Full Re Pot

Industrial Training Report: Universiti Teknologi Malaysia
2009
1.0 EXECUTIVE REPORT
I have gained lots of experiences and lessons during my industrial training at Kilang Sawit Felcra Nasaruddin (KSFN) for ten weeks. From the beginning of this training until the end, I have done sort of analysis in this mill laboratory as this laboratory responsible for quality control of its crude palm oil and palm kernel production. First, for daily activities, I have done analysis of oil losses in press cakes, sludge, mesocarp, empty bunch, fibre cyclone, abnormal and unripe bunch by doing extraction. Every extraction was used hexane as a solvent and it took approximately forty-five minutes to complete each extraction, or until the colour of the solvent (hexane) remains clear. Second, there have been analyses of softener and boiler feedwater. The softener was only tested for its hardness, whereby the boiler feedwater should be tested its hardness, pH, Total dissolved solid (TDS), caustic alkalinity, sodium sulphite, and sodium chloride. Third, there were also analyses of kernel efficiency for the samples such as dry kernel, wet kernel, wet shell, bagged kernel, ripple mill, light particles, press cakes and fibre cyclone. I was also doing FFA analysis for the dispatched oil. The parameter for the good oil is below 5.00%. The chemicals used in analysis of FFA are I.P.A as a solvent, phenolphthalein as an indicator, and sodium hydroxide as a titrant. Besides, I went to mill to see and learn the stages in processing the crude palm oil and palm kernel, starting from the loading ramp until production of crude palm oil and palm kernel production. There are several compulsory rules that should be obeyed by the workers while working in the mill such as use the safety helmet, safety boots and ear plugs for self-protection. I was also given chance to climb up to the top of settling tank to see whether sludge present in the oil and BST tank in order to see the measurement of the crude palm oil depth inside the tank. I was also brought to see the full stages of water treatment began with clarifier. We have to climb the clarifier which has about 20 feet height in order to see
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clearly the water that have been collected from the tube well flow into clarifier and then treated with sodium hypochlorite and then ran through water tank. From the water tank, the water will be filtered before flow to treated water storage tank. The water from the water storage tank will go to the softener tank. Here some clear chemical reaction will be taken part which the hardness of the water which is ion-exchange softening and lime softening. Then come to deaerator. The function of deaerator is to remove dissolved gases that can cause boiler tube corrosion. Then lastly, the water will be transferred to boiler feed to be heated to generate steam for the purpose of heat energy production to be used in the mill. Then, I also visited effluent treatment plant. The plant was quite huge. I can see the way the sludge from the mill flowed first to cooling ponds and then went to anaerobic ponds and then oxidation ponds before will be removed to the nearby river. The water at the last pit before being removed out was clear brown colour and gave no smell. That is all the general information about the job or work that I have done and experienced here.
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2.0 INTRODUCTION 2.1 ORGANIZATION BACKGROUND
Federal Land Consolidation and Rehabilitation Authority (FELCRA) was established in 1966 with the objective to develop rural sector by helping its community to participate in national economic activities hence to improve their standard of living. FELCRA then is known as FELCRA Berhad since September 1st 1997 due to its corporatization. It has become a fully government owned company. With the change of its corporate entity, FELCRA is now able to explore new business opportunities aligned with national development aspiration. FELCRA Berhad which is armed with plantation management and core activities skills now diversifying its activities into industrial and service sectors as well as other growing sector. FELCRA Corporate Mission is: 1. Stay true to the philosophy of No. 1 Grateful Participant and continue to grow with them through its motto Growth With Equity. 2. Managing, overseeing and protecting the interest of the targeted group which is Participant Community. 3. Executes Social Obligation Programme and redevelop existing plantations into a more profitable sector. 4. Diversify its profitable activities while planning and executing export oriented programme. Simultaneously FELCRA Berhad is also aiming to achieve a successful conglomerate identity.
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Their Corporate Vision is to remain as No. 1 Plantation House and continue to grow with other related activities. Kilang Sawit FELCRA Nasaruddin (KSFN) which is located at KM 37 Jalan Tronoh, Bota Perak Darul Ridzuan is the second mill of FELCRA Berhad. Its areas is about 20 hectares. It is first developed and operates in 1988 with the mill capacity is 30 tm/hour. KSFN major production is Crude Palm Oil and Palm Kernel. My industrial training for about 10 weeks at KSFN was supervised under Mr. Abdul Wahid bin Yusoff in the mill laboratory. The roles of the mill laboratory personnel can be summarized as:1. Responsible for testing product quality and losses at the variable stations and carrying out tests related to process and quality control. 2. Responsible for monitoring product quality (production, dispatch and storage) and losses. 3. Responsible for informing the mill management problems on quality, losses and aspects related to process and quality control. 4. Assist mill management to conduct investigation into problems on quality, losses and aspects related to process and quality control. 5. Responsible for efficient raw water treatment at optimum chemical consumption. 6. Responsible for boiler water analysis. 7. Responsible for monitoring boiler water characteristics and taking corrective action to prevent scale formation and corrosion in boilers and to enable clean steam to be produced at optimum cost. 8. Responsible for the preservation of the mill laboratory.
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2.2 ORGANIZATION CHART
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2.3 INTRODUCTION OF PALM OIL
Palm oil (Elaeis guineensis) was first recognized in West African countries. It has been used spreadly as a cooking oil among West African people. European merchants trading with West Africa occasionally purchased palm oil for use in Europe, but as the oil was bulky and cheap, palm oil remained rare outside West Africa. In the Asante Confederacy, state-owned slaves built large plantations of oil palm trees, while in the neighbouring Kingdom of Dahomey, King Ghezo passed a law in 1856 forbidding his subjects from cutting down oil palms. Palm oil became a highly sought-after commodity by British traders, for use as an industrial lubricant for the machines of Britain's Industrial Revolution, as well as forming the basis of soap products. Palm was introduced to Java by the Dutch in 1848[3] and Malaysia (then the British colony of Malaya) in 1910 by Scotsman William Sime and English banker Henry Darby. The first plantations were mostly established and operated by British plantation owners, such as Sime Darby. From the 1960s a major oil palm plantation scheme was introduced by the government with the main aim of eradicating poverty. Settlers were each allocated 10 acres of land (about 4 hectares) planted either with oil palm or rubber, and given 20 years to pay off the debt for the land.[citation needed] The large plantation companies remained listed in London until the Malaysian government engineered their "Malaysianisation" throughout the 1960s and 1970s.[4] In Malaysia, B.C. Sekhar was instrumental in setting up the Palm Oil Research Institute of Malaysia (Porim) and was its founder and chairman. Sekhar established Porim as one of the premier centers for oils and fats research in the world.
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3.0 DUTY REPORT 3.1 PALM OIL MILL PROCESSING
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3.1.1 Reception Station
Weight Bridge
Grading FFB
Loading Ramp
FFB Truck For grading Fresh Fruit Bunch (FFB), the current practice used is human graders. The FFB is graded according to degree of freshness, ripeness, size of the bunch stalk, percentage of loose fruit and formation of FFB according to the standard set by MPOB. The FFB must be processed as soon as possible to ensure the better quality of the palm oil. The figure below shows the grading of the FFB.
Ripe Bunch
Underripe Bunch
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Dura Bunch
Overripe Bunch
Unripe Bunch
Dirty Bunch
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Diseased Bunch
Empty Bunch
Long-Stalk Bunch
Loose Fruit
Old Bunch
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Pest Damaged Bunch
Rotten Bunch
Small Bunch
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3.1.2 Sterilization Sterilization in palm oil milling is the most important process because it will determine the efficiency and effectiveness of the downstream process and even refining in order to produce high quality palm oil. Sterilization of FFB is the process whereby the FFB is loaded in cages and pushed into sterilizers where they are cooked under the temperature of 140oC at steam pressure 40 psig for 45 minutes. The purposes of sterilization are to deactivate the lipolytic enzymes which can increase the amount of Free Fatty Acid (FFA) in bunches. This process also looses the fruit from bunch to facilitate stripping, removes the impurities, softening the mesocarp of the fruit to facilitate further treatment of the fruit during digestion and pressing, and heating and partial dehydration of the nut for easier kernel recovery. Sterilizer condensate is drained after every sterilization cycle. To ensure the quality of the palm oil, the FFB must be processed within 24 hours.
3.1.3 Stripping In this process, the sterilized FFB is hoisted and emptied into the rotary drum stripper. The purpose of stripping/threshing is to separate the fruit from the bunch stalk through repetitive lifting and dropping of the bunch by gravity forces. The empty bunch will be discarded.
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3.1.4 Digestion and Pressing Digester is used to mash the loose fruits so that the mesocarps are separated from the nuts under a high temperature of about 95oC. It facilitates the oil release with the help of thermal and mechanical energy. The digester used consists of a steam-heated cylindrical vessel fitted with a central rotating shaft carrying a number of beater arms. The fruit is broken up through the action of the rotating beater arms. Hydraulic press is fitted with a plunger that match cage diameter. Pressing is done while mash is hot (80-90oC) at psi. Hot oil water mixture with suspended solids is expelled through perforations leaving press cake in cage. Press cakes are the mixed fibre and nuts, press cakes will then enter into a depericarper drum.
3.1.5 Clarification The purpose of clarification is to separate the oil from its entrained impurities. The crude oil produced from the press process contains mixture of palm oil, water, cell debris, fibrous material and non-oily solids. Hot water is added to mixture to reduce its viscosity. The dilution provides a barrier causing the solids to fall to the bottom of the container and the lighter oil flow into crude oil tank. The diluted mixture passed through vibrating screen to remove coarse fibre. The screen mixture is boiled from one or two hours and then allowed to settle by gravity in the large tank so
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that the palm oil being lighter than water and will separate and rise to top. The clear crude oil is emptied into a reception tank. This clear oil still contains traces of water and dirt. The parameter of the moisture must be reduced to 0.15- 0.25 percent in order to prevent the increase FFA through autocatalytic hydrolysis of the oil. The oil is then continuously skimmed from the top to a content of 0.6 percent water and 0.2 percent impurities. Temperature in the tank is kept in 95oC to enhance the separation process. Hence, the oil from the crude oil tank will be flowed to continuous settling tank/ clarifier tank. In clarifier tank, the mixture oil separated produces crude palm oil and sludge. The crude palm oil will be transferred to oil tank whereby the sludge will be flowed to sledge tank. Sludge is a mixture phase that still contains oil. The sludge is then reprocessed to get the remained oil. Decanter is normally used to process the sludge becoming 3 phase which light phase, heavy phase and solid. Light phase is a liquid that contain the most amount of oil. Therefore, this liquid phase should be transferred to crude oil tank to reprocess. Heavy phase is a liquid that contain small amount of oil. This heavy phase will be transferred to fat pit before being flowed to effluent pond. At fat pit, oil is produced because of the heavy phase accumulation. The oil then flowed to crude oil tank to reprocess. While solid is a mixture that contain maximum of 3.5 percent oil from the sample weight. Solid that produced will be applied in farm.
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3.1.6 Crude Palm Oil Storage The purified and dried oil is transferred to a tank for storage prior to despatch from the mill. Normally, the temperature of oil storage is maintained around 50oC by using hot water or low-pressure steam heating coils to prevent solidification and fractionation. Iron contamination from the storage tank may occur if the tank is not lined with a suitable protective coating.
Kernel Recovery 3.1.7 Depericarpring
Depericarper and Polishing Drum Depericarping commonly refers to the process of removing fibre from the nuts. This is achieved through the use of a rotating drum fitted with baffles. The fibre-nut mixture is fed into the drum rotating at 15rpm. The baffles elevate the fibre-nut mixture and allow them to drop. As they fall, a current of air is passed through them which blows the partially dried fibre to the exit.
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3.1.8 Nut Cracking
Nut Cracker Cracking is achieved when the kernel passes through two rollers rotating in opposite directions. Movement of the rollers imposes pressure on the kernel and causes the shell to break, releasing the kernel. In other mills, nuts are cracked by a centrifugal cracker. Nuts fed into the cracker are thrown out of slots and hurled against a cracking ring. The nutcase breaks upon impact and releases the kernel. One disadvantage associated with the centrifugal cracker is that nuts with long fibres at the tail may not crack if the fibre side comes against the cracking ring.
3.1.9 Kernel and Shell Separation Generally, there are two ways of achieving this and both of these mimic that of the traditional set up. These methods are known as dry/pneumatic and wet separation. In the dry separation, which is likened to winnowing in the local set up, fragments of light shells and those with long fibres that may have densities a little lower than that of the kernels are blown out of the separator. The second (wet) separation is achieved through the use of water and clay viscous mixture. The clay is used to help the shells to sink to the bottom while the kernels float on top of
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the water-clay mixture. After separation, the kernels are dried before being pressed for the oil. The clean nuts may then be conveyed to a nut silo for drying.
nuts
kernel & shell
Winnower
Hydro Clay Bath
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3.2 ROUTINE TESTING FOR PROCESS AND QUALITY CONTROL For process control, it is necessary to sample the waste product discharged for evaluation of oil and kernel losses and several other oil, sludge, kernel and other samples are also analysed. 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 analysed and that, further, samples of each of oil dispatched from the mill after storage in these tanks must be examined. The various samples that are needed for a full process and quality control are: 3.2.1 MPD ( or Material Passing to the Digesters)
MPD MPD (or Material Passing to the Digesters) is the total fruit, calyx leaves, apikelets and undeveloped fruit that have been thrashed out of sterilized bunches.
MPD analysis has two important functions in process control which is first to provide quantitative assessment (partial) of the quality and composition in the fruit that is being processed. Second, MPD results may be used as a feedback for altering or setting optimum process conditions especially in the pressing station, to minimize oil losses.
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3.2.2 Oil in sterilized fruit ( FFA)
FFA analysing FFA (or Free Fatty Acids) are formed by the splitting of the fatty acids from the triglycerides and FFA tests assess the degree of this acid formation. FFA has been the principal criterion of palm oil quality. An upper limit of 5% FFA at port is imposed by consumers and oil with FFA higher than 5% is considered inferior and a discount is levied because of greater loss of oil during refining. To keep within the 5% standard set by consumers, producers must achieve an oil of about 3% FFA at mill end, allowing 2% for acid rise during storage and transit.
FFA is determined by direct titration with sodium hydroxide using phenolphthalein indicator. The free fatty acid is calculated as palmitic acid from the formula: % FFA = 25.6 x t x N W titration in ml normality of sodium hydroxide weight of oil used
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Where t N W
= = =
2009
3.2.3 Diluted crude oil from screw presses (oil content by volume)
Crude Palm Oil Dilution The crude oil from the screw press contain say, approximately 10% of Nos (nonoily solid) and about 25% of water will be very viscous and almost impossible to pump, screen or settle satisfactorily.
Due to this reason, it must be diluted with hot water before the clarification process is started. Samples of the diluted crude oil must be taken and examined frequently during milling in order to control the degree of dilution.
During milling, a sample of 500 ml of the diluted crude oil passing to the crude oil tank is taken. These samples are taken to the laboratory at once and analysed by centrifuging. This is done by thoroughly stirring the 500 ml sample and filling two graduated laboratory centrifuge tubes to the 10 ml mark without delay.
The volume occupied by the oil is noted after centrifuging and expressed as percentage to the total volume of sample.
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Dilution by volume of crude oil (%) 0 50 55 60 65 70 75 80 85 90 95 100
Approximate oil by volume in diluted crude oil (%) 64.3 41.4 40.1 38.8 37.6 36.5 35.5 34.5 33.6 32.7 31.8 31.1
Assumption has been made for the calculation of the undiluted crude oil would have contained 60% by weight of oil. A dilution around 70% is found to be the satisfactory compromise between overdilution and under-dilution. A dilution of 70% means the volume of warm water is 70 parts over 100 parts of volume of crude oil.
3.2.4 Continuous Settling Tank Oil Samples ( Moisture Contents )
Settling Tank
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The continuous settling tank function as converting the incoming stream of screened, heated, diluted crude oil into a stream of top oil and sludge.
It is desirable to monitor the tank performance throughout milling although the tank operates automatically and normally gives an adequate separation.
The procedure used in this analysis is similar to that the described for sampling and centrifuging of diluted crude oil samples.
The oil percentage by volume in the sludge is recorded and also the percentage of water (mixed with dirt) in the top oil.
Regular checks of this nature and recording the results, together with temperature, useful information about the behavior of the continuous settling tank is obtained and any undesirable trends may be observed and action taken in time.
3.2.5 Oil Before and After Oil Purifier (Moisture and Dirt Contents)
It is normal routine practice to sample this oil as it passes from the crude oil tank to the oil purifier and to measure its moisture and dirt contents in order to ensure the continuous clarifier is giving satisfactory top oil.
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A compromise solution which is found to give reasonable reliable results provided processing conditions do not change too frequently during the day is to collect one sample for every hour from each sampling point in a small bottle fitted with a screwed cap. The bottle capacity is 100 ml and would be filled to the brim and capped with no attempt being made to bulk the oil.
All the small sample bottles of oil are labeled and sent to the laboratory and are quickly bulked there to give a large composite sample from each point.
The composite sample from each point is analysed for mixture and dirt content after well mixed.
It may be noted if more than one oil purifier is in use, separate oil samples should be collected for each.
3.2.6 Production Oil
The oil from the oil purifier that is passed through vacuum dryer before pumping to storage and it is necessary to sample the oil as produced from the pipeline taking the oil to the storage tank.
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The similar method as described in previous section is used to prevent accidental loss of moisture.
A 500 ml sample is prepared in the laboratory by bulking and quickly mixing the individual samples and filling and capping the 500 ml laboratory sample bottle.
This sample is examined for percentage of moisture content, percentage of FFA, percentage of insoluble impurities and peroxide value. The peroxide value may be measured on a bulked sample made by mixing similar remainders of the daily samples accumulated over three or four days if required.
3.2.7 Storage oil
Samples may be taken once a week from each storage tank and analysed for FFA, VM, Dirt and PV in order to check on any deterioration occurring between production and despatch. The oil should be sampled from the bulk storage tank as according to the sampling procedures for sampling oil from the bulk storage tanks.
This procedure is useful as it indicated what tonnages and qualities of oil are available for despatch in each tank.
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3.2.8 Despatched oil
It is also necessary to test the oil on despatch in addition to sampling and analysing production and storage oil.
If the oil leaves the mill by road tanker, each tanker load must be sampled immediately after loading whilst it is still well mixed.
The despatch oil should be tested for its DOBI. DOBI is a ratio of carotene (provitamin A) and secondary oxidation (extinction at 269 nanometers). Carotene breaks down as more and more secondary oxidized products are formed as the oil deteriorates. Dividing the two gives an indirect net result of oxidation that is amplified and is picked up by the DOBI test. The test is carried out using a spectrophotometer, which measures the absorption of a known light wavelength by carotene and the secondary oxidation products present in the oil.
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Badly oxidised oil is difficult to refine and products made from it will be off-flavour, offcolour and have poor shelf life. Such products can be easily detected by the palate even at very low concentrations. This simply means the oil smells and tastes bad. The DOBI readings can be used to differentiate CPO as the colour of the final oil is as shown.
3.2.9 Sludge Ex-Sludge Centrifuge
It is important to control the oil loss in effluent from the sludge centrifuge as the oil can vary considerably.
Sludges
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Efficient oil recovery is a necessary pre-requisite for subsequent successful treatment of the effluent.
One oil-loss determination per day covering the bulked sample from all centrifuges would be sufficient for control purposes. If high Oil/Nos figures are obtained from this sample, individual centrifuges can be checked.
3.2.10 Sterilizer Condensate (Oil Loss)
The sterilizer condensate should be sampled and analysed for the oil content. Sampling of one cycle per sterilizer per shift is normally adequate for daily control of individual sterilizers.
Acceptable oil contents in sterilizer condensate are in the range 0.4-0.8% of the condensate. Oil contents higher than 0.8% may be due to a combination of the presence of excessive quantities of losses fruit in the bunch and conditions of sterilization.
Sterilizer Condensate
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3.2.11 Sterilized empty bunch (oil loss)
Empty bunch The objective of sampling the sterilized empty bunch is to determine the oil loss.
Oil loss on dry matter should be lower than 6%. Higher values are mainly caused by the high percentage of injured fruitlets and/or excessive stereilization and/or high percentage of over-ripe fruitlets.
3.2.12 Press Cake
Press The sampling objective of the press cake is to determine the oil loss in the fibre and the percentage of nuts broken in the press. Besides, the oil loss on wet nuts and the % fibre nuts in the press cake are also determined.
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The residual oil of fibre is dependent upon the type of extraction press used. The fibre can have oil content on non-oily solids (Nos) as high as 11%. Oil content of fibre from screw and zuto-hydraulic presses can be as high as 9% and 10% oil/Nos respectively.
Many factors can affect oil losses in fibre. The most likely are temperature of digesters and sterilization.
The percentage of broken nuts is usually less than 3% in the case of manualhydraulic presses, 10% in screw presses and 15% in auto-hydraulic presses. If higher values are obtained, this may be due to fruit composition (low fibre/nut ratio in press), poor digestion, mash composition and excessive press-pressures as in the case of the screw press, and over-drainage of digester as in the case of auto-hydraulic presses.
3.2.13 Fibre from Depericarper Cyclone
Fibre Cyclone
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Some of the nuts and kernels are smashed during press-extraction process. Debris part is light enough to be blown off in the depericarper. The sampling objective is to determine the magnitude of the kernel loss. This should be examined daily.
The moisture content of the fibre also being measured in order to assess the drying efficiency of the cake conveyor and also the Nos content of the fibre is determined to know the kernel extraction efficiency. The percentage of kernel to fibre should not exceed 2%.
3.2.14 Nuts before Nuts Silo
Nuts These nuts are sampled and analysed for the moisture content of kernel in the nuts. The moisture determination of the nuts from the press cake should be carried out daily.
3.2.15 Nuts- Ex Nut Silo
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Kernels
These nuts are sampled and analysed for a moisture content of kernel in the nuts and the percentage of kernel to dry nuts. These measurements should be carried out daily.
3.2.16 Cracked Mixture Ex-Nut Cracker
Broken Kernels
This cracked mixture should be sampled and analysed for percentage of broken kernels in the cracked mixture and the nut cracking efficiency. These measurements should be carried out daily and serve as a check on the performance of the nut cracker.
3.2.17 Light Particle ( Kernel Losses)

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The measurement of the kernel losses in the light particle should be carried out daily. The loss should not be exceeding 4.0% by weight.
3.2.18 Kernel Ex-Hydroclaybath
Wet Kernels This kernel is analysed to ensure the content of shell and dirt in the kernels coming out of the top of the kernel hydroclaybath is not excessive and there is not an abnormally high proportion of broken kernels. This analysis has to be done daily.
3.2.19 Wet Shells Ex-Hydrocclaybath
Wet Shells
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A sample of the wet shells is taken and sampled daily in order to check the content of kernels in the wet shells passing from the shell hydrocyclone is not excess.
3.2.20 Kernel Loss on Dry Nut Basis
The kernel loss on dry nut basis should be carried out at least once a week in order to have an overall perspective of the extraction efficiency of the kernel plant.
3.2.21 Bagged Kernels
Bagged Kernels
The bagged kernels should be analysed daily to determine the percentage of shell, dirt, broken kernels, moisture, oil content of the kernel, discolourisation test and the FFA of the palm kernel oil.
3.2.22 Despatched Kernels
If the bagged kernels remain in store at the mill for several weeks before despatch, the moisture content may change somewhat and it may be desirable for control
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purposes to sample and measure the moisture and the shell and dirt contents of the bags kernels in a particular shipment the oil content of the kernel and FFA of the palm oil are also measured and they may be measured on a bulked sample made by mixing the daily sample accumulated over three or four days.
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3.3 ESTIMATION OF THE OIL EXTRACTION EFFICIENCY The method used in the estimation of the weight of waste products and the determination of oil losses at the following point: i) On the bunch stalk. The oil is absorbed from the fruit during the course of sterilizing or stripping. ii) In the press fibre. When the digested sterilized fruit is pressed, a small amount of oil always remains in the press fibre and is measured by samping the cake and analysing the fibre. iii) On the nuts. The surface of the nuts is in contact with the oily fibre and a very small amount of oil becomes absorbed on the surface of the nuts and must be measured. iv) In the waste water (sludge), from the clarification station. This water always contains a small proportion of oil, which is mostly absorbed on the finely divided non-oily solids present.
Oil Extraction
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3.4 ESTIMATION OF EFFICIENCY OF KERNEL EXTRACTION The kernel losses that are measured occur at the following points: i) In the cyclone fibre for example in the fibre that passed out of the top of the nut/fibre separator and is transported by air to the cyclone where it is deposited. These kernels are present because of some nuts are inevitably broken during pressing nad some of their kernels are released and are carried over with the fibre. ii) In the wet shell emerging from the hydrocyclone bath. Some of these kernels are free means unattached to shell and either as whole or as broken pieces. Some may have small pieces of shell attached and others present in split nuts before cracking so that part of a kernel is still firmly attached to a large piece of shell. iii) In the dry shell and dust removed by blowing from the cracked mixture. The proportion of blowing to total shell may vary and will depend upon the velocity of the air in the CM blower. Some of the small nuts may also yield kernels if the hydrocyclone causes them to be recycled to the crackers.
iv)
In the kernel winnowing rejects. It may occasionally necessary to reduce the shell content of the kernels leaving the dryer before they are bagged.
Kernel Loss Analysis

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3.5 BOILER WATER TREATMENT
A boiler is a closed vessel in which water under pressure is transformed into steam by the application of heat. In the boiler furnace, the chemical energy in the fuel is converted into heat, and it is the function of the boiler to transfer this heat to the contained water in the most efficient manner. The boiler should also be designed to generate high quality steam for plant use. A boiler must be designed to absorb the maximum amount of heat released in the process of combustion. This heat is transferred to the boiler water through radiation, conduction and convection. The relative percentage of each is dependent upon the type of boiler, the designed heat transfer surface and the fuels. The proper treatment of boiler water is important to ensure the operation of steam boiler operates effectively with the aim of: i) ii) iii) iv) Prevention of scaling in boiler Prevention of corrosion in boiler Prevention of stress corrosion cracking Prevention of steam contamination Scale deposits on the waterside heating surfaces can cause poor heat transfer and loss of thermal efficiency. They can also lead to overheating of the metal and the development of corrosion beneath the deposit. Foaming of the boiler water can result in entrainment and carryover of water and boiler salts into the steam system.
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Water Treatment Schematic
3.5.1 External Treatment External treatment is applied to water prepared for use as boiler feed water, usually refers to the chemical and mechanical treatment of the water source. The goal is to improve the quality of this source prior to its use as boiler feed water, external to the operating boiler itself. Such external treatment normally includes clarification, filtration, evaporation, softening, deionization and deaeration.
3.5.1.1 Clarification The process of clarification is used to remove must suspended solid particles and some dissolved matter. To speed up the process, chemical coagulants are injected to gather small particles into larger masses. The resulting sludge is removed from the bottom of the unit and the clarified water is drawn from the top by overflowing into a launder.
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Clarifier
Chemical: Sodium Hypochlorite
3.5.1.2 Filtration Filtration removes precipitate solids. Filters contain one or more layers or granular media- sand, gravel, and the like- that remove particles of decreasing size as water passes through. There are two types of filters used: gravity or open filter and pressure filter. The pressure filter moves water through increasingly fine granular layers at higher speed than the gravity filter. The filtration process reduces the solids in clarified water from 20- 30 ppm to 1 ppm or less.
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3.5.1.3 Softening Water softening is a treatment to remove impurities in water such as calcium, magnesium, iron and silica which can cause hardness to water. Common treatment used in water softening is lime softening and ion exchange. Lime softening is involves such a complicated chemical reactions. This reaction is important to change the calcium and magnesium compounds in water into calcium carbonate and magnesium hydroxide which are least soluble compounds and will eventually remove from the bottom of the water. The pH of the water must be raised by the addition of lime in order to produce calcium carbonate and magnesium hydroxide. Normally, calcium compounds in water will be removed at a pH of about 9.0 9.5 whereby magnesium compounds require a pH of 10.0 10.5. When soda ash is used to remove noncarbonated hardness, higher pH is required which is 10.0 10.5 for calcium compounds and 11.0 11.5 for magnesium compounds.
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Removal of Carbonate Hardness 1. Addition of lime (calcium hydroxide) to react with CO2 in the water before it softens the water. The reaction is: Carbon dioxide + Lime = Calcium carbonate + Water CO2 + Ca(OH)2 = CaC03 (ppt.) + H2O
2. For Magnesium compounds, the reaction is slightly different. First, magnesium bicarbonate reacts with lime and produces calcium carbonate (which precipitates out of solution). Magnesium bicarbonate + Lime = Calcium carbonate + Magnesium carbonate + Water Mg(HC03)2 + Ca(OH)2 = CaC03 + MgC03 + 2H2O
3. Then the magnesium carbonate reacts with lime and creates more calcium carbonate and magnesium hydroxide. Both of these compounds are able to precipitate out of water. Magnesium carbonate + Lime = Calcium carbonate + magnesium hydroxide I MgC03 + Ca(OH)2 = CaC03 + Mg(OH)2
Removal of Noncarbonate Hardness 1. Noncarbonate hardness compound will have different reaction from the carbonate compound. To remove noncarbonated compound, soda ash will be added to the water along with lime. The reaction is: Magnesium sulfate + Lime = Magnesium hydroxide + Calcium sulphate
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MgS04 + Ca(OH)2 = Mg(OH)2 + CaS04
2. The resulting compounds are magnesium hydroxide, which will precipitate out of solution, and calcium sulphate. The calcium sulphate then reacts with soda ash: Calcium sulphate + Soda Ash = Calcium carbonate + Sodium sulphate CaS04 + Na2C03 = CaC03 + Na2S04
3. The resulting calcium carbonate will settle out of the water. The sodium sulphate is not a hardness-causing compound, so it can remain in the water without causing problems.
The second method is ion exchange softening. Ion exchange softening exchanges calcium and magnesium ions in water for sodium ions as the hard water passes through a softener. The softener is similar in design to a pressure filter, with resins in place of the filter media During treatment, water enters the softener and is directed by a baffle. The water passes through a bed of resin underlain by a bed of gravel, and then is collected by an under-drain and piped out of the softener. The resins are insoluble solids with attached cations or anions capable of reversible exchange with mobile ions of the opposite sign in the solutions, which pass through them. Zeolite is one of various types of resins that can be used in ion exchange unit. In ion exchange softening, sodium ions are attached to the insoluble solids of the resins. Sodium ions are exchanged for calcium and magnesium ions in the water when water passes through the softener.
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The calcium and magnesium ions are retained on the resin grains. Sodium ions then replace the calcium and magnesium in the water that leave the softener. Since sodium ions do not cause hardness, the treated water will have zero hardness. To prevent corrosion due to excessively soft water, some quantity of the source water is blended with the softened water downstream of the softener to ensure that the product water has permissible hardness. Ion exchange softening is effective at removing both carbonate and noncarbonate hardness and is often used for waters high in noncarbonate hardness and with a total hardness less than 350 mg/L.
Regeneration After backwashing, the softener is ready to be regenerated. This is the part of the process in which sodium is replace the magnesium and calcium ions on the resin so that the softener can be used to treat more hard water. A salt solution, known as brine, is allowed to flow through the softener for about an hour in order to regenerate the resin. The salt dissociates into its constituent ions Na+ and CI- when dissolved in water. The sodium ions replace the calcium and magnesium ions on the resin in the following manner (where R preceding an ion means that the ion is bound to the resin. RCa + NaCl RMg + NaCl RNa + CaCl2 RNa + MgCl2
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Regeneration of Resins in Softener Calcium chloride, magnesium chloride, and excess sodium chloride flow to waste during regeneration. The figure above shows the regeneration process in ion exchange softener. The brine must be rinsed out of the softener after the brine has been given a sufficient contact time. During the rinse cycle, fresh water is passed through the unit as it would be during treatment, but with the effluent going to waste. Usually rinse takes about 20 to 40 minutes. Since the calcium, magnesium, and sodium salts are corrosive and toxic to the environment, both the spent brine from regeneration and from the rinse must be disposed of carefully. Spent brine is sometimes discharged in sewers or into streams at very high dilutions. Alternatively, the brine can be disposed of in a landfill.
Softener Tank
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3.5.1.4 Deaeration The purposes of deaeration are: i) ii) To remove oxygen, carbon dioxide and other noncondensable gases from feed water To heat the incoming makeup water and return condensate to an optimum temperature for: Minimizing solubility of the undesirable gases Providing the highest temperature water for injection to the boiler
Oxygen, carbon dioxide and ammonia are the most common source of corrosion of boiler water system. Of these dissolved gases, oxygen is the most aggressive. Even a small concentration of this gas can cause serious corrosion. One of the most serious aspects of oxygen corrosion is that it occurs as pitting. This type of corrosion can produce failures even though only a relatively small amount of metal has been lost and the overall corrosion rate is relatively low. The degree of oxygen attack depends on the concentration of dissolved oxygen, the pH and the temperature of the water. Because oxygen pitting is the most common cause of economizer tube failure, this vital part of the boiler must be protected with an oxygen scavenger, usually catalyzed sodium sulfite. In order to assure complete corrosion protection of the economizer, it is common practice to maintain a sulfite residual of 5-10 ppm in the feed water and, if necessary, feed sufficient caustic soda or neutralizing amine to increase the feed water pH to between 8.0 and 9.0. Below 900 psi excess sulfite (up to 200 ppm) in the boiler will not be harmful. To maintain blowdown rates, the conductivity can then be raised to compensate for the extra solids due to the presence of the higher level of sulfite in the boiler water. This added consideration (in
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protecting the economizer) is aimed at preventing a pitting failure. Make the application of an oxygen scavenger, such as catalyzed sulfite, a standard recommendation in all of your boiler treatment programs. Normally, plant oxygen levels vary from 3 to 50 ppb. Traces of dissolved oxygen remaining in the feed water can then be chemically removed with the oxygen scavenger. Oxygen scavengers are added to the boiler water, preferably in the storage tank of the deaerator so the scavenger will have the maximum time to react with the residual oxygen. Under certain conditions, such as when boiler feedwater is used for attemperation to lower steam temperature, other locations are preferable. The most commonly used oxygen scavenger is sodium sulfite. It is also easily measured in boiler water. In most cases it is the oxygen scavenger of choice. There are instances in some higher pressure boilers (generally above 900 psig), that some of the sulfite may decompose and enter the steam, causing problems in the condensate systems and condensing steam turbines. In these cases, substitute (usually organic-based) oxygen scavengers can be used. Phosphate is used almost as often as oxygen scavengers. However, phosphate also plays several important roles in boiler water treatment: It buffers the boiler water pH to minimize the potential for boiler corrosion It precipitates small amounts of calcium or magnesium into a soft deposit which can then accumulate in mud drums or steam drums rather than as hard scale. y It helps to promote the protective oxide film on boiler metal surfaces Common phosphate compounds added to treat boiler water include sodium phosphate (monosodium phosphate, disodium phosphate or trisodium phosphate) or sodium polyphosphate.
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They all function approximately the same; the choice of which to use depends on the quality of the boiler water and the handling requirements of the user.
3.5.2 Internal Treatment The purpose of an internal treatment is to 1) React with any feed-water hardness and prevent it from precipitating on the boiler metal as scale; 2) Condition any suspended matter such as hardness sludge or iron oxide in the boiler and make it non-adherent to the boiler metal; 3) Provide anti-foam protection to allow a reasonable concentration of dissolved and suspended solids in the boiler water without foam carry-over; 4) Eliminate oxygen from the water and provide enough alkalinity to prevent boiler corrosion.
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The most common used of chemical in internal treatment of boiler water is:1) Sulphite-based Chemical Function as preventing oxygen pitting and general corrosion on boiler tubes and internals.
2) Phosphate-based Chemical Function as preventing hard scale formation and other deposition on the boiler internal heating surfaces.
3) Alkali-based Chemical Function as preventing hard scale formation and maintaining the correct pH and alkalinity condition in the boiler water.
4) Sludge Conditioner Function as rendering boiler sludge and precipitation in a mobile condition thus preventing them to settle on boiler surfaces as scales and deposits.
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3.6 ANALYSIS OF BOILER WATER
The procedure below is used to test boiler water.
Chloride-
i) 50 ml boiler water ii) 5 - 10 drops potassium chromate iii) Titrate with silver nitrate until the solution turns brown FORMULA: X times 20
Hardness
i) 100 ml boiler water ii) Add hardness tablet iii) Pour in Ammonia Buffer Solution iv) Wait until the solution turns blue color v) If the color unchanged, titrate with EDTA solution until the solution turns blue.
pH
i) Take 100 ml boiler water sample. ii) Test the pH with pH tester.
TDS
i) 100 ml boiler water ii) 3 drops phenolphthalein red color iii) Titrate with Acetic Acid 30% until the solution color turns neutral iv) Test with DS meter
Caustic Alkalinity
i) 20 ml filtered boiler water ii) 5-10 drops phenolphthalein

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iii) 1 gm Barium Chloride Solid iv) Titrate with Sulphuric Acid 0.02 N until the red solution turns to neutral. FORMULA: X times 50
Sodium Sulphite
i) 0.5 g starch Souble ii) 50 ml boiler water iii) 4 ml Sulphuric Acid 6.5 % iv) Titrate with Potassium Indate Iodide until the solution turns blue FORMULA: X times 25
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3.7 EFFLUENT TREATMENT Nowadays, most of the palm oil mill effluent (POME) is treated by biological process in which based on aerobic and anaerobic ponding system. Effluent treatment using ponds is an economical ways to produce effluent that highly purified. This treatment system uses proper maintenance and monitoring as the process relies solely on microorganisms to break down the pollutants. KSFN Effuent Treatment Plant
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3.7.1 Anaerobic Pond Anaerobic pond is normally used to treat high concentration industrial waste without the present of oxygen. All the activity in the pond is in anaerobic decomposition. The pond is about 8 to 12 feet deep. Scums are formed on the surface of the pond to avoid the air from mixing with the waste water. The bacterial activity in anaerobic process can be summarized as
CO2, CH4 H2S Acid-Forming Bacteria
Organic matter
Organic Acid Acid-Splitting Methane Forming Bacteria
CH4 and CO2
From the figure, we can see that the organic matter is break down and converted to organic acid with gaseous by- products of carbon dioxide, methane and hydrogen sulfide. The digestion process in which gasification process then occur in order to convert the organic acids to methane and carbon dioxide. Acid- splitting methane forming bacteria are strict and lobes and very sensitive to environmental conditions of temperature, pH and anaerobiosis. The general operating temperature and pH conditions for anaerobic sludge digestion are:Temperature - Optimum - General Operating Range pH - Optimum - General Limits
98OF (35OC) 85OF to 95OF
7.0 to 7.1 6.7 to 7.4
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3.7.2 Aerobic/ Oxidation Pond In aerobic pond, oxygen present throughout the pond and all the activity is in aerobic decomposition. The deep of the pond is only 2 feet, so that the sunlight can reach through the depth of the pond, which will let the algae grow throughout. The oxygen will gives off to allow the aerobic microorganism to live. The aerobic action involving bacteria is illustrated as follows:-
Organics + NH4 + O2 Protozoa Bacteria + NO3 + CO2 + H2O
light Algae
In aerobic breakdown, most of dissolved oxygen is supplied by the photosynthetic activity of algae in the ponds and no artificial aeration is provided. The organic loading on the lagoon is maintained at a level which allows a symbiotic relationship between bacteria and algae to exist
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whereby the photosynthetic algae utilize the CO2 released in the respiration and bacteria benefit through the release of the oxygen by the algae.
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4.0 RECOMMENDATION
No doubt, I feel thankful to be able to experience an industrial training. By doing industrial training for about ten weeks, I have gained knowledge and experience which I cannot reach during my lecture. But, ten weeks duration time for industrial training is not enough to me to experience the work completely as I have not been able to carry out any project or research. So, I am recommending the university authority to make the duration for industrial training longer in order to get more knowledge and experiences.
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5.0 CONCLUSION I am very happy and thankful to UTM for providing this obligation industrial training for my course. With this beneficial training, it helps me to understand more about the theory that have been learned during my lecture. I am able to apply to the job that I have done here. Besides, I can see clearly how chemical reactions play its part in boiler water treatment, effluent treatment and routine analysis in this mill laboratory. Through this training, it gives me the beneficial information about the real working sector. I am also able to improve my communication skill and get mingle around with people with different job level. Last but not least, the hardship that I have been through when applying the place for my industrial training make me realize that searching for job is may as hard as this. So, with this training, I set myself to grab any chance, knowledge and experience so that I can apply it for my future career. By now, I am ready to seek for a job after I have graduated someday.
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REFERENCES
Alice K., Peter K.V. (2007). Commercial Crops Technologies. Horticulture Science Series. 8, 304-305 Igwe J.C., Onyegbado C.C. (2007). A Review of Palm Oil Mill Effluent (Pome) Water Treatment. Global Journal of Environmental Research. 1, 1-9 Lawrence K.W., Yung T.H., Howard H.L. (2004). Handbook of Industrial and Hazardous Wastes Treatment. CRC Press. 2nd edition. 720-722 Malek M.A. (2004). Power Boiler Design, Inspection and Repair. Mc. Graw Hill Professional. 525 Oke.P.K. (2007). Development and Performance Evaluation of Indigenous Palm Kernel Daul Processing Machine. Journal of Engineering and Applied Sciences. 4.701-705 Schroeder C. D. (1991). Solutions to boiler and cooling water problems. Springler. 2nd edition.
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APPENDICES Appendix 1: Appendix 2: Appendix 3: Appendix 4: Appendix 5: Appendix 6: Photos Palm Oil Mill Processing Chart Boiler Water Treatment Flow Chart Boiler Water Test Result Form Oil Loss Result Form Kernel Loss Result and Calculation Form
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Industrial Training Report: Universiti Teknologi Malaysia

1.0 EXECUTIVE REPORT

Industrial Training Report: Universiti Teknologi Malaysia

Industrial Training Report: Universiti Teknologi Malaysia

2.0 INTRODUCTION 2.1 ORGANIZATION BACKGROUND

Industrial Training Report: Universiti Teknologi Malaysia

Industrial Training Report: Universiti Teknologi Malaysia

2.2 ORGANIZATION CHART

Industrial Training Report: Universiti Teknologi Malaysia

2.3 INTRODUCTION OF PALM OIL

Industrial Training Report: Universiti Teknologi Malaysia

3.0 DUTY REPORT 3.1 PALM OIL MILL PROCESSING

Industrial Training Report: Universiti Teknologi Malaysia

3.1.1 Reception Station

Industrial Training Report: Universiti Teknologi Malaysia

Industrial Training Report: Universiti Teknologi Malaysia

Industrial Training Report: Universiti Teknologi Malaysia

Pest Damaged Bunch

Industrial Training Report: Universiti Teknologi Malaysia

Industrial Training Report: Universiti Teknologi Malaysia

Industrial Training Report: Universiti Teknologi Malaysia

Industrial Training Report: Universiti Teknologi Malaysia

Kernel Recovery 3.1.7 Depericarpring

Industrial Training Report: Universiti Teknologi Malaysia

3.1.8 Nut Cracking

Industrial Training Report: Universiti Teknologi Malaysia

kernel & shell

Hydro Clay Bath

Industrial Training Report: Universiti Teknologi Malaysia

Industrial Training Report: Universiti Teknologi Malaysia

3.2.2 Oil in sterilized fruit ( FFA)

Industrial Training Report: Universiti Teknologi Malaysia

Industrial Training Report: Universiti Teknologi Malaysia

Dilution by volume of crude oil (%) 0 50 55 60 65 70 75 80 85 90 95 100

3.2.4 Continuous Settling Tank Oil Samples ( Moisture Contents )

Industrial Training Report: Universiti Teknologi Malaysia

Industrial Training Report: Universiti Teknologi Malaysia

3.2.6 Production Oil

Industrial Training Report: Universiti Teknologi Malaysia

3.2.7 Storage oil

Industrial Training Report: Universiti Teknologi Malaysia

3.2.8 Despatched oil

Industrial Training Report: Universiti Teknologi Malaysia

3.2.9 Sludge Ex-Sludge Centrifuge

Industrial Training Report: Universiti Teknologi Malaysia

3.2.10 Sterilizer Condensate (Oil Loss)

Industrial Training Report: Universiti Teknologi Malaysia

3.2.11 Sterilized empty bunch (oil loss)

3.2.12 Press Cake

Industrial Training Report: Universiti Teknologi Malaysia

3.2.13 Fibre from Depericarper Cyclone

Industrial Training Report: Universiti Teknologi Malaysia

3.2.14 Nuts before Nuts Silo

3.2.15 Nuts- Ex Nut Silo

Industrial Training Report: Universiti Teknologi Malaysia

3.2.16 Cracked Mixture Ex-Nut Cracker

3.2.17 Light Particle ( Kernel Losses)

Industrial Training Report: Universiti Teknologi Malaysia

3.2.18 Kernel Ex-Hydroclaybath

3.2.19 Wet Shells Ex-Hydrocclaybath

Industrial Training Report: Universiti Teknologi Malaysia

3.2.20 Kernel Loss on Dry Nut Basis

3.2.21 Bagged Kernels