Chapter 3 Technical Feasibility

CHAPTER 3 TECHNICAL FEASIBILITY 3.1 METHOD TO MAINTAIN SUSTAINBILITY 3.1.1 Tilting Sterilizer Sterilization is the most important unit process as it will determine the efficiency and the effectiveness of downstream milling process and also refining process. In this plant design project, tilting sterilizer is chosen to implement in the proposed plant due to its advantages. Tilting sterilizer is a type of horizontal sterilizer where it can be tilted into inclined position. The operation of tilting sterilizer is same like the conventional horizontal sterilizer during the sterilization process. The only difference is the use of conveyor to transfer the FFB and SFB into the sterilizer instead of using cages under inclined position. The working principle of tilting sterilizer is shown in Figure 11. During the time of cooking FFB, the tilting sterilizer is in horizontal position like the normal conventional method in cooking the FFB [28]. Once the steaming process is completed, the sterilizer is tilted in an inclined position allowing the SFB be poured out under gravity into the conveyor and send into a collection hopper. At the time it in the inclined position, new batch of FFB will fed into the sterilizer from the top. After filling in the FFB, the sterilizer is lowered to horizontal position and ready for steaming process.

Figure 11: The operation of Tilting Sterilizer.

Although the sterilization process of tilting sterilizer is similar to the conventional sterilizer, it offers a lot of advantages in term of steam consumption, minimum breakdown, safety and manpower. The steam consumption for a conventional sterilizer is around 272.6 kg steam/ton of FFB. However, the steam consumption of tilting sterilizer is 200 kg steam/ ton of FFB. The lesser steam consumption of tilting sterilizer will reduce the energy consumption of the proposed plant which in turn reduces the operating cost and maintenance cost for boiler and steam turbine in the power plant. Besides that, the used of tilting sterilizer will reduce the breakdown of sterilization station. In conventional method, cages are moving by using tractors and winches. Breakdown normally occurred in the sterilization station when transferring the cages. Times is spent to move the cages and it is very human dependable. Workplace accidents also occurred during the transferring of cages in and out the sterilizer. The steaming process is occurred in high temperature where workers tend to injure when monitoring the cooking process. Implementing the tilting sterilizer can help to increase the workplace safety and minimum the breakdown due to the automation system to filling in the FFB and discharge the SFB. Apart of that, the tilting sterilizer is easy to operate where the fully automated features only required 2-3 operators to operate the complete sterilization station. This also helps to reduce the manpower in our proposed mill. By implementing the tilting sterilizer in our proposed plant, the system can be lead to improvement in productivity and consistency in throughput. The proposed mill is able to run smoothly and achieve the target production capacity per day. The constant throughput can make sure other byproducts able to produce on time and maintain the income of the proposed mill throughout the year. Hence, tilting sterilizer is a technology that able to sustain the operation of the proposed palm oil mill. 3.1.2 Production of EFB Fiber Over the last decade, the interest to use biomass as a renewable resource has grown rapidly especially for energy and material applications. EFB is the largest amount of solid biomass generated from palm oil milling activities. Instead of applying the conventional methods to handle the EFB, the proposed mill will produce EFB dried fiber

from EFB by undergo a series of machining steps to reduce it moisture content [24]. Figure 12 shows the EFB dried fiber after reduction of moisture content.

Figure 12: The EFB dried fiber. The common methods to handle EFB in palm industries are by incinerating the EFB, mulching and dumping into landfills. These methods tend to produce environmental problems where burning the EFB in an incinerator will release dark smoke. Dark smoke will contains innumerable substances of unknown toxicity which caused the effects on the environment in the form of global warming, photochemical ozone or smog formation. Mulching is another common method used to dispose EFB in palm oil mills. Mulching will cause soil pollution as EFB contains high amount of oil residue where many palm oil mills did not carry out oil recovery of EFB. Hence, oil spill will occur on palm oil plantation. Indiscriminate dumping of EFB also causes the additional methane emission into the atmosphere. Methane is one of the greenhouse gases that contributed to global warming. The GWP value of methane is around 21. By introducing the EFB fiber production line, the proposed mill is able to handle the large volume of EFB via an eco-friendly way. The production process is pollution free and no hazard making it a long term solution to handle this solid biomass. On other hand, the market demand of replacement fiber for natural fiber makes EFB fiber a promising venture. The selling price up to RM 680/ton makes it able to increase the revenue of the proposed palm oil mill [24]. The plant is able to sustain in a long term period at the same time it can generate wealth from waste by utilizing the solid biomass. This proposed method is able to bring positive impacts toward people, profit and planet.

3.2 PRODUCT SPECIFICATIONS AND PROPERTIES 3.2.1 Crude Palm Oil In the proposed palm oil mill, the main product is CPO. According the MALAYSIAN STANDARD, the crude palm oil produced by every palm oil mill needs to meet the standards issued by MPOB. Crude palm oil is defined as the oil derived from freshly pulp of the fruit of Elaeis guineensis Jacq by mechanical expression [5]. In general, the standard requirements of palm oil can be divided into Identity Characteristic and Quality Characteristic. 3.2.1.1 Identity Characteristic Figure 13 shows the identity Characteristic of palm oil where the ranges given are not mandatory and are considered as guideline levels.

Figure 13: Guideline identity characteristics for palm oil.

3.2.1.2 Quality Characteristic The color of crude palm oil shall be bright, clear and orange-red. Besides, crude palm oil shall be free from foreign and rancid odor. At the time of shipment, the crude palm oil shall conform to the requirement prescribed in Table 5. Table 5:Quality requirements for crude palm oil. Characteristics Free fatty acid (as

Special Quality Grade 2.5

Standard Quality Grade 5.0

palmitic), % max Moisture and Impurities, % max Peroxide value , meq/kg max Anisidine value, max Color, 133.35 mm max DOBI, min

0.25 1.0 4.0 2.8

0.25 2.0 5.0 2.3

3.2.2 Palm Kernel Palm kernel is the edible seed from oil palm tree. The kernels are brown, oval between 1 and 2 cm long and have a shell that is as hard as stone. Figure 14 shows the palm kernel. It is normally sell to other company to produce palm kernel oil.

Figure 14: Palm kernel. 3.2.3 EFB Fiber

EFB fiber is the green products from the proposed plant which able to replace the use of natural fiber. Table 6 shows the characteristic of EFB fiber that produced in the proposed plant. The EFB fiber will sell in baler form for local or oversea distribution. The baler fiber will in the size between 100 Kg with dimension 510 mm X 760 mm X 510 mm [24]. Table 6: Characteristic of EFB Fiber. Property

Value

Size Moisture Content Calorific

75-250 mm 17.5% 18800 kJ

3.3 PALM OIL MILLING PROCESS 3.3.1 Raw Material In palm oil milling process, the raw material is freshly pulp of the fruit from species Elaeis guineensis Jacq which also known as FFB. The raw material need to process within 24 hours after harvesting. This is to avoid the rise in free fatty acid during prolong storage. Apart from that, the process also needs water and steam to produce CPO. Water is used as boiler feed to generate steam. A boiler is used for steam generation and it consists of two principal parts namely the furnace, which usually provides heat through the burning of a fuel, and the boiler itself which is a device responsible for the heat changes of water into steam [18]. The steam will used in power station to generate electricity by steam turbine. On the other hand, diesel generator also used diesel to generate power for palm oil mill. Furthermore, the mill also required diesel for vehicle usage such as tractors and showler. 3.3.2 Methods 3.3.2.1 General Process Description In the proposed palm oil mill, the main products are CPO. Meanwhile, the byproducts are palm kernel and EFB fiber. CPO is produced from FFB by passing a series

of mechanical processes. A sequence of processing steps had been established to extract high yield of good quality CPO. Meanwhile, the palm kernel will undergo a separate process and used to produce dry kernel. The dry kernel will be sent to another factory for further processed. During the milling process, waste products will be formed which known as biomass. The biomass include EFB, palm shell and mesocarp fiber. EFB will undergo a series of pretreatment process to produce value added products which is also another by-product of the proposed mill known as EFB fiber. While the remaining biomass will be utilized for other used in the proposed mill. The overall palm oil processing included the receptions of FFBs, sterilizing and threshing of bunches to free the palm fruit, digestion and pressing out the oil. The crude oil will undergo further clarification and purification before store in the oil room. 3.3.2.2 Fresh Fruit Reception The first stage to produce CPO is receiving FFBs. Figure 15 shows the lorry carried the FFBs entering the mill by passing through the weigh bridge. The initial weight of the truck will be determined. After sending the FFBs, the weight of the truck will be determined again. Hence, the quantity of the FFBs received can be calculated by subtracting the final weight of the lorry from its initial weight.

Figure 15: The truck passing through the weigh bridge and its weight was recorded. 3.3.2.3 FFB Loading Ramp

Loading ramp hopper is the temporary place to store FFBs before processing. Figure 16 shows a typical loading ramp in palm oil mill. It is a sliding platform made of mild steel where lorry unloading the FFBs. The conveyor will transfer the FFBs into the cages.

Figure 16: The loading ramp in palm oil mill. 3.3.2.4 Sterilization Station Tilting sterilizer as shown in Figure 17 is used in the sterilization station. The automated feeder will transfer the FFBs into the sterilizer and transfer out the SFBs to threshing station. The sterilization process is running for 90 minutes at pressure of 50 psig. The steam consumption is 200 kg steam/ ton FFB [28]. The stream usually enters sterilizer through a single pipe at the top of the vessel and a spreader plate is fitted running the whole length of the sterilizer. Although some stream goes out with the condensate where most of it is passed to atmosphere through a stream exhaust valve at the top of the sterilizer.

Figure 17: The tilting sterilizer in sterilization station. 3.3.2.5 Threshing

The SFBs from the tilting sterilizer will flow to the thresher via auto feeder. The thresher will rotate to detach the fruitlets from the bunch. Figure 18 shows the typical thresher used in the palm oil mill. The EFB will send to bunch crusher for crushing. This is to make sure that 100% of stripping sterilized fruits from bunch. Then, the sterilizer fruitlets will send to digester and EFB will send to EFB fiber production line.

Figure 18: Thresher used to detach sterilized fruitlets. 3.3.2.6 Digestion Digestion process is carried out to reheat the stripped fruits so that the pericarp loosened from nuts. This is carried out in the steam heated vessels provided with stirring arms and known as digester or kettles. The digester has vertical rotating shaft which are attached to the stirring arms. A typical digesters used in palm oil milling process is shown in Figure 19. The stirring arms will stir and rub the fruits to loosen the pericarp from the nuts and at the same time breaking open as many of the oil cells as possible. The digester is kept full since the digested fruit is drawn off continuously from the bottom of the vessel while freshly stripped fruit is added at an equal rate. It is essential for good digestion that the level of fruit in the digester kept as high as possible all the times at about 90°C. This is to maximum the holding time and stirring effect per revolution. The effect of inadequate digestion is to increase the oil loss in press fiber and this is one way in which it may be detected. However, the results of poor digestion are noticeable if the press cake is examined when pieces of undigested pericarp will be found in the fiber and some of these pieces may even be still attached to nuts.

Figure 19: The Digester used in palm oil milling process. 3.3.2.7 Pressing After digestion process, the fruits will be pressed by batch type hydraulic press to obtain oil. The screw press machine is shown in Figure 20. The nuts and fiber will be pushed out and for further processing. Before pressing, the cage is filled with digested fruit to ensure that the press cake formed is divided into conveniently sized portions. When the press cage is full with fruit, a heavy top plate is moved into place to close the top of the cage. The hydraulic pressure is gradually built up. The maximum pressure is maintained for several minutes before it is released. Then, the top plate is withdrawn and the sections of cake expelled by raising the ram.

Figure 20: The batch type hydraulic press used in palm oil milling process. 3.3.2.8 Screening

The fluid coming out of the press is a mixture of palm oil, water, cell debris, fibrous material and ‘non-oily solids’. Because of the non-oily solids the mixture is very viscous. Hot water is therefore added to the press output mixture to thin it. The addition of dilution water with temperature of 100 °C provides a barrier causing the heavy solids to fall to the bottom of the container while the lighter oil droplets flow through the watery mixture to the top when heat is applied to break the emulsion (oil suspended in water with the aid of gums and resins). The diluted mixture is passed through a screen to remove coarse fiber before send to clarification tank. Vibrating screen is used to remove all fibrous material from crude oil and recycle them to the digester. A typical vibrating screen used in palm oil mill is shown in Figure 21.

Figure 21: A Vibrating Screen used in palm oil milling process. 3.3.2.9 Clarifying and Drying of CPO The oil mixture is heated to 85-90◦C and allowed to separate in the clarification tank. A settling time of 3 hours is acceptable. Oil from the top is skimmed off and purified in the centrifuge prior to drying in vacuum dryer. The final crude palm oil is then cooled and stored. The lower layer from the clarification tank is sent to the centrifugal separator where the remaining oil is recovered. The lower layer is known as sludge which is the waste generates from this stage. The oil is dried in vacuum dryers, cooled and sent to storage tanks. Figure 22 to 25 show the oil clarifier, centrifuge, oil purifier and oil dryer used in clarification station.

Figure 22: Oil clarifier

Figure 23: Centrifuge

Figure 24: Oil purifier

Figure 25: Oil dryer

3.3.2.10 Oil Storage CPO produced will store in storage tank before dispatching from the mill. The storage tanks used in palm oil mill are shown in Figure 26. Normally, the temperature of the storage will maintained at around 50 °C. Hot water or low pressure steam heating coils will be used to prevent solidification and fractionation. Besides that, the storage tank needed to be lined with suitable protective coating to prevent iron contamination from the tank. The quality of crude oil must be kept. Hence, the FFA content must be below 3-5% while DOBI is need above 2.3. The impurities and moisture is allowed below 0.025% and 0.15%.

Figure 26: The oil storage tanks used to store CPO. 3.3.2.11 Palm Kernel Processing After the pressing process, the oil is transferred to oil room while the nut and the fiber will go further processing. Depericaping is the process which separates the nut and fiber. There are two ways for separation of nut and fiber either by mechanical separation or air separation. In the proposed mill, air separation is chosen to separate the nut and fiber. Before the separation, CBC is used to loosen the nuts from the fibers. At the same time, moisture of the fibers and the nuts are slightly removed. There are L-shape angles to increase the surface area and thus to increase efficiency of loosening fibers and nuts. The speed of rotation of ribbon is slightly higher than the others conveyor. It is around 65 rpm. Increasing the length of CBC will increase the separation time and thus improve the separation efficiency.

In addition, good sterilization, digestion and pressing process will ensure the fruit is cooked well. The pericarp will easily be detached from the nuts and will also help the breakage of shell from kernel. Then, the fibers and nuts are separated by air separator/air lock. The fibers are sucked up by air while the nuts drop down. The fibers are transferred to fiber cyclone. The fiber cyclone creates a momentum to remove moisture from fibers. The fibers then are transferred by conveyor to boiler. For vertical column type air separator, the high velocity will affect the fibers going upward and the nuts will fall downward. Vertical air current is maintained absolutely parallel through whole height and cross section of the column in order to ensure the high efficiency in separation. The fiber is sucked by a fan through the open lower end of the column and is blown to fiber cyclone. The separated nuts drop conveyor. The nut is expected with presence a little bit of fibers. For nuts, they are transferred into polishing drum to loosen the kernel from the shell and then, they are easily separated. After that, the nuts are transferred into nut silo for drying purpose. There is shaking grate in the nut silo to control nut flow and ensure their retention time in silo. It will distribute the nut evenly. Then, nuts are transferred into ripple mill to crack the nuts. There are un-cracked nuts, partially cracked nuts, whole kernels, broken kernels, dirt and shells. Then, they are passed through the winnowing system in order to blow out the small dirt and shell. Next, they are passed through the air lock or de-stoner to remove the big particles, such as stones. Stones will fall down and light particles are sucked to upper side. They are transferred into vibrating screen to separate the particles and oil. After that, they are transferred into hydro cyclone to separate the whole kernels, broken kernels and shells. After the separation, the kernels are transferred into kernel silo for drying while the shells are transferred to shell line. Lastly, dried kernels are transferred into kernel bunker for storage while the shell is keep at shell storage. The kernel bunker and shell storage place are shown in Figure 27.

Figure 27: Kernel bunker and shell storage. 3.3.2.12 EFB Fiber Production Firstly, the crushed EFB from threshing process were being transferred to EFB collection point. The crushed EFB were being shredded into a smaller size before it is being pressed in the EFB press machine. Shredded EFB were being pressed in order to extract the liquor from the bunch. Next, the fibers were transferred into the Hammer Mill Machine in order to break the fibers into single strand fiber. The strand fibers will in the size between 76-250 mm. The fibers were then undergoes a drying process by using a Rotary Dryer with dust remover system. This process will reduced the moisture content of the fibers below 17.5 %. Lastly, the dried strand fibers will undergo the last process that is to be bailed into a more compact size like blocks using a bailing machine. The baler fiber will in the size between 90-100 Kg with dimension 510 mm X 760 mm X 510 mm. After being bailed, the EFB baler fiber is then ready for market. Figure 28 shows the by-products, EFB baler fiber.

Figure 28: The baler fiber produced from EFB.

3.3.2.13 Boiler Station Boiler is the closed vessel in which water or other fluid is heated under pressure. The fluid is then circulated out of the boiler for use in various processes or heating applications. The main functions of the boiler house are to convert chemical energy to heat energy, to transfer the heat energy to the water in the water circuit and convert it to steam, supply steam for generating electricity and to supply steam for other process units in the mill. There are 2 types of efficient boiler, such as fire tube boiler and water tube boiler. In this scenario, the water tube boiler is used. The flow of boiler house is shown in Figure 29. Normally, mesocarp fiber and palm shell are used as fuel for boiler and are transferred by conveyor. At the same time, the water is pumped into the boiler. Firstly, the water will flow in steam drum. After that, the hot water will flow down to mud drum which keeps the hot water. Then, the water will flows through tubes and the heat is transferred into water through glass tube. Then, the water becomes steam and steam will flow into steam drum again.

Figure 29: The flow of boiler house.

After complete combustion, the ashes are taken away by Induced Draft (ID) fans and pass through air lock which separates the ash and smoke. Ashes will take away into dust collector cone while smoke will be discharged through chimey. Light brown haze should be observed but white smoke is allowed because white indicates excess secondary air. However, the black smoke indicates heavy erratic firing or lack of secondary air. The ashes are manually taken out by the operators through doors of furnace. After certain period of combustion, ashes will stick to the boiler tubes and it will affect the heat transfer. So, the blowers are used to clean the scaling of the boiler. Manual cleaning is also required. The wet steam flows into superheater which converts the wet steam into dry steam at temperature of 250°C. After that, the dry steam passes through the main steam stop valve and meet the water separator which separate the condensate because condensate will damage the turbine. The steam will generate the electricity in turbine at pressure of 31 and 32 bars. After that, the steam will be stored in steam receiver for supplying to heating applications. 3.3.2.14 Power Station In power station, steam turbine and diesel generator are used to generate electricity for operating all the motors and internal usage in the mill. Steam turbine plays an important role in power generation. A steam turbine is a mechanical device that extracts thermal energy from pressurized and converts it into useful mechanical work. Heat energy of steam is converted to kinetic energy and finally is changed to electrical energy. The main equipment used in power station is shown in Figure 30.

Figure 30: The steam turbine and diesel generator. 3.3.2.15 POME Station Ponding system is the most common treatment method for POME. This system is reliable, stable and capable of producing a final discharged with BOD less than 100mg/L. A typical effluent ponds system is shown in Figure 31.

A2

Figure 31: Effluent ponds system.

Effluent ponds play an important role in all factories. The sludge or waste water will be managed before they go into river or into ground. Firstly, factory hot sludge is pumped into effluent ponds. The temperature is around 53°C and pH is 4.5. The BOD is 3000 ppm that means quantity of oxygen is very low. BOD is the amount of dissolved oxygen needed by aerobic biological organisms in a body of water to break down organic material present in a given water sample at certain temperature over a specific time period. The cooling pond plays a role to cool down the sludge with combining the waste water from primary aerobic pond. The sludge is pumped into anaerobic pond A1, B1 and C1. The retention time of this three ponds are 8 hours. After 8 hours, the sludge A1 will discharge into anaerobic pond A2 while the sludge from B1 and C1 will discharge and combine into anaerobic pond BC1. The Biology Genesis activates the natural bacteria in pond and they function to build up the reaction. They will change the dissolved solid into suspension solid. So, the upper solid is easily removed. Then, they will discharge into BC2. Sludge from A1 is discharged into anaerobic pond A2 and A3. At the same time, waste water from anaerobic pond BC2 will discharge A3. Then, the combined sludge will go into primary aerobic pond A4, A5 and BC3. The BOD of primary aerobic pond will decrease. Then, the effluent is pumped into the bio-tower that acts as filtration medium. The plastic coils trap the solid and the remaining waste water will flow to bottom of bio-tower. The remaining waste water flow into polishing pond F1 and is pumped into clarifier. The clarifier separates the solid and liquid by momentum. There is the bypass between pond F1 and pond F2 in order to avoid overflow of the effluent. The waste water flows into settling pond which separates the solid by their size. Finally, the waste water flows into polishing pond F1 and discharge into trenches or flat bed. The flat beds play role to filter the contaminant. The BOD of output of the effluent must be kept below 100 ppm which is standardized by Department of Environment. The oxygen content is higher and do not lead side effect to the environment. The color of pond is greenish and the bubbles on the surface of pond can be observed. It is concluded by the bacteria is active and can functions well.

3.3.2.16 Raw Water Treatment Station

Figure 32: Flow chart of raw water treatment plant. Raw water is required as boiler feed and others process in palm oil mill. 4 basic steps involved in water clarification are pH adjustment, coagulation, flocculation and filtration. The flow chart of raw water treatment plant is shown in Figure 32. pH of raw water is needed to be neutralized. Overflow raw water pond is used to store the overflow raw water. Normally, the tests of pH, the total hardness and turbidity of raw water are carried in treatment plant. Soda (sodium carbonate) is dosed into raw water to increase the pH. After that, the raw water is dosed alum as coagulant (aluminium sulphate) to clog the dissolved solid into suspended solid. This process is called as charge neutralization

process. Polymer as flocculant is added into raw water when the water is too dirty and very yellowish color. Then, the water flows into clarifier. The solids are sedimentated at the bottom of the clarifier. The clarifier used in water treatment plant is shown in Figure 33. The drain valve is opened to discharge the suspended solid out to drainage system until the water is looked clean. Clean water will flows into concrete holding pond. There are line for factory usage and line for daily usage. For factory usage, the water is pumped into sand filter No. 1 and No. 2 for removal sand. Then, the water can is pumped to overhead water tank No. 1 for storage.

Figure 33: The water clarifier. In the line for factory, the chlorine is not dosed in water because the chlorine will precipitate and oxidize the pipes, then will lead the breakage of piping system in factory. For daily usage, the water is pumped into earth pond or drinking pond and to sand filter No.3 and sand filter No. 4. The sand filter used in raw waste treatment system is shown in Figure 34. After that, chlorine is added into water because chlorine can kill bacteria. Lastly, the clean water is pumped to overhead water tank No. 2. Normally, piping system in this line is made by stainless steel in order to prevent rusting and corrosion occurs. The analysis of pH, the total hardness, turbidity and chlorine content are carried out to ensure the quality of water produced.

Figure 34: The sand filter.

3.4 EQUIPMENT SIZING AND SPECIFICATION In the proposed palm oil mill, the main product is CPO. Meanwhile, the by-products are palm kernel and EFB fiber. A series of mechanical processes is used to produce those products. The Table 7 shows the quantity of the main equipment required in the proposed plant and the specification of the respective equipment. The selection of equipment is based on the capacity per batch of FFB will be processed. The FFB being processed for each batch is 30 ton with total of 8 batches will be processed to achieve design capacity of 240 ton FFB/day. The equipment for wastewater treatment plant and raw water treatment plant is not included in this study. The costs of the wastewater treatment plant and raw water treatment plant will be estimated using Lang formula in the economic feasibility part. Table 7:The main equipment and its specification. [9] No Machinery FRUIT RECEPTION 1. Road Weighbridge

2.

Fruit Loading Ramp

Quantity

Specification

1

    

Model - Avery Berkel J 311 Type - Electronic Weighbridge Capacity - 40 ton Power - 0.05 kW Dimension - 2 m (L) X 3 m (W) X 0.3 m (H)

1

  

Type - Vertical sliding gate Capacity - 12 door X 15 ton = 180 ton Power - 5.6 kW

STERILIZATION STATION 3. Tilting Sterilizer

1

       

Model - Besteel Size 30 T Type - Pressure Vessel Capacity - 30 ton / hour Power - 23 kW Shell Length – 7.8 m Diameter - 3.2 m Inlet & Outlet Door – 1.5 m Plate Thickness – 0.015 m

THRESHING STATION 4. Thresher

1

     

Model - CB Thresher Type - Rotary Drum Capacity - 30 ton / hour Power - 18.5 kW Length - 5.5 m Diameter - 2 m

1

    

Model - KH-7.60 Type - Double Deck Bunch Crusher Capacity - 10 ton / hour Power - 15 kW Dimension - 2.219 m (L) X 0.9 m (W) X 1.264 m (H)

5.

Bunch Crusher

DIGESTION STATION 6. Digester

2

      

Model - CB Vertical Digester Type - Unjacketed Capacity - 20 ton / hour Power - 29.8 Kw Volume - 3500 L Height – 3.1 m Diameter - 1.3 m

PRESSING STATION 7. Screw Press

2

    

Model - CB Screw Press Type - Twin Press Capacity - 20 ton / hour Power - 18.5 kW Dimension - 2.32 m (L) x 0.7 m (W) x 0.78 m (H)

CLARIFICATION STATION 8. Vibrating Screen Separator

2

    

Model - AMKCO Double Deck Vibratory Separator Type - Vibro Energy Capacity - 15 ton / hour Power - 1.86 kW Diameter - 2.1 m

9.

Hot Water Tank

1

   

Model - Xb 6000L Separator Type - Storage Tank Capacity - 6000 L

10.

Sand Trap Tank

1

    

Model - LST1-12 Type - Cylindrical conical bottom Capacity - 12,000 L Height - 2.4 m Diameter - 1.8 m

11.

Crude Oil Tank

1

   

Model - KDE-S-12000L Type - Rectangular Storage Tank Volume - 12000L Dimension - 4.8 m (L) x 2.4 m (W) x 1.2 m (H)

12.

Continuous Settling Tank

1

    

Model - IY-CXGC Type - Cylindrical conical bottom Volume - 120,000 L Height - 6.2 m Diameter - 4.95 m

13.

Pure Oil Tank

1

  

Model - ZG-25,000L Type - Cylindrical conical bottom Volume - 25,000 L

14.

Sludge Separator

1

   

Model - AMKCO Single Deck Vibratory Type - Vibro Energy Capacity - 15 ton / hour Power - 1.6 kW

15.

Sludge Oil Tank

1

  

Model - VEN 30 Type - Cylindrical conical bottom Volume - 30000 L

16.

Sludge Buffer Tank

1

  

Model - DY-CG-002 Buffer Tank Type - Cylindrical Volume - 3000 L

17.

Sludge Drain Tank

1



Model - XG Sludge Tank

18.

Oil Purifier

2

 

Type - Steel tank rectangular section Volume - 18,000 L

   

Model - Alfa Laval Purifier MFPX 307 Type - Electromotor Capacity - 6 ton / hour Power - 7.5 kW

19.

Vacuum Oil Dryer

OIL STORAGE TANK 20. Oil Storage Tank

   

1

1

  

Model - PT Vacuum Dryer Type - Vacuum Pump Capacity - 15 ton / hour Power - 11 kW

Model- CFL-Y Oil Tank Type - Storage Tank Volume - 1000000 L

CPO Daily Storage Tank

1

  

Model - T-S1000 Oil Tank Type - Storage Tank Volume - 500000 L

DEPERICARPING STATION 22. Cake Breaker Conveyor

1



Model - DG Cake Breaker Conveyor

21.

   

Type - Semi scroll, unjacketed model screw Capacity - 12 ton / hour Power - 11 kW Dimension - 22m (L) X 0.8m (W)

23.

Depericarper Vertical Column

1

    

Model - DG DP012 Type - Induced Draught Capacity - 12 ton / hour Power - 11 kW Dimension - 8m (L) X 0.8m (W) X 4m (H)

24.

Nut Polishing Drum

1



Model - DG D06

25.

Pneumatic Fiber Transport System (Including Ducting, Fiber Cylone, Fan, Airlock)

1

    

Type - Rotary without roller sprocket Capacity - 6 ton / hour Power - 7.5 kW Diameter - 1m Length - 5m

 

Model - DG Palm Oil Pneumatic System Type - Induced Draught(Fiber Cylone), Fan (Suction), Airlock(Rotary) Capacity - 6 ton / hour Power - 49 kW Dimension - 8.5m (L) X 3.5m (W) X 4m (H)

  

KERNEL STATION 26. Nut Silo

1

    

Model - TCK05605 Type - Cylindrical Storage Tank Capacity - 30000L Diameter - 2.5m Length - 6m

27.

1

   

Model - VG-8T Type - Ripple Mill Capacity - 6 ton / hour Power - 11 kW

Ripple Mill

28.

Claybath (Including Mixer and Clay Solution Tank, Conical Separation Tank, Pump, Discharge Pump, Vibrating Screen)

1

  

Model - DG Claybath System Capacity - 6 ton / hour Power - 11 kW

29.

Kernel Silo

1

  

Model - BC30 Type - Circular section with conical bottom Capacity - 30000L

BOILER STATION 30. Boiler

1

    

Model - Takuma N 600 Type - Water Tube Boiler Capacity - 36 ton / hour Working Pressure - 22 bars Temperature - 260°C

POWER STATION 31. Steam Turbine

1

    

Model - W-1350C Type - Non-Condensing (Back-pressure) Capacity - 28 ton / hour Output Power - 1200 kW Speed - 5400 rpm

32.

Back Pressure Vessel

1

   

Model - BEITE 012 Type - Pressure Vessel Capacity - 12000L Working design Pressure : 3.5 kg/cm²

33.

Diesel Engine Set

1

  

Model - Komatsu SAA6D125-P400 Output Power - 450 kW Dimension - 3.3 (L) x 1.12 (W) x 1.79 (H)

34.

Fuel Tank

1

    

Model - Fuel Oil Double Wall AST - ULC S602 Type - Cylindrical Fuel Tank Capacity - 20000L Diameter - 1.94 m Length - 4.5 m

EFB STATION 35. EFB Shredder Machine

1

   

Model - SE/BCE-1 L Capacity - 6 ton / hour Power - 75 kW Dimension - 3.1m (L) X 2.2m (W) X 1.3m

36.

1

   

Model - SE/SSP 50 Capacity - 6 ton / hour Power - 45 kW Dimension - 3.8m (L) X 2m (W) X 1.25m (H)

EFB Fiber Press

37.

Hammer Mill Machine

1

   

Model - YTH-7.100 Capacity - 6 ton / hour Power - 75 kW Dimension - 1.145m (L) X 1.07m (W) X 1.35m (H)

38.

Rotary Dryer

1

    

Model - BN30 Type - Rotary Capacity - 6 ton / hour Power - 30 kW Dimension - 5.5m (L) X 3.5 (W) X 3m (H)

39.

Baler Machine

1

   

Model - SHBA2-200 Capacity - 15 baler / hour Power - 35 kW Dimension - 7.6m (L) X 5.1m (W) X 5.1m (H)

3.5 WASTE PRODUCTS A large amount of biomass is produced at palm oil mills during the processing of FFB. Those biomass included palm shell, mesocarp fiber and EFB. In conventional method, palm shell and mesocarp fiber will used as boiler fuel to generate electricity for internal usage. Meanwhile, the old disposal methods of EFB are burning in incinerator, dumped in landfills and sell to plantation for mulching. As the EFB will be utilized to produce EFB fiber, the waste products in this proposed mill are palm shell and mesocarp fiber. Palm shells are the shell factions left after the nut has been removed in the palm oil mill. Figure 35 shows the bulk physical and chemical characteristics of palm shell. For every one ton of FFB processed, 5 % of palm shell will be produced. Palm shells are used as boiler fuel in steam power plant due to its high calorie value and low content of ash and sulphur [7]. Therefore, all the palm shell produced will be used to generate energy in our proposed plant.

Figure 35: bulk physical and chemical characteristics of palm shell. Mesocarp fiber is another waste product from palm oil milling process. Mesocarp fiber is contained in the oval shaped palm fruit which consists of yellowish red oily flesh

mesocarp and single seed Palm Kernel Nut. The mesocarp fiber is then separated from Palm Kernel Nut by cyclone separator. Mesocarp fibre contains less than 6% oil residue with calorific value of 19000kJ/kg [7]. Figure 36 shows the mesocarp fiber on the fresh oil palm fruit. Since palm oil mill is self-sufficient in energy, the mesocarp fiber is mixed with kernel shell and being utilized as a medium of boiler fuel to generate electricity for the proposed mill.

Figure 36: The mesocarp fiber on the fresh oil palm fruit. 3.6 TECHNOLOGY AND ALTERNATIVE ROUTES FOR PRODUCING CRUDE PALM OIL 3.6.1 Continuous and Conventional Sterilization In order to maximize the production of CPO in a palm oil mill, various technologies have been developed by the people in the industry. Being the first process in the mill, sterilization is a crucial part of the whole processes since it influences the quantity and the quality of CPO produced later. FFBs are cooked using steam as the heating medium in a sterilization process. A lot of steam is used in this part of the mill that accounts thirty to sixty percent of the total process steam supplied from the boiler. Therefore, the type of sterilizer technology chose greatly affects steam and power consumption of the sterilization process.

With the growing demand for energy efficiency at palm oil mills, the selection of sterilizer is based mainly on its relevance to steam and power consumption because this will affect the overall energy efficiency of the palm oil extraction process. It is vital to ensure that the sterilizer operates correctly so that it will produce minimum oil loss and generate proper oil extraction rate. Oil losses that correspond from sterilizing process are oil losses in condensate, empty fruit bunch, un-striped bunch and partly striped bunch. Basically sterilizers are design to operate continuously or in batches. The conventional and continuous type processes are described to select most economical sterilizer technology. In a conventional sterilization, the sterilization process of fresh fruit bunches is carried out in cylindrical pressure vessels that lies horizontally or vertically. The concept of conventional sterilization is shown in Figure 37. After that they are filled with steam under pressure as a batch process. The most common type of sterilizer used is the horizontal sterilizer fitted with two quick opening doors [11]. Fruit cages are used to transfer the bunches in and out of sterilizers, and various other equipment are needed for handling these cages, including overhead cranes, tippers, conveyors, transfer carriages and tractors. Currently, there are many types of innovation and improvement of conventional type sterilizers such as cage material handling using indexing system, CMC Systems, Vertical Sterilizer and Tilting Sterilizer. To comply with the amount of FFB processed per day, palm oil mill owners usually choose one of these technologies to be implemented. The introduction of a three peak cycle process in the sterilization process allows a synchronized integration. This involves the discharge of condensate and air in the pressure vessel, fasten pressure built and evenly distributed steam. From this batch type process, time and steam usage can be saved. With horizontal position, the cylindrical vessel sterilizer has fairly good disposition because the oil palm fresh fruit bunches placed in cages with a low stacking height are more uniformly spread out in this position across the length of the elongated vessel, as opposed to a vertical sterilizer. Thus, when pressurized steam is injected into the interior of the horizontally positioned cylindrical vessel, the steam can reach out to different directions and corners of the contents within

the cages thereby helping treatment of the fruit bunches. Due to the low stacking height of the fruit bunches in the cages, condensate drains out freely from the fruit bunch stack facilitating heat penetration. Batch process however arrests the oil quality deterioration due to enzymatic activity. Considerable space and a system of rails are required to facilitate the fitting of the cages and the charging and discharging of the sterilizers. Generally, when the received crops are less in capacity, the fruit bunches will be bulked and processed the next day. This will result in the increment of FFA content in the fruits and leads to poor quality of CPO.

Figure 37: Concept of Conventional Sterilization Process. Continuous type sterilization process is also famously adopted in palm oil mill due to its much beneficial factors if compared to batch sterilization. The concept of continuous sterilization process is shown in Figure 38. The continuous sterilizer was introduced as an alternative to pressure vessels and batch process of sterilization and offer advantage in terms of use of unpressurised heating cabin and steady steam demand for the sterilization process [12]. In current technology, the process is carried out in a heating cabin operating with steam at atmospheric pressure. Initially, the fruit bunches are split using a mechanical splitter machine before it is transported by scraper conveyor within the heating cabin to expose the material to steam. The splitting of the fruit bunches facilitates steam penetration into inner layers of the fruit bunch. A significant advantage of continuous sterilization over batch sterilization is that it renders the palm oil milling process a continuous operation from start to finish, making it cost-effective to automate the bunch handling operations. It also eliminates the use of

sterilizer cages, rail tracks, overhead cranes, tippers, transfer carriages and tractors and thereby facilitates the design and construction of mills having significantly smaller footprints than conventional mills The process leads to improvements in the design of mills, reduces the number of process operators, lowers the operating and maintenance costs, and simplifies mill operation. Mills using the process can be more easily supervised and automated. By avoiding the use of pressure vessels for sterilization and cages and cranes for the handling of bunches, palm oil mills are made safer for operators. The use of conveyors in place of cages also minimizes spillage of fruits and oil making mills cleaner. Although the new process is carried out using steam at low or atmospheric pressure, the process significantly improves strippability of bunches as researched by Sivasothy. A plus point is that avoiding fluctuations in the steam flow to the sterilization process provides a considerable advantage in maintaining overall process steam pressures and temperatures in the mill. However, the continuous sterilizer suffers a significant disadvantage in terms of high steam consumption.

Figure 38: Concept of Continuous Sterilization Process.

3.6.2 Common Batch Sterilizers 3.6.2.1 Horizontal Double-Door Sterilizer with Wire Rope Winch System for Cage Movement One of an outdated technology of a conventional palm oil mill is the usage of wire rope winch system for cage movement. In the reception area of a palm oil mill, FFBs will be loaded through a loading ramp hopper to feeding point. Then, they are fed into the fruit cages which act as holder of FFB to be sterilized inside a long horizontal sterilizer. The wire rope winch system is used to transport the fruit cages from the loading area. It is a human dependable system since operators need to manually handle the rope between the fruit cages and the winch system during an operation. After fed with FFB, the fruit cages will be transported using the system to pull them along a rail track system into the sterilizer. The process of marshaling is facilitated by arranging 7 cages in train order. The train of cages runs out at the further end of the arches by means of wire rope attached to hydraulic capstans [23]. An intermediate between the loading area and the sterilizer is the cage transfer carriage which acts as lane changer for the cages. Figure 39 to 41 show the typical equipment in conventional sterilization station.

Figure 39 to 41: The conventional sterilization station with the used of winch system and horizontal sterilizer. After sterilization process, once again the train of fruit cages will be winched into the tippler to be rotated for unloading purposes. The system is specially design for palm oil mill horizontal line pull for position in between sterilizer rail track line. It consists of bogies, winch, wire rope and hook, guide bollard, rail track system and fruit cages transfer carriage. The conventional system is still considered impractical due to the facts

that the sterilizer uses horizontal technology which posed greater impacts towards the workers safety and health. Some of the work activities require operators to perform the works manually such as closing and open the sterilizer door, install and uninstall chain from cages, working in confined space, and replace packing of sterilizer door. 3.6.2.2 Horizontal Double-Door Sterilizer with Indexing System for Cage Movement A better way to replace the wire rope winch system is the usage an auto-cage transporter known as the indexing system [11]. It is a cage material handling that eliminates the need and use of tractors, bulldozers, capstans and winches that have been applied in a conventional system. The so called twin cage indexer system is only suited for long horizontal double door sterilizer installed in a palm oil mill. The system is less maintenance, bumper-to-bumper cage movement for single cage and/or twin cage movement. Figure 42 shows the indexing system for cage movement. Furthermore, it is a much efficient material handling system for the sterilization process to perform synchronization and control of equipment from fruit reception to sterilizer station and to threshing and press station, leading to improvement in productivity and consistency in throughput.

Figure 42: Indexing system for cage movement. On top of the sterilization process, a platform is installed providing a good view of the production area. An advantage of the indexing system is it improves working conditions and safety for operators as well as reducing manual handling of the cages. Besides that, it is easier to monitor via an automation system with remote console panel

control. Moreover, the system has low maintenance cost due to the reduced wear and tear by good and precise cage movement. Using a single touch control on push buttons, the system provides ease of operation. In terms of control, the indexing system use auto mode to move the hydraulic cylinder on indexer, manual operation to operate via push buttons and by-pass operation to operate via local panels. 3.6.2.3 Horizontal Single-Door Sterilizer with Compact, Modular, Continuous Systems for Cage Movement Another method for the movement of fruit cages is the CMC system. If compared to the indexing system, the CMC system is only for horizontal sterilizer with single door in sterilizer station. It is also for owner looking for an enhanced automated material handling and steam management process controlled in a smaller foot print area [11]. Figure 43 shows the CMC system that implemented in the sterilization station. The CMC system is actually derived the cage movement from the indexing system. The indexer movement is based on twin cage. As the building footprint is small, thus the CMC system is compact, modular, continuous run material handling system for the sterilization process to perform synchronization and control of flow of FFB from loading ramp to sterilizer station and then to threshing and press station. This leads to significant improvement in productivity and enhanced throughput.

Figure 43: CMC system for cage material handling.

Similar to the indexing system, a platform on top of the sterilization process is also installed to view the production area. One of the important benefits is the CMC system is an automated process of continuous flow and integration of material handling to sterilization process. Less cage movement operation is needed too due to its smaller footprint area. Akin to the indexing system, CMC system also improves the working conditions, work safety for operators, ease of monitoring, low maintenance cost and ease of operation. The control mechanism is in the same way as that in indexing system except there is no by-pass operation. 3.6.2.4 Vertical Sterilizer Modern batch-type sterilization, the vertical sterilizer enables a “one way traffic” operation of a palm oil mill [19]. Figure 44 shows a typical vertical sterilizer. This is due to the loading of FFBs from the top of the sterilizer and discharged at the bottom. Then it is directly transported to the stripping station for the separation of fruitlets and bunches. Its handling system moves away completely from the conventional fruit cages doublehandling arrangement. It is designed to sterilize FFB at superior steam efficiency of 60 minutes cooking (for 30 tons FFB) gives a greater preservation of FFB quality. FFB is fed into the vertical sterilizer using the robust scrapper bar conveyers at control of a push button. All these handling is completed using only maximum two operators.

Figure 44: Vertical Sterilizer.

Operation cost saving is proven to be halved compares to conventional cages system. Capital investment for vertical sterilization system is so far the lowest amongst the other sterilization system available in the market. It is also a relatively greener technology due to it approximately 40% savings in steam consumption compares to conventional horizontal sterilization technology. The less amount of steam used resulted in relatively reduced condensate produced; which eventually minimized the total POME, a high strength liquid waste generated during milling process. Other than that, the steam consumption is low with minimal heat loss. Small space is also needed as a requirement to install the sterilizer in the sterilization area of a palm oil mill. However it needs a water filling system and auger discharge making a delay for the process. A disadvantage of using the vertical position sterilizer is that the oil loss is high due to the compacted fruits at the bottom. Furthermore there is still dead space during its operation which reduces the capacity and throughput. However, due to considerable stacking height and resulting fruit bunch compression in the vertical vessel, air removal and condensate drainage from the fruit bunch stack is restricted and this impedes heat penetration. The design requires higher steam pressure with multiple-peak cycles and a longer sterilization time for effective heat treatment of the fruit bunches resulting in higher steam consumption. 3.6.2.5 Tilting Sterilizer Of all the batch type sterilizers, the most up-to-date technology is the tilting sterilizer. An award winning equipment developed to improve many issues in palm oil mill is what makes this sterilizer the most efficient way of sterilization process [28]. This is the type of sterilizer that will be implemented in the proposed mill. Figure 45 shows a typical tilting sterilizer. A very good reason to install the tilting sterilizer in a new palm oil mill is that it needs only 30% of the space occupied by horizontal sterilizer. Simple design with fewer moving parts, the tilting sterilizer completely diminished the usage of FFB cages, rail tracks, transfer carriages, capstans, bollards, winches, overhead-cranes, hoists, cage indexer system, cantilever bridges, tipper, pushers and tractors, EFB press, EFB splitter and SFB post heating cooker. These produce a very low construction cost because of less machinery and reduced down-time. To top that, only 2 to 3 operators are

needed to operate a multiple sterilizer station that results in lower operation and maintenance costs in conjunction with much fewer moving parts. Steam consumption also reduced by half of conventional system with the achievement of the shortest steaming time in industry of 45-50 minutes. Furthermore, it has a minimum dead space by compaction of fruits inside the sterilizer during an operation. Besides that, the tilting sterilizer minimizes oil loss oil loss in Empty Fruit Bunches, no oil drips, and condensate is directly used for dilution. Higher quality oil extraction can be obtained in comparison with other sterilizers along with the oil recovery in condensate recovered. As of the energy efficiency, lower power consumption by the lesser machinery than conventional system. Moreover the sterilizer itself is easier and safer to operate than the conventional horizontal sterilizers due to the fact that direct loading through the conveyer from the FFB loading area. In terms of clean working environment, an automatic operation with safety interlocks is applied in the system. As the name implies the tilted position allows FFB to slide and roll down during filling making sure that minimum damage of FFB.

Figure 45: A tilting sterilizer.

3.7 PROCESS FLOW SHEET 3.7.1 Process Operation Chart Process operation chart is the simple graphic representation that gives an overall view for the entire process. It includes the points where materials are produced and the sequence of inspection for all operations. It also shows the chronological sequence for all activities. 3.7.1.1 Process Operation Chart of EFB Fiber Production EFB Shredding

Pressing

Hammering

Drying

Dried Strand Fiber

Bailing

EFB BALER FIBER

Liquor

3.7.1.2 Process Operation Chart of Palm Oil Milling Processes FFB

Sterilization of Fresh Fruit Bunches

Threshing/Strip ping

EFB

Fruit Digestion

Pulp Pressing

Screening Depericarping

Clarifying

Fiber

Drying

Purifying

Cracking Separation I

Drying

Winnowing Separation I Separation

CPO Sludge

Drying

Kernel

Shell

3.7.2 Process Block Diagram Process block diagram is the flow diagram that gives an overview of the process structure with process units. It represents the main processing section in terms of functional blocks. In process block diagram, the material balance for the overall processes is included. In the proposed mill, the plant capacity is 240 ton FFB/day. This is a batch process where 8 batch of CPO will produce per day. For every ton of FFB be processed, 21% of CPO will produced. The palm kernel and EFB produced from every one ton of FFB be processed are 5.6% and 22% respectively. The process units is based on one day production where the amount of FFBs be processed per batch is 30 ton. The block diagram of CPO and EFB fiber are based on one day production. For one day production, the total feed in of EFB into EFB fiber production line is 52,800 kg. The total feed in of FFBs is 240,000 kg per day. The detailed calculation of mass balance will show in the following part. 3.7.2.1 Process Block Diagram of EFB Fiber Production 52,800 kg/day EFB Shredding 52,800 kg shredded EFB/day Pressing

10,560 kg Liquor/day

42,240 kg shredded EFB/day Hammering 42,240 kg single strand fiber/day Drying 24,000 kg dried strand fiber/day Bailing 240 Baler Fibers/day (100 kg each) 3.7.2.2 Process Block Diagram of Palm Oil Milling Processes

18,240 kg Moisture/day

240,000 kg FFB/day

48,000 kg Steam/day at 50 Psig

68,472 kg Condensate/day

Sterilization of Fresh Fruit 211,200 kg Sterilized FFB/day

Threshing/Stripping

9,600 kg Steam/day

8,328 kg Exhaust Steam/day

52,800 kg EFB/day

158,400 kg Sterilized Fruitlets/day

Fruit Digestion 84,000 kg Crude Oil/day

Screening 126,000kg Diluted Oil/day

168,000 kg Digested Fruitlets/day

42,000 kg Dilution Water/day

Depericarping

21,600 Kg Oil + Water (Recycle Oil)/day

Clarifying

96,600 kg Sludge /day

51,000 kg Settled Oil/day 120 kg Dirt Purifying and Water/day 50,880 kg Oil/day 480 kg Drying Moisture/day

Separation I 96,000 kg Sludge/day

Separation II 26,400 kg Water/day

600 kg Sand/day

84,000 kg Press Cake/day

Pulp Pressing

50,400 kg Production oil/day 74,400 kg sludge/day

37,800 kg Wet Nuts/day

Drying

2,280 kg Moisture/day

35,520 kg Dry Nuts/day

Cracking 35,520 kg Cracked 7,440 kg Mixture/day Light Shell Winnowing and Dust/day 28,080 kg Shell and Kernel/day 12,480 kg Shell/day 15,600 kg Wet Kernel/day

Separation

26,400 kg Water/day

Drying 170,472 kg Effluent/day

3.7.3 Process Flow Diagram

46,200 kg Fiber/day

13,440 kg Kernel/day

2,160 kg Moisture/day

The process flow diagram is the central to the design task. It indicates the general flow of plant processes and equipment. It shows the process route and process conditions of each station. The flow diagram of process plants is based on ISO 106298. 3.7.3.1 Process Flow Diagram of Palm Oil Milling Processes Figure 46 is the process flow diagram for CPO and palm kernel production. There a total of 40 streams in the production line. The stream 1 to stream 27 is the process routes for CPO production. The stream 28 to stream 40 is the process routes for palm kernel production. Table 8 shows the detailed description of the process condition in each stream with the used of equipment.

Figure 46: Process flow diagram of Palm Oil Milling Processes.

Table 8:The description of process flow diagram.

Stream Process 1 Sterilization

Equipment Tilting Sterilizer

2

Threshing

Thresher

3 4

EFB fiber production Transferring Fruitlet

Refer section 3.7.3.2 Conveyor

5

Digestion

Digester

6

Pressing

Screw Press

7

Separating Nut and

Depericarper & Nut

Fiber

Polishing drum

8

Screening

Sand Trap Tank

9

Screening

Vibrating Screen Separator`

10

Sand Disposal

Sand Trap Tank

11

Recycle Sterilized

Conveyor

12

Fruitlets Storing CPO

Crude Oil Tank

13

Clarification

Continuous Settling Tank

14

Storing Pure Oil

Pure Oil Tank

15

Purification

Purifier

16

Storing Purified Oil

Holding Tank

Process Condition  Pressure=50psig  Temperature=150 °C  Time=90 minutes  Pressure= 14.696 psi  Temperature=32 °C  Time=30 minutes Refer section 3.7.3.2  Pressure= 14.696 psi  Temperature=32 °C  Pressure= 14.696 psi  Temperature=90 °C  Time=30 minutes  Pressure= 14.696 psi  Temperature=32 °C  Time=30 minutes  Pressure= 14.696 psi  Temperature=32 °C  Time=60 minutes  Pressure= 14.696 psi  Temperature=100 °C  Time=30 minutes  Pressure= 14.696 psi  Temperature=32°C  Time=30 minutes  Pressure= 14.696 psi  Temperature=100 °C  Pressure= 14.696 psi  Temperature=32 °C           

Pressure= 14.696 psi Temperature=90 °C Pressure=14.696 psi Temperature= 90 °C Time=120 minutes Pressure=14.696 psi Temperature= 90 °C Pressure=14.696 psi Temperature= 60 °C Time=120 minutes Pressure=14.696 psi

17

Removing Sludge

To POME Pond

18

Drying

Vacuum Dryer

19

Storing CPO

CPO Tank

20

Dispatch CPO

Shipment Truck

21

Sludge Separation I

Sludge Buffer Tank

22

Sludge Separation II

Sludge Drain Tank

23.

Removing Sludge

Sludge Separator

24.

Recycling Oil From

Sludge Oil Tank

25.

Sludge Clarifying Recycle

Continuous Settling

26.

Oil Removing Sludge to

Tank To Sludge Pit

27.

Sludge Pit Discharge Sludge

To POME Pond

28.

Remove Impurity

Pneumatic Fiber

29.

From Fiber Nut Drying &

System Nut Silo

Storing 30.

Burning Fiber

Boiler

31.

Cracking

Ripple Mill

32.

Winnowing

Winnowing Column

33.

Purifying Fiber

Fiber Cylone

                  

Temperature= 70 °C Pressure=14.696 psi Temperature= 70 °C Pressure=14.696 psi Temperature= 90 °C Time=60 minutes Pressure=14.696 psi Temperature= 50 °C Time=30 minutes Pressure=14.696 psi Temperature= 30 °C Pressure=14.696 psi Temperature= 70 °C Pressure=14.696 psi Temperature= 70 °C Pressure=14.696 psi Temperature= 70 °C Pressure=14.696 psi Temperature= 70 °C

 

Pressure=14.696 psi Temperature= 90 °C

 

Pressure=14.696 psi Temperature= 70 °C

   

Pressure=14.696 psi Temperature= 70 °C Pressure=14.696 psi Temperature= 40 °C

           

Pressure=14.696 psi Temperature= 40 °C Time=60 minutes Pressure=30 psi Temperature=180 °C Pressure=14.696 psi Temperature= 40 °C Time=60 minutes Pressure=14.696 psi Temperature= 40 °C Time=60 minutes Pressure=14.696 psi

34.

Burning Fiber

Boiler

35.

Separating Shell and

Claybath

Kernel 36.

Storing Shell

Shell Bunker

37.

Kernel Drying

Kernel Dryer Track

38.

Burning Shell

Boiler

39.

Storing Kernel

Kernel Silo

40.

Dispatch Kernel

Shipment Truck

                

Temperature= 40 °C Pressure=30 psi Temperature=180 °C Pressure=14.696 psi Temperature= 40 °C Time=60 minutes Pressure=14.696 psi Temperature= 40 °C Pressure=14.696 psi Temperature= 80 °C Time =60 minutes Pressure=30 psi Temperature=180 °C Pressure=14.696 psi Temperature= 40 °C Pressure=14.696 psi Temperature= 40 °C

3.7.3.2 Process Flow Diagram of EFB Fiber Production Figure 47 is the process flow diagram for CPO and palm kernel production. There a total of 40 streams in the production line. The stream 1 to stream 10 is the process routes for EFB fiber production. Table 9 shows the detailed description of the process condition in each stream with the used of equipment.

Figure 46: Process flow diagram of EFB Fiber Production.

Table 9:The description of process flow diagram. Stream Process 1 Transfer EFB to

Equipment Conveyor

Process Condition  Pressure= 14.696 psi  Temperature=32 °C

2

conveyor Transfer EFB to

Conveyor

Pressure= 14.696 psi Temperature=32 °C

3

Collection Point Shredding EFB

 

EFB Shredder

                    

Pressure= 14.696 psi Temperature=32 °C Time=60 minutes Pressure= 14.696 psi Temperature=32 °C Time=60 minutes Pressure= 14.696 psi Temperature=32 °C Pressure= 14.696 psi Temperature=32 °C Time=60 minutes Pressure= 14.696 psi Temperature=100 °C Time=120 minutes Pressure= 14.696 psi Temperature=32 °C Time=60 minutes Pressure= 14.696 psi Temperature=32 °C Pressure= 14.696 psi Temperature=32 °C

Machine 4

Pressing EFB

EFB Fiber Press Machine

5

Removing Liquor

To POME Pond

6

Hammering

Hammer Mill Machine

7

Drying

Rotary Drying

8

Baling

Baling Machine

9

Storing

To EFB Fiber store

10

Dispatch EFB Fiber

Shipment Truck

3.8 PROCESS SCHEDULING 3.8.1 Process Scheduling Description In the proposed mill, the plant capacity is 240 ton FFB/hours, a total of 8 batch FFBs will be processed. The amount of FFB being processed is 30 ton per batch. At the same time, 8 batches of palm kernel and EFB fiber will be produced. Table 10 shows the time for each batch of the CPO, palm kernel and EFB fiber production. Table 10: Processing Time. PRODUCTIO

BATCH 1

BATCH 2

BATCH 3

BATCH 4

BATCH 5

BATCH 6

BATCH 7

BATCH 8

N CPO

9AM

11AM

1PM

3PM

5PM

7PM

9PM

11PM

-

-

-

-

-

-

-

-

PALM

6.30PM 1PM

8.30PM 3PM

10.30PM 5PM

12.30AM 7PM

2.30AM 9PM

4.30AM 11PM

6.30AM 1AM

8.30AM 3AM

KERNEL

-

-

-

-

-

-

-

-

EFB FIBER

7PM 11AM

9PM 1PM

11PM 3PM

1AM 5PM

3AM 7PM

5AM 9PM

7AM 11PM

9AM 1AM

-

-

-

-

-

-

-

-

5PM

7PM

9PM

11PM

1AM

3AM

5AM

7AM

3.8.2 Process Scheduling of CPO Production TIME PROCESS

8

9

10

11

12

13

14

15

16

17

18

BATCH 1 STERILIZATION THRESHING DIGESTION PRESSING SCREENING CLARIFICATION PURIFICATION DRYING STORAGE BATCH 2 STERILIZATION THRESHING DIGESTION PRESSING SCREENING CLARIFICATION PURIFICATION DRYING STORAGE BATCH 3 STERILIZATION THRESHING DIGESTION PRESSING SCREENING

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CLARIFICATION PURIFICATION DRYING STORAGE BATCH 4 STERILIZATION THRESHING DIGESTION PRESSING SCREENING CLARIFICATION PURIFICATION DRYING STORAGE BATCH 5 STERILIZATION THRESHING DIGESTION PRESSING SCREENING CLARIFICATION PURIFICATION DRYING STORAGE BATCH 6 STERILIZATION THRESHING DIGESTION PRESSING SCREENING

CLARIFICATION PURIFICATION DRYING STORAGE BATCH 7 STERILIZATION THRESHING DIGESTION PRESSING SCREENING CLARIFICATION PURIFICATION DRYING STORAGE BATCH 8 STERILIZATION THRESHING DIGESTION PRESSING SCREENING CLARIFICATION PURIFICATION DRYING STORAGE

3.8.3 Process Scheduling of Palm Kernel Production TIME

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PROCESS BATCH 1 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 2 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 3 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 4 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 5

DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 6 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 7 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 8 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING

3.8.4 Process Scheduling of EFB Fiber Production

TIME PROCESS

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BATCH 1 SHREDDING PRESSING HAMMERING DRYING BALING BATCH 2 SHREDDING PRESSING HAMMERING DRYING BALING BATCH 3 SHREDDING PRESSING HAMMERING DRYING BALING BATCH 4 SHREDDING PRESSING HAMMERING DRYING BALING BATCH 5 SHREDDING PRESSING HAMMERING

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DRYING BALING BATCH 6 SHREDDING PRESSING HAMMERING DRYING BALING BATCH 7 SHREDDING PRESSING HAMMERING DRYING BALING BATCH 8 SHREDDING PRESSING HAMMERING DRYING BALING

3.9 MATERIAL BALANCE 3.9.1 Law of Conservation of Mass The mass balance calculation was made based on the law of conservation of mass. The capacity of the proposed palm oil mill was 240 ton FFB/day. For every one ton of FFB processed in the mills, 22 % of empty fruit bunch, 19.25% of mesocarp fiber, 5.3% of shell and 5.6% palm kernel were produced. All material balance data are based on [4], [7], [24] and [26]. The mass balance was calculated based on the law of mass balance by with the formula as follow: Minput=Moutput Where Minput = Mass input (kg), Moutput = Mass output (kg) The basis of mass balance was set at one day. 3.9.2 Material Balance of Palm Oil Milling Process 3.9.2.1 Sterilization Station The first stage to produce crude palm oil was to cook the FFB by using steam at pressure of 50 psig. The sterilization process was carried out for 90 minutes under temperature of 150°C. For every one ton of FFB processed, a total of 200 kg steam was required for tilting sterilizer. The steam loss that occurred from this process was 3.47 % for one ton of FFB be processed. This process also generated 88% of SFB and 28.53% of condensate. Calculation:

240,000kg FFB/day

48,000 kg Steam/day at 50 psig

Sterilizatio n 68,472 kg 8,328 kg Exhaust Condensate/day Steam/day

211,200 kg SFB/day

Mass input Solid FFB = 240, 000 kg FFB/day or 240 ton FFB/day 

Non-solid

Steam = 

200 kg steam ×240 ton FFB /day=48,000 kg steam/day ton

Total mass input = 240,000 kg FFB/day + 48,000 kg steam/day = 288,000 kg/day

Mass output Solid SFB = 240,000 kg FFB/day x 88% = 211,200 kg SFB/day  Non Solid Exhaust steam = 240,000 kg FFB/day x 3.47% = 8,328 kg Exhaust Steam/day Condensate = 240,000 kg FFB x 28.53% = 68,472 kg condensate/day 

Total mass output = 211,200 kg SFB/day + 8328 kg Exhaust Steam/day + 68,472 kg condensate/day = 288,000 kg/day

3.9.2.2 Threshing Station In this process, the cooked FFB were fed into a stripper drum to dislodge the fruitlets. The amount of fruitlets obtained was 75% of SFB. A waste product was generated in this station which known as EFB. The quantity of EFB was accounted 22% of every one ton processed FFB. Calculation:

211,200 kg SFB/day

Threshing 52,800 kg EFB/day

158,400 kg Sterilized Fruitlets/day

Mass input 

Solid

SFB = 211,200 kg SFB/day 

Total mass input = 211,200kg/day

Mass output 

Solid

EFB = 240,000 kg FFB/day x 22% = 52,800 kg EFB/day Sterilized Fruitlets = 211,200 kg SFB/day - 52,800 kg EFB/day = 158,400 kg sterilized fruitlets/day 

Total mass output = 52,800 kg EFB/day + 158,400 kg Sterilizer fruitlets/day = 211,200 kg/day

3.9.2.3 Digestion Station Digestion process is carried out to reheat the sterilized fruitlets and separated it from nuts. This is carried out in the steam heated vessels provided with stirring arms and known as digester. In this process, the amount of steam required was 6.1% of the amount of the feed. Calculation: 9,600 kg Steam/day 158,400 kg Sterilized Fruitlets/day Mass input 

Solid

Digestion

168,000 kg Digested Fruitlets/day

Sterilized fruitlets = 158,400 kg Sterilized Fruitlets/day 

Non-solid

Steam = 158,400 kg Sterilized Fruitlets/day x 6.1% =9,600 kg steam/day 

Total mass input = 158,400 kg Sterilized Fruitlets/day + 9,600 kg steam/day= 168,000 kg/day

Mass output 

Solid

Digested Fruitlets = 168,000 kg Digested Fruitlets/day 

Total mass output = 168,000 kg/day

3.9.2.4 Pressing Station Screw press was used to compress the digested fruitlets to squeeze out the oil. Approximately 50% of crude oil will produced from the digested fruitlets, the remaining solid residual will send to a separation process for recovery mesocarp fiber, palm kernel and palm shell. Calculation: 168,000 kg Digested Fruitlets/day

Pressing 84,000 kg Press cake/day

Mass input 

Solid

Digested fruitlets = 168,000 kg Digested Fruitlets/day 

Total mass input = 168,000 kg/day

84,000 kg Crude oil/day

Mass output 

Solid

Press cake = 168,000 kg Digested Fruitlets/day x 50%= 84,000 kg Press cake/day 

Non-solid

Crude oil = 168,000 kg Digested Fruitlets/day x 50%= 84,000 kg crude oil/day 

Total mass output= 84,000 kg Press cake/day+ 84,000 kg crude oil/day= 168,000kg/day

3.9.2.5 Screening Station For every one ton of FFB processed, dilution water is added in the ratio of 1:2 to the crude oil. Calculation: 42,000 kg Dilution Water/day

84,000 kg Crude oil/day

Screening

126,000 kg Diluted Oil/day

Mass input Non-solid Crude oil = 84,000 kg Crude oil/day Dilution water = 84,000 kg Crude oil/day x 50% = 42,000 kg dilution water/day 

Total mass input = 84,000 kg Crude oil/day + 42,000 kg dilution water/day = 126,000 kg/day

Mass output Non-solid

Diluted oil= 126,000 kg diluted oil/day 

Total mass output = 126,000 kg/day

3.9.2.6 Clarification Station The ratio of recycle oil to diluted oil is 0.171:1. Both of them will flow in the crude oil tank. After 1-3 hours, 45.01 % of settled oil will be produced and the remaining is sludge. 76.6% of sludge will produced from the amount of diluted oil. The sludge will undergo separation process I to remove sand. The amount of sand removed is 0.62 % of the sludge. Then, the sludge will undergo separation process II to recover oil where its amount is 22.5% of the sludge. The remaining amount of sludge is discharge to sludge pit. Calculation: 126,000 kg Diluted oil /day

Clarification 51,000 kg Settled oil/day

21,600 kg Recycle Oil/day

96,600 kg Sludge/day

Separation I

600 kg Sand/day

96,000 kg Sludge/day

Separation II Mass input 

74,400 kg Sludge/day

Non-solid

Diluted Oil =126,000 kg Diluted oil /day Recycle Oil=126,000 kg Diluted oil /day x 0.171 = 21,600 kg Recycle Oil/day 

Total mass input = 126,000 kg Diluted oil /day+21,600 kg Recycle Oil/day=147,600kg/day

Mass output 

Solid

Sand from separation I = (126,000 x 76.6%) kg sludge/day x 0.62% = 600kg sand/day Sludge = (126,000 x 76.6%) kg sludge/day x 77% =74,400 kg sludge/day 

Non-solid

Settled Oil = 126,000 kg Diluted oil /day x 40.5% = 51,000 kg Settled oil/day Recycle Oil=126,000 kg Diluted oil /day x 0.171 = 21,600 kg Recycle Oil/day 

Total mass output = 600kg sand/day + 74,400 kg sludge/day+51,000kg Settled oil/day + 21,600 kg Recycle Oil/day= 147,600 kg/day

3.9.2.7 Purification Station The settled oil will then undergo purification to produce oil. In this process, 0.235% of dirt and water is removed. Calculation: 51,000 kg Settled Oil/day

Purification

120 kg Dirt and Water/day

50,880 kg Oil/day Mass input 

Non-solid

Settled Oil = 51,000 kg Settled Oil/day 

Total mass input = 51,000 kg/day

Mass output Solid Dirt and water = 51,000 kg Settled Oil/day x 0.235%= 120 kg Dirt and Water/day



Non-solid

Oil= 51,000 kg Settled Oil/day x (100-0.235) %= 50,880 kg Oil/day 

Total mass output = 120 kg Dirt and Water/day+50,880 kg Oil/day=51,000kg/day

3.9.2.8 Oil Drying Station The purified oil will undergo drying process with the removed of 0.94% moisture of its content before produce the production oil. The production oil produced is 21% for every one ton of FFB been processed. Calculation:

50,880 kg Oil/day

Mass input 

Drying

480 kg moisture/day

50,400 kg production oil/day

Non-solid

Oil=50,880 kg Oil/day 

Total mass input = 50,880 kg/day

Mass output Non-solid Production Oil = 240,000 kg FFB/day x 21% = 50,400 kg production oil/day Moisture = 50,880 kg Oil/day x 0.94% = 480kg moisture/day 

Total mass output = 50,400 kg production oil/day + 480kg moisture/day =50,880 kg/day

3.9.3 Material Balance of Palm Kernel Production 3.9.3.1 Depericarping Station In this stage, press cake from pressing process will undergo depericarping process to separate mesocarp fibers and nuts. Around 19.25% of mesocarp fiber will formed from every one ton of FFB to be processed. From the depericarping process, 45% of press cake is wet nuts. Calculation:

84,000 kg Press Cake/day

Depericarping

37,800 kg Wet Nuts/day

46,200 kg Mesocarp Fiber/day Mass input 

Solid

Press cake = 84,000 kg Press cake/day 

Total mass input = 84,000 kg/day

Mass output 

Solid

Mesocarp fiber = 240,000 kg FFB/day x 19.25% = 46,200 kg Mesocarp fiber/day Wet nuts = 84,000 kg Press cake/day x 45% = 37,800 kg Wet Nuts/day



Total mass output = 46,200 kg Mesocarp fiber/day+37,800 kg Wet Nuts/day = 84,000kg/day

3.9.3.2 Silo Drying Station The wet nuts will undergo drying process to produce dry nuts. During the process, 6.03% of moisture will formed from the amount of feed. Calculation:

37,800 kg Wet Nuts/day

Drying

35,520 kg Dry Nuts/day

2,280 kg Moisture/day Mass input 

Solid

Wet nuts = 37,800 kg Wet Nuts/day Total mass input = 37,800 kg/day Mass output 

Solid

Dry nuts = 37,800 kg Wet Nuts/day x (100-6.03) % = 35,520 kg Dry Nuts/day 

Non-solid

Moisture = 37,800 kg Wet Nuts/day x 6.03% = 2,280 kg Moisture/day



Total mass output = 35,520 kg Dry Nuts/day + 2,280 kg Moisture/day = 37,800kg/day

3.9.3.3 Nut Cracking Station Palm nuts that had been dried in the silo dryer station were fed to this station to encounter a breakdown process. Calculation:

35,520 kg Dry Nuts/day

Cracking

35,520 kg Cracker Mixture/day

Mass input 

Solid

Dry nuts = 35,520 kg Dry Nuts/day 

Total mass input =35,520 kg/day

Mass output 

Solid

Cracked mixture = 35,520 kg Cracker Mixture/day 

Total mass output = 35,520 kg/day

3.9.3.4 Winnowing station In this station, shells and dust are drawn to the boiler using pneumatic separation which known as winnowing. Around 20.94 % of shells and dust are removed from cracked mixture. Then, the palm shell and kernel mixture will undergo further separation process. Calculation:

35,520 kg Cracker Mixture/day

Winnowing

28,080 kg Shell and Kernel/day

7,440 kg Light Shell and Dust/day Mass input Solid Cracker mixture = 35,520 kg Cracker Mixture/day 

Total mass input = 35,520 kg/day

Mass output Solid Light shell and dust = 35,520 kg Cracker Mixture/day x 20.94% = 7,440 kg Light Shell and Dust/day Shell and Kernel mixture = 35,520 kg Cracker Mixture/day x (100-20.94) % = 28,080 kg Shell and Kernel/day 

Total mass output = 7,440 kg Light Shell and Dust/day + 28,080 kg Shell and Kernel/day = 35,520 kg/day

3.9.3.5 Hydrocyclone Station In the hydrocyclone, separation of kernels from their shells occurred based on the specific gravity. The core of the kernels would move upwards the hydrocyclone, while the shells would fall under the hydrocyclone. Water is added in the ratio of 0.94:1 to kernel and shell mixture in this process which then discharge to effluent pond. For every one ton of FFB processed in the mills, 5.2% palm shell was produced. Calculation: 26,400 kg water/day

Separation

15,600 kg Wet Kernel/day

28,080 kg Shell and Kernel/day 26,400 kg water/day

12,480 kg Palm Shell/day

Mass input Solid Shell and Kernel mixture = 28,080 kg Shell and Kernel/day 

Non-solid

Water input = 28,080 kg Shell and Kernel/day x 0.94 = 26,400 kg water/day 

Total mass input = 28,080 kg Shell and Kernel/day +26,400 kg water/day= 54,480 kg/day

Mass output Solid Palm Shell = 240,000 kg FFB/day x 5.2 % = 12,480 kg Palm Shell/day Wet Kernel = = 28,080 kg Shell and Kernel/day-12,480 kg Palm Shell/day=15,600 kg Wet Kernel/day 

Non-solid

Water output = 26,400 kg water/day 

Total mass output = 12,480 kg Palm Shell/day+15,600 kg Wet Kernel/day+26,400 kg water/day=54,480 kg/day

3.9.3.6 Kernel Drying Station

Kernels from the hydrocyclone were fed into a kernel dryer. In this process, the water content as much as 13.84% contained in the kernels was evaporated. For every one ton of FFB processed in the mills, 5.6% palm kernel was produced. Calculation: 15,600 kg Wet Kernel/day

Drying

13,440 kg Dry Kernel/day

2,160 kg Moisture/day Mass input 

Solid

Wet Kernel = 15,600 kg Wet Kernel/day 

Total mass input = 15,600kg/day

Mass output 

Solid

Dry Kernel = 240,000 kg FFB/day x 5.6% = 13,440 kg Dry Kernel/day 

Non-solid

Moisture = 15,600 kg Wet Kernel/day x 13.84% = 2,160kg moisture/day 

Total mass output = 13,440 kg Dry Kernel/day+2,160kg moisture/day= 15,600kg/day

3.9.4 Material Balance of EFB Fiber Production 3.9.4.1 EFB Shredding Station The amount of EFB produced is 22% for every one ton of FFB to be processed. The EFB will transfer to EFB collection point and undergo shredding process to produce shredded EFB. Calculation: 54,800 kg EFB/day

Shredding

Mass input 

Solid

EFB = 240,000 kg FFB/day x 22% = 54,800 kg EFB/day 

Total mass input =54,800 kg/day

Mass output 

Solid

Shredded EFB = 54,800 kg shredded EFB/day 

Total mass output = 54,800 kg/day

3.9.4.2 Pressing Station

54,800 kg shredded EFB/day

Shredded EFB were being pressed in order to extract the liquor from the bunch. The moisture content of EFB will remove around 19.3%. Calculation: 54,800 kg shredded EFB/day Mass input 

Pressing

42,240 kg shredded EFB/day

10,560 kg Liquor/day

Solid

Shredded EFB = 54,800 kg shredded EFB/day 

Total mass input = 54,800kg/day

Mass output 

Solid

Shredded EFB = 54,800 kg shredded EFB/day-10,560 kg Liquor/day=44,240 kg shredded EFB/day 

Non-solid

Liquor=54,800 kg shredded EFB/day x 19.3% = 10,560 kg Liquor/day 

Total mass output = 44,240 kg shredded EFB/day+10,560 kg Liquor/day=54,800kg/day

3.9.4.3 Hammering Station The fibers were transferred into the Hammer Mill Machine in order to break the fibers into single strand fiber. Calculation:

42,240 kg shredded EFB/day

Hammering

42,240 kg single strand fiber/day

Mass input 

Solid

Shredded EFB=42,240 kg shredded EFB/day 

Total mass input = 42,240kg/day

Mass output 

Solid

Single stand fiber = 42,240 kg Single strand fiber/day 

Total mass output = 42,240kg/day

3.9.4.4 Drying Station The fibers were then undergoes a drying process by using a Rotary Dryer with dust remover system. This process will remove the moisture content of the fibers around 43.2%. Calculation:

42,240 kg Single strand fiber/day

Drying 18,240 kg Moisture/day

Mass input 

Solid

Single stand fiber = 42,240 kg Single strand fiber/day

24,000 kg dried strand fiber/day



Total mass input = 42,240 kg/day

Mass output 

Solid

Dried strand fiber = 42,240 kg Single strand fiber/day-(100-43.2) %= 24,000 kg dried strand fiber/day 

Non-solid

Moisture = 42,240 kg Single strand fiber/day x 43.2% = 18,240 kg moisture/day 

Total mass output = 24,000 kg dried strand fiber/day+18,240 kg moisture/day=42,240 kg/day

3.9.4.5 Bailing Station The dried single strand fiber will bailed into baler fiber. The baler fiber will in the size 100 Kg with dimension 510 mm X 760 mm X 510 mm. Calculation: 24,000 kg dried strand

Baling

240 Baler Fibers (100 kg each)

fiber/day Mass input 

Solid

Dried stand fiber = 24,000 kg dried strand fiber/day 

Total mass input = 24,000kg/day

Mass output 

Solid

Baler fiber = 24,000 kg dried strand fiber/day/100kg = 240 baler fiber



Total mass output = 24,000 kg/day