PALM OIL MILL PROCESSINGBENEDICT DAD KNOWLDEN

A147029

INDUSTRIAL TRAINING 2015/2016NATIONAL UNIVERSITY OF MALAYSIA

(JKMB)

KKS-TANAH MERAH PALM OIL MILL, SIME DARBY PLANTATION

(TANAH MERAH, NEGERI SEMBELAN)

INTRODUCTION

Mill Background

Mill's Objectives/Targets

Process Flow/operation

Projects/Task

Conclusion

Mill Background

• One of Sime Darby's 44 mills in malaysia.

• Designed by Amsterdam.

• Commissioned on 28th February1978.

• Capacity of 30 metric ton per hour.

• Land occupied = 4.5 hectares

Mill's Objectives/Targets

• To produce Crude Palm oil.– Premium Quality

(FFA<=1.2).– Standard Quality

(1.2<FFA<1.5).

• To achieve maximum OER

• Productivity must be 30 MT/hr

Process Flow/OperationReception

Sterilizer

Digester

Press Cake

Cracker

Winnower

Diluted Crude Oil

Fiber

Nut Bin

Shell

Empty Bunch

Recycle Water

Sludge

Sterilizer Condensate

Solid Waste (POME)

Crude Palm Oil (Dispatch)

Palm Kernel

(Dispatch)

Process Flow Chart FFB from Field

ThresherC.O. Vibrating Screen

Screw Press

DCO Tank

Clarifier

Depericarper

Pure Oil TankSludge Tank

Sludge Centrifuge

Rotary Screens

E.T.P

Vacuum Dryer

Purifier

CPO Storage Tank

Shell Compartment

Boiler

Hydro Cyclone

Kernel Silo

Bulk Kernel Silo

EFB Ramp

Steam Turbine

USB

ElectricitySteam

Hot Water

MPD

Shell (Dispatch)

EFB

Shell

Undiluted Crude Oil

Screen Solids

Centrifuge Waste

R.S.O.

Typical Palm Oil Mill Process Flow (Crude Oil)

Moisture< 0.18%Dirt < 0.02%PQ < 1.2% FFAStd Oil < 5% Max FFA

Effluent Treatment

Plant

Sludge

Purifying

Reception

Sterilization

Pressing

Screening

Clarifying

Threshing

Drying

Oil Recovering

Recovered

OilOil Storage Tank

Typical Palm Oil Mill Process Flow (Kernel)

• .

Admixture< 6%Moisture < 7%

Heater

Cyclones

Shell & FibreBoile

rTurbine

Reception Threshing

Nut Cracking

Sterilization

Winnowing

Depericarping

Hydrocyclone

Pressing

Kernel Despatch Silo

Projects/Task

Bearings and Gearbox

Critical Machines

Machinery List

Familarization(Station)

Work Schedule

Familarization (Stations)

1. Reception Station2. Fruit Handling Station3. Sterilization Station4. Threshing Station5. Pressing Station6. Depericarping Station7. Kernel Recovery

Station

8. Clarification Station9. Palm Product Storage

and Dispatch Station10. Effluent Treatment

Plant11. Water Treatment Plant 12. Boiler Station13. Power Generation

Station

The following are the 13 main stations at the palm oil mill required to be operational during processing of the palm fruit:

Reception and Fruit Handling

FFB weigh IN. Palm Products weigh out consignment checked

• FFB is put in cages• 2.25mt per cage.

• Fertilization• EFB is transported to

estate

• to assess the grade of FFB• Aid in OER determination

• Hoist and Crane• travel in one axis• Lifting and Tilting Operation

Machinery List

Conveyors Motors Gearbox

• Scrapper• Ribbon• Belt• Bucket

• Synchronous• Induction• Star(Y)/Delta• Squirel Cage

• Coupling size• Ratio

Conveyor Details

Conveyor

Motors

Critical Machines

Boiler.

Cake Breaker Conveyor

Turbine

Sterilizer

Screw Press

Depericarping Drum

1. BOILER

General Description:-

A boiler is a closed vessel in which water or other fluid is heated under pressure. The fluid is then circulated out of the boiler for use in various processes or heating applications.

BOILER

The main functions of the station are as follows:‑– To convert the chemical

energy in the palm shell and fibre to heat energy in boiler furnace.

– To transfer the heat energy to the water in the water circuit of the boiler and convert it to steam.

– To supply steam to the Power Station for generating electricity.

– To supply steam for other process units in the mill.

BOILER• Water tube boiler.

– High pressure(40psi) boiler.

– Produce superheated steam at 390°C or higher.

– Water at the bottom of the steam drum flow back to the feed water drum via large-bore 'downcomer tubes', where it helps pre-heat the feed water supply.

– To increase the economy of the boiler, the exhaust gasses are also used to pre-heat the air blown into the furnace and warm the feed water supply.

BOILER

Combustion Theory• To achieve good

combustion, there are 3 important factors: -1. Time2. Temperature3. Turbulence

DESIRABLE RESERVES IN BOILER WATER (Phosphate Base)

Remarks:Chemical Dosage (RWT) = x ppm/1000 X Water Consumption X Operation Hrs

2. Cake Breaker Conveyor

• Function– Convey press cake

to winnower.– While conveying, it

breaks the cake in order to separate the nuts from fiber.

3. STEAM TURBINE

General Description:-

A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into useful mechanical work.

Heat Energy (Steam)

Kinetic Energy (Velocity)

Electrical Energy (Alternator)

STEAM TURBINE

STEAM TURBINE

MAIN COMPONENT

1. Inlet Flange2. Combination Trip and Throttle Valve (Combo Valve)3. Governor4. Inlet Casing (Steam Chest)5. Exhaust Flange6. Nozzles and Blades7. Bearings8. Shaft Seals9. Turning Gear

STEAM TURBINE

INLET FLANGE

• Steam Supply go through to the inlet flange prior to turbine.

• Steam can go through after the valve is open.

STEAM TURBINE

COMBINATION TRIP AND THROTTLE VALVE

• Over speed Trip valve is mechanically actuated that interrupts the supply of steam to the turbine during an over speed condition or other emergency.

• Throttle valve is to control the amount of steam entering the turbine and thereby determines the speed and power produced by the turbine.

STEAM TURBINE

GOVERNOR

• The governor sense the speed of the turbine and open or close the throttle valve, as appropriate, to maintain the set speed

STEAM TURBINE

INLET CASING

• Inlet casing (Steam chest) is the casing section containing the high pressure inlet steam.

• Steam enters the inlet casing from the combo valve and travels through nozzles in the nozzle block and turn the wheel.

STEAM TURBINE

EXHAUST FLANGE

• The flange connects the turbine to the user’s exhaust steam line or back pressure vessel

STEAM TURBINE

LABYRITH

TURBINE BLADE

STEAM TURBINE

STEAM TURBINE

TRIPPING MECHANISM

STEAM TURBINE

MAINTENANCE OF STEAM TURBINE

4. STERILIZER

Reception

Sterilizer

Functions:•To loosen the loose fruit•To stop enzymatic FFA rise•To dehydrate the fruit & nut•To soften the mesocarp

STERILIZER

5. SCREW PRESS

General Description:-

• Screw Press is designed and developed for the efficient extraction of palm oil from oil palm fruits.

• It also minimizes the broken nut level to enhance kernel recovery.

• The Screw Press has been widely and successfully used for Palm Oil Mill.

SCREW PRESS

Digester

Kernel Recovery Plant

Oil Recovery Plant

Functions:•To condition the fruits in digester•To extract optimum oil.

Reception

Sterilization

Threshing

Digester / Screw Press

Screw Press

SCREW PRESS

KERNEL RECOVERING STATION - DEPERICARPING.

Fibre Cyclone

Foreign material

Polishing Drum

DepericarperFunctions:•To separate fiber from nuts

through vacuum suction•To polish the nuts for cracking•To remove foreign material

Reception

Sterilization

Threshing Pressing

Fibre

KERNEL RECOVERING STATION - DEPERICARPING.

• Function– Remove dirt

from nuts.– Rotate

continuously to ensure fiber nut separation

– Polish nut for cracking

CONCLUSION

• The operation of a palm oil mill is essential in that, mill uses its own source of energy to maximize production of crude oil.

• Energy conservation is sustained• Recyclability is encouraged

THANK YOU