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The Extraction of Palm oil

Posted by Flora Sawita Labels: , , , ,

Introduction


This introductory article gives a brief description of the process of extracting palm oil in a modern factory. Detail descriptions are contained in other articles found at this site. A typical process flow diagram is included. Pictures are included in this article to make thing clearer to people unfamiliar to the oil Palm industry.

Palm oil factories are normally generate their own electricity. Electricity is generated by burning the waste products of the fruits, fibre and shell in a boiler. The boiler generates steam which drives a steam turbine to produce electricity. Palm oil mills are located in plantations that are far away from major towns and as such they also treat their own water supply.

The extraction process is a series of separating processes. These are described below.

    

A Ripe oil Palm Fruit Bunch                                                                   An Oil Palm Tree

Harvesting.

Palm oil is extracted from oil palm fruits. Oil palm trees grow in the tropics and originated in Africa. The fruit bunch is cut when it is ripe as shown in the picture.  The harvested fruit bunches are sent the processing plants by trucks for the extraction of Palm Oil.

Fruit Reception
The arriving fruit usually in trucks is dumped into a FFB (Fresh Fruit Bunch) hopper. It is then transferred to fruit cages. The cages are then moved into a steriliser.

Sterilisation

 The steriliser is similar in function of a pressure cooker. The fruits are heated with steam at a pressure of 45 psig for about one hour. This cooking process softens the fruits, enables the separation of the fruit from bunches and stops the enzymes that cause the increase of FFA (Free fatty acids) in the fruits.

Threshing

In the next stage the fruit cages are tipped and conveyed to a threshing machine. This machine a rotary drum of about 2 meters in diameter.  The drum rotates and bunches get lifted up and dropped when they reach the top of the drum. This action helps the detachment of fruits from the bunches and the separated fruit lets fall through the slots of the drum to a conveyor below.

Pressing

The fruits are conveyed to a digester which mashes up the fruitlets so that when the mash is pressed in a screw press the oil is extracted efficiently. The output from the screw press is crude palm oil and press cake. The extracted oil is mixed with fruit particles, water, sand and dirt.  The press cake consists of palm fibre and nuts.
The press cake is the transferred to the depericarpper for further processing.
The crude oil is first screened with a vibrating screen to remove the course fibres and other dirt and it is then pumped to the clarification station for further processing.

Clarification Station

The oil is pumped to a heated vertical tank where the separation of oil from the sludge (mixture of water and dirt) takes place by gravity. The oil is skimmed from the top and the remaining dirt removed in a purifier. The heated clean oil is the passed to a vacuum chamber for the removal of the remaining moisture. The oil is the pumped to storage tanks for sale as crude palm oil.

Press Cake processing.
The press cake is conveyed in a conveyor that assists the break up the cake to a depericarper. The depericarper is a square box that with a strong suction. The air removes the fibres and transports them to a cyclone. The fibre from the cyclone is sent to the boiler for burning as fuel for the generation of steam.
The nuts being heavier drop to the bottom of the depericarper and are cleaned in a rotary drum and transported to a silo for intermediate storage.

Nut Processing
The nuts from the nut silo are first cracked in a nut cracker. The cracked mixture which consists of kernels and shell is the processed to separate the shells and kernels. This is done in air columns and by a water bath in a hydro-cyclone. The shell is sent to the boiler house to be used as fuel. The kernels are dried in a silo and then packed in bags for sale. Other factories extract oil from the kernel.

Power Generation.
In a palm oil mill all the electricity required for processing can be generated from the waste products of the palm fruits. The diesel generators are only required for start up and shut done of processing in a well operated palm oil mill.
The fibre from the fruits after pressing and shell from cracked nuts are sent to the boiler for burning as fuel. The steam generated by the boiler is used to drive a steam turbine which is coupled to an alternator to generate electricity.


Water Treatment
In the palm oil mill process water is required for the steam generation, oil clarification, cleaning and domestic requirements. The quantity of water required is determined by the processing capacity of the mill, for example a 30 tons per hour mill will require 30 cubic meters of water per hour. Most palm oil mills are located in plantations that are far away from towns. This requires most palm oil mills to treat their water requirements. The treatment plants purify the water for process use and then further treat it for use in the boilers.

Effluent Treatment

The palm oil process uses water to separate the oil from sludge and solids in a tank. After the removal of oil, the waste water (effluent) is discharged from the mill. This effluent contains particles of vegetable matter and needs to be treated before discharge to the environment. The effluent needs to be treated because the vegetable matter in the liquid will decompose and during the decomposition process, the vegetable matter will use oxygen in the water. Therefore before the discharge of the effluent to a water course we let the decomposing process take place by keeping the effluent in ponds and let bacteria decompose the vegetable matter in the waste water.



This then is a simple explanation of the palm oil process.

http://www.palmoilmill.co.nz/index.php?option=com_content&view=article&id=48:the-extraction-of-palm-oil&catid=47:ffb-reception&Itemid=71

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Sterilising Station

Posted by Flora Sawita Labels: , , ,

Purpose:
The purpose of sterilising FFB (Fresh Fruit Bunches) is to treatment them for further processing.
What is sterilising?
Sterilising is a process where the fruit bunches are cooked under steam pressure. Cooking is normally carried out under 3 bar pressure (45 pounds per square inch – psi) for approximately 90 minutes.
During the cooking process the fruits become soft and the enzymes that produce free fatty acid are deactivated. The fruits are also easier to be detached from the bunch after the sterilising process. During the heating under pressure and the subsequent realising of pressure there is a moisture loss from the fruit bunch of about 10%. The loss of moisture from the stalk joining the fruit to the bunch enables the fruit to be easily separated from the bunch. The separation of the fruit from bunches is carried out in the next stage of the palm oil extraction process, called threshing.


Picture of sterilisation station

The sterilising Process.

The fruit bunches are loaded into the fruit cages. The cages with the fruits are pushed into the sterilisers. The movement of cages can be by hydraulic cylinders mounted on the floor in between the rail tracks or by winches.
Once the cages are inside the steriliser the doors are closed. The cooking is by steam. This is let in by opening of the inlet valves. In most palm oil mill the opening and the closing of steam valves is automated and controlled by a simple programmer.
The fruits are normally cooked under steam pressure for 90 minutes. Once the cooking is complete and the steam exhausted from the steriliser. The doors are opened and the fruit cages pulled out of the steriliser.

The cages are the emptied either by being lifted by a crane and rotated on to a thresher or rotated at ground level by a tipper.

The steriliser is a pressure vessel and as such it should be designed to pressure vessel design codes. The shell thickness of the steriliser is normally 12mm. The bottom half of the inside of the steriliser is lined with liners of mild steel or stainless steel so that when the wear they can be replaced. The liners protect the body of the steriliser from wear and extend the life of the steriliser.  The doors and the dish end of the steriliser should be protected by full liners. The doors are expensive to replace. The body of the steriliser is insulated so that the heat loss is minimised.

The sterilising capacity for a palm oil mill depends on the design capacity of the mill. The sterilised fruit must be available at the right time in the right quantity so the mill can achieve the designed processing capacity.
As a sterilising cycle take approximately 2 hours -cooking time and door opening and closing.
Therefore for 30 tons per hour processing capacity the sterilising capacity should be 60 ton. If the mill is designed with cages of 10 tons the mill should have two sterilisers of 3 ten ton cages each. The fruit cage size normally varies from 2.5 tons to 20 tons depending on the design of the mill.

http://www.palmoilmill.co.nz/index.php?option=com_content&view=article&id=50:sterilising-station&catid=48:sterilization-station&Itemid=71

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Crude Palm Oil Quality

Posted by Flora Sawita Labels: , , ,

The quality of Crude Palm oil is determined by the percentage of Free Fatty Acid, the percentage of dirt, the percentage of Moisture and the Dobi Index (Bleachibility index).
The generally accepted standards for good quality Crude Palm oil are 
1. Free Fatty Acid – Below 5%
2. Dirt in oil Below 0.01 %
3. Moisture in oil Below 0.1 %
4. Dobi Value Above 250.　


FFA. (Free Fatty Acid)

The main cause of FFA being above 5% is due to the crop quality. FFA increase once the crop is harvested. Any delay in processing either in the plantation or the mill will cause the FFA to increase. The mill can reduce the increase the FFA rise by processing the crop as soon as it arrives at the mill. This is achieved by having a minimum balance every day. The balance FFB at the end of each processing day should be equivalent to two hours mill processing capacity. This quantity is required so that when the mill starts the old FFB can be processed to produce fibre and shell for boiler fuel. During the two hours of processing the fresh FFB can be sterilised so that the mill can process FFB continuously.

Dirt and Moisture.

The quantity of dirt and moisture in the pure oil before the purifier depends on the efficiency of the clarification tank. The dirt in the pure oil is reduced in the clarification tank due to dirt settling out in the clarification tank as it is denser than pure oil. If the clarification tank is not function efficiently then the quantity of dirt will be too much for the oil purifier to remove and dirt in the production oil will be above the allowed limit.
The clarification tank is working efficiently when the oil layer is always more than 500 mm. To achieve this at all times it is suggested that the skimmer height is set to 10 cm. The skimmer height is the difference between the level of the oil outlet at the oil skimmer and the sludge outlet
 
                    Picture of a Typical Continous Clarification Tank
Once the correct setting of the skimmer height is achieved in a mill and clean oil is flowing out of the clarification tank, then the skimmer height is correct. At the end of the processing shift it is wrong to decrease the skimmer height to recover the oil in the clarifier tank. The oil layer must be left in the tank so that when the mill is started up the next day clean oil is obtained. The operation of the clarification tank is explained in an other article on this site.
The purifiers must be in operation correctly to remove most of the remaining dirt and some moisture.
To remove the balance of moisture the oil has to pass through the vacuum dryer.
To manage the CPO quality the following samples must be taken and analysed.
Sample
Frequency
Location
Analyse For
Remarks
Oil after Clarifier Once every two hours Outlet of Clarifier. Dirt and Moisture If dirt more than 0.1% and/or Moisture >0.5%.
Increase skimmer height.
Check that the oil outlet pipe of the Clarifier tank does not have any holes.
Production Oil Every Two Hours After oil purifier Dirt and Moisture If dirt more than 0.01% and/or Moisture >0.1%.
Clean the purifier.
If automatic cleaning purifier then, shorten the automatic cleaning cycle.
If a problem is suspected then the frequency of the sampling must be increased and the operation of the clarifier examined.

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Palm Oil Milling Process

Posted by Flora Sawita Labels: , , , , , , , , ,

Edible Oil Processing - Production


PALM OIL MILLING PROCESS


Introduction
Palm oil is extracted from fresh fruit bunches (FFB) by mechanical process, where a mill commonly handles 60 to 100mt per hour of FFB. The modern palm oil mill of today is based predominantly on concepts developed in the early 50s (Mongana Report). An average size FFB weighs about 20-30kg and contains 1500-2000 fruits (Figure1). The FFBs are harvested according to harvesting cycles, and delivered to the mills on the same day. The quality of crude palm oil is dependent on the care taken after harvesting, particularly on the handling of the FFBs.
Figure 1
Figure 1. Fresh fruit bunches waiting for processing at palm oil mill
A palm oil mill produces crude palm oil and kernels, as primary products and biomass as secondary product. The capacity of mills varies between 60- 100 tons FFB/h. A typical mill has many operation units as shown in Figure 2. This comprises of sterilization, stripping, digestion and pressing, clarification, purification, drying and storage. For the kernel line, there are steps such as nut/fibre separation, nut conditioning and cracking, cracked mixture separation, and kernel drying, storage. The dried kernels are often sold to palm kernel crushers for extraction of crude palm kernel oil. In some integrated plants, kernel crushing facilities exist side by side at the same complex.
Figure 2
Figure 2. Flow chart for the palm oil process (from Sivasothy, 2000).

Sterilisation

This first step in the process is crucial to the final oil quality as well as the strippability of fruits. Sterilization inactivates the lipases in the fruits, and prevents build-up of free fatty acids (FFA). In addition, steam sterilization of the FFBs facilitates fruits being stripped from the bunches. It also softens the fruit mesocarp for digestion and release of oil, and conditioning of nuts to minimize kernel breakage. Air is removed from the sterilizer by sweeping in steam in single-peak, double-peak or triple-peak cycles. In general, bunches are cooked using steam at 40psig. in horizontal cylindrical autoclaves for 60-90 minutes. The length of the sterilizer is dependent on the number of cages required for operation of the mill. Each cage can hold 2.5 to 10tons of FFB. Steam consumption varies from 140 kg/ton FFB for a single-peak cycle to 224 kg/ton FFB for a triple – peak cycle (Sivasothy et al.1986). Inadequate sterilzation affects the subsequent milling processing stages adversely.
In recent years, new technology on sterilization saw the introduction of continuous sterilizers. Sivasothy’s (2006) continuous sterilizer showed improved fruit strippability, even with usage of low pressure steam or atmospheric steam. The new system consists of conveyor belt taking crushed FFBs into the continuous sterilizer, where the fruits are sterilized and subsequently discharged. This reduces much of the machinery associated with conventional sterilizers. In addition, there are cost savings in terms of manpower requirements, and maintenance.
Vertical sterilizers are also available, which are much cleaner and easier to operate than conventional sterilizers.
Another type of sterilizer technology, the Tilting sterilizer (Loh, 2010) also eliminates much of the machinery associated with conventional sterilizers. The technology is the latest design that offers improved milling efficiency, and reduced labour and maintenance cost.
Figure 3
Figure 3. A conventional sterilizer

Stripping

Stripping or threshing involves separating the sterilized fruits from the bunch stalks. Sterilized FFBs are fed into a drum stripper and the drum is rotated, causing the fruits to be detached from the bunch. The bunch stalks are removed as they do not contain any oil. It is important to ensure that oil loss in the bunch stalk is kept to a minimum. The stalks are often disposed by incineration, giving ash as potash fertilizer, and fuel for boilers. Others are transported to the plantations for use as fertilisers in mulching near the palms. The total oil loss absorbed on the stalks depends on the sterilizing conditions and partly on the way the stripper is operated. Prolonged sterilization will increase oil loss in stalks. Irregular feeding of the stripper may also result in increase of oil loss in stalks. Stalks which have fruits still attached on them are called hard bunches, and have to be recycled back to sterilizers for further cooking. Hard bunches are detected by visible inspection.

Digestion and Pressing

After stripping, the fruits are moved into a digester where, the fruits are reheated to loosen the pericarp. The steam heated vessels have rotating shafts to which are attached stirring arms. The fruits are rotated about, causing the loosening of the pericarps from the nuts. The digester is kept full and as the digested fruit is drawn out, freshly stripped fruits are brought in. The fruits are passed into a screw press, where the mixture of oil, water, press cake or fibre and nuts are discharged. Improvements in press designs have allowed fruits to undergo single or multiple pressing. Second stage pressing on the press cake fibres enables more oil to be extracted.

Clarification

A mixture of oil, water, solids from the bunch fibres is delivered from the press to a clarification tank. In the conventional process, separation of the oil from the rest of the liquor is achieved by setting tanks based on gravity. The mixture containing the crude oil is diluted with hot water to reduce its viscosity.A vibrating screen helps remove some of the solids. The oil mixture is heated to 85-90◦C and allowed to separate in the clarification tank. A settling time of 1-3 h. is acceptable. Oil from the top is skimmed off and purified in the centrifuge prior to drying in vacuum dryer. The final crude palm oil is then cooled and stored. The lower layer from the clarification tank is sent to the centrifugal separator where the remaining oil is recovered. The oil is dried in vacuum dryers, cooled and sent to storage tanks.

Decanters

Decanters are also used in some mills as an alternative to separating the suspended solids from crude palm oil in a clarification tank. Various design of decanters are available. Their usage is however, hampered by higher maintenance costs from the wear and tear. An advantage to the use is the reduction in palm oil mill effluent. Sulong and Tan (1996) had proposed a membrane filter press for oil and solids recovery. The cake is discharged as solid waste for fertilizer production or animal feed, while the oil is recovered.

Oil Losses during Processing

Oil losses in mills vary from mill to mill, and much attention is given to the control of oil loss. The main oil loss are from sterilizer condensate, empty bunches, fruit loss in unstrapped bunches, press cake fibre, nuts and sludge. Over-ripe bunches will lose more oil during sterilization. To minimize this, shorter sterilizer cycles are used, or better control of bunch ripeness and quality will help ensure less wastage. A typical oil loss in sterilizer is estimated to be 0.1% to FFB. Oils recovered from sterilizer condensate should be used as technical oils, as they often contain higher iron content and would reduce oil stability if mixed with the crude production oil.

Kernel Production

The press cake from the digester is fed to a vertical column (depericarper) where air is channeled to lift the fibre, thus separating the fibre from the nuts. The nuts are passed to a polishing drum at the bottom of the depericarper, where pieces of stalks are removed. A nutcracker cracks the nuts after the conditioning and drying process. A ripple mill is also used instead of nut cracker. The mixture of cracked nuts and shells are separated via a winnowing system, followed by a hydrocyclone or a clay bath. A hydrocyclone uses centrifugal force to separate the kernel from the shell using water. The clay bath principle works on the specific gravity of kernel of 1.07 and the shell of 1.17. The kernels will float while the shells sink in a clay bath mixture of SG 1.12. The kernels are then dried in hot air silos to moisture content of less than 7%. About 0.4mt of kernels are produced with every mt of CPO.

Biomass

The amount of solid palm oil waste available from a mill can be substantial. This consists of empty fruit bunches (EFB), palm kernel shell, mesocarp fibres, and possibly solids from decanters. In most cases, this biomass especially, the EFB, palm kernel shell and mesocarp fibres are used as fuel in the mill, generating enough electricity for running the mill. Besides usage as fuel, the biomass together with fronds and trunks can be left in the fields as fertilizers. EFBs can also be combined with polyurethane ester (PU) to prepare medium density fibreboard, giving higher impact strength and better water resistance (Khairiah, 2006).
Table 1. Dry basis calorific value of palm waste materials (Source: Yap, 2010).
Type of biomass Average calorific value(kcal/kg)Range (kcal/kg)

  Empty fruit bunches1879518000-19920
  Fibre1905518800-19580
  Palm kernel shell1888418880-18895
  Nut2448124256-24830



Treatment of Raw Palm Oil Mill Effluent (POME)

A palm oil mill produces an average of 0.65 tonne of raw palm oil mill effluent (POME) from every ton of FFB processed. POME is the main cause of environmental pollution due to its high acidity, high biological demand (BOD) and chemical oxygen demand (COD). Conventionally, anaerobic digestions in ponding systems or aerobic treatments are able to bring the BOD levels to below 100 mg L-1. Open steel tank digesters are used for tapping the biogas for power consumption. In Malaysia, certain areas have more stringent requirements (BOD of less than 20mg L-1. Tertiary systems have been developed as new systems to provide effluent treatment in a more sustainable manner, as well as achieving the standards required by regulatory bodies. These include biological sequencing batch reactors, bio-filtration systems, systems with high aeration rates, activated sludge plants with aerobic reactors, bio-flow polishing plants, as well as membrane bioreactors. More palm oil plantations are investing into these technologies to harvest the biogas for fuel, and re-use other biomass materials for fertilizers, bio-composite materials, etc.

References

  • Khairiah, B and Khairul, A.M.A. Bio composites from oil palm resources. Journal of Oil Palm Research, April, 103-113 (2006).
  • Loh, T.K. Tilting sterilizer. In: Palm Oil Engineering Bulletin, No 94, pp. 29-42 (2010). MONGANA Report, Volume 1 and 2 Coopérative des Producteurs et exportateurs de l’huile de palme du Congo Belge. (1955).
  • Sivasothy, K., Shafil, A.F. and Lim, N.B.H. Analysis of the steam consumption during sterilization., Workshop on recent developments in palm oil milling technology and pollution control, Kuala Lumpur, p. 19, Malaysian Palm Oil Board, Kuala Lumpur )(1986).
  • Sivasothy, K. Advances in Oil Palm Research, Vol 1, 747, Y. Basiron, B.S. Jalani, and K.W. Chan (eds) , Malaysian Palm Oil Board, Kuala Lumpur) (2000).
  • Sivasothy, K. Continuous sterilization: the new paradigm for modernizing palm oil milling. Journal of Oil Palm Research, April, 144-152 (2006).
  • Sulong, M. and Tan, R.C.W. Filtration system for crude palm oil clarification and purification. In: Proc. Of the 1996 PORIM International Palm Oil Congress, Kuala Lumpur, pp. 410-424. (B. Muhamd, A.N. Ma, M.S. Affandi, Y.M. Choo, A. Kuntom, C.L. Chong, A.G.M. Top, K. Yaakob, S. Ahmad, J. Thambirajah, Z.A.A. Hassan and R. Masri (eds), Malaysian Palm Oil Board, Kuala Lumpur)(1996).
  • Yap, A.K.C. Palm waste as alternative fuel for cement plant. Palm Oil Engineering Bulletin No 91, 13-21 (2010).

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Palm Oil Mill Operation, processing and process , production quality control, effluent disposals and maintenance course

Posted by Flora Sawita Labels: , ,

Palm Oil Mill Operation, processing and process , production quality control, effluent disposals and maintenance course

OBJECTIVES

    To acquire overall broad knowledge of fundamentals and practices of palm oil FFB grading and analysis, mill productions, operations, managements and process quality control.
    To enhance, develop and provide a suitable platform to increase work productivity
    To learn overall process quality control in order to achieve high oil and kernel extractions for production cost reduction.
    To appreciate the significance of process planning to achieve smooth running of mill and to ensure the maximum/optimum productivity and with minimum breakdowns.
    To educate qualified professionals to solve problem encountered during processing of palm oil.

"KNOWLEDGE is POWER, MONEY, CONFIDENCE, SECURITY"


Palm Oil Mill Operation and Processing - Module 1
Target : Introduction to facts and informations for better understanding of Mill operations ,palm oil processing and quality control to increase OER and KER.

    Origin of oil palm tree.
    Oil palm nursery
    Anatomy of oil palm tree.
    Anatomy of palm fruits
    History of palm tree
    Fresh Fruit Bunch composition
    Type of fruits-Tenera,Dura,pisifera
    Fruitlets to bunch Ratio
    FFB and Fruitlets Quality Report
    Harvesting,Transportation and handling of FFB.
    Health and Nutritional facts of palm oil for consumption
    Field practices and Management for FFB
    Plantation practices to boost yield, OER and KER.
    Workforce and manpower –attitude,dedication,work quality,Trained etc..
    Uses of palm oil
    Video on oil palm tree.
    Video on environmental and oil palm matters.(PORIM-AOCS)
    Palm Products and General Discussions


Palm Oil Mill Operation and Processing - Module 2
Target : Advantages & disadvantages of conventional sterilization with continous sterilization

    Introduction to modern palm oil Mill (Video)
    Model Of Mills
    System Of Processing –Conventional Methods -Ilustrations
    Mill Process Stations,Flow Diagrams,Process Charts
    Administrative Office Functions,Duties and Responsibility
    Weighbridge -Computerised / Manual ,Purpose,Calibration,Yearly Inspections

           -Upkeep,Lightning Protection,Operation,Procedures
           -Issues on malpractice and control.etc..Rain/Flood and Load Cells.

    Bunch Reception –FFB grading station,FFB categorization and                               Analysis ,Hiping up and long storage of FFB.
    Loading Ramp- Design,Operation, Functions and capacity etc
    Filling of FFB into cages– FIFO system,Level of FFB..etc
    Total number of cages is essential to avoid delay in processing and to achieve mill throughput.
    Transportation of FFB cages to sterilizers– Use of Captains,Tractors,Bob Cat.
    Sterilization Plant—Sterilizer Vessels- Design,Operations,Functions .
    Sterilization Techniques-Single,Double,Treble peak systems Automatic or Manual operation.
    Sterilization Charts,Time Records, charging and discharging of steam and cages records.
    Blowdown and blowoff Chambers, Fat Pit — Operations and Functions.
    Safe operating procedures and awareness. (Safety)
    Importants of educated trained workers to avoid any major accidents.
    Weight loss during sterilization — Moisture Loss – Results and Reports
    Improper sterilization causes High Oil Loss — Profit Loss...
    Continuous sterilization—Video illustration with comparison between conventional methods of sterilization . Advantages and disadvantages between the two methods.
    Marshalling Yard –Captains,Crane or Tippler operations — Purpose etc..


Palm Oil Mill Operation and Processing - Module 3
Target : Coverage of operation & processing

    Water Source— River,ponds,canals,streams etc..
    Water treatment plant — Design,Operation,Functions,Machineries,Equipments,Chemicals.
    Boiler Station — Design,Operation,Functions,Machineries,Types,Softeners, Deaerator,Feed Water Tank and Pumps.etc
    Softners — Care and regeneration—Purpose.
    Power House — Design,Operation,Functions,B.P.Vessel,Diesel Engines, Electrical Control and Distribution Panels and Turbine.
    B.P.Vessel — Control Of Steam flow, Distribution and Pressure Levels.
    Turbine — Boiler steam pressure fluctuations — Process Delay,Temperature Loss, Low Throughput.
    Electrical Distribution Panel — Supply of Electricity and syncronisation.
    Turbine — Video on Turbine Care.
    General Discussions on main problems on co-ordination,breakdowns, uneven supply of steam and steam management.
    Threshing Station — Design,Operation, Functions,Double Threshing, Disposal of Empty Bunches-Incinerater,Mulching etc.
    Digestors — Design,Operation,Functions,Care,Stirring Arms, Temperatures and steam injection-Homogenisation etc.
    Presses — Design,Operation,Functions,Care,Types,Temperature and Amps Control, Automatic or Manual operation etc.
    Cake Breaking Conveyor — Design,Operation,Functions,R.P.M set, Overload,Cover — Moisture and Dust etc.
    Deprecarper — Design,Operation,Functions,Size, Suction Fan air velocity adjustments.etc..
    Boiler Fuel Storage Flatform — Care for fire hazards etc.
    General Discussions ,comments ,upgrades,imporovements..etc..


Palm Oil Mill Operation and Processing - Module 4
Target : Coverage of operation & processing

    Clarification Station (Without Decanter) — Design,Operation,Functions, Purpose, Reports .

           A) Vibrating Screen
           B) Crude Oil Tank
           C) Sand Trap
           D) Vertical Clarifier or Continuous Settling Tanks
           E) Sludge Tanks
           F) Sludge Vibrator G)Boiling Tank
           H) Clean Oil Tanks
           I) Sludge Separators
           J) Purifiers
           K) Vacuum Drier.
           L) Storage and Despatch Tanks.

    Clarification Station (With Decanter System)— Design, Operation,Functions, Purpose, Reports. Additional — Decanter, Sludge Drier etc..
    System Of Operation — Crude Oil or Sludge as Feed to Decanter. Advantages and Disadvantages. Reports.
    Sludge Drier — Use Of Boiler Flue Gas for Drying –Production of Dried Palm Oil Mill Effluent (POME)— sold as solid Fetiliser.
    Others — Disposal of liquid waste water,Temperature controls,Water Dilution,Hot Water,Vacuum levels,care,Maintenance, Wear and Tear of machinery Parts and replacements.
    General Discussions and improvements with reference to Mill Audit.


Palm Oil Mill Operation and Processing - Module 5
Target : Coverage of operation & processing (kernel recovery plant)

    Kernel Recovery Plant — Design,Operations,Functions,Purpose.

            A) Nut Bins,
            B) Nut Vibrator/distributor
            C) Nut Crackers-Types
            D) Hydrocyclone
            E) Mud Bath
            F) Kernel Driers
            G) Kernel Storage Bunkers and Kernel Despatch Tanks

    Others — Mud Bath S.G control- Use Of Salt or Calcium,Nut Dryness, Cracking, Kernel Losses control, Kernel Overdrying. Adjustment and setting of vortex at Hydrocyclone. Water compartment leaks.Waste Water discharge etc.
    Kernel Despatches
    General Discussions and suggestions— Mill Audit Reference— Improvements and upgrades.
    Main Problem Areas and solutions..
    Video On Palm Oil Operation and Processing.


Palm Oil Mill Operation and Processing - Module 6
Target : Production report , mill visit, goal setting & course exam.

    Summary Of Daily, Monthly,Yearly Production Report Review.
    Action Plan,Assessments,improvements with reference to Mill audit Report..
    Video on Palm Oil Mill Operation and Processing.
    Goal Settings and implementations
    Mill Visit—Practical approach and general Mill Audit.
    Presentation of Test papers for participant assessment on Palm Oil Operation and processing.


Palm Oil Mill Process and Production Quality Control - Module 7
Target : Procedures and methods of quality control

    Introduction
    Function Of Quality Control
    Laboratory Operations.
    Role Of Mill Laboratory
    Quality Analysis for palm oil
    Mill Losses Control
    Essential Laboratory Equipments-purpose and uses.
    Record Books Maintained in Laboratory
    Quality control on Mill Products
    Methods and procedures of sampling,sampling points at mill,Frequency of sampling,Average sample volume for final testing at Laboratory.
    Mill sampling and the importance.
    Specific Sampling procedures for various stations at Mill
    Test Methods—Solvent Extraction,Titration, Fibre analysis, Oil and Kernel Losses analysis, Samples from various stations, etc...
    Sampling procedures for production oil,Despatch Oil and Palm Kernel Production and Despatches.
    Visit to Laboratory to do Practical and General Discussions.


Palm Oil Mill Process and Production Quality Control - Module 8
Target : Procedures and methods of quality control at various stations

    Water Treatment Plant — Sampling,Analysis,Results,Purpose,Actions -

          A) Raw / River Water,
          B) Cachment Ponds
          C) Pond Water
          D) Treated Tap Water
          E) Settling Tanks
          F) Sand Filter etc..

    Boilers — Sampling,Analysis,Results,Purpose, Actions.Reports.

          A) Treated Softner water
          B) Deaerated Water
          C) Boiler Feed Water
          D) Boiler Water etc..

    Sterilizers — Sampling,Analysis,Results,Purpose,Actions.

          A) Sterilizer Condensate
          B) Final Discharge to Effluent Ponds

    Presses — Sampling,Analysis,Results,Purpose,Actions

          A) Presscake — Fibre and Nuts
          B) Crude Oil below presses.

    Deprecarper — A) Cyclone Fibre collected at boiler platform
    Clarification Station — Sampling,Analysis,Results,Purpose,Actions (without Decanter)

              A) Verical Clarifier Under flow sludge and oil.
              B) Separator Recovered oil and waste water.
              C) Boilout Tank discharge.
              D) Before and After Purifier Oil.
              E) Vacuum Drier Oil.
              F) Storage Tank Oil.

    Clarification Station — A) Oil Phase B) Decanter Solid C) Drier Solid (With Decanter)
    Kernel Plant — Sampling,Analysis,Results,Purpose,Actions

             A) Whole Nuts from Nut Bins
             B) Cracked Mixture from Ripple Miller
             C) Winnower Dry Shells
             D) Wet Shells and Wet Kernels from Mud bath or Hydrocyclone
             E) Wet Kernels from Kernel Drier. Dried Kernels from Kernel Drier Prior to Despatch.

    General Discussions and Practical at Laboratory

NOTE : For all the above Reports slides will be shown with examples and explanations.

Palm Oil Mill Process and Production Quality Control - Module 9
Target : Procedures and methods of quality control at various stations

    Palm Oil Analysis,Tests and Procedures:

           A) Free Fatty Acid (FFA) Test
           B) Moisture Test
           C) Dirt Test
           D) Peroxide Value Test etc..
           E) Other Tests

    DOBI (Deterioration Of Bleachbility Index) Test:

          A) Methods
          B) Test Procedures
          C) DOBI Index
          D) Categorization Of DOBI Value

    Field and Mill factors that causes for low DOBI Value.
    Causes for the variations in DOBI Value between Mill and Refinery
    Production and Despatch Kernel Analysis and Tabulations
    Histogram Of Nuts — Size Variations and the relationship to KER.
    Laboratory Chemicals and their health Hazards.
    FFB Analysis Methods and Reports.
    Summary Of Assesment and action Plan :

         A) Quality Control
         B) Process Control
         C) Fresh Fruit Bunches
         D) Pollution Control

    Effluent Analysis and Control.(Reports)
    Review Of All analysis in Full Detail.
    Latest all analysis by fast and quick method with spectrophotometer will be introduced.


Palm Oil Mill Process and Production Quality Control - Module 10
Target : Detailed analysis and calculations to determine mill efficiency, etc

    Production Process Reports :

           A) Prodution Oil Quality
           B) Kernel Production Quality
           C) Production Control - Oil Losses and Kernel Losses
           D) Quality Control on CPO at Press.
           E) Quality Control on Presscake
           F) Nut Breakage at Presses.
           G) Process Control Ripple Mills and Cracked Mixture.
           H) Process Control Nuts and Kernels
            I) Unstripped Bunches Count
           J) Stripped Bunches Catagarisation. (Tabulation)

    Mill Oil Losses to FFB.
    Mill Kernel Losses to FFB
    Moisture Loss in FFB during Sterilization
    Fruitlets to Bunch
    Oil Extraction Efficiency
    Kernel Extraction Efficiency.
    Oil and Kernel Losses Calculations to FFB.
    Ripeness influence :

           A) Oil to Mesocarp
           B) Oil to Bunch (FFB) ( Calculations)
           C) Kernel to Nut
           D) Kernel to Bunch(FFB)

    Main Factors that influence and contribute to oil and kernel Extractions
    In Palm Oil Mill— Rainfall, Soil Conditions,Sunshine,Fertiliser etc…….
    General Discussions and comments.
    Examination on Quality Control in Palm Oil Mill .


Palm Oil Mill Effluent Treatment- Module 11
Target : Effluent treatment analysis & various types of treatments

    Introduction
    Source of Palm Oil Effluent produce.
    Types of Palm Oil Mill Effluent Treatments— Malaysian Choice — Ponding System— Recommended and accepted by DOE and PORIM
    Mill capacity and Quantity produce — Calculation of Pond Capacity – Number of ponds– High retention time– Low BOD.
    Water course discharge or Land Appliation or Both DOE sandards.
    List of waste parameters.(Reports & Tabulations)
    Characteristics of Palm Oil Mill Effluents.(POME)
    Collection and removal of oil prior to discharge to ponds at Long settling ponds or at settling tanks and Fat Pit and temperature controls.
    Biological Digestion
    Anaerobic Digestion
    POME –Biological treatment system monitoring and testing.
    DOE standards and parameters.
    Direct discharge of POME into water course and the damage to Environment.
    Sketch of standard ponding system with various ponds.(Drawing)
    BOD reduction at various stages at pond. (Tabulation)
    Effluent Ponds at Hillside — By Gravity flow etc.(Slide)


Solid Waste Disposal in palm oil mill - Module 12
Target : Methods of disposal and visit to mill and effluent treatment plant

    Solid Waste in Palm Oil Mill: a) Empty Bunches b) Decanter Solids
    Disposal Of Solid Wastes:

           A) Empty Bunches send to field for Mulching
           B) Some used as Boiler Fuel
           C) Burnt in Incinerators

    Government rules and regulations for Effluent discharge to water course,Solid discharge to land and chimney smoke to atmosphere for palm oil mills in Malaysia.
    Mill and Laboratory Visit : Practical Study.
    General Discussions Goal Setting.
    Motivating slide shows— Philosopy, YOU are the WINNER.
    Finally Test and question Papers for evaluation.


Maintenance in palm oil mill - Module 13 (additional)
Target : Palm Oil Mill Machineries and Maintenance Auditing, Assessment, and Improvement Activity

    Types of maintenance
    Computerised maintenance, operation and systems
    Station/Machinery/Equipment
    Checklist - Mill Audit
    Problem Identification
    Corrective Actions
    Case Studies


END OF TRAINNING
THANKS FOR LEARNING ,
YOUR ATTENTION,
TIME SPENT AND
TO YOUR MANAGEMENT

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