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Sterilizer
Clarification
Hydrocyclone
Condensate
Sludge
Discharged
/
BOD30 ;
COD ;
/
/
Total solid ;
Suspended solid
;
2500-5000
2000-5000
2000-5000
4500-5000
4000-10000
3000-5000
3500-5000
3000-5000
2500-5000
1000-5000
1500-5000
1500-5000
6000-3000
6000-3000
1500-2000
20-50
20-30
; 30-80
Total nitrogen ;
500-100
500-1000
20-30
pH
4.0-4.5
4.0-4.5
5.5-6.2
Temperature ; 0C
80-90
80-90
30
From table above, it can be seen that the clarification waste has very low pH
value, high value of BOD and solid levels. In addition, it contains about 1% of oil. The
temperature of the waste is normally above room temperature and is about 80 to 900C.
These conditions of the effluent make treatment difficult and very limited methods of
treatment either a single or a series of sludge traps where further oil can be recovered
from the waste before proceeding into a common sump to be pumped up for treatment
purpose.
b) Anaerobic Pond
The mixed waste is exposed to anaerobic reactions inside the anaerobic
pond for a certain retention time. The waste will be decomposed anaerobically
by anaerobic bacteria. Anaerobic breakdown of the organic matter consists of
several stages, acidification and a gasification stage which produce primarily
methane (CH4) and carbon dioxide (CO2) and very little of hydrogen sulphide
(H2S). During the acidification stage of organic matter will be decomposed into
new cells which are called acid formers and together with organic acids. The
organic acids will react with hydrogen gas to form other new cells which are
called methane formers and at the same time methane and carbon dioxide are
liberated. The methane bacteria are sensitive to acidic conditions and therefore
the pH of pond should not be allowed drop below 6.75.
&
day time. Solids entering the pond will deposit on the bottom and organic
matter in this sludge layer will undergo anaerobic breakdown.
Soluble fermentation products will enter the liquid layer above and then
broken down anaerobically along the soluble and colloidal organic in the
incoming waste from the supernatant liquor. Under properly controlled
conditions the growth of algae occurs in the facultative pond and will supply
oxygen for further bacterial breakdown of the organic matter. The retention
period of this facultative stage is about 20 days and the depth of 8 feet is
expected good BOD removal shall occur.
d) Algae Pond
After the facultative reaction, the waste is passed to a series of two or
more shallows ponds known as algae ponds which is the aerobic stage. It has a
retention time of 7 days for each. These algae ponds are wholly in aerobic
condition throughout of its depth of 4 ft. In this pond, the organic loading is
very low and therefore with the help of sunlight to allow the existence of the
interaction between the bacteria and algae whereby the photosynthesis algae
utilize the CO2 released in bacterial respiration and the benefit for the bacteria
through the releasing of oxygen by algae. It is expected the final pond shall be
able to reduce the BOD and solids level to the DOEs acceptable limits.
Figure 4.0
ii.
Incinerators that burn the empty fruit bunches (EFB) for recovery of
potash ash
Smoke and dust emissions are the main concerns due to incomplete combustion
of the solid waste materials. Palm oil mill is generally self-sufficient in terms of energy
requirements due to the availability of adequate quantities of the fibre and shell
materials that are used as solid fuel in the steam boiler.
CHAPTER 5
ANALYSIS IN LABORATORY
5.1
Introduction
In palm oil mill, the effectiveness of an assessment oil extraction and quality of
products where production oil and kernel had been carried out by analyzing the sample
everyday in palm oil mill laboratory. The quality of palm oil manufactures of edible
products made from palm oil desire to purchase oil which will refine consistently well,
and at reasonable cost to facilitate the making of end-products have good colour, flavor
and keeping properties. In addition, the quality in palm oil can be defined as the extent
which properties of the oil meet consumer requirements.
For quality control purposes it is obvious that regular samples of the oil as
produced and sent to the storage tanks from the factory must be taken and analyzed
and that, further samples of each batch of oil despatched from the mill after storage in
these tanks must be examined.
In addition representatives samples of kernel as bagged must be examined and
if appreciable delay occurs before these kernels leave the mill it may be also desirable
to sample and analyze the kernels as despatched.
For process control, it is necessary to sample the waste product discharged for
evaluation of oil and kernel losses and sludge. The percentage of oil loss is defined at
sludge mixture raw material, sludge of condensate and sludge of trap. The sample is
taken at light particle transport system, fibre cyclone and wet shell for calculating the
percentage of kernel loss. The other analysis is mass passing to digester (MPD)
analysis. MPD analysis is very important to ensure the quality of fruit have been
thrashed out of sterilized bunches is controlled.
5.2
Free fatty acids are formed by splitting of the fatty acids from triglycerides and
FFA tests assess the degree of this acid formation. FFA has been principal criterion of
palm oil quality. An upper limit of 5% FFA at port is imposed by consumers and oil
with FFA at higher than 5% is considered inferior and a discount is levied because of
greater loss of oil during refining. Procedures of oil about 3% FFA at mill end and 2%
for acid increase during storage and transit must be achieved for keeping within 5%
which is standard percentage of FFA meet consumers requirement.
FFA is determined by direct titration with sodium hydroxide (NaOH) using
phenolphthalein indicator. FFA is calculated as palmitic acid from
formula:.
% FFA
Where,
=
t
= titre in mL
Volatile matter in palm oil is given by the mass lost on heating in oven at 105
20C, expressed as percentage of the mass of the oil.
It is possible to produce oils with extremely low moisture contents, but values
in the range 0.07- 0.13% are preferred in Malaysia because it has been found that
lower moisture contents can results in rapid increase in FFA of oil and reduce
bleachability.
5.2.3 Dirt
The insoluble impurities are determined by filtration through glass fibre filter
and calculated as weight percentage of the oil. The maximum dirt content allowed has
been 0.01% and dirt content higher than this encourage the growth of lipolytic microorganisms which is responsible for the increasing of FFA, by acting as a source of
nutrients for the lipolytic micro-organisms.
5.3
Kernel Analysis
2
0
-
Where V
( -
=)
100
( -
Where A
and added to the loose shell and dirt. The shell and dirt are weighted together to the
nearest 0.5 g.
Formula in calculating dirt in palm kernel:-
)=
100
Where A
B
5.4
Figure 5.0
(%)
10
(%)
(
)
( )
%
= 100 -
10
broken nuts in cracked mixture. Besides, when the amount of cracked mixture entering
LPTS is high, it also can cause the kernel loss. The limit percentage of LPTS on
sample should be lower than 2%. For determination of kernel loss in LPTS, the
sample was separated into 2 parts according to its broken kernel and free shell. The
mass of broken kernel is weighted. The formula in calculating kernel loss in LPTS:-
100
For the case of fibre cyclone, the low efficiency of hydrocyclone is one of the
factor for kernel loss. Moreover, the kernel loss is high when FFB are not well-treated
during sterilization. The percentage of kernel loss in fibre cyclone should not higher
than 2%. For determination of kernel loss in fibre cyclone, the sample was separated
into broken kernels, half nuts and uncracked nuts. The mass of each is weighted. The
percentage of kernel loss in fibre cyclone is calculated as follows:Let,
So,
+
%
level
=a
=b
=c
a/1
= mass a
b/3
= mass b
c/2
= mass c
+
=
10
uncracked
determined in wet shell which is separated into broken kernels, half nuts,
nuts and whole kernels. Mass of each is weighted. The percentage of kernel loss in wet
shell is obtained by counting the number of each category of kernels thus obtains
as
below:Let,
=a
=b
=c
=d
So,
a/1
= mass a
b/3
= mass b
c/2
= mass c
d/1
= mass d
+
+
%
10
In preventing the kernel loss, nut cacker should be well-function. The position
of damper in LPTS part should be checked. Besides, the air suction should be
maximized in fibre cyclone to reduce the fibre into nut cracker. The last suggestion to
prevent the kernel loss is controlled the cone level adjustment in hyrocyclone and the
vortex finder.
5.5
thrashed out or sterilized bunches i.e. the total sterilized fruit without the empty bunch.
The sample of MPD analysis is taken at the thresher conveyor before the fruit elevator
in 1 kg. Each sample should be analyzed for percentage by weight of whole fruit with
nuts and nuts. For whole fruit with nut, mesocarp is squeezed out from each fruit.
While for the nuts, there are separated normal parthenocarps (undeveloped fruit and
non-oil bearing), abnormal parthenocarps (normal whole fruit without nut and oil
bearing) and calyx leaves and spikelets. (Example of report at Appendix)
5.6
The boiler and softener water must be tested twice a day, once in the morning
and the other one in the evening. The hardness of the water after softener must be
checked daily to make sure that it is below than 5 ppm, and then the softeners must be
regenerated either by the laboratory or the boiler water chargeman.
The water hardness is defined by the capacity of water to precipitate soap. The
ionic species in the water causing the precipitation was later found to be primarily
calcium and magnesium. Certain other ions species that were found to contribute to the
water hardness are iron, zinc and manganese. The measure and control of water
hardness is essential to prevent scaling and clogging in boiler.
The hardness level as ppm calcium carbonate, CaCO3 is determining by
titration with EDTA. The solution is first added to buffer solution to meet the pH
requirement which is 10. The indicator chelates with the metal ions such as magnesium
or calcium to form a red colour solution. The metal ions complex with EDTA as it was
added. After all free metal have been complexed with the indicator to form a blue
colour solution. The colour changed from red to blue is the end point of the titration.
A sulphite concentration must be maintained from 30 to 50 ppm. The value
must be in range to prevent pitting and oxidation of metal components as in the boiler
water. High level of sulphite made the pH is lower which an acidic and promote the
CHAPTER 6
6.1
Conclusion
Mempaga Palm Oil Mill one of the branch in Felda Palm Industries Sdn. Bhd.
Felda is one of the biggest corporate company in Malaysia. By training under Feldas
scheme, a lot of knowledge and experience can be gained and built. Moreover
Mempaga Palm Oil Mill is suitable for the future engineer especially from Universiti
Malaysia Pahang to choose as place for industrial training. From this industrial
training, student can learn the process of palm oil production. The daily analysis is
done to monitor and determine the quality of palm oil processes in this mill. Besides,
the laboratory attendances also analyzed the boiler feed water and softener water to
make sure that the steam generated has sufficient chemical. Student also is exposed on
how to treat the waste product to produce beneficial things.
In addition, the knowledge can be gained for the mill maintenance example in
controlling the losses from mixed raw material and sludge condensate. Besides, I also
learned how to overcome the problem example to transfer the storage oil either bulk
storage 1, 2 or 3. This is one of the important things as engineer in palm oil mill to
decide which bulk storage tank needed to be transferred.
6.2
Recommendations
Based on experience for a few months in Mempaga Palm Oil Mill, these
recommendations can be taken into consideration to upgrade future practical training
in this mill:i.
Student should be given a task related to the process in palm oil mill which is
appropriate with the course taken.
ii.
REFERENCES
APPENDIX A
FELDA PALM INDUSTRIES SDN BHD
KILANG SAWIT MEMPAGA
RUMUSAN ANALISA MPD
No Borang:
FPI/L4/QMS-MPD1
Pind 0
Tarikh
Berat
Sample
TRUE
Nuts
Berat
[gm]
Mesocarp
TRUE
Berat
[gm]
TRUE
Abn Path
Berat
Nuts
Berat
[gm]
TRUE
[gm]
Norm.
Path
Berat
[gm
]
Cal.
Leaves
Berat
%
[gm]
Oil
Content
Ripe
Unripe
APPENDIX B
KILANG SAWIT MEMPAGA
LAPURAN HARIAN ANALISA KERNEL / FIBRE
TARIKH :
BIL :
SAMPLE
E
1.
BERAT
SAMPL
BROKEN
NUT
NUT
TOTAL
NUT
FIBRE /
NUT %
BROKEN
HALF
UNCRACKED
TOTAL
NUT
NUT
NUT
KERNEL %
PRESS
CAKE
1
2
3
4
5
6
2.
FIBRE
CYCLONE
BERAT
SAMPLE
LINE 1
LINE 2
3.
L.T.P.S
BERAT SAMPLE
BROKEN KERNEL
LINE 1
LINE 2
4.
CRACKED
BERAT
BROKEN
HALF
UNCRACKED
WHOLE
TOTAL
MIXTURE
SAMPLE
KERNEL
NUT
NUT
KERNEL
KERNEL %
BEFORE
BERAT
BROKEN
HALF
UNCRACKED
FREE
TOTAL
HYDRO
SAMPLE
KERNEL
NUT
NUT
SHELL
DIRT
WET
BERAT
BROKEN
HALF
UNCRACKED
WHOLE
TOTAL
SHELLS
SAMPLE
KERNEL
NUT
NUT
KERNEL
LOSS
WET
BERAT
BROKEN
HALF
UNCRACKED
FREE
TOTAL
KERNEL
SAMPLE
KERNEL
NUT
NUT
SHELL
DIRT
PROD.
BERAT
BROKEN
HALF
UNCRACKED
FREE
TOTAL
KERNEL
SAMPLE
KERNEL
NUT
NUT
SHELL
DIRT
1
2
3
4
5.
CYCLONE
LINE 1
LINE 2
6.
1
2
3
4
7.
1
2
3
4
8.
1
2
3
4
5
6