 0.3 kg BOD/m3/Day ) Rate of Re-circulation of Anaerobic effluent Anaerobic - HRT 5 days return to seeding pond ( 50 % ) Pump size number of pumpsets BOD of Effluent at Sludge pit - 25,000 mg / L at Anaerobic pond discharge - 5,000 mg /L at Aeration pond discharge - 50 mg /L at Stabilisation pond discharge - 20 mg / L Aeration pumpsets Flow rate Drive motor Number required MT FFB / hr 1 30 45 60 90 120

kg kg kg kg kg kg

200 140 600 150 110 1,000

6,000 4,200 18,000 4,500 3,300 30,000

9,000 6,300 27,000 6,750 4,950 45,000

12,000 8,400 36,000 9,000 6,600 60,000

18,000 12,600 54,000 13,500 9,900 90,000

24,000 16,800 72,000 18,000 13,200 120,000

m3 m3 m3

1 24 1,800

30 720 54,000

45 1,080 81,000

60 1,440 108,000

90 2,160 162,000

120 2,880 216,000

kg kg kg kg

39.6 0.36 39.24 7.2

1188 10.80 1177.2 216

1782 16.20 1765.8 324

2376 21.60 2354.4 432

3564 32.40 3531.6 648

4752 43.20 4708.8 864

5 6

m3 m3 / hr KW unit

120 0.5 0.33 1

3600 15 3 1

5400 22.5 4.5 1

7200 30 6 1

10800 45 9 1

14400 60 12 1

kg kg kg kg

4.5 0.90 0.009 0.0036

135 27.00 0.27 0.108

202.5 40.50 0.405 0.162

270 54.00 0.54 0.216

405 81.00 0.81 0.324

540 108.00 1.08 0.432

m3 / hr at TDH 20 kw units

2 1 x 7.5

45 5.625 2 x 5.5

67.5 8.4375 2 x 7.5

90 11.25 2 x 10

135 16.875 4 x 5.5

180 22.5