Documente Academic
Documente Profesional
Documente Cultură
Sludge
Storage
Storage Tank
Tank
Effluent
EffluentTreatment
TreatmentPlant
Plant
CPD 30203 (JAN 2016)
1. Reception
Weight
Weight bridge
bridge
FFB Truck
Loading
Loading Ramp
Ramp
Grading
Grading FFB
FFB
Over Ripe Bunch
Unripe Bunch
Under ripe bunch
Ripe bunch
Empty bunch
Old Crop
Long stalk bunch
1. Reception
Fresh fruit arrives from the field as bunches or
loose fruit.
Weight the fresh fruit in the truck using weight
bridge.
Grading the FFB to identify the quality of bunches.
The quality standard achieved is initially
dependent on the quality of bunches arriving at the
mill.
1. Reception
The mill cannot improve upon this quality but can
prevent or minimize further deterioration.
The field factors that affect the composition and
final quality of palm oil are genetic, age of the tree,
agronomic, environmental, harvesting technique,
handling and transport
10
2. Sterilisation
Receive
Receive
Sterilizer
Sterilizer
11
2. Sterilisation
The purposes of sterilization are:
prevents build-up of free fatty acids (FFA) in the
oil by inactivates the lipases in the fruits
loosens the fruits from bunches to facilitate
stripping
softens the fruit mesocarp for digestion and
release of oil
preconditioning of nuts to reduce kernel
breakage
CPD 30203 (JAN 2016)
12
2. Sterilisation
The sterilisers consists of a long cylindrical
pressure vessel of about 1.8m diameter, with
rails running along the length of the interior.
The fruit is loaded into cages
These cages are pushed on the rails into the
steriliser.
Once the steriliser has been loaded and
closed, steam is introduced.
CPD 30203 (JAN 2016)
13
2. Sterilisation
Pressure is built up to about 3 kg/cm 2 which
corresponds to a temperature above 130 oC
for 1hr.
When high-pressure steam is used for
sterilization, the heat causes the moisture in
the nuts to expand.
14
2. Sterilisation
When the pressure is reduced the
contraction of the nut leads to the
detachment of the kernel from the shell wall,
thus loosening the kernels within their
shells.
15
3. Threshing/Stripping Station
Thresher
Thresher
Mulching
Mulchingat
atfield
field
Empty Bunches
16
3. Threshing/Stripping
The purpose of stripping is to separate the
fruits from the empty bunch
Modern mills used drum stripper
The drum rotates at about 22 rpm
Sterilized FFBs are fed into a drum stripper
and the drum is rotated, causing the fruits to
be detached from the bunch
CPD 30203 (JAN 2016)
17
3. Threshing/Stripping
The bunch stalks are removed as they do
not contain any oil and being disposed by
incineration, giving ash as potash fertilizer,
and fuel for boilers
It is important to ensure that oil loss in the
bunch stalk is kept to a minimum
Prolonged sterilization will increase oil loss
in stalks
CPD 30203 (JAN 2016)
18
3. Threshing/Stripping
Irregular feeding of the stripper may also
result in increase of oil loss in stalks.
Stalks which have fruits still attached on
them are called hard bunches, and have to
be recycled back to sterilizers for further
cooking. Hard bunches are detected by
visible inspection
19
Function:
to digest the fruit lets
Maximize oil extraction with minimize broken nut
To break press cake before depericarping
Digester
Digester
Oil
Oil Recovery
Recovery Plant
Plant
Kernel
Kernel Recovery
Recovery Plant
Plant
Screw
Screw Press
Press
20
21
22
23
24
5. Clarification
The crude oil from the press consists of a mixture
oil, water and other non-oily solids
Consists of 4 stages:
Screening
Clarifying
Oil recovery
Purifying
25
5. Clarification (Screening)
Vibrating
Vibrating Screen
Screen
Waste
screen
Oil have
been screen
CPD 30203 (JAN 2016)
26
5. Clarification (Screening)
The main purpose is to separate crude oil from dirt
A mixture of oil, water, solids from the bunch fibres
is delivered from the press to a clarification tank.
The mixture containing the crude oil is diluted with
hot water to reduce its viscosity
27
5. Clarification (Screening)
The dilution (addition of water) 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)
A vibrating screen helps remove some of the
solids
28
Purifying
Purifying
CPO
Clarifier
Clarifier Tank
Tank
Underflow
Sludge
Oil
Oil Recovery
Recovery
CPD 30203 (JAN 2016)
29
5. Clarification (Clarifying)
The purpose is to collect oil from crude oil using
continuous settling tank.
Separation of the oil from the rest of the liquor is
achieved by setting tanks based on gravity.
The screened mixture is boiled from one or two
hours and then allowed to settle by gravity in the
large tank so that the palm oil, being lighter than
water, will separate and rise to the top
30
Recovered Oil
Clarifier
Clarifier
Function:
To collect oil from sludge
using decanter
Effluent
Effluent
Treatment
Treatment
Plant
Plant
Underflow
Sludge
Sludge
DECANTER
DECANTER
CPD 30203 (JAN 2016)
31
32
5. Clarification (Purifying)
CPO
Purifier
Purifier
Dirt < 0.02%
33
5. Clarification (Purifying)
The purpose is to purified the crude palm oil
Oil from the top is skimmed off and purified
in the centrifuge prior to drying
The dirt level must be less than 0.02%
34
6. Drying
Vacuum
Vacuum Dryer
Dryer
Moisture < 0.18%
Sludge
Effluent
EffluentTreatment
TreatmentPlant
Plant
35
6. Drying
The purpose is to reduce moisture content
of crude palm oil using vacuum dryer
The oil must be dried to prevent increasing
of FFA through autocatalytic hydrolysis of
the oil
The moisture content must be less than
0.18%
36
7. Storage of CPO
Moisture< 0.18%
Dirt
< 0.02%
DOBI
> 2.3
FFA
< 3%
Sludge
Storage
Storage Tank
Tank
Effluent
EffluentTreatment
TreatmentPlant
Plant
CPD 30203 (JAN 2016)
37
7. Storage of CPO
The purpose is to keep CPO with controlling
of quality
The final crude palm oil is then cooled and
stored.
Storage is in welded steel tanks contain
heating coils to prevent crystallization and
subsequent settling out of the solid phase.
38
7. Storage of CPO
May be filled with carbon dioxide or other
inert gas above the oil to prevent oxidation
The temperature is controlled between 32
40oC during storage
Temperature should be kept as low as
possible to minimise deterioration in quality
during storage
39
7. Storage of CPO
The quality of CPO have to maintain at:
Moisture< 0.18%
Dirt < 0.02%
DOBI > 2.3
FFA < 3%
40
Moisture< 0.18%
Dirt
< 0.02%
DOBI
> 2.3
FFA
< 3%
Palm Oil
Mill
Buyer
Buyer
CPO
CPO Storage
Storage Tank
Tank
Function:
To keep CPO before delivery to Buyer
41
Heater
Kernel
Kernel
Despatch
Despatch Silo
Silo
Shell
&
Fiber
Boiler
Boiler
Cyclones
Cyclones
Turbine
Turbine
42
Depericarper
Depericarper
Fibre
Fibre
Fibre
Cyclone
Cyclone
Polishing
Polishing Drum
Drum
Nuts
CPD 30203 (JAN 2016)
43
44
45
Nut
Nut
Cracker
Cracker
Secondary
Secondary
Depericarper
Depericarper
46
47
Shell
Winnower
Winnower
Winnower
Winnower
Cyclone
Cyclone
Nut
Kernel
&
CPD 30203 (JAN 2016)
Shell
Function:
Separately shell from
kernel with pneumatic
system
48
49
Heating
Heating
Kernel
Shell
Shell
Shell
Cyclone
Cyclone
Hydro
Hydro Clay
Clay bath
bath
CPD 30203 (JAN 2016)
50
51
52
Heater
Admixture< 6%
Moisture < 7%
FFA
< 5%
Function
To dry and Keeping The
kernel
Kernel
Kernel
Despatch
Despatch Silo
Silo
Shell
&
Fiber
Boiler
Boiler
Cyclones
Cyclones
Turbine
Turbine
53
54