CLEVER HOUSE Crude Palm Oil Production Project fileSepration of Shell and Kernel: after separation from the nut, the nut will get into the cusher to be crushed into shell and kernel

CLEVER HOUSE Crude Palm Oil Production Project

Production Processes of Crude Palm Oil

The palm trees are the perennial oil plants which growing at tropical area, It has features of large capacity and low cost. The palm oil has been became one of the largest capacity edible oil in the world, it's widely used in food processing, cooking, biodiesel production, etc.

The followings are the introduction of crude palm oil production processes:

The fresh fruit bunches(FFB) will get into the fruiting period after growing three years. The FFB will be picked by farmer then transport to the crude palm oil production workshop, the they will be processed:

1. Weighting: The FFB gets into the factory through the weighbridge to weight the raw materials to calculate the production cost.

2. Unloading: the FFB will get through the slide ramp for screening to remove the impurities, then the FFB will get into the conveyor to be transported to sterilizing tank. The time from picking to sterilizing process shall not too long, because over 24 hours the free fatty acid(FFA) will rise which is not good for the following processing.

3. Sterilization: after getting into the sterilizing tank, the FFB will be cooked by high temperature, this section is the preparation for the following crafts.

4. Threshing: the FFB will be soften in the sterilizing process, then through the threshing and screening by the thresher, the palm fruits will separate with the empty fruit bunches.(EFB)

5. The EFB can be transported and stored for fuel or fertiliser.

6. Digesting: after the thresher, the palm fruits will get into this digester, it will stir and crush the palm fruits.

7. Pressing: the crushed fruits will be pressed in the oil presser through spirals.

8. Fiber Separation: the pressed cake fiber will be crushed then get into the winnowing system to separate the fiber and nut.

9. Sepration of Shell and Kernel: after separation from the nut, the nut will get into the cusher to be crushed into shell and kernel. Then the kernel and shell be be separated through winnowing and water washing system, the shell can be used as fuel for boiler, the kernel will be dried for stroage.

10. Oil Clarification:the crude oil(CPO) that after pressing has some content water and impurities, through the pretreatment of sand settling tank and vibrating screen, the crude oil will get into the vertical oil settling tank for heating, finally the crude oil will separated into clear oil and dirty oil. The clear oil will be dried then transported to oil storage tank, the dirty oil will get through sand settling system and certifuge for recycling.

11. Oil Transportation: manufacture the oil transporting pipelines according to the actual conditions.

12. Water Treatment: usually the source water will be lead into factory from the near river, then though primary clarification and filtration, the water will processed by osmotic and reverse osmosis treatment to rech the water standard for boiler.

13. Power System: the power is mainly offer by steam turbine generating unit, and also the diesel generating unit.

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Palm Tree Production Index

136 trees/Ha=20-23t

FFB/Ha/year

CPO = 4-5t/Ha/year

CPKO = 1t/Ha/year

15-20

bunches/tree/year

FFB = 1000-3000 Fruits

FFB = 10-25kg

FFB = 20%CPO； 2%CPKO

Weight of a fruit = 8-13g

清油离心机

Crude Palm Oil (CPO) Production Craft

Thresher Drum

FFB

汽车衡 Truck load

斜果平台 conveyor

杀酵站 conveyor

脱果机

污水 Effluent Weight bridge Loading ramp Steriliser

输送

Friut&empty

三相卧螺离心机

Digester

捣碎罐

conveyor

果子提升机 Fruit 果子

bunches

油 Centrifuge

油沙克龙sand

cyclone

Digest &steam

压榨机(presser)

Friut elevator

汽轮发电

机蒸汽

empty bunch

transportation

空果串储站

污油sluge oil

毛油经沉淀过滤立式澄油罐

CRUDE FITTER

Clarifier Tank

清油罐

Pure Oil

Tank

油饼

oil&cake

饼

Cake

核破碎机 Kernel Crusher

Fibre cyclone

纤维沙克龙

Nut

果核

Trubin steam

锅炉(boiler)

输送机

作为肥料燃料纤维使用

Used as fertiliser,

fuel

清油离心机

一二级风选系统

Grade 1 and 2 winnowing system

kernel

壳shell 壳仓shell

BIN

centrifuge

仁洗涤系统

Kernel Washing System

湿仁wet kernel 仁烘干仓kernel

silo

输送transfor

仁储仓

kernel

油干燥器oil drier 2000T油

罐tank

油泵oil pump 发油棚

Oil loading shed

bin

5

PRESSING

RBDPK

Olein

PKC PKO

RBDPK

Stearin

RBD Olein

RBD Stearin

Description of Main Section

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Unloading Ramp：

As for the palm fruit unloading, cleaning, storage

platforms, all hydraulic segmented discharge. they

discharge fruits by all hydraulic type and sectional

type.

Threshing:

Through strong vibration to seprate the fruits

from the fruit bunches.

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Pressing Section

Digesting ：Stir the fruit and cook again

Pressing : Separate the fruit from nut and get

crude palm oil and nut. The presser adopts

double spiral hydraulic type discharing which

improve the production efficiency greatly.

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Main Section Description

Sterilization Section

Sterilization: Using high temperature to soften the palm fruits and kill the bacterias(145℃， 90-120 minutes),

after this process the fruit will separate from the bunches

easily and also it will increase the moisture content of the

fruits, which will helpful for extracting the oil and

separate the shell and kernel easily. Also this process can

stop the decomposition of enzyme to avoid the rising of

free fatty acid.

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Clarification Section

Clarification: Separate the crude oil and sludge

to get content 90% oil. The oil from the presser

includes 45%-55% water, sludge and other

things.

Purification: Oil purification process -

improving purity

Drying: use the continuous vaccum drier to

remove the water, the water content can reduced

to 0.1%.

NUT & KERNEL

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Depericarper Crushing（ Hydrocyclone Separator: Through floating dry

processing the fruit core and fibers

separated. Fiber and other lighter stuff

was blown appearance

Crushing (Crusher): stone cracked open

grain separation kernel and shell. In

Hydrocyclone, the use of kernel and

core-shell particle proportion to their

separation.

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power house

Power House (power house): the use of diesel

powered generators and turbine generators,

more environmentally friendly energy

production and electricity consumption to

power.

Steam Boiler

Steam Boilers (Steam boiler):

has a strong output, high thermal

efficiency, stable and reliable operation,

overload capacity, fuel, wide applicability,

environmental protection and many other

advantages.

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RAW WATER SUPPLY:

Source water piping (RAW WATER

SUPPLY):

the use of remote substation

technology, more energy, improve

production efficiency.

Water Treatment:

After settling, filtration, dosing and other

processes to ensure that the water

quality, but also to ensure oil quality.

2. Palm oil refining and fractionation

(8ATM) ≦20Kg/t

1.2-2kwh/t

5-30Kg/t

≦24%*

(8ATM) ≦45Kg/t

≦12kwh/t ≦3Kg/t

≦5kwh/t ≦0.05Kg/t ≦0.3%

40-120 12-18

18x42 25x50

Economic and technical indicators Bleaching section

Steam (8ATM) ≦ 20Kg / t oil

Electric 1.2-2kwh / t oil

Clay 5-30Kg / t oil, crude oil colors may be based

on

Refining consumption ≦ 24% * waste clay (dry

basis)

Deodorizing section

Steam (8ATM) ≦ 45Kg / t oil

Power ≦ 12kwh / t oil

Diesel ≦ 3Kg / t oil

Circulating water system power consumption ≦ 5kwh / t oil

Citric acid ≦ 0.05Kg / t oil

Refining consumption ≦ 0.3%

Note: According to the technical features of normal

production process, steam-based

In the last between 40-120, electricity consumption is about

12-18 or so; specific

Circumstances determined according to the quality of crude

oil;

Annex VI:

Plant size 18x42 m; covering about 25x50 meters, removing 13

Palm oil refining and fractionation process

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30-60

Bleaching section: degumming oil deodorization oil after

preheating, heating into the premixing tank from clay, clay pot

through the metering device is added to the mix tank, mixing,

then the mixture of clay and oil into the decolorization reaction

decoloring tower, stay in the bleaching tower in about 30-60

minutes, the decolorization the pump into the Armagh filter,

will waste clay and oil separation, oil filter decolorization after

the removal of residual clay particle precision filter by first,

after entering the condensate tank to remove moisture and

volatile matter. The decolorization process temperature control

adjustable. Filtration system manual automatic oil inlet,

circulation, filtration, steamed cake, slag and other operations.

A device for trapping odor design in the bleaching section, set

the odor steam purge in the circulating water trap, eliminate

odor decolorization process of pollution.


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Deodorization section: gas material from the

bleached oil bleaching section it will enter the

deodorization section removal of free fatty acids

and unpleasant. The deodorization tower to

remove these compounds with steam under high

vacuum conditions;

This is deodorization and one of the main function,

in fact, refining in the absence of colloid in the

process of plant oil, deacidification deodorization

section is the section, oil deodorizer fatty acids

were separated under high vacuum, so as to

achieve the purpose of deacidification

deodorization.


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This section is a vacuum section:

deodorization provides good vacuum for

decolorization, removal of acid;

Major equipment: vacuum pump, its

function is through a combination of water

and steam, the vacuum pump to form a low

pressure area, decolorization,

deodorization high flow to the low pressure

area, gradually makes the decolorization,

deodorization to form a vacuum, so that the

oil in the pigment and its small molecular

fatty acid, odor material removal;


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C1001-C1010,

PU1001-PU1010

C1001-C1010

This section is to shop: crystallization section; palm oil, after the heat exchanger heating clarification into the crystallizer C1001-

C1010,start stirring and cooling water circulation pump PU1001-PU1010,start crystallization process; when the crystallization tank C1001-

C1010 water shortage, opening the freezing water in the freezingcrystallization; program design depends on crude oil, wax and oilratio. During the

crystallization period, the oil cooling filter according to predetermined temperature cooling curves, guaranteed to produce a good crystal. In the crystallization

process, thetemperature gradient calculation computer itself, oil and water temperature were measured and recorded by the

microprocessor,temperature programmed to control, to realize the process stagedifferent to different water temperature, to ensure that the

wholecrystallization during the cooling curve smoothing, the crystallizationcan be carried out in the most suitable conditions, but not in a large number

of crystal exothermic crystallization to destruction, to ensure the formation of a stable crystal, make it more conducive to the next step of filtering, while

cooling the precise way to ensure maximumadaptability and batch number.


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Centrifuge: pH and temperature, full reaction, centrifuge

rotating at high speed when the oil soap were isolated, in

general, palm oil without centrifuge, also need not

increase the number of phosphoric acid.

Centrifuge: pH and temperature, full reaction, centrifuge

rotating at high speed when the oil soap were isolated, in

general, palm oil without centrifuge, also need not increase

the number of phosphoric acid.


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Vertical crystallizing tank: crystallization tank

through a coil of chilled water temperature to the

required temperature, so that the solid lipid to form

stable crystal.

Horizontal crystallization pot: crystallization tank

through a coil of chilled water temperature to the

required temperature, so that the solid lipid to form

stable crystal.


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Diaphragm filter: separating the good crystalline oil solid

fat and oil

Control room:

this operation panel, operation management can control

any equipment in the workshop.

2013-10-31

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CLEVER HOUSE Crude Palm Oil Production Project fileSepration of Shell and Kernel: after separation from the nut, the nut will get into the cusher to be crushed into shell and kernel