palm kernel oil extraction various process …...palm kernel oil extraction: distillation for cases...

Palm Kernel Oil Extraction

Various Process alternatives

16th Latin American Congress on Fats & Oil ASAGA

Rosario – ARGENTINA / Oct 31 - Nov 4 (2015)

Desmet Ballestra Group, Zaventem, Belgium Represented by David de Schaetzen

Palm Kernel

Palm Kernel

Hard Shell

Fruit of the Oil Palm

Palm Kernel Oil Extraction: Process alternatives

Starting after : - Shell and Kernel separation (+ Drying & Cleaning ) …

oil palm kernel oil palm shell


Starting with : Palm Kernel composition :

oil palm kernel

- Oil : ~ 50% - Moisture : < 7% - Protein : ~ 9,5% - Fiber : ~ 8% - husks & impurities : < 1% - free of stones

To get : Palm Kernel oil & Palm Kernel Meal - Lauric Acid (C12H24O2) : 50%

- Oleic Acid (C18H34O2) : 16% Oleo chemicals (soap)

- Low protein : ~19% - Fiber : ~16% Ruminants or “Fuel”


Case 1 = Full Press (single step pressing) Case 2 = Full Press (double step pressing) Case 3 = Pre-Press + Solvent Extraction Case 4 = Direct Solvent Extraction

… For 350 TPD PK Seed ...


Case 1 = Full Press (single step pressing) Case 2 = Full Press (double step pressing) Case 3 = Pre-Press + Solvent Extraction Case 4 = Direct Solvent Extraction

Case 1 : Full Press

(Single step)

Case 2 : Full Press

(Double step)

Case 3 : Pre-Press

Solvent Extraction

Case 4 : Direct

Solvent Extraction

PK Inlet Seed (50% Oil) Seed (50% Oil) Seed (50% Oil) Seed (50% Oil)

Hammer Mill

Cracking

Flaking (double)

Cooking

Press (1st step)

Press (2nd step)

Oil Screening

Cake cooler

Solvent Extraction

PK Outlet Cake (10% oil) Cake (8% Oil) Meal (0,7% Oil) Meal (0,8% Oil)


PREPARATION

Palm Kernel Oil Extraction: Hammer Mills

For 350 TPD PK - 2 x STOLZ model RME 17

with 90 kW + Fan 11 kW = 202 kW

For all Cases (1, 2, 3 & 4) - to pre-break the kernel before cracking

mills - & minimize the maintenance

requirements of the cracking rolls.

- Frequent replacement of Hammers and Screens - ~0,2 USD/T.

Palm Kernel Oil Extraction: Cracking

For all Cases (1, 2, 3 & 4)

For 350 TPD …. - 2 x BUHLER model OLCB 4-316

with 2 x 30 kW = 120 kW

- Frequent re-corrugation & reduced life time of rolls : ~0,4 USD/T.

- to reduce size of PK and get consistent particle size.

Palm Kernel Oil Extraction: Flaking

- to shorten path to and from oil containing cells & facilitate solvent penetration and oil extraction

For Cases (3 & 4) only : before Solvent Extraction

- PK : Double flaking to lower hexane residual in meal

Area / Volume 50:1

Area / Volume 200:1

Palm Kernel Oil Extraction: Flaking

For 350 TPD …. - 2 x 2 BUHLER model OLCB 4-316 with

90 kW = 360 kW

- Frequent re-grinding of rolls & reduced life time of rolls : ~0,60 USD/T.

For Cases (3 & 4) only : before Solvent Extraction

Palm Kernel Oil Extraction: Cooking

- Cooking to get optimum mechanical pressing.

For Cases (1, 2 & 3) : before Press

For 350 TPD Case 1 :

Full Press (Single step)

Case 2 : Full Press (Double

step)

Case 3 : Pre-Press Solvent

Extraction

Drying to 3% 4% 4%

Sizing 9 x stages Dia 4,5 m

8 x stages Dia 4,5 m

6 x stages Dia 4,5 m

Installed power 132 kW 110 kW 90 kW

Steam 150 kg/T 135 kg/T 120 kg/T

Palm Kernel Oil Extraction: Presses

- Mechanical extraction through screw press

For Cases (1, 2 & 3) : with Press

Worm Assembly


- Liquid being ‘expelled’ through


Lining bar and Drainage cage



PK Cake : High Fiber content High friction and very abrasive !!! kWh !! & Maintenance !! (Worm assembly, lining bar, …)

Oil & Cake Production



For 350TPD PK Seed

Case 1 : Full Press

(Single step)

Case 2 : Full Press

(Double step)

Case 3 : Pre-Press

Solvent Extraction

Oil in cake 10% 8% 20%

Presses 6 x ST600’s 2 x ST600’s 6 x ST600’s 1 x ST600’s

Installed power 6 x 200 kW 2 x 200 kW 6 x 200 kW 1 x 550 kW

Absorbed power 60 kWh/T ! 25 kWh/T !! 60 kWh /T !! 30 kWh/T

Maintenance 4 USD/T 4 USD/T 0,5 USD/T

- Rosedowns Press Sterling ST600

Palm Kernel Oil Extraction: Oil clarification &

For Cases (1, 2 & 3) : after Press

- Oil decanter …

Cake cooling

For 350 TPD PK

… Total Installed power ~55 kW

- Cake cooler …

Model WESTFALIA RCD 305-00 15 kW


SOLVENT EXTRACTION

9TH TRAY

6TH TRAY

5TH TRAY

4TH TRAY

2N D TRAY

1ST TRAY

7TH TRAY

8TH TRAY

3R D TRAY

SEED = Oil + Meal

Hexane

Water

MEAL OIL

Air

Extractor Toaster Distillation Condenser Absorption

Oil + HexaneOil +

HexaneMeal +

HexaneMeal +

Hexane

Hexane

HexaneAir +

Atmospheric

Vacuum

Atmospheric Vacuum

Palm Kernel Oil Extraction: Solvent Extraction

For Cases (3) after Pre-press

PK Cake with < 20% Oil :

- 175 TPD PK Meal - 40 TPD PK Oil

For Cases (4) Direct Solvent Extraction

PK Flake with 50% Oil :

- 175 TPD PK Meal - 175 TPD PK Oil

@ Ambient temperature

@ 55-60 °C temperature

Palm Kernel Oil Extraction: Solvent Extraction

For Cases (3 & 4) after Pre-press & Direct Extraction

9TH TRAY

6TH TRAY

5TH TRAY

4TH TRAY

2N D TRAY

1ST TRAY

7TH TRAY

8TH TRAY

3R D TRAY

SEED = Oil + Meal

Hexane

Water

MEAL OIL

Air

Extractor Toaster Distillation Condenser Absorption

Oil + HexaneOil +

HexaneMeal +

HexaneMeal +

Hexane

Hexane

HexaneAir +

Atmospheric

Vacuum

Atmospheric Vacuum

Leaks

Hexane Losses

Palm Kernel Oil Extraction: Extractor


Hexane losses 2,25 kg / T

For Cases (4) Direct Extraction

Hexane losses 2,5 kg / T

Quantifiable losses conc. lt/MT

Meal 0.75 kg/kg 500 ppm 0.594 92.9%

Oil 0.20 kg/kg 50 ppm 0.015 2.3%

Water 50 lt/MT 20 ppm 0.001 0.2%

Vent gas 2 m3/MT 10 g/m³ 0.029 4.6%

Total quantifiable 0.435

Fugitive losses

Number of leak points does not increase proportionally to capacity.

5000 TPD plant: 0.15 – 0.3 lt/T 500 TPD plant: 0.4 – 0.8 lt/T

Palm Kernel Oil Extraction: Extractor


Extractor : 41 m³ Motor : 0,75 kW 7 pumps – 5,5 kW


P2B

P15 P3/1 P3/2 P3/3 P3/4 P3/5 P3/6 P2A

P1HP

Fresh Solvent

from 20A

Full Miscella to 17

49/P1

Steam

To 46B

8A

2

3

4

8B/2

5

Spent Flakes to 70

58/P1

Safety Vent to Outside of building

Purge to outside of Building

Drain to Floor

36P

Vent to 20C

Vent to 20C

Client Supply

8A/CFLAKES fromPREPARATION

1A

1B

Extractor : 91 m³ Motor : 2,2 kW 7 pumps – 11 kW Percolation ! – Flake moisture < 7%

For 350 TPD PK Seed

Meal with Oil

Meal with Hexane

Hexane

Oil with Hexane

Palm Kernel Oil Extraction: Desolventizer


Hexane in meal : 44% Steam : 220 kg/T Desolventizer - Dia 3,0 m Installed power : 160 + 55 kW (DT + Fan)


For 350 TPD PK Seed

Predesolventizing

Desolventizing

Toasting & Stripping > 100°C

11TH TRAY

7TH TRAY

6TH TRAY

5TH TRAY

4TH TRAY

8TH TRAY

1ST TRAY

3R D TRAY

9TH TRAY

10TH TRAY

2ND TRAY

Steam

Dryer (Hot air)

Cooler (Cold air)

Hexane in meal : 37,5% Steam : 145 kg/T Desolventizer - Dia 2,5 m Installed power : 110 + 30 kW

(DT) + (Fan)

Palm Kernel Oil Extraction: Distillation



For 350 TPD PK Seed

2nd Stage Evaporator Separator

Sieve Tray Oil Stripper

Steam

175TPD PK Oil (50%) Meal Inlet @ Amb Temperature Steam : 155 kg/T Inst. power : 55 kW + 130 kW (Distillation) + (Cooling water)

40TPD PK Oil (20%) Meal Inlet @ 55-60°C Steam : 50 kg/T Inst. power : 20 kW + 75 kW

(Distillation) + (Cooling water)


SUMMARY Table

What is the most economical process ?

Palm Kernel Oil Extraction: Summary - Electricity Case 1 :

Full Press (Single step)

Case 2 : Full Press

(Double step)

Case 3 : Pre-Press

Solvent Extraction

Case 4 : Direct

Solvent Extraction Hammer Mill 2 x (90 + 11) kW 2 x (90 + 11) kW 2 x (90 + 11) kW 2 x (90 + 11) kW

Cracking 4 x 30 kW 4 x 30 kW 4 x 30 kW 4 x 30 kW

Flaking (double) 4 x 90 kW 4 x 90 kW

Conveyor - Others 30 kW 30 kW 30 kW 30 kW

Cooking 132 kW 110 kW 90 kW -

Presses 6 x 200 kW 8 x 200 kW 1 x 550 kW -

Oil Screening + Cake cooler 55 kW 55 kW 55 kW -

Conveyor - Others 50 kW 50 kW 50 kW -

TOTAL Preparation 1789 kW 2167 kW 1482 kW 737 kW Extractor - - 56 kW 95 kW

Desolventiser - - 110 + 30 kW 160 + 55 kW

Distillation & cooling water - - 20 + 75 55 + 130

TOTAL Extraction - - 290 kW 495 kW

TOTAL kW Installed 1789 kW 2167 kW 1773 kW 1232 kW

TOTAL Abs Power 98 kWh/T 119 kWh/T 95 kWh/T 64 kWh/T

Palm Kernel Oil Extraction: Summary

Case 1 : Full Press

(Single step)

Case 2 : Full Press

(Double step)

Case 3 : Pre-Press

Solvent Extraction

Case 4 : Direct

Solvent Extraction Hammer Mill 0,20 USD/T 0,20 USD/T 0,20 USD/T 0,20 USD/T

Cracking 0,40 USD/T 0,40 USD/T 0,40 USD/T 0,40 USD/T

Flaking (double) 0,60 USD/T 0,60 USD/T 0,60 USD/T 0,60 USD/T

Conveyor - Others 0,10 USD/T 0,10 USD/T 0,10 USD/T 0,10 USD/T

Cooking 0,05 USD/T 0,05 USD/T 0,05 USD/T -

Presses 4,00 USD/T 4,00 USD/T 0,50 USD/T -

Oil Screening + Cake cooler 0,10 USD/T 0,10 USD/T 0,10 USD/T

Conveyor - Others 0,10 USD/T 0,10 USD/T 0,10 USD/T -

Extraction - - 0,15 USD/T 0,15 USD/T

TOTAL 4,95 USD/T 4,95 USD/T 2,05 USD/T 1,25 USD/T

Maintenance cost

Palm Kernel Oil Extraction: Summary

Case 1 : Full Press

(Single step)

Case 2 : Full Press

(Double step)

Case 3 : Pre-Press

Solvent Extraction

Case 4 : Direct

Solvent Extraction Preparation (Cooking) 150 kg/T 135 kg/T 120 kg/T -

Extraction

Desolventizer - - 145 kg/T 220 kg/T

Distillation - - 55 kg/T 155 kg/T

TOTAL 150 kg/T 135 kg/T 320 kg/T 375 kg/T

Seam consumption

Case 1 : Full Press

(Single step)

Case 2 : Full Press

(Double step)

Case 3 : Pre-Press

Solvent Extraction

Case 4 : Direct

Solvent Extraction

TOTAL - - 2,25 kg/T 2,5 kg/T

Hexane consumption

Palm Kernel Oil Extraction: Summary - Final Plant Palm Kernel Capacity 350 TPD Oil content : 50 % Cake/Meal : 175 TPD Oil : 175 TPD

PK oil : 900 USD/Ton PK Cake / Meal : 50 USD/Ton Steam cost : 15 USD/Ton Elec cost 0,07 USD/kWh Hexane cost : 1 USD/kg Day of production / year 330 days/Years

Case 1 : Full Press

(Single step)

Case 2 : Full Press

(Double step)

Case 3 : Pre-Press

Solvent Extraction

Case 4 : Direct

Solvent Extraction

USD/Year USD/Year USD/Year USD/Year Oil left in Cake/Meal 10 % 5.454.167 8 % 4.363.333 0,7 % 381.792 0,8 % 426.848 Electrical consumption 98 kWh/T 793.457 119 kWh/T 961.108 96 kWh/T 776.160 64 kWh/T 517.440 Steam consumption 150 kg/T 259.875 135 kg/T 233.888 320 kg/T 554.400 375 kg/T 649.688 Maintenance cost 5,0 USD/T 571.725 5,0 USD/T 571.725 2,1 USD/T 236.775 1,3 USD/T 144.375 Hexane consumption - kg/T - - kg/T - 2,25 kg/T 259.875 2,5 kg/T 288.750 Total : 7.079.224 6.130.054 2.209.002 2.027.100

USD/Year USD/Year USD/Year USD/Year

Oil left in Cake/Meal 10 % 5.455.000 8 % 4.365.000 0,7 % 380.000 0,8 % 425.000

Electrical consumption 98 kWh/T 795.000 119 kWh/T 960.000 96 kWh/T 775.000 64 kWh/T 515.000

Steam consumption 150 kg/T 260.000 135 kg/T 235.000 320 kg/T 555.000 375 kg/T 650.000

Maintenance cost 5,0 USD/T 570.000 5,0 USD/T 570.000 2,1 USD/T 235.000 1,3 USD/T 145.000

Hexane consumption - kg/T - - kg/T - 2,25 kg/T 260.000 2,5 kg/T 290.000

Total : 7.080.000 6.130.000 2.205.000 2.025.000

Desmet Ballestra …

palm kernel oil extraction various process …...palm kernel oil extraction: distillation for cases...

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