SOY OIL PROCESSING INDUSTRYPRESENTED BY: MALAYSIA BOLEH RESEARCH & CONSULTANCY

MALAYSIA BOLEH RESEARCH & CONSULTANCY

MR. MOHD HILMI MOHD IDRIS MS. ADLINA SNAWI MR. MUHAMMAD SUFFIAN AHMAD MR. ABDUL MAJID IBRAHIM MR. SHAHRUDDIN KASSIM MR. ZAKARIA ABU HASAN MR. FAZIL MAT ZAIN MS. ZURAIDAH KORNAIN MS. ZAUYAH TARMIZZI MR. MARZUKI ZAINAL ABIDIN

MALAYSIA BOLEH RESEARCH & CONSULTANCY

PROCESS FLOW DIAGRAM

Process Flow DiagramTestingYardBig SilosDay SiloscreenerDe-StonerCrackerCookerFlakersDryerExtractorEconomiserEvaporatorStripper Cum DryerStorage TanksCRUDE OILDT-DCScreenerLump-crusherOversized lumpMixing & PackingStorage TanksDOCcycloneWET DOCPREPARATORY SECTIONSEED UNLOADING & CLEANING SECTIONSOLVENT EXTRACTION PLANT

TestingYardBig SilosSEED UNLOADING & CLEANING SECTION

Day SiloscreenerDe-StonerCrackerCookerFlakersDryerPREPARATORY SECTION

ExtractorEconomiserEvaporatorStripper Cum DryerStorage TanksCRUDE OILDT-DCScreenerLump-crusherOversized lumpMixing & PackingStorage TanksDOCcycloneWET DOCSOLVENT EXTRACTION PLANT

MATERIAL FLOW DIAGRAM (Hexane)

ExtractorEconomiserEvaporatorCondenserDT-DCCyclone(Miscella+Hexane)Stripper Cum Dryer(Jet + Chiller)Water-Solvent Separator

Loss Material Flow DiagramDOCMISCELLASOLVENT EXTRACTION PLANT

MAJOR WASTE STREAMS/AREAS OF LOSSES

MAJOR WASTE STREAMS/AREAS OF LOSSES

PROCESSPLACES/AREASWASTE/LOSS1TransportationConveyor & Bucket Elevator Seed Husk Stone 2Big Silo to Day Silo3Preparatory SectionDay Silo to Screener Cracked Seed Dust Husk 4De-Stoner Mud Balls Stone5Mechanical CrackerNIL6Condensed the soy seedCooker Steam Water 7FlakingFlakers Soy Seed8DryingDryerNIL

MAJOR WASTE STREAMS/AREAS OF LOSSES

PROCESSPLACES/AREASWASTE/LOSS9Solvent Extraction (Crude Oil Production)Rotary Type Extractor (RTE) Hexane10Distillation Hexane11Stripper Hexane12Condenser Hexane13Water/Solvent Separator Waste Water Hexane14DesolventDT-DC(De-Oiled Cake Production) Hexane Moisture Heat15Cooling Moisture Heat16SeavingNIL17PackagingNIL

FISHBONE DIAGRAM

MANMETHODMACHINEENVIRONMENTFISHBONE DIAGRAM

Hexane LossMATERIALHigh humidityPoor air qualityProcess control not effectivePoor equipment calibrationNo standard operating procedurePoor soy seed qualityPoor hexane qualityPoor steam qualityHuman errorLack of trainingLack of motivationInefficient machineDT-DCRTEJetconRTEChiller condenserEconomiserStripper(Dryer)Hexane/water seperatorEvaporatorHexane supply systemHexane recovery systemLeakage

PROPOSED GP OPTIONS

GP OPTIONS

GP OPTIONDESCRIPTION1NEW EQUIPMENT Up to date & efficient machine Upgrade Total Preventive Maintenance2NEW MATERIAL/ CHEMICAL Replace Hexane (hexane is hazardous to health, substitute with more environmental friendly chemical) Better quality of soy seed3ALTERNATIVE SUPPLIER To supply better quality of soy seed4METHODOLOGY Develop Standard Operating Procedures (SOP) Implement EMS (ISO 14001) Equipment calibration

GP OBJECTIVES & TARGETS

GP CONSULTANCY REPORT BY MALAYSIA BOLEH TEAMSOY BEAN OIL REFINING PROCESS

GP CONSULTANCY REPORT BY MALAYSIA BOLEH TEAM

SOY BEAN OIL REFINING PROCESS

1

2

3

4

5

6

OBJECTIVE

TARGET

PROGRAM

ACTION

RESPONSIBLE PERSONS

TIME

FRAME

1.1 Minimise Hexane Usage

2.1

Reduce consumption by 10% within one (1) year

3.1.1

Maintenance (Total Productivity Maintenance TPM)

Condition-based Maintenance - CBM

4.1.1

Implement TPM & CBM

5.1

5.1.1

Head of Dept

5.1.2

Maintenance Mgr

5.1.3

Maintenance Technicians

5.1.4

Contractors

6.1.1

Start Immediately & monitor within one (1) year.

Annual review.

3.1.2

Improve Calibration of equipment

4.1.2

Scheduled calibration

5.1.2

Approved Calibration Agency or Company

6.1.2

Continuous-based on equipment validity

3.1.3

Replace old and unreliable equipment

4.1.3

Reliablity Trending and Analysis

5.1.3

Maintenance Manager

6.1.3

Continuous-based on equipment condition and techno-economics

3.1.4

Improve Hexane Quality from Supplier

4.1.4

Testing of raw material

5.1.4

Testing engineer/technician

6.1.4

One (1) year.

Annual review.

1

2

3

4

5

6

OBJECTIVE

TARGET

PROGRAM

ACTION

RESPONSIBLE PERSONS

TIME

FRAME

1.2

Reduce moisture content in seed

2.2

Reduce moisture to minimum acceptable limits

3.2

Incoming seed testing

4.2.1

Enforce Contract Specifications

4.2.2

Test for moisture at Incoming Goods

5.2

5.2.1

Head of Dept

5.2.2

Testing Mgr

5.2.3

Testing engineer/technician

5.2.4

Contractors

6.2

Start Immediately & monitor within one (1) year.

Annual review.

1.3

Reduce husk content in seed

2.3

Reduce husk to minimum acceptable limits

3.3

Incoming seed testing

4.3.1

Enforce Contract Specifications

4.3.2

Test for husk at Incoming Goods

5.3

5.3.1

Head of Dept Contract & Operations Sect

5.3.2

Testing Mgr

5.3.3

Testing engineer/technician

5.3.4

Contractors

6.3

Start Immediately & monitor within one (1) year.

Annual review.

1.4

Optimise flake thickness in Flaker

2.4

Optimise flake to acceptable limits

3.4

3.4.1

Implement TPM & CBM

3.4.2

Measure flake thickness

3.4.3

Ensure reliability of equipment

4.4.1

Use TPM

4.4.2

Testing for flake thickness using specialised tools.

4.4.3

Use good quality equipment

5.4

5.4.1

Head of Dept Contract & Operations Sect

5.4.2

Testing Mgr

5.4.3

Testing engineer/technician

5.4.4

Contractors

6.4

Start Immediately & monitor within one (1) year.

Annual review.

GP CONSULTANCY REPORT BY MALAYSIA BOLEH TEAMSOY BEAN OIL REFINING PROCESS

123456OBJECTIVETARGET PROGRAM ACTION RESPONSIBLE PERSONSTIMEFRAME1.2 Reduce moisture content in seed 2.2Reduce moisture to minimum acceptable limits3.2Incoming seed testing 4.2.1Enforce Contract Specifications4.2.2Test for moisture at Incoming Goods 5.25.2.1Head of Dept5.2.2Testing Mgr5.2.3Testing engineer/technician5.2.4Contractors6.2Start Immediately & monitor within one (1) year.Annual review.1.3 Reduce husk content in seed 2.3Reduce husk to minimum acceptable limits3.3Incoming seed testing 4.3.1Enforce Contract Specifications4.3.2Test for husk at Incoming Goods 5.35.3.1Head of Dept Contract & Operations Sect5.3.2Testing Mgr5.3.3Testing engineer/technician5.3.4Contractors6.3Start Immediately & monitor within one (1) year.Annual review.

GP CONSULTANCY REPORT BY MALAYSIA BOLEH TEAMSOY BEAN OIL REFINING PROCESS

123456OBJECTIVETARGET PROGRAM ACTION RESPONSIBLE PERSONSTIMEFRAME1.4Optimise flake thickness in Flaker2.4Optimise flake to acceptable limits3.43.4.1Implement TPM & CBM 3.4.2Measure flake thickness3.4.3Ensure reliability of equipment 4.4.1Use TPM 4.4.2Testing for flake thickness using specialised tools.4.4.3Use good quality equipment5.45.4.1Head of Dept Contract & Operations Sect5.4.2Testing Mgr5.4.3Testing engineer/technician5.4.4Contractors6.4Start Immediately & monitor within one (1) year.Annual review.

GP POLICY

GP : POLICYWe are committed to :

Answer the societal demands for higher productivity in a sustainable manner with preserving the environment.Ensure the natural environment on which society depends is not degraded and polluted. Make a better and cost-effective approach in implementing efficient and innovative GP solution. Assist other companies in gaining their competitive advantages and cost-effective reduction of waste and emissions.