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Component And Process Flow Of Palm Oil Mill

1627 words - 7 pages

COMPONENT AND PROCESS FLOW OF PALM OIL MILL

CHE RAHMAT CHE MAT
UNIT PENGILANGAN & PEMPROSESAN BAHAGIAN KEJURUTERAAN & PEMPROSESAN

PALM OIL MILL

RAW MATERIAL FRESH FRUIT BUNCH (1 Tonne) MAIN PRODUCTS

CRUDE PALM OIL (20 – 22 %) BY-PRODUCTS

PALM KERNEL (5 -6 %)

EMPTY FRUIT BUNCH (20 – 22 %)

FIBRE (12 – 14 %)

SHELL (5 – 6 %)

POME (60 – 65 %)

BOILER ASH

Process Flow Palm Oil Mill
FFB LORRY FRESH FRUIT BUNCH (FFB) STRIPPER EMPTY BUNCH HOPPER CAGE STERILISER TIPPER FFB HOPPER

Fruitlets
FRUIT ELEVATOR

Fibre
DIGESTER

FIBRE CYCLONE

SCREW PRESS

Press Cake
SLUDGE TANK 1

DEPERICATER

NUT POLISHING DRUM CLARIFIER

BOILER

Press Liqour
...view middle of the document...

Basic Information
 Location plan of the mill  Expected crop projection for 20 years  Topographic map of the selected mill site  Un-interrupted availability of water for processing & distance of the water source from the mill  Commissioning date and  Distance to the nearest national grid (NEW)

Location
 Reasonably central – transportation cost  3 km away from the nearest settlement - DOE  Close to water source  Access to main road – dispatch  Gentle sloppy terrain 10 m high – loading ramp  Effluent ponds – gravity feed facility

Planning Stage
 Select a large area eg. 60 ha - mill infra structure & a RE power plant.  Prepare the mill layout- leave out effluent ponds  Prepare 0.5 metre interval contour of the site  Superimpose the mill layout on this  Locate the mill entrance  Check the shape of of the remaining land & draw the layout of the effluent ponds OR  Consider tank digestion, gas collection for RE

Average Mill cost
Cost Centres Rough % 40 45 10 20 tph 8.8 9.9 2.2 30 tph 9.6 10.8 2.4 30>60 tph 10.4 11.7 2.6 60 tph 14.4 16.2 3.6

Mech. Works
Civil works Electrical Consultants/ others TOTAL (RM Million)

5
100

1.1
22

1.2
24

1.3
26

1.8
36

Propriety Equipment (branded machines)
       Boilers Diesel generators Steam generators Screw presses Oil purifiers Sludge separators Vacuum dryers        Cranes/ tippers Weighbridges Pumps Nut crackers Water softeners De-aerators Sterilizer automation

Mill sizing
       Planted area Predicted yield Annual crop Monthly crop Peak month 113% Daily crop (peak) Hourly capacity = 8,000 ha = 25 t/ha/yr = 200,000 t = 16,667 t = 18,833 t = 724 t (26day/mth) = 36 t (20 hrs/day)

 The mill size should be 45 tph capable of delivering 36 tph (80%) as the monthly average.

Mill rated capacity vs actual
No. Rated capacity 1 2 3 4 10 tph 30 tph 60 tph in 2 lines 45 tph Actual monthly avg. 10 tph 27 tph 48 tph 36 tph Factor 100% 90% 80% 80%

5

90 tph in 2 lines Law of Diminishing

72 tph Returns ?

80%

Plant Sizing (Basis)

Plant Sizing - Basis
1.Loading Ramps The hoppers must be able to keep at least 8 hours crop. i.e Mill t/put x 8hrs excluding cages. For a 30 tph mill 30 x 8 = 240 tonnes. Must not dump crop on hopper

Plant Sizing - Basis
2. Sterilizers Fix the cage weight preferred : say 5 kg Number of cages per sterilizer: say 6 numbers Sterilization time : say 80 minutes per charge Number of sterilizers : 2 units double doors Weight per charge = 6 x 5 = 30 tonnes Throughput for this set up = 30 x 2 x 60 = 45 t /hr 80 There is sample surplus capacity to give 30 tph Mill is expandable to 45 tph

Plant Sizing - Basis
3. Presses • Install 3 presses, capacity: 15 tph each OR • Install 2 presses, capacity : 20 tph each. This is capable of 26 tph OR • Install 4 presses 10 tph each

Plant Sizing - Basis
4. Nut Station The most comfortable throughput for the nut station on a single line is 30 tph...

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