oil palm mill system and process

OIL PALM MILL SYSTEMS & PROCESS 0

OOIILL PPAALLMM MMIILLLL,, SSYYSSTTEEMMSS AANNDD PPRROOCCEESSSS.. BByy NNooee ll WWaammbbee cckk (( RRee vvii sseedd JJuunnee,, 11999999 ))

& 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.


& 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) To be suitable in every respect for processing fruit from Tenera palms; b) To recovery with the minimum loss the palm oil and the kernels; c) To produce oil and kernels of the highest quality; d) To facilitate the disposal of the shell, fibre; and empty bunches; e) 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.

f) 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; g) To be reliable and suitable for local conditions of labour supervision and maintenance. h) 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.

i) 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.

j) Designed for cost effectiveness for operation and maintenance. & 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.


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. & 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.

TENERA MATERIAL COMPOSITION ( PORLA STD ) Empty bunch 25% = Nos 7% = ash 0.5%

= water 16% = Oil 2% Evaporation 10%

Fruitlets 65% = nuts 15% = kernel 6 % = pericarp 50% = NOS 7.5% = water 19.5%

Total PFB 100% = Oil 23% ==== Total Oil Plus FFA = 25% to Palm Fruit Bunch


& 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 harvester’s 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 PROCESSING. The flow diagram and matrix relating to the processing of fruit from Tenera 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. Once this enzyme has been inactivated the rise of the FFA is virtually stopped. 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.


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 automatic 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.

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.

A STERILISER STATION WITH SINGLE DOOR STERILISERS


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


The fruit mash then passes to the screw presses (capacities of 10–16Mt 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) The crude oil which consists of water, dirt and palm oil. This is passed to the purification

section; b) Nuts: 15% of the ffb. Is separated by the depericarper and kernel plant for the recovery of the

kernels; c) 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). 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.


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.

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 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 60ºC 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 260ºC 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.


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.


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, clarification 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


The table below presents the typical physical and chemical properties of raw effluent from Oil palm milling process.

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 – BOD 20 mg / l Standard B – For discharge to waterways shall be less than - BOD 50 mg / l Standard C – For discharge to land & field shall be less than - 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 Oil Palm Mill Schematic Process Flow q Oil Palm Process Matrix q Process Mass flow and losses during Production Noel Wambeck / October. 1997 / Revised June 23, 1999.

PARAMETER MEAN pH 4.1 BOD 25,000 COD 53,630 Total Solids 43,635 Suspended Solids 19,020 Volatile Solids 36,515 Ammoniacal Nitrogen 35 Total Nitrogen 770 Oil and Grease 8,370 * All values except pH are in milligrams per liter ( mg / L) Source : PORIM

ALTERNATIVE CAGE TIPPLER SYSTEM

DECANTER FOR SOLIDS REMOVAL

EMPTY BUNCH DISPOSAL BY INCINERATION FIELD APPLICATION OR OIL RECOVERY

DRY KERNEL 7% moisture 4.6% dirt.

CRUDE PALM OIL 0.09% moist. 0.009% dirt.

Designed by Noel Wambeck - 25th. July 1992

05b. Matrix OPM Process.xls

MATRIX OIL PALM MILL PROCESS. BASED ON MALAYSIA TENERA MATERIAL WITH 25% OIL CONTENT

POINT SAMPLE AT POINT Mill Capacity: mt FFB / Hr > 1 3 5 10 20 30 45 60 90 120% / FFB OIL WATER SOLID OTHER Weight in kg.

A Fresh fruit bunches 100 25 48.5 26.5 kg 1,000 3,000 5,000 10,000 20,000 30,000 45,000 60,000 90,000 120,000

B Empty bunches 25 0.75 18 6.25 0 250 750 1,250 2,500 5,000 7,500 11,250 15,000 22,500 30,000

B1 Liquid from EB Press 8.3 0.249 7.387 0.664 0 83 249 415 830 1,660 2,490 3,735 4,980 7,470 9,960

B2 Potash ( Bunch ash ) 0.5 0.5 5 15 25 50 100 150 225 300 450 600

C Fruitlets on bunch 66 24.25 37 7 0 660 1,980 3,300 6,600 13,200 19,800 29,700 39,600 59,400 79,200

C1 Fruitlets in Empty bunch loss 2 0.735 1.121 0.212 0 20 60 100 200 400 600 900 1,200 1,800 2,400

D Digested mash 64 23.52 35.88 6.79 0 640 1,920 3,200 6,400 12,800 19,200 28,800 38,400 57,600 76,800

D1 Press Cake 26 1.56 10.9 14.0 0 260 780 1,300 2,600 5,200 7,800 11,700 15,600 23,400 31,200

D2 Extraction CPO & water ex-press 38 21.96 15.2 0.84 0 380 1,140 1,900 3,800 7,600 11,400 17,100 22,800 34,200 45,600

E Wet Fibre & Nuts to depericarper 25.75 1.55 10.82 13.39 0 257 771 1,285 2,570 5,140 7,710 11,565 15,420 23,130 30,840

E1 Wet Fibre to boiler 12.0 1.08 3.60 6.48 0 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400

E2 Wet Nut Ex- winnowing 13.75 0.47 0.76 12.53 0 137 411 685 1,370 2,740 4,110 6,165 8,220 12,330 16,440

F Cracked Mixture 12.5 0 125 375 625 1,250 2,500 3,750 5,625 7,500 11,250 15,000

F1 Kernel 5.5 0 55 165 275 550 1,100 1,650 2,475 3,300 4,950 6,600

F2 Shell 7 0 70 210 350 700 1,400 2,100 3,150 4,200 6,300 8,400

F3 Water for Hydrocyclone 80 80kg 0 80 240 400 800 1,600 2,400 3,600 4,800 7,200 9,600

F4 Clay for Claybath system 5 5kg 5 15 25 50 100 150 225 300 450 600

G Crude oil diluated with water 53.2 21.96 30.4 0.84 0 532 1,596 2,660 5,320 10,640 15,960 23,940 31,920 47,880 63,840

G1 Clarified crude oil to Purifier 25.00 21.96 2.20 0.84 0 250 750 1,250 2,500 5,000 7,500 11,250 15,000 22,500 30,000

G2 Sludge to Separator 42.31 21.74 19.81 0.8 0 423 1,269 2,115 4,230 8,460 12,690 19,035 25,380 38,070 50,760

H Clean oil to Oil dryer 23.91 21.74 2.17 0 239 717 1,195 2,390 4,780 7,170 10,755 14,340 21,510 28,680

H1 Clean & dry CPO to stoarge tank 21.52 21.50 0.01 0.009 0 215 645 1,075 2,150 4,300 6,450 9,675 12,900 19,350 25,800

J Raw water 1000 1000kg kg 1,000 3,000 5,000 10,000 20,000 30,000 45,000 60,000 90,000 120,000

J1 Boiler feed water 700 700 kg kg 700 2,100 3,500 7,000 14,000 21,000 31,500 42,000 63,000 84,000

J2 Precess water 120 120kg kg 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400

J3 Domestic water 180 180kg kg 180 540 900 1,800 3,600 5,400 8,100 10,800 16,200 21,600

K Solid waste fuel to boiler ( 30% moist.) 43 0.01 12.9 30.09 430 1,290 2,150 4,300 8,600 12,900 19,350 25,800 38,700 51,600

K1 Fibre 12 0.016 3.6 8.384 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400

K2 Shell 8 0.008 1.2 6.792 80 240 400 800 1,600 2,400 3,600 4,800 7,200 9,600

K3 Light particals 0.5 0.0005 0.025 0.4745 5 15 25 50 100 150 225 300 450 600

K4 De-oiled empty bunches 22.5 0.008 6.75 15.742 225 675 1,125 2,250 4,500 6,750 10,125 13,500 20,250 27,000

L Boiler steam generation ( kg / ton FFB ) 660 660kg 660 1,980 3,300 6,600 13,200 19,800 29,700 39,600 59,400 79,200

L1 Turbine steam requirement 600 600kg 600 1,800 3,000 6,000 12,000 18,000 27,000 36,000 54,000 72,000

L2 Sterilisation steam requirement 540 540 kg 540 1,620 2,700 5,400 10,800 16,200 24,300 32,400 48,600 64,800

L3 Process heating steam requirement 120 120 kg 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400

M Wast water Effluent ( kg / ton FFB ) 1000 1000kg kg 1,000 3,000 5,000 10,000 20,000 30,000 45,000 60,000 90,000 120,000

M1 From Clarification 550 kg 550 1,650 2,750 5,500 11,000 16,500 24,750 33,000 49,500 66,000

M2 From Steriliser condensate 150 kg 150 450 750 1,500 3,000 4,500 6,750 9,000 13,500 18,000

M3 From PK recovery plant 80 kg 80 240 400 800 1,600 2,400 3,600 4,800 7,200 9,600

M4 Boiler blow down 120 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400

M5 From OTHERS & cleaning 100 kg 100 300 500 1,000 2,000 3,000 4,500 6,000 9,000 12,000

N Power generation ( kw / ton FFB / hr ) 25 KW 25 75 125 250 500 750 1,125 1,500 2,250 3,000

N1 Process 20 KW 20 60 100 200 400 600 900 1,200 1,800 2,400

N2 Mill lighting & grounds 2 KW 2 6 10 20 40 60 90 120 180 240

N3 Domestic 3 KW 3 9 15 30 60 90 135 180 270 360

Perunding AME / POMProMatrix / 16th November 1998 /nw. 5/10/00

PROCESS MASS FLOW AND LOSSES DURING PRODUCTION

Based on Tenera material

Oil content 24% PRODUCT WASTE LOSS

FFA 2.5% max kg kg kg

Out Flow Evaporation 12100 kg 12.3 Oil Loss 0.3

25 Empty bunches 24.587.7 kg Oil Loss 0.5

31.14 Solids62.7 kg 31.56 Liquids

Water 6.56

31.56 kg Non-oily solids 2

Oil Loss 0.75Oil 22.25

Evaporation 3.8431.14 kg 16.19 Oil Loss 0.1

Fibre 12Kernel Loss 0.25

Evaporation 1.714.95 kg Oil Loss 0.1

Kernel Loss 0.15NUTS Shell 8

5.4 Kernel 5

100 27.25 70.6 2.15

22.25 92.7% Total OIL loss in kg 1.75

5 92.6% Total kernel loss in kg 0.4

Moisture % 0.09 Moisture % 7Dirt % 0.009 Dirt % 5FFA % 3.5 FFA % 2.5

Noel Wambeck Feb.1999

QUALITY

OIL CLARIFICATION

DEPERICARPER

KERNEL RECOVERY

TOTAL in kg

CPO Yield

Palm Kernel Yield

EXTRACTION

( Including FFA as Oil )

FFB input in kg

STERILISER

STRIPPING

TYPICAL FLOW DIAGRAM OF AN EFFLUENT TREATMENT PONDING SYSTEM FOR A 30 MT FFB PER HOUR OIL PALM MILL.

Perunding AME/ ETP Flow Diagram

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

Cooling Pond No 2

302 m3 each Pond 1 day HRT

RAW EFFLUENT INPUT 432 m3/day BOD 25,000 ppm.

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

RECYCLE PUMP

Recycle Activated Sludge ( 100%) 18m3 per hour

Acidification Pond No.1 12 x 15 x 2.5

Acidification Pond No.2

Anaerobic Pond No.1 16 x 160 x 6

Anaerobic Pond No.2

Anaerobic Pond No.3

Anaerobic Pond No.4

Aerobic Pond No.1

16 x 80 x 2.5

Aerobic Pond No.2

302 m3 each Pond 1 day HRT

6629 m3 each Pond 61days HRT

2,611 m3 each 12 days HRT

Pipeline / Tanker

RECYCLE PIPE LINE

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

05g. MatrixPOMEffluent.xls

MATRIX OF AN OIL PALM MILL PROCESS & WASTE WATER EFFLUENT PONDING SYSTEM.

Item Details

1 Milling capacity MT FFB / hr 1 30 45 60 90 120

2 Effluent Generation Ratea. FFB moisture kg 200 6,000 9,000 12,000 18,000 24,000 b. Sterilizer condensiate kg 140 4,200 6,300 8,400 12,600 16,800 c. Clarification station kg 600 18,000 27,000 36,000 54,000 72,000 d. Kernel Plant kg 150 4,500 6,750 9,000 13,500 18,000 e. Other & washwater kg 110 3,300 4,950 6,600 9,900 13,200 Total per hour in kg. kg 1,000 30,000 45,000 60,000 90,000 120,000

3 Flow rate of EffluentPer Hour m 3 1 30 45 60 90 120Per Day ( 24 hours ) m 3 24 720 1,080 1,440 2,160 2,880 HRT of 75 days m 3 1,800 54,000 81,000 108,000 162,000 216,000

4 Suspended Solidsat Fat / Sludge pit ( 22,000 mg/L ) kg 39.6 1188 1782 2376 3564 4752at Final discharge ( 200 mg/L ) kg 0.36 10.80 16.20 21.60 32.40 43.20 Rate of aerobic Biosolids produced kg 39.24 1177.2 1765.8 2354.4 3531.6 4708.8

5 Organic loading Rate ( 0.3 kg BOD/m3/Day ) kg 7.2 216 324 432 648 864

6 Rate of Re-circulation of Anaerobic effluentAnaerobic - HRT 5 days m3 120 3600 5400 7200 10800 14400return to seeding pond ( 50 % ) m3 / hr 0.5 15 22.5 30 45 60Pump size KW 0.33 3 4.5 6 9 12number of pumpsets unit 1 1 1 1 1 1

7 BOD of Effluentat Sludge pit - 25,000 mg / L kg 4.5 135 202.5 270 405 540at Anaerobic pond discharge - 5,000 mg /L kg 0.90 27.00 40.50 54.00 81.00 108.00 at Aeration pond discharge - 50 mg /L kg 0.009 0.27 0.405 0.54 0.81 1.08at Stabilisation pond discharge - 20 mg / L kg 0.0036 0.108 0.162 0.216 0.324 0.432

8 Aeration pumpsetsFlow rate m3 / hr at TDH 20 2 45 67.5 90 135 180Drive motor kw 5.625 8.4375 11.25 16.875 22.5Number required units 1 x 7.5 2 x 5.5 2 x 7.5 2 x 10 4 x 5.5