SYNOPSIS by Wambeck

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OOIILL PPAALLMMPPRROOCCEESSSSSSYYNNOOPPSSIISS

By Noel Wambeck. - June, 1999

Volume I OIL PALM MILL, SYSTEMS AND PROCESS


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OIL PALM PROCESS SYNOPSIS

Volume 1 - OIL PALM MILL SYSTEMS AND PROCESS.

1.0 INTRODUCTION

2.0A BRIEF OF THE WRITER's EXPERIENCE

3.0 BRIEF HISTORY OF OIL PALM

*Palm Oil Processing Flow Chart

*Picture of Palm Fruit & Fruit Bunches

* Uses of Palm Oil

4.0 HISTORY OF OIL PALM PLANTATIONS IN INDONESIA

5.0 OIL PALM MILL, SYSTEMS AND PROCESS

*Palm oil mill schematic process flow chart

*Matrix Oil Palm Mill Process

* Pictures of sections the oil palm milling process

* Process Mass Flow and Losses During Production

* Typical Empty bunch Incinerator.

* Typical Effluent ( Ponding ) Treatment system of Anaerobic & Aerobic process.

*Matrix of Oil Palm Mill Process & Waste Water Effluent Ponding System.

6.0AN ENVIRONMENTAL CONTROL PLAN (ECP)

*Potential Hazards and Control Plan.*Oil Palm Mill Environment Control and Waste Disposal Flow Chart.

*Placement Avenue for empty bunch, fonds and treated effluent for land application.

*POME Sludge process with the Decanter & Dryer - Schematic flow diagram.

*Schematic diagram for Boiler three element control and scrubber system.

*General layout of Anaerobic & Aerobic ETS.

*Typical Layout of an Oil Palm Mill with the ECP effluent treatment plant.

*Typical Furrow Layout.

* Oil Palm Tree Matrix - Oil Palm Components, Biomass and analysis

7.0 OIL PALM MILL PROCESS MONITORING & CONTROL (PMC) SYSTEM.

8.0 THE DEVELOPMENT OF OIL PALM IN MALAYSIA.

9.0 THE OIL PALM EXTRACTION PROCESS MATCHING WITH TYPE OF FFB.

10.0 OILPALM EMPTY BUNCH DISPOSAL BY INTEGRATED INCINERATION.

11.0 FAO- FEEDING PIGS IN THE TROPICS : CHAPTER 4 - AFRICAN OIL PALM.

12.0 PREPARATION OF AN OIL PALM MILL PROJECT

*Matrix for oil palm mill project.

* Project manager's checklist.

* Typical project monthly report

Continue next page >

By Noel Wambeck - June 1999


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CONTENTS

13.0 OIL PALM MILL DESIGN BASIS

* Specific Gravities and Densities of Oil Palm Components & Substance.

14.0 REFINING PROCESS FOR PALM OIL AND OTHER DOWNSTREAM PROCESSES

* Introduction to Refining process for palm oil and other downstream processes.

* Rationale of an integrated oil palm mill and refinery complex project.

15.0 USEFUL INFORMATION

* Palm Oil Registration & Licensing Authority Activities.

*PORLA Fresh Fruit Bunch Grading Manual

* PORLA Fresh Fruit Bunch Grading Form

*PORLA Basic Extraction Rate for Oil & Kernel based on year planted.

16.0 ABBREVIATIONS & GLOSSARY USED IN THE OIL PALM INDUSTRY

The complete Oil Palm Process Synopsis set includes the following:

Vol.2 - TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL

Vol.3 - OIL PALM MILL MAINTENANCE MANUAL


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OIL PALM PROCESS SYNOPSIS

Volume 2. TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL

1.0 INTRODUCTION

2.0 A BRIEF OF THE WRITER's EXPERIENCE

3.0 TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL

A Introduction

B PreparationC Test procedures.

D Finalization

E Taking over and certification test.

F Training and Manpower

4.0 APPENDICES

A. Master list of machinery

B Checklist of oil palm mill.

C Electric motor list

5.0 SPECIFICATION FOR MACHINERY

6.0 MECHANICAL & ELECTRICAL DRAWINGS


Vol.1 - OIL PALM MILL, SYSTEMS & PROCESS

Vol.3 - OIL PALM MILL MAINTENANCE MANUAL

Noel Wambeck June 1999.


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OIL PALM PROCESS SYNOPSISVolume 3. - OIL PALM MILL MAINTENANCE MANUAL

1.0 INTRODUCTION

2.0 A BRIEF OF THE WRITER's EXPERIENCE

3.0 WELCOME TO PRODUCTIVE MAINTENANCE

4.0 STORE AND PARTS MAINTENANCE

5.0 MAINTENANCE OF HYDRAULIC SYSTEMS

6.0 DIGESTER USE AND MAINTENANCE

Effective use of the Digester.

Digester operating instructions and spare parts.

7.0 TWIN SCREW PRESS USE AND MAINTENANCE

Operating instructions & spare parts manual.

Effective use of the screwpress.

8.0 MULTI-HYDROCYCLONE SYSTEM

Use of the Multi-Hydrocyclone system

Automatic Triplex Multi-Cyclone Desanding System - Westfalia type ADP-100-3

9.0 DECANTER FOR CLARIFICATION SYSTEM.

Alfa Laval

Westfalia

10 CENTRIFUGE OIL PURIFIER

Alfa Laval

Westfalia

China

11 SLUDGE CENTRIFUGE SEPARATOR

Alfa Laval

Westfalia

Star Bowl Type - Local

12 NUT CRACKING MACHINE

UDW rotor ring type - use and maintenance

Ripple mill type - use and maintenance


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Contents . Page 2.

13 HYDRO CLAYBATH USE AND MAINTENANCE

14 GEARBOX & GEARMOTOR USE AND MAINTENANCE

15 MAINTENANCE GLOSSARY & TERMINOLOGY

16 GLOSSARY OF BEARINGS

17 COMPRESSED AIR TERMINOLOGY AND SYSTEMS

18 PIPE FITTING AND VALVE GLOSSARY & TERMINOLOGY

19 PUMP MAINTENANCE

Pump maintenance programs pay.Pump maintenance.

Why Seals Fail.

Pump performance checklist.

Pump seal maintenance.

Troubleshooting Electro-Hydraulic Pumps.

20 ROLLER CHAIN DRIVES

Roller chain drives installation.

Roller chain maintenance.

Roller chain drives maintenance.

Roller chain drives lubrication.

Roller chain drives - Troubleshooting Guide.

21 V-BELT INSTALLATION AND MAINTENANCE.

22 USEFUL TABLES.


Vol.1 - OIL PALM MILL, SYSTEMS & PROCESS.

Vol.2 - TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL.

Noel Wambeck June 1999.


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OOIILL PPAALLMMPPRROOCCEESSSSSSYYNNOOPPSSIISS- Oil Palm Process Handbook -

By Noel Wambeck. - June, 1999

This oil palm process synopsis or handbook intents to be a series of reference books to therecipient, Manager, Engineer and people who are involved in the oil palm industry, itcontains information such as the function, activities, the milling process and systems,

specification of products, by- products, processing mill and plant design basis, theoperation, commissioning, maintenance, useful data, flow charts and graphs etc.

The handbook also hopes to encourage the expansion of product development and

improved oil palm processing facilities, which can lead to greater commercialisation of oilpalm, its products and to the betterment of the manager, engineer and all who seekknowledge.

The Oil Palm Process Synopsis handbook is in three volumes, which are:

Volume 1. Oil Palm Mill, Systems and Process including the Preparation of an oilpalm mill project and enclosures.

Volume 2. Testing and Commissioning manual including specifications &drawings

Volume 3. Oil palm mill maintenance manual including proprietary equipmentinstallation and operation manuals.

The handbooks sized A4 with retractable binder hinged for flexibility in terms of beingexpandable whereby, occasional periodical in an update manner and series distribution canbe filed into this handbook for continuous usage.

The contents of this handbook are also available in CD-ROM

The writer acknowledges with sincere appreciation the generous assistance given him bycolleagues and friends who made many valuable suggestions.

Any error or omissions are regrettable.

June 1999 Noel Wambeck.


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A Brief on the writers experience.

Noel Wambeck @ Nurehsanborn in Penang during the Japanese occupation to JamesGodfry Wambeck and Dorothy Symons of Dutch descendents.

Educated at St. Xaviers Institution in Penang with an engineering diploma from GurneyTechnical Institute, Kuala Lumpur in the year 1969.

Married to Fadilah A. Hamid in 1990 a Singaporean and fathered four children, two boys

and twin girls.

30 years experience in the Agro-based engineering field of project management, projectstudy, appraisal, market development of equipment, plant, system design and its

implementation in such areas as edible oils industry, food processing plants, Rubberprocessing, Co-generation systems, pollution, effluent treatment and control systems.

Some of the projects commissioned, are Padang Piol Oil palm Mill (Felda), Sarawak Oilpalm mill (CDC), Fuji Oil refinery project ( Singapore) Ghana Rubber processing plant

(Ghana), World bank projects PNP X Bekri, Betung PNP III Aek Raso Oil Palm Mills (Indonesia ) Nalfico Premier for Palm kernel oil solvent extraction plant ( Malaysia)

Indopalma extraction & refining of edible oils project ( Czech & Slovak) Coconut milkproduction for S&P Coconut Sdn Bhd (Malaysia) Rotary Dryer for Tioxide project (ICIMalaysia) Study on Pricing and distribution policies for Veg.Oils in Indonesia (ADB)

Study on EB treatment / co-generation & PK crushing mill for Higaturu POM. ( CDC /PNG ) Study of production capabilities and marketing potential for coconut oil by

products in Chuuk ( Fed.States of Micronesia) OPIL Oil palm Mill (India) PORIM Oilpalm Mill ( Guthrie / PORIM) Kunak & Lumadan Oil palm mills ( Project manager with

Konsultan Proses for Borneo Samudera Sdn Bhd. Sabah).

He has consulted for commercial clients such as United Brands U.S.A., Cargill,Experience Inc., GFA International Management Consulting GMBH as well as donoragencies such as World Bank, KFW Bank (Germany), ADB, IBRD, UNIDP, CDC in

Central America, Africa and Asia, including Malaysia and Indonesia.

Noel Wambeck is at present an associate partner of Perunding AME ConsultingEngineers with on going assignments for consultancy services.

The assignments are for oil palm mills for Borneo Samudera Sdn Bhd, Sabah, projectstudy for PT. Kebun Ganda Prima in Kalimantan, Indonesia, project study for Low Yat

Group in Sabah and detail engineering for the M&E works for a dry mixed cement plantfor Chuan Cement Industries of Singapore.

June, 1999.


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Brief History of Oil Palm( Its development in Malaysia).

by Noel Wambeck. - 8thNovember 1993. (Revised)

The oil palm ELAEIS GUINEENSIS grows around the globe in a zone of 10

degrees latitude to the north and south of the equator.

Its utilization as basic nourishment had always been of vital importance to theinhabitants of this equatorial regions and its existence is reported as long as 3000BC, when palm oil was known to the Egyptians under Pharaohs reign.

The Oil Palm originates from Africa where there is a wealth of oil palm geneticmaterial.

The natives of Guinea coast who had made a living by raiding for slaves, wereinduced to find a new occupation in processing and selling the oil for export; forthrough the trade in palm oil firmly established before 1850.

It has been selected by the Africans over the ages to provide palms with a highproportion of kernels and palm with a high yield of palm oil.

The first planting of oil palm of the Deli type, brought from Africa and planted in the

Buiterzorg botanical garden, Java, Indonesia in 1848, four plants being received,two from Bourbon and two from Holland and during the ten years of experimentalobservation, showed very good growth, and fruited.

Their progeny was distributed from 1853 forwards and the stock in the DutchIndies, in general, came from them.

The palm was brought to Singapore about 1870, probably from Java. Theseseeds was soon distributed to various places, chiefly to gardens of those whocared to grow it as an ornamental tree.

In 1879 Buitenzorg gardens in Java had sent seeds to Sumatra and the palm grewwell; so that Sumatra appears to have received its first two supplies of the palmfrom Buitenzorg stock, one direct and the other through Singapore.

Some of the oldest palms on the St. Cyr tobacco estate in Sumatra, figured byRutgers are recorded as from seed from the botanical gardens of Singapore; andthese trees, in turn, supplied material to many other places in Sumatra. The ideaof a common origin is supported by and large the characters which all the old treeshave in-common.


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Rutgers thinks that the actual trees of 1879 were subsequently removed to makeroom for the town of Medan as this tree race is the old Deli type.

The material bred from these palms is referred to as DURA DELI. It is very stable

and uniform in oil and kernel contents.

The vernacular names for the palm in Java are salak minyak, klapa sawit andklapa sewu. The tree was then freely distributed in that island, and about1906 interest in the oil palm was aroused among Malayan planters, who planted afew trees on their estates by way of experiment.

The new era of advancing communications and transport, fueled the growth ofliberalism in Europe as telegraph system was introduced in 1856, the postalsystem in 1862 and the opening of the Suez canal in 1869.

The fast growth of plantations in the Golden era of plantation companies, beforethe first world war saw the expansion in acreage, productivity and diversification ofcrops.

In 1903, the department of Agriculture made several importation of seeds to BatuTiga experimental plantation and the public gardens in Kuala Lumpur.

The foundation of the Industry is generally attributed toM. Adrien Hallet , a Belgianwith some knowledge of the oil palm in Africa, who planted palms of Deli origin in1911 in the first large commercial plantation in Sumatra.

Hallets plantings on Sungei Liput, Atjeh and Pulu Radja, Asahan estates arerecorded as being contemporary with the establishment of 2,000 palms byK. Schadt, on his Tanah Itam Ulu concession in Deli.

He also recognised that the avenue palms growing in Deli were not only moreproductive than palms in Africa, but had a fruit composition superior to the ordinaryDura palms of the west coast.

A potential oil content of 30% in the fruit was recongnised in the early 90s.

The climate of Malay Peninsula and Eastern Sumatra has proven ideal for growing

Elaeis or Oil Palm trees.

In the meantime, a Frenchman M. H. Fauconnier, who had been associated withHallet, had established during 1911 and 1912 some palms of Deli origin at RantauPanjang in Kuala Selangor. These palms were in full bearing by 1917 and in thatyear the first seedlings were planted on an area later to be known as Tannamaramestate.


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It was during this period that the DURA palm and Pisifera palm were cross toproduce a hybrid progeny, that all modern planting and milling systems aredesigned.

Thus the birth of the Malayan Hybrid palm TENERAwas introduced to the OilPalm Industry.

The second commercial oil palm plantation, also in the Kuala Selangor district,was developed at Elimina Barlows estate ( Sungei Buluh ) Selangor in 1919 andthe first 40 acres planted in 1920.

In 1922, selected seeds from the experimental plantation were planted at the newexperiment plantation in Serdang, Selangor. During this period the boost inprices of major commodities before the first world war, was the main factor in theexpansion of plantations in Malaya.

The number of plantations increased from 1925 to 1930 with an expansion in thedevelopment in the Palm Oil processing Mills which began only at the beginning ofthe nineteenth century when its possibilities were realized, alike in Europe andAmerica.

There are two oils in the fruit, one in the fruit wall ; the other is in the kernel.

The methods of manufacture, then employed was badly, often abominablyprepared, if the working be quoted from a letter from Accra, Gold coast, in 1877and printed in the Kew bulletin ( 1889 p 263 ) whereby the writer describes thebunches of fruit as cut down from the tree and heaped in the open air for 7 to 10days, during which the pedicels become weak and the fruit easy to detached.

The dry fruit bunch is then shaken off and fruitlets gathered together. A hole abouta meter deep is dug in the ground and lined with banana leaves; into this hole thefruitlets are put and left for a period between three weeks and three months fordecomposition to set in, and the pericarp to become quite soft.

Part of the accumulation of fruitlets, if not decomposed enough, will next be boiled

in an iron or earthware pot and returned to the heap, and the entire quantitytransferred to another hole, which is lined with rough stones, where it is poundeduntil the pericarp and kernel are separated.

The pericarp are folded into a coarse cloth, and by twisting the ends, the oil isextracted and the nuts are collected manually.


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Another method, which was used in Portuguese West Africa; describes that thefruit, after they have been detached from the pedicels are put into baskets andsubmerged in swamps to ferment, before they are beaten in order to detach thefruit from the kernel and are again left to ferment for a few days before the oil is

extracted. Off course, oil so crudely process is full of fatty acids, even up to 80%FFA or sometimes called a Hard oil .

At first the Africans offered in trade the oil of the kernel mixed into the oil of thepericarp; and as they commonly cracked the shell by heat, the addition imparted apeculiar smell to the mixture; but, about 1870 the market began to offer a price forthe kernel, which activated the interest of the locals to collect and sell the wholekernels to the trading stations, who than bagged them for export.

Primitive methods of processing palm oil with crude machines during the courseof the development of the extraction process, saw changes such as the handpress, centrifugal basket, hydraulic press and the present day screw press, whichalso changed the process system, flow and Mill layout design.

The method in winning the oil in the early 1900s was that the bunches weretransported from the field to a convenient place, where they remain for the fruitbunch to soften, so that the fruitlets may be removed. Next the detached fruitletsare sterilized by heat; and this kills the enzymes, which would otherwise spoil theoil by leading to the production of fatty acids.

Keeping in mine that most of the equipment, machinery and plants were designedto handle Dura type material in the early 1900s and not until 1960s did the changein the Mill design take place, when Tenera type material made its prominentappearance in Malaya, when most of the further developments took place in theMill layout and selection of processing equipment.

Modern Palm Oil Mills with screw presses were first introduced into Mongana (Zaire ) in the early 1950s and soon after, about 1956 in Malaya at Jendarata Mill (United Plantations ) and Limablas, Slim river Mill ( Socfin ) henceforth to processMalayan Tenera type material ( D X P ) fresh fruit bunches.

The search for new process and the development of oil palm extraction plants,equipment and machinery continues ..................... End.


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Kernel

Shell

Mesocarp


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THE HISTORY OF PLANTATIONS IN INDONESIA.

1

THE HISTORY OF PLANTATIONS IN INDONESIA

Noel Wambeck June 21st 1992 ( Revised )

To appreciate the present developments in the Indonesian Oil palm industry, one has to look

back into the history of plantations in Indonesia.

Large plantations were first established 170 years ago by the Dutch colonial administration, and

term what was known as Cultuur Stelsel ( forced cultivation ) .

Oil Palm Plantations today are not only divided into large and small holding plantation, but also

Nucleus Estates Schemes or ( PIR ) which constitutes a form of cooperation between large

plantation companies and small holders.

Development of the plantations since 1830 to present day operations are as follows:

Period I. ( 1830 to 1870 )

During this period, plantation consist of camps established by the Government, then the Dutch

Government on the cultuur stelsel system with forced labour.

But prior to this period, trade went on in the normal way between the VOC a Dutch trading

company and with Indonesian growers with chosen agents who were important to the Dutch.

The agents were mostly ethnic Chinese, officials of the Indonesian Kingdoms or Dutch

nationals.

The VOC set up a number of warehouses in areas near a port to facilitate the trade.

The commodities were the products grown by the Indonesian farmers which were controlled and

managed by VOC who later on handed over the monopolized trade to the Dutch Government

which brought about the start of the Dutch colonial power in Java.

The process of domination of the country was hampered by the situation in Europe for a period,

when the Netherlands was under the French Napoleon rule.

The Napoleon war from 1800 - 1816 and then the Diponegoro war from 1825 to 1830, caused

financial problems, which prom the Dutch Governor Daendles at that point of time to surrender

Indonesia to Britain for a period, and after the defeat of Napoleon, the Dutch regained a foothold

and power in Indonesia.

The Dutch Government with the lack of funds, took on a program to cope with the budget deficit,whereby the cultuur stelsel was introduced which started the forced cultivation in 1830 the

farmers were forced to set aside one fifth of their land to grow export crops and further to work

60 days per year, without pay for the Government.

The cultuur stelsel system earned the Dutch Government 18 million guilders a year or 60% of

the Dutch budget revenue.


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The first crops to be grown were, sugar and indigo, but later the crops range were diversified to

include coffee, tea, tobacco, pepper, cinnamon and cotton of which coffee grew to become the

main crop.

Plantation were established in West Java for Sugar, coffee and pepper whereas indigo was

stopped after it turned out to be not profitable as a synthetic substitute was discovered.

The first plantation of palms of the Deli type was made in Java in 1859, and during the ten yearsof experimental observation, showed very good growth, and fruited.

It was brought to Singapore about 1870, probably from Java, seed was soon distributed to

various places, chiefly to gardens of those who cared to grow it as an ornamental tree.

In 1879 Buitenzorg had sent seed to Sumatra and the palms grew well; so that Sumatra

appears to have received its two first supplies of the palm from the Buitenzorg stock, one direct

and the other through Singapore.

Some of the oldest palms in Sumatra, those on the St Cyr tobacco estate, figured by Rutgers

are recorded as from seed from the Botanic gardens of Singapore; and these trees, in turn,

supplied offsprings to many other places in Sumatra.

The idea of a common origin is supported by the characters which all the old trees have in

common.

Rutgers thinks that the actual trees of 1879 were subsequently removed to make room for the

town of Medan as this tree race is the old Deli type.

The vernacular names for the palm in Java are ' salak minyak ', ' klapa sawit and ' klapa sewu'.

The tree was then freely distributed in that island, and about 1906 interest in the oil palm was

aroused among Malayan planters, who planted a few trees on their estates by way of

experiment.

Period II ( 1870 to 1900 )

Liberalism in Europe in 1850 opposed the cultuur stelsel system enforced by the colonial

countries which marked the begaining of the privatisation of plantations in Indonesia.

The new era of advancing communications and transport, fuel the growth of liberalism in Europe

as telegraph system was introduced in 1856, the postal system in 1862 and the opening of the

Suez canal in 1869.

The Agrarian law in 1870 made it possible for private companies to secure land title for 75 years,

which were considered long enough for plantations.

Dutch ownership of plantations companies, mushroomed with the support of Dutch Government,

banks, trading houses, communications and transport facilities.

The Dutch built railways to facilitate transport of the plantation commodities and irrigation

systems for the crops.


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In Deli north Sumatra, investors were allowed to lease the land owned by the Sultan for 75 years

and growing of the reknowned Deli tobacco was established and later on orther plantations were

opened to include Rubber, Coffee and Oil Palm estates.

Period III. ( 1900 to 1930 )

The fast growth of plantations in the Golden era of plantation companies, before the first world

war saw the expansion in acreage, productivity and diversification of crops.

The first rubber plantation was established in 1905 and followed by Oil palm plantation in 1911.

The importance of Chinese tea was changed for Assam tea and Arabica coffee for Robusta.

The Indonesian Kings or Sultans had their powers reduced in 1915 and the Dutch authorities

began collecting tax on land.

During this period the boost in prices of major commodities before the first world war, was the

main factor in the expansion of plantations in Indonesia.

The number of plantations increased from 2130 in 1925 to 2467 in 1930 with an expansion in the

acreage from 2.6 million hectares to 2.8 million.

Period IV ( 1930 to 1940 )

The depression period which began with the crisis in 1929 resulted with a steep fall in prices,

whereby the supply exceeded the demand for most commodities including plantation crops in

the world market which hit rock bottom in 1933.

According to the Javasche Ban, exports in 1933 were worth only 40% of the export prices for

the same commodities in 1929.

The global recession forced the Government to impose restriction on production and exportsthrough a quota system on tea, rubber, sugar and copra in 1933.

Farmers were even prohibited to tap rubber, under what was called ' rubber restrictie' whereby

the Dutch government offered cash compensation for rubber plantations.

A team was set up to supervise the distribution of the compensation of which the government

charged levies on certain plantation crops to finance research and marketing promotions.

The number of plantations and acreage is shown in the table below:Details 1930 1933 1938

---------------------------------------------------------------------------------------------------------------------------

Plantations. 2467 2395 2402

Acreage held under HGU ( Ha) 2,876,000 2,410,000 2,485,000

Acreage cultivated (Ha) 1,048,000 1,089,000 1,171,000

source ; Institute of Asian Studies.

Many sugar mills were forced to shut down operations as a result of the recession; leasing of

small holder's lands declined by 51% where many concession holders with land title (HGU)

returned the land to the government, resulting in a sharp shrinkage in the acreage of plantations.


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Period V. ( 1940 to 1950 )

The advent of world war II in 1941, communication with the Netherlands ceased and in March

1942, Japanese forces landed on Java and the occupation of Indonesia.

All development hauled as many foreign planters and owners left the country or were arrested by

the Japanese; leaving the larger plantations without proper management, however the small

holders of local Indonesian farmers increased in numbers as they had to be self-sufficient;resulting in the expansion of small holding plantations.

The Japanese authorities took over the management of plantations and reinstated forced

cultivation of the land.

The Dutch which returned to resume colonial administration in Indonesia, after Japan

surrendered, relied mainly on plantations for finance.

Rehabilitation of some of the plantations, where it was possible under the tense situation as the

during this time, were the plans made by the locals for the war of independence of Indonesia.

The original foreign owners of the plantations could only regain and operate their plantations in

the areas where the Dutch military could effectively maintain authority.

Period VI. ( 1950 to 1970 )

This period marked by the consolidation and fostering of plantations which were still productive;

pre and post independence of Indonesia.

The process of transferring ownership was made between Indonesian private companies and the

colonial or foreign owners which took place from 1959 to 1962 during the campaign to free Irian

Jaya from the Dutch colonial rule.

The number of plantations, continued to decline and the acreage reduced from 1,819,000 Ha in

1950 to 841,800 Ha in 1970.

The plantations were managed and operated by state-owned companies in 1962 which were

gradually changed into limited companies.

The Indonesian Government took direct control over British, Malayan and Singapore plantations

in Indonesia; following the campaign against the establishment of the new Malaysia which was

later returned to its original owners, when the control was lifted towards the end of the 60's.when

Indionesia and Malaysia resume a relationship.

The implementation of the Agrarian law No. 5 in 1960, replaced a similar Dutch law the

Agrarische Wet of 1870.

The law maintained the controlling rights by the state over land.

The law regulated the land title as follows:

a. The land title for exploitation was for 25 years and could be extended to 35 years.

b. Concession rights was lifted and replaced with HGU.

c. HGU for land wider than 25 hectares was available only for a company based in

Indonesia.


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d. A HGU land was at least 5 hectares and no wider than 25 hectares could be held by

an individual

A concession holder was required to convert its land title to HGU and in the process the holder

is required to hand over part of the land to the state to be given to a new private company which

resulted an increase in the number of private plantation companies.

Period VII. ( 1970 to date )

The new order period, called the ' Repelita' ( five year development plan.) marked the start of the

phase development of the plantation sector, with the focused on improvement of productivity and

efficiency.

The main commodities were given greater attention for development are sugar, rubber and oil

palm as a number of state owned plantation companies received credit aid from the world bank

to improve productivity and efficiency.

The Government's prime concern was for the farmer, and in the middle of the 1970's introduced

a new system for development of plantations for the small holder which is known as the " small

holder nucleus pattern ( PIR ); A state plantation company ( PTP ) planning to expand its

acreage must use the PIR pattern whereby under the system, PTP act as an agent of

development of the tree crop projects.

Private companies could use the National Private Plantation (PBSN) scheme without having to

use the PIR pattern.

Working relations between small holders and the large plantations companies were maintained

through the selling of crop by the small holder and purchase by the PTPs who is responsible for

the processing and marketing of finished products.

The Government have adopted two systems in the development of the plantation sector, such asin the intensification and diversification programs; One is based on the initiative of the farmer

with government guidance and the other is program oriented, based on the government program

with partial or integrated approaches.

The partial approach is assistance to plantation companies by providing part of production,

usually in the form of seedlings and guidance, while the integrated approach, the government

provides all production factors which includes fund, management, operation and marketing.

Great progress has been made in Indonesia in recent years to improve the lot of its citizens.

The Indonesian oil palm industry have also advanced and are poised for a major leap forward;

this has been made possible by an enlightened Government and by the efficient implementation

of the government directives.

BIBLIOGRAPHY.

Selected documents, data, studies and books available in the project file are :

Economic Products of the Malay Peninsula by I.H. Burkill dated 1935.

Indonesia tree crop processing project 6949-IND dated 11th Jan 1988.


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6

Study on Indonesian plantations and market of Palm Oil 1990 Book by PT. Capricorn Indonesia Consult Inc.

Progress and development of Oil palm industry in Indonesia by Adlin U Lubis dated Sept.1991.

Notes from the Institute of Asian Studies.


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OIL PALM MILL SYSTEMS & PROCESS 0

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BByyNNooee ll WWaammbbee cckk ((RRee vvii sseeddJJuunnee,,11999999))

&INTRODUCTION

The aim of the writer of this paper is to provide an overall brief description of the Oil Palm Millflow process and its systems employed based on concept and collective experience of the firm.

Any errors in intention are regrettable

The synopsis of the Malaysian Oil Palm Industry success is basically due to the followingfactors:

Commercially sound investment with state encouragement.

Practical Project Study Preparation.

Good management of the plantation who will provide for and ensure good geneticalplanting material, soil conditioning, harvesting, collection standards, handling andtransportation of FFB to the mill and let nature do the rest.

Proper selection of the process system, machinery equipment and plant ( eg. Process

matching with type of FFB ) for high extraction yield, quality palm oil and palmkernel.

Efficient transportation of the finished production to the bulking station or refinery.

Good shipping facilities for loading and discharge of the finished products for the

export market.

And last but not the least, a dedicated and loyal workforce whose ambition is filledwith grit.

Malaysian engineers can to-day provide Oil Palm Mill and process systems designs toachieve lower production cost, train and organize a stable work force, which will

maintain the oil palm mill effectively and produce the best quality product at maximumyield extraction for the minimum cost.


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&THE REQUIREMENT OF A MODERN OIL PALM MILL.

The requirements of a modern oil palm mill shall be with consideration for and incorporation of thelatest technology available in the Industry and to include the following :

a) To be suitable in every respect for processing fruit from Tenera palms;

b) To recovery with the minimum loss the palm oil and the kernels;

c) To produce oil and kernels of the highest quali ty;

d) To facil itate the disposal of the shell, fi bre; and empty bunches;

e) To incinerate the empty bunches for the recovery of the potash for ferti li zer or to treat the empty

bunch to recover 0.25% additional oil and used as fuel to produce steam for more valuable electrical

power generation.

f) The plant and process shall be Environmentall y fr iendly and to dispose of waste water (sludge) in

such as a way as not pollute local rivers and waters;

g) To be reliable and suitable for local conditions of labour supervision and maintenance.

h) Consideration and the incorporation of safety aspects that comply with Occupational Safety and

Health act, such as to provide for good ventil ation, working space, dust free and noise levels within

permissible limits.

i ) The incorporation of operating procedures, equipment, plant and process systems to meet the

ecological , hygienic and cleanliness of the plant on par with good food manufacturing industri al plant

standards.

j) Designed for cost effectiveness for operation and maintenance.

&THE PALM.

Practically all the oil palm planted in the Far East are directly related to one, two or four oil palmswhich were brought from Africa and planted in the Buiterzorgbotanical gardens in Java in 1848.

The material bred from these palms is referred to as Dura Deli. It is very stable and uniform in Oil andkernel content.

An average content of the fresh fruit bunch ( FFB ) is 25% oil, 5.5% kernel, 6% shell, 9% fibre, 25%

empty bunch ( EB ) and the balance is moisture.

In recent years another parent has been introduced to produce the material referred to as Tenera.

The same Dura Dali palm is used to produce the Tenera palmseed but it is pollinated with pollen froma selected Pisifera palm ( the selected Pisifera when self pollinated produce fruit with a small kerneland little shell ).

The resultant Tenera material produces fruit with more oil than Dura material, the same kernels as Durabut less shell than Dura.


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For this reason, it is now always planted in preference to the straight Dura Deli and it is for Teneramaterial that all modern oil palm mill systems should be designed.

The quality of the palm oil and kernels is at its highest just before harvesting, collection and milling.

The extent to which the oil is degraded depends on the system used and the care with which isexecuted.

&TENERA BUNCH COMPOSITION.

The bunch composition will very from bunch to bunch and from tree to tree particularly in respect ofshell thickness but the average bunch content for Tenara material (D x P) with an assumed averagecomposition of Fresh Fruit Bunch ( FFB )or now called Palm Fruit Bunch ( PFB )from matured

palms having a maximum 2.5 ffa for the extraction of Crude Palm Oil and Palm Kernel.

&HARVESTING.

Harvesting is normally a 6 to 8 day cycle. It is important that the fruit must not be harvested before it isripe, that is until the process of photosynthesis, which converts the carbohydrates into fat, is well inadvance.

The oil content of unripe mesocarpmay be in the order of 35% whereas the oil content of ripe mesocarpis usually between 50% and 55%.

The harvesting of under ripe fruit can cause losses in the order of 8% of the possible yield.

TENERA MATERIAL COMPOSITION ( PORLA STD )

Empty bunch 25% = Nos 7% = ash 0.5%= water 16%= Oil 2%

Evaporation 10%

Fruitlets 65% = nuts 15% = kernel 6 %= pericarp 50% = NOS 7.5%

= water 19.5%Total PFB 100% = Oil 23%

====

Total Oil Plus FFA = 25% to Palm Fruit Bunch


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&FREE FATTY ACID ( FFA)

The FFA content of the oil in the bunch before harvesting may be in the order of 0.1% whilst the FFAof the oil in the same bunch when it is received at the mill will never be less than 1%, normally in theorder of 3%, and is frequently above 3% under bad conditions.

A low FFA content is the first characteristic to which edible oil refiners pay attention.

A premium of 1% of the sale price is paid for every one percent, should the FFA content be below 5%and the Refining loss will be 1.25% to 1.80% per 1% of FFA.

The rise in the FFA content from harvest to mill will make possible the harvesting of riper fruit withhigher oil content and recovery of higher quality oil with a lower FFA.

The riper the fruit the more vulnerable it is to damage during transport and handling.

Of all different stages of processing, the harvesting of the palm tree and the transport of fruit to theedible oil refiner has the most effect on quality.

&FRUIT COLLECTION AND TRANSPORT.

There are two basic systems used for fruit transport.

One is the collection of fruit directly into the sterilizer cages and the other is the collection of thefruit in trucks or trailers and then transferred into sterilizer cages at the oil palm mill.

The transfer system isless costly but results in some loss of oil and a higher FFA content due

to the extra handling and damage to the fruit.

The other system requires that the sterilizer cages be taken to the field for direct loading fromthe collection points.

At such points the harvesters place the fruit on nets which are lifted by crane to load gently into thesterilizer cages.

At the time when the fruit is lifted in the nets it is convenient to weigh, using a weighing cell.

This is particularly important for the collection of small holder crops.


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OIL PALM PROCESSING.

The flow diagram and matrix relating to the processing of fruit from Tenera palms is shown in theappendix enclosed.

1.0 FFB Reception.

The FFB bunchesloaded on trucks, cages or trailer are weighed on arrival at the mill and ondeparture when empty by weighbridge of 50 ton capacity and automatically recorded, that iscomputerised.

After weighing-in process of the truck, cage or trailer, the PFB are dumped into the inclined hopperat the ramp that will hold 900 mt PFB ( 2 lines of 15 bays x 30 mt PFB ).

Modern mills in Malaysia are equipped with the following in the reception area of the mill:

A. Load cell ( pitless ) 50 tons weigh bridge of 3.3m W x 15m L and computerised.

B. Larger loading ramp with double door hoppers of 30mt capacity per bay.

C. FFB Cage and bogie with capacities of 5, 7 and 10 mt of wheel spanned of 800mm gauge.

D. FFB loading into cages by conveyor system

E. Straight line railway system with Cage transfer carriage located at both ends of the railtrack

system to facilitate easier operation of the 2-door sterilizer and shunting of the cages can behandled easily with the capstan and Bollard.

On opening the hopper door ( 2 doors to a bay ) the bunches drop into the 7mt cages with bogies placedbeneath it.

The loaded PFB cages are then conveyed by the transfer carriage on the rail track and pushed into thesterilizer, by a winch and ballard system for sterilization.

2.0 Sterilization.

The sterilizer process is done in 5, 7 and today 10 tons capacity FFB cages which are pushed into longcylindrical steel vassel with special doors and subjected to steam at approximately 3 BAR.

One of the effects of sterilisation is to inactivate the fruit enzyme. Once this enzyme has beeninactivated the rise of the FFA is virtually stopped.

The objective after harvesting is to sterilize the fruit as quickly as possible with the minimum ofhandling and damage.

In addition to arresting the development of the FFA content, the sterilizing of the fruit also facilitates:

a. The purification of the palm oil by coagulating nitrogenous and mucilaginous matter and thuspreventing the formation of emulsions during verification of the crude oil.


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b. The extraction of the crude palm oil by freeing the fruits from the bunch stalks and by breakingthe oil cells in the mesocarp.

Majority of mills today has programmable automatic control systems to cater for proper sterilization of90-minute cycle.

Sterilisation is a simple process but it is essential, for the proper operation of the mill so that it isdone correctly. This operation is the largest user of steam in the mill.

3.0 Stripping.

After the sterilisation the sterilised fruit in 3.5 mt PFB Cages are then winched out of the steriliservassal by the arrangement of Bollard & winch and then placed in position for the remote controloverhead hoist, for the activity of emptying the FFB into the threshing machine which will separate theempty bunches from fruit.

Or for larger capacity mill with 5 mt FFB cages and above, into the cage Tippler machine a ring

structure for emptying the contents of FFB onto a scraper type conveyor and transported to the threshermachine for stripping of the fruitlets from bunch.

The fruit is then conveyed by screw conveyors and bucket elevators to the Pressing or Extractionstation.

New mills have included in their design bunch crusher and secondary thresher system for recovery offruitlets of large or poorly sterilised bunches which are difficult to strip.

A STERILISER STATION WITH SINGLE DOOR STERILISERS


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4.0 Empty Bunches.

Empty bunches from 25% of the total weight of the ffb. They are then returned to the field as fertilizerafter incineration for the recovery of resultant potash, in conventional mills.

They have no food value and have a high silica content. When properly incinerated they yield 0.3 to0.5% of potash.

Utilisation of empty bunche for field applicationas fertiliser supplement is found to be cost effectiveby some plantation groups and to the others justification of logistics, other constrains or practicalexperience? seems to be the objection for use of EFB in the field.

In recent years a system has been introduced in Malaysia for the Treatment of Empty Bunches whichrecovers a further 0.25% of the oil on ffb from the empty bunches and at the same time reduces themoisture content to approximately 35% so that they can be used as additional solid waste fuel for steamand power generation, required for other down stream process.

5.0 Oil Extraction.

The efficient extraction of the crude oil from Tenera fruit has presented problems but these have beenovercome by the development of the continuous screw press, which is now used in all modern factories.

The fruit from the stripper passes to digesters, which complete the breaking of the oil cells with slowmoving arms. Digesters have a capacity of above 3 cubic metres.

TYPICAL SIDE VIEW OF THE EXTRACTION STATION


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The fruit mash then passes to the screw presses (capacities of 1016Mt FFB per hour) which press thecrude oil out through holes in the side of the press cage. The press cake, which is discharged from theend of the press, contains the fibre and the nuts.

The three products separated in this section are :

a) The crude oil which consists of water, dirt and palm oil. This is passed to the purificationsection;

b) Nuts: 15% of the ffb. Is separated by the depericarper and kernel plant for the recovery of thekernels;

c) Fibre: Approximately 15% of the ffb weight with moisture content of 37%. The residual oilcontent should be between 6% and 8% of oil to dry fibre.

The fibre should also retain as far as possible the phophatides and other non-glyceridesimpurities. The fibre separated in the deparicarper winnowing system is conveyed to the boileras fuel.

The proper design of the extraction section is important. Unsatisfactory practices such as excessivedrainage of the crude oilbefore the extraction press leads not only to purification problems and losses

but also to the higher absorption of iron by the palm oil.

The importance of reducing the absorption of heavy metal, copper and iron is indicated by thetotox value. For the production of superior quality palm oil, stainless steel moving the wearing

parts should be used for extraction units (such as the digester and screwpress).

6.0 Kernel Recovery

The conditioning of the nuts starts in the sterilizer and the separation starts in the screw presses. After

the screw press the nuts and the fibre traverse a heated breaker conveyor which further separates themand removes moisture from the fibre.

The fibre and nuts then pass into a pneumatic separating column, called the winnowing columnfittedwith IC damper in operation, depending on the number of presses in operation.

The fibre is blown into a cyclone close to the boiler and the nuts pass down a polishing drum, designedto handle a verity of nuts which removes any attached dirt or fibres and tramp iron.


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The nuts are conditioned in nut silos before being cracked in centrifugal nutcrackers or / and in presentday Rippler mills. After cracking, the cracked mixture is separated in the double winnowing separatingcolumn for dry separating system or separated in hydrocyclones or clay baths.

These processes are wet. A modern Hydroclay bath separator is more efficient than a hydrocycloneseparator when processing more than 15% Dura materialin the cracked mixture.

A supply of suitable clay at the rate of approximately 450 kg to 100 tons of ffb is necessary for theclay separator system. Both systems depend upon the density of the shell being greater then thedensity of the kernels.

The higher yield of PK compensates the addition cost of clay or kaolin required for the Hydro-claybath separator process.

The shell and kernels are washed and the kernels are passed to a kernel dryer to normalize themoisture content of 7% so as to minimize the development of FFA during storage and shipment.

It is also advantages to sterilizer the kernels before shipment or storage with steam at atmosphericpressure.Kernel plants designed for Dura derived nuts are not suitable for the processing of Teneraderived nuts. There have been a number of experimental designs, which have proved failures.

Caution and a wide experience are required in selecting the proper equipment and design forkernel recovery plant.

7.0 Palm Oil Purification

The modern purification or oil classification station is designed to recover and purify the crude oil asquickly as possible with the minimum heating and exposure to air.

This is to minimize the damage by oxidation, which is caused by the exposure of crude oil to air athigh temperature.

A. Press cake to winnowing

B. Ejection of Nuts

C. Fibre to cyclone

D. Removal of dirt & tramp iron

A DEPARICARPER, WINNOWING COLUMN AND POLISHING DRUM STATION FOR FIBRE & NUTS SEPARATION


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The process begin at the crude oil tank of the extraction station and ends at oil cooler as finished CPOwith dirt contents of 0.009% and moisture contents of 0.09%.

The major effluent problem is eliminated by the decanter system, which removes the semi-solidsludge for treatment, by the sludge dryer, which reduces the moisture of the sludge from 45% to10%.

Adequate heat for drying of the sludge is obtained from the boiler exhaust flue gasses.

The composition of the dryer decanter cake is shown in Appendix.

The major contributor to poor quality oil is oxidation.

Oxidation measured by the totox value, starts when the oil is above 60C and exposed to airDuring processing, storage and shipment.

8.0 Steam and Power Generation.

Utilization of existing energy resources is indispensable not only for large industrial processes but alsofor small production plant and in particular oil palm mills where the balance between heat and powerare required for production process which are pre-condition for a combined heat andpower ( CHP) scheme. Or commonly referred to as C0-GENERATION SYSTEM.

Solid waste fuel in the form of shell, fibre and empty bunches which are by-products of the process areutilized as fuel for the boiler.

Steam is required for processing at the approximate rate of 500kg per hour per ton ffb.

This steam can be easily raised in a reasonably efficient water tube boiler with fuel available from theFibre, shell and empty bunch. Power is required at the approximate rate of 15 to 25 Kw per ton ffb.

This can be easily be provided by placing a back-pressure single stage steam turbine between theboiler and the header of the mill processing system.

Steam is generated from the boiler at a pressure of say 20 Bar.g and into the steam turbo alternator at18.5 Bar.g at 260C with back pressure of 3.16 Bar.g for the mill process which is convenient andeffective for process Heating.

The additional power generated in this system is made possible by burning of the empty bunches asshown in the enclosed Fuel /Steam /Power balance and Steam Production from 1 Ton Solid Waste Fuelfor a Oil Palm Mill.

Every ton of FFB can produce 733 kg steam and 30kw power shown, in the diagram below :

A system has been introduced for the treatment and disposal of empty bunches and recovery of palm oiland at the same instance reduces the moisture contents of the empty bunches to approx. 45 % so thatthey can be used as solid waste fuel for the boiler and production of additional steam and electrical

power.


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Every ton of FFB can produce 733 kg steam and 30kw power shown, in the diagram below :

Steam is produced by water tube boilers at pressures and temperatures higher ( 20 bar.g 207 deg. C )than required for the process. First it is expanded in steam turbines, and then led into the processwhere the latent heat contained in the exhaust steam ( 3.16 bar.g ) is utilized for sterilisation of FFBand heating systems in the process.

The diagram below show a typical CHP scheme of a modern oil palm mill.

The energy released during the expansion of steam is converted by the turbine into mechanical power todrive an alternator.


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There is a direct relationship between the number of palms cultivated and the corresponding harvestyield of a given plantation area processed by the mill, the primary energy available in the by productfuel, and power / heat requirement of the mill

A properly design Oil Palm Mill will not only provide sufficient steam and electrical power for itsoperation requirement but will provide an additional 17 to 33 % more power for other plannedintegrated down stream processes, domestic use or sold to other consumers of power.

9.0 Effluent Control.

SOURCE OF SOLID WASTE, EFFLUENT & POLLUTION

Effluent discharge quantities in Oil palm mills is dependent on the extent of design of the millingprocess systems, in-plant process control, equipment maintenance and good house-keeping.

The solid waste or by-products in the oil palm milling process, consist of :

Empty bunches

Shell and fibers

Decanted solids

Sludge centrifuge solids

Boiler ash

De-sludging of ponds.

Solid waste such as treated empty bunches ( de-water ) of approximately 25% to FFB and recovereddryed sludge of approximately 3% to FFB are by products that will be utilized in the plantation and sold

as produces.

The shell and fiber are sources of solid waste fuel for co-power generation in the oil palm mill.

Waste water from the sterilizer condensate, clarification effluent and hydro-cyclone or claybathdischarges are sufficiently contaminated and require treatment.

Some of the sources waste water discharged from the steam turbine condensate / cooling system andboiler blow down are relatively clean and can be put to good use in the process such as for the dilutionsystem, screw press, oil gutter spraying and for the factory floor cleaning requirements.

The liquid effluent total quantity of 0.6 to 1 mt per ton of FFB between the generating sources being asfollows :

Sterilizer condensate

Calrification station

Hydrocyclone / Claybath.

Other waste water


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The table below presents the typical physical and chemical properties of raw effluent from Oil palmmilling process.

The total liquid effluent could well increase if mill process wash water is included.

The effluent is not toxic but it has a biochemical oxygen demand of above 25,000 (BOD) which makesit objectionable to fish life when introduced in relatively large quantities in waterways and rivers.

The objective is to treat the oil palm mill effluent discharge so as to comply with conditions imposed bythe Department of Environment (DOE) for disposal in accordance to standards as follows:

Standard A. - For discharge to rivers shall be less than BOD 20 mg / lStandard B For discharge to waterways shall be less than - BOD 50 mg / lStandard C For discharge to land & field shall be less than - BOD 500 mg / l

A system to treat affluent by ponding or Oxidation ponds is commonly adopted in Malaysia.

The system of Anaerobic and Aerobic process in general conform to regulations which require asizeable area of 65 to 75 days retention time for the ponds, proper monitoring, cost for power forcirculation pumps and aerators, de-sludging of ponds, maintenance and supervision but at times areunstable as a result of a reduction of ponding volume due to silting with sludge, weather conditions and

by contamination.

Many systems are being tried but no generally accepted system has yet emerged.

The systems tried including centrifuges, fitters, sun bed drying, air flotation / coagulation andmechanical extended aeration plants.

Some pilot systems include Methane production units and Effluent free system or Zero discharge by

means of a multi-Stage condensing unit and Thermal Oxidation plant to produce dry sludge in the finishproduct as POME which is sold as fertiliser and filler for animal feed.

The search for new designs and systems continues..

q Oil Palm Mill Schematic Process Flowq Oil Palm Process Matrixq Process Mass flow and losses during Production

Noel Wambeck / October. 1997 / Revised June 23, 1999.

PARAMETER MEAN

pH 4.1BOD 25,000

COD 53,630Total Solids 43,635

Suspended Solids 19,020

Volatile Solids 36,515

Ammoniacal Nitrogen 35Total Nitrogen 770

Oil and Grease 8,370

* All values except pH are in milligrams per liter ( mg / L) Source : PORIM


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ALTERNATIVECAGE TIPPLERSYSTEM

DECANTER FORSOLIDS REMOVAL

EMPTY BUNCHDISPOSAL BYINCINERATIONFIELD APPLICATIONOR OIL RECOVERY

DRY KERNEL 7% moisture 4.6% dirt.

CRUDE PALM OIL 0.09% moist. 0.009% dirt.

Designed by Noel Wambeck - 25th. July 1992


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05b. Matrix OPM Process.xls

MATRIX OIL PALM MILL PROCESS. BASED ON MALAYSIA TENERA MATERIAL WITH 25% OIL CONTENT

PO INT SAMP LE AT POINT Mill Capacity: mt FFB / Hr > 1 3 5 10 20 30 45 60 90 120

% / FFB OIL WATER SOLID OTHER Weight in kg.

A Fresh fruit bunches 100 25 48.5 26.5 kg 1,000 3,000 5,000 10,000 20,000 30,000 45,000 60,000 90,000 120,000

B Empty bunches 25 0.75 18 6.25 0 250 750 1,250 2,500 5,000 7,500 11,250 15,000 22,500 30,000

B1 Liquid from EB Press 8.3 0.249 7.387 0.664 0 83 249 415 830 1,660 2,490 3,735 4,980 7,470 9,960

B2 Potash ( Bunch ash ) 0.5 0.5 5 15 25 50 100 150 225 300 450 600

C Fruitlets on bunch 66 24.25 37 7 0 660 1,980 3,300 6,600 13,200 19,800 29,700 39,600 59,400 79,200

C1 Fru it le ts in Empt y bu nc h lo ss 2 0.735 1.121 0.212 0 20 60 100 200 400 600 900 1,200 1,800 2,400

D Digested mash 64 23.52 35.88 6.79 0 640 1,920 3,200 6,400 12,800 19,200 28,800 38,400 57,600 76,800

D1 Press Cake 26 1.56 10.9 14.0 0 260 780 1,300 2,600 5,200 7,800 11,700 15,600 23,400 31,200

D2 Ext ract ion CPO & water ex -p ress 38 21.96 15.2 0.84 0 380 1,140 1,900 3,800 7,600 11,400 17,100 22,800 34,200 45,600

E W et Fi br e & Nu ts to dep er ica rpe r 25.75 1.55 10.82 13.39 0 257 771 1,285 2,570 5,140 7,710 11,565 15,420 23,130 30,840

E1 Wet Fibre to boiler 12.0 1.08 3.60 6.48 0 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400E2 Wet Nut Ex- winnowing 13.75 0.47 0.76 12.53 0 137 411 685 1,370 2,740 4,110 6,165 8,220 12,330 16,440

F Cracked Mixture 12.5 0 125 375 625 1,250 2,500 3,750 5,625 7,500 11,250 15,000

F1 Kernel 5.5 0 55 165 275 550 1,100 1,650 2,475 3,300 4,950 6,600

F2 Shell 7 0 70 210 350 700 1,400 2,100 3,150 4,200 6,300 8,400

F 3 Water for Hydrocyclone 80 80kg 0 80 240 400 800 1,600 2,400 3,600 4,800 7,200 9,600

F 4 Clay for Claybath system 5 5kg 5 15 25 50 100 150 225 300 450 600

G Crude oi l di lua te d w it h wat er 53.2 21.96 30.4 0.84 0 532 1,596 2,660 5,320 10,640 15,960 23,940 31,920 47,880 63,840

G1 Cla ri fied c rude o il to Pur if ie r 25.00 21.96 2.20 0.84 0 250 750 1,250 2,500 5,000 7,500 11,250 15,000 22,500 30,000

G2 Sludge to Separator 42.31 21.74 19.81 0.8 0 423 1,269 2,115 4,230 8,460 12,690 19,035 25,380 38,070 50,760

H Clean oil to Oil dryer 23.91 21.74 2.17 0 239 717 1,195 2,390 4,780 7,170 10,755 14,340 21,510 28,680

H1 Clea n & dr y CPO to st oa rg e t ank 21.52 21.50 0.01 0.009 0 215 645 1,075 2,150 4,300 6,450 9,675 12,900 19,350 25,800

J Raw water 1000 1000kg kg 1,000 3,000 5,000 10,000 20,000 30,000 45,000 60,000 90,000 120,000

J1 Boiler feed water 700 700 kg kg 700 2,100 3,500 7,000 14,000 21,000 31,500 42,000 63,000 84,000

J2 Precess water 120 120kg kg 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400

J3 Domestic water 180 180kg kg 180 540 900 1,800 3,600 5,400 8,100 10,800 16,200 21,600

K Sol id waste fue l to boi le r ( 30% moist .) 43 0.01 12.9 30.09 430 1,290 2,150 4,300 8,600 12,900 19,350 25,800 38,700 51,600

K1 Fibre 12 0.016 3.6 8.384 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400

K2 Shell 8 0.008 1.2 6.792 80 240 400 800 1,600 2,400 3,600 4,800 7,200 9,600

K3 Light particals 0.5 0.0005 0.025 0.4745 5 15 25 50 100 150 225 300 450 600

K4 De-oiled empty bunches 22.5 0.008 6.75 15.742 225 675 1,125 2,250 4,500 6,750 10,125 13,500 20,250 27,000

L Boi le r s team generat ion ( kg / ton FFB ) 660 660kg 660 1,980 3,300 6,600 13,200 19,800 29,700 39,600 59,400 79,200

L1 Tur bi ne s tea m re qui rement 600 600kg 600 1,800 3,000 6,000 12,000 18,000 27,000 36,000 54,000 72,000

L2 Ste ri li sa tion steam requi rement 540 540 kg 540 1,620 2,700 5,400 10,800 16,200 24,300 32,400 48,600 64,800

L3 Process heat ing s team requi rement 120 120 kg 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400

M W as t wat er E ff lue nt ( k g / t on FFB ) 1000 1000kg kg 1,000 3,000 5,000 10,000 20,000 30,000 45,000 60,000 90,000 120,000

M1 From Clarification 550 kg 550 1,650 2,750 5,500 11,000 16,500 24,750 33,000 49,500 66,000

M2 From St er il ise r co nd en sa te 150 kg 150 450 750 1,500 3,000 4,500 6,750 9,000 13,500 18,000

M 3 From PK recovery plant 80 kg 80 240 400 800 1,600 2,400 3,600 4,800 7,200 9,600

M4 Boiler blow down 120 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400

M 5 From OTHE RS & cleaning 100 kg 100 300 500 1,000 2,000 3,000 4,500 6,000 9,000 12,000

N Power generat ion ( kw / ton FFB / h r ) 25 KW 25 75 125 250 500 750 1,125 1,500 2,250 3,000

N1 Process 20 KW 20 60 100 200 400 600 900 1,200 1,800 2,400

N2 Mill lighting & grounds 2 KW 2 6 10 20 40 60 90 120 180 240

N3 Domestic 3 KW 3 9 15 30 60 90 135 180 270 360

Perunding AME / POMProMatrix / 16th November 1998 /nw. 5/10/00


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PROCESS MASS FLOW AND LOSSES DURING PRODUCTION

Based on Tenera material

Oil content 24% PRODUCT WASTE LOSS

FFA 2.5% max kg kg kg

Out Flow Evaporation 12

100 kg 12.3 Oil Loss 0.3

25 Empty bunches 24.5

87.7 kg Oil Loss 0.5

31.14 Solids

62.7 kg 31.56 Liquids

Water 6.56

31.56 kg Non-oily solids 2

Oil Loss 0.75

Oil 22.25

Evaporation 3.84

31.14 kg 16.19 Oil Loss 0.1

Fibre 12

Kernel Loss 0.25

Evaporation 1.714.95 kg Oil Loss 0.1

Kernel Loss 0.15

NUTS Shell 8

5.4 Kernel 5

100 27.25 70.6 2.15

22.25 92.7% Total OIL loss in kg 1.75

5 92.6% Total kernel loss in kg 0.4

Moisture % 0.09 Moisture % 7

Dirt % 0.009 Dirt % 5

FFA % 3.5 FFA % 2.5

Noel Wambeck Feb.1999

QUALITY

OIL CLARIFICATION

DEPERICARPER

KERNEL RECOVERY

TOTAL in kg

CPO Yield

Palm Kernel Yield

EXTRACTION

( Including FFA as Oil )

FFB input in kg

STERILISER

STRIPPING


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TYPICAL FLOW DIAGRAM OF AN EFFLUENT TREATMENT

PONDING SYSTEM FOR A 30 MT FFB PER HOUR OIL PALM MILL.

Perunding AME/ ETP Flow Diagram

FAT PIT EFFLUENT OIL RECOVERY STATION

WASTE WATER FROM :

Steriliser Condensate, Clarification Station

Kernel recovery station and wash water

CoolingPond No 1

12 x 15 x 2.5

Cooling

Pond No 2

302 m each Pond

1 day HRT

RAW EFFLUENT

INPUT 432 m3/day

BOD 25,000 ppm.

FINAL DISCHARGE

TO PLANTATIONFLOW RATE OF > 432 m3 / DayBOD REDUCTION = 99.6 %

> LESS THAN 100 PPM BOD

RECYCLE PUMP

Recycle Activated Sludge ( 100%) 18m3 per hour

AcidificationPond No.112 x 15 x 2.5

Acidification

Pond No.2

AnaerobicPond No.116 x 160 x 6

Anaerobic

Pond No.2

Anaerobic

Pond No.3Anaerobic

Pond No.4

AerobicPond No.1

16 x 80 x 2.5

Aerobic

Pond No.2

302 m each Pond

1 day HRT

6629 m each Pond

61days HRT

2,611 m3each

12 days HRT

Pi eline / Tanker

RECYCLE PIPE LINE

Facultative Pond932m3 2 days HRT

16 x 30 x 2.5


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05g. MatrixPOMEffluent.xls

MATRIX OF AN OIL PALM MILL PROCESS & WASTE WATER EFFLUENT PONDING SYSTEM.

I tem Details

1 Milling capacity MT FFB / hr 1 30 45 60 90 120

2 Effluent Generation Rate

a. FFB moisture kg 200 6,000 9,000 12,000 18,000 24,000

b. Sterilizer condensiate kg 140 4,200 6,300 8,400 12,600 16,800

c. Clarification station kg 600 18,000 27,000 36,000 54,000 72,000

d. Kernel Plant kg 150 4,500 6,750 9,000 13,500 18,000

e. Other & washwater kg 110 3,300 4,950 6,600 9,900 13,200

Total per hour in kg. kg 1,000 30,000 45,000 60,000 90,000 120,000

3 Flow rate of Effluent

Per Hour m 3 1 30 45 60 90 120

Per Day ( 24 hours ) m 3 24 720 1,080 1,440 2,160 2,880

HRT of 75 days m 3 1,800 54,000 81,000 108,000 162,000 216,000

4 Suspended Solids

at Fat / Sludge pit ( 22,000 mg/L ) kg 39.6 1188 1782 2376 3564 4752

at Final discharge ( 200 mg/L ) kg 0.36 10.80 16.20 21.60 32.40 43.20

Rate of aerobic Biosolids produced kg 39.24 1177.2 1765.8 2354.4 3531.6 4708.8

5 Organic loading Rate ( 0.3 kg BOD/m3/Day ) kg 7.2 216 324 432 648 864

6 Rate of Re-circulation of Anaerobic effluent

Anaerobic - HRT 5 days m3 120 3600 5400 7200 10800 14400

return to seeding pond ( 50 % ) m3 / hr 0.5 15 22.5 30 45 60

Pump size KW 0.33 3 4.5 6 9 12

number of pumpsets unit 1 1 1 1 1 1

7 BOD of Effluentat Sludge pit - 25,000 mg / L kg 4.5 135 202.5 270 405 540

at Anaerobic pond discharge - 5,000 mg /L kg 0.90 27.00 40.50 54.00 81.00 108.00

at Aeration pond discharge - 50 mg /L kg 0.009 0.27 0.405 0.54 0.81 1.08

at Stabilisation pond discharge - 20 mg / L kg 0.0036 0.108 0.162 0.216 0.324 0.432

8 Aeration pumpsets

Flow rate m3 / hr at TDH 20 2 45 67.5 90 135 180

Drive motor kw 5.625 8.4375 11.25 16.875 22.5

Number required units 1 x 7.5 2 x 5.5 2 x 7.5 2 x 10 4 x 5.5


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PERUNDING AME Consulting Engineers 1

AN ENVIRONMENTAL CONTROL PLAN (ECP)By Noel Wambeck April 1999.

FOR THE PROPOSED OIL PALM MILL WITH AN INTEGRATED EFFLUENT TREATMENT AND

DISPOSAL SYSTEM, AIR POLLUTION AND SOLID WASTE DISPOSAL SYSTEM.

01. INTRODUCTION.

The proposed Environmental Control Plan (ECP) will exploit every practical avenue toprovide a complete effective system for Effluent treatment, solid waste disposal, air pollutioncontrol and minimising of the environmental impact, to the requirements and expectations of

DOE, local authorities and inhabitant indemnity.

The Department of Environment has set a target for Oil palm mills to achieve 100 percent

compliance by the year 2000 in terms of meeting emission and effluent discharge standards,which are :

Environmental Quality ( Licensing ) regulations 1977.

Environmental Quality ( Prescribed Premises) (Crude Palm Oil ) Regulations 1977(Amendment) 1982.

Environmental Quality ( Clean Air ) Regulations 1978.

The overall objective of this project report is to determine and advise the client on the

following :

1 Proposed project needs in terms of design, cost, capacity, manpower requirements andproject schedule.

2 Selection of the Oil Palm Mill complex location.

3 Provide detail design and specification, supervision, commissioning, training ofpersonnel and guarantee performance for the proposed project.

4 Care in the implementation of the project, and not to endanger the environment byproviding the proper process, system and method for the treatment of effluent for 100 %land application, solid waste disposal and the control of noise and air pollution.


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02. PROJECT SALIENT DATA.

The following salient data is used in the design calculations:-

2.1 Milling capacity ( MT / FFB per hour. ) : 30 mt per hour720 mt FFB per day

2.2 Amount of Empty Bunches for disposal (mt / hr.) : 7. 5 mt per hourBased on the ratio of 25% Empty bunches to FFB 180 mt per day

Empty bunch decomposing period : 90 daysArea required for mulching ( 2333m3 / Ha ) : 26 Ha

2.3 Ratio of raw effluent (POME) to FFB : 60 %

2.4 B.O.D. level of raw effluent (POME) : 25,000 mg/l

2.5 Processing hours based on peak operation : 24 hours.

2.6 Average flow rate of effluent (POME ) : 18 m3 / hror 432 m3 / day

2.7 Effluent ( waste water ) treatment system :1 No. Sterilizer condensate oil recovery tank : 120 m31 No. Sludge oil recovery tank : 120 m32 Nos Fat pits : 20m3 volume : 40 m32 Nos Cooling Ponds : 256m3 each : 461m3 / hr HRT 2.13 days1 No. Mixing Pond 461m3 : 461m3/ hr HRT 1.07 days3 Nos Digesting Tanks : 3720m3 each : 11,160 m3 HRT 25.8 days4 Nos Aeration reactor : 2000m3 each : 8000 m3 HRT 4 days

1 No. Sludge drying bed : 6 x 30 m : 180 m21 No. Sludge Clarifier : 225.6.m3 : 225.6m3 HRT 12.5 hr1 No. Treated effluent holding tank

B.O.D. level of Final discharge : < 20 mg/lTotal BOD reduction : 99.9 %

2.10 Proposed site area : 122 ha

Area allocated for Oil palm mill complex : 12 ha

Percolation Rate of liquid Effluent on proposed land : 560m3 / day / ha

Area allocated for field / Land disposal of final effluent : 69 hain trenches / furrows ( based on 90 days cycle )

2.11 Boiler Gas Volume : 30 m3/ s

2.13 Dust load : 4000mg/ NM3 max.

2.14 Boiler Air Emission : < 0.4g / NM3


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03. SOURCE OF SOLID WASTE, EFFLUENT & POLLUTION

Effluent discharge quantities in Oil palm mills is dependent on the extent of design of the millingprocess systems, in-plant process control, equipment maintenance and good house-keeping.

The solid waste or by-products in the oil palm milling process, consist of :

Empty bunches

Shell and fibers

Decanted solids

Sludge centrifuge solids

Boiler ash

De-sludging of ponds.

Solid waste such as treated empty bunches ( de-water ) of approximately 25% to FFB and recovereddryed sludge of approximately 3% to FFB are by products that will be utilized in the plantation and soldas produces.

The shell and fiber are sources of solid waste fuel for co-power generation in the oil palm mill.

Waste water from the sterilizer condensate, clarification effluent and hydro-cyclone or claybathdischarges are sufficiently contaminated and require treatment.

Some of the sources waste water discharged from the steam turbine condensate / cooling system andboiler blow down are relatively clean and can be put to good use in the process such as for the dilutionsystem, screw press, oil gutter spraying and for the factory floor cleaning requirements.

The liquid effluent total quantity of 0.6 m to 1m per ton of FFB between the generating sourcesbeing as follows :

Sterilizer condensate Calrification station

Hydrocyclone / Claybath.

Other waste water

The table below presents the typical physical and chemical properties of raw effluent from Oil palmmilling process.

PARAMETER MEAN

pH 4.1BOD 25,000

COD 53,630Total Solids 43,635

Suspended Solids 19,020Volatile Solids 36,515

Ammoniacal Nitrogen 35Total Nitrogen 770

Oil and Grease 8,370

* All values except pH are in milligrams per liter ( mg / L) Source : PORIM


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04. POLLUTION CONTROL SYSTEM.

The proposed Pollution control and treatment systems are :

4.1 THE DISPOSAL OF EMPTY BUNCH.

4.2 THE PROCESS OF THE INTEGRATED DECANTER DRIER SYSTEM

4.3 THE ANAEROBIC & AEROBIC EFFLUENT TREATMENT SYSTEM.

4.4 DISPOSAL OF TREATED EFFLUENT FOR LAND APPLICATION.

4.5 CONTROL OF AIR EMISSIONS.

The brief process description of the above systems are as follows:

4.1 THE DISPOSAL OF EMPTY BUNCH.

Empty bunch a solid waste product of the Oil Palm Milling process has a high moisture content ofapproximately 55 65% and high in silica content , form 25% of the total weight of Palm Fruit Bunch.

The treated Empty bunch are mechanically crushed ( de-watered and de-oiled ) in the process but arerich in major nutrients and contain reasonable amounts of trace elements. They have a value whenreturned to the field as mulch for the enrichment of soil.

The use of empty bunch for field application as mulching material is preferred by the client, thereforewe shall confine to this method of disposal of empty bunch for the proposed oil palm plantation.

The land application .mulching system is said to have a cost savings of RM 250 per ha annually inplace of fertiliser supplement.

In Perak state, several estates have this system of land application of empty bunch mulching, includingSeri Pelangi, Nova Scotia, Jendarata Estate, since 1973 on a commercial scale.

Other mills that used the same method of disposal are; Ulu Basir, UIE, Southern Perak, ChangkatChermin, Topaz Emas, Foong Lee etc

To do this, adequate hopper and conveyor system will be provided at the oil palm mill site for storageand an arrangement of tractor & trailer with a capacity of 5 -10 mt EFB shall be deployed for thetransportation of the treated empty bunches ( de-watered ) to the field for disposal.

On arrival at the estate, the train of two or more trailers are parked on the road adjacent to the inter rowto be mulched and with the aid of the extended draw-bar, the trailers are unhitched one from the other.

The trailers are towed one at a time into the inter rows and tipped while slowly moving forward.

The empty trailers are then hitched back one to the other by lifting with the tractor draw-bar and pinsput into position, they than return to the mill to repeat the process.


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The drainage pattern in most fields is four palm rows to a drain, to ensure that all palms benefit frommulching, the empty bunches are applied in the avenue between row 2 and 3, and between palm pointsin the two outer drain side rows ( see the diagram of the Placement of empty bunches in the appendix.)

In the latter, the side-tipping trailers are particularly useful. Manual labour is used to make minorimprovements where leveling may be required.

The rate of application ranges between 75 to 100 tons empty bunches per hectare.

In conclusion, bunch mulching of oil palms on a commercial scale is recommended as a

viable proposition in plantation where the terrain and ground conditions allow

mechanisation of the operation.

4.2 THE PROCESS OF THE INTEGRATED DECANTER DRIER SYSTEM

( FOR THE PRODUCTION OF SOLID WASTE SLUDGE ( POME ) AS ANIMAL FEED OR FERTILISER. )

The Decanter Drier integrated system reduces the volume and handling of oil palm mill effluentdischarge of about 75% of the total BOD load discharge from the mill.

The system also provide a means of a dust collecting system for the boiler flue gas with the advantageof being able to produce an added value by product of dried sludge ( POME ) for animal feed orfertiliser, resulting in better returns on investment of the project.

The source of solid waste effluent are :

1. Decanter solids

2. Steriliser condensate sludge3. Clarification station sludge4. Boiler ash5. De-sludging of the effluent treatment system6. De-sludging of all process tanks

The use of the Decanter in the oil clarification station for the removal of solid matter, reduces the loadon the separator and static clarification settling tank by about 50 75% while there is not change in theload on the other machinery of the clarification station process.

Process dried sludge has certain properties:

Releases nutrients slowly

It supplies trace elements And it improves water retention.

The system proposed has been developed and in operation over 20 years at United Plantations Mills,Keck Seng and several other mills in Malaysia and Indonesia.


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The proposed system details are as follows :

A. Multi cyclone separator.

The multi cyclone will remove coarse sand and other solid matters with a particle size of more than 50microns or about 50% of the solid matter from the crude oil.

B. The Decanter system.

The decanter will remove approximately 90% of all suspended solids from the crude oil.

C. Rotary Drum drier. Solid sludge is conveyed by the screw conveyor and fed to the Rotary Drum Drier located close to the

boiler house for heating by the Boiler flue gas.

The rotary drum drier in which the flue gas from the boiler, is in direct contact with the wet solidsdischarged from the decanter, multi cyclone and oil pit effluent recovery system.

Flow of the flue gas and solids is con-current. The flue gas is tapped from the chimney above theboiler fan.

The ducting size would be the same size of the chimney and the portion of the chimney above theducting is closed with a damper for flue gas control.

The diamension of the rotary drum drier is 2 meter in diameter and about 15 meter in length.

D. Dried sludge clarification screen.

The dried sludge material with a moisture content of 10% is discharged at the end of the rotary drumdrier and conveyed by a screw conveyor and fed to the vibrating screen.

A circular vibrating screen will screen the dust and sludge grains before the mixing and packing inpolybags for storage as the finished product and sold to buyer.

The product POME ( Palm Oil Mill Effluent Dried sludge )

The best prospects for POME as an animal feed because of its ability to substitute some of theexpensive imported components of feed meals and as a fertiliser, POME is a good source of major andminor nutrients.

Commercial value of POME fertiliser is about RM 500 per ton and sold to plantations, flower gardens,golf club application to turf etc.

A comprehensive analysis of dried sludge is given in the table below:

% % p.p.m.

Moisture 5 15 N 1.8 2.3 B 20

Ash 15 22 P 0.3 0.4 Cu 20 50Silica 7 10 K 2.5 3.2 Fe 3000-5000

Ether extract 11 13 Mg 0.6 0.8 Mn 50 70

Crude Fibre 11 14 Ca 0.6 0.8 Zn 20 100

Crude Protein 11 13


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In conclusion, we can say that dried sludge or POME improves the water availability,

carbon and nitrogen content, a provider for microbial activities in soil and a useful

source of plant nutrients for crops grown on normal or degraded land.

An added attraction of the system that is of growing importance, is the reduction in airpollution brought about by scrubbing of the boiler flue gas in the drier and finally its

yields an income as waste by-product.

4.3 THE ANAEROBIC & AEROBIC EFFLUENT TREATMENT SYSTEM.

The effluent is not toxic but it has a biochemical oxygen demand of above 25,000 (BOD)which makes it objectionable to fish life when introduced in relatively large quantities inwaterways and rivers.

The effluent treatment system developed for use in this project shall be of a modern biological

system, characterised by the anaerobic and aerobic process phases.

The total effluent from the proposed Oil palm mill process is approximately 0.6 tons per ton ffb. whichis made up of :

1. Sterilizer condensate2. Classification station dicharge of effluent3. Hydrocyclone / Claybath waste water4. Boiler blow down.5. Wash water, make up the balance.

The proposed Anaerobic & Aerobic effluent treatment system, shall be located within the oil palm millcomplex, that will require an area of approximately 100 m x 100m ( 1 ha ) and will consist of :

Sterilizer and Sludge oil recovery tank

Fat trap pits

Compressed air flotation unit.

Cooling & Mixing tanks

Anaerobic digesting tanks

Aeration reactors Solids removal clarifer Effluent metering.

Drying bed.

Final effluent holding tank

Monitoring & control system

Pumps and Air compressor

Inter-connecting piping, valves and fittings.

A schematic flow diagram and system calculations are enclosed in the appendix.


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The system will be monitored on site for pH, volatile fatty acids (VFA), total alkalinity (TA) andsolids contents whereas the more complex tests for BOD, COD, ammoniacal nitrogen (AN) and totalorganic nitrogen (TKN) analysis will be sent out to reputable laboratory for samples test.

The proposed effluent treatment system shall be procured from experience environmental controlequipment and system vendor who will guarantee its performance.

Full advantage is to be made of the decanter and the decanter solids dryer, design to dry all ofthe wet solid sludge removed from the system.

To this end part of the sludge outlet water is to be used at the screwpress, in place of the existingdilution water, to assist the transport of the crude oil to the clarification plant.

THE PROCESS

The effluent treatment system will include two main parts, the anaerobic section and aerobicstabilisation process before the final discharge of treated palm oil mill effluent onto the plantation forpalm tree irrigation.

The condensate discharge from the sterilizers is pumped to the post static clarifier an oil recoverysystem tank.

The oil skimmers removes the highly contaminated oil from both the clarifier and sludge decanter tankwhich is isolated in a special drumming holding tank.

The sludge will than pass through a CAF unit for the removal of disolved oils, grease by flotationprocess etc, before being fed to the cooling pond.

Every precaution is to be taken to ensure that this oil cannot and does not contaminate the crude oilsystem.

The objective is to reduce the loading of the effluent treatment system by the removal of the oil andsolid matter in sterilizer condensate at an early stage.

The deoiled sterilizer condensate is then discharged in to its own isolated effluent collection pitAnd overflow to the effluent treatment system.

The sludge slurry which are drained from the static clarifier and sludge decanter tank aredischarged to the drying bed or conveyed to the rotary sludge dryer for the drying process.

The anaerobic phase is favoured by higher temperature and the absence of air.

The influent from the sterilizer sludge pit and the clarification pit is to be pumped to the cooling pondand than to the mixing pond.

The anaerobic process start to take place in the first pond and end at the digester tanks.

There the complex organic materials are first solubilized by the extra cellular enzymes and thenconverted to volatile acids by acid producing bacteria.


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In the last methane fermentation phase the volatile acids are transformed to methane and carbondioxide.

The process is to be accelerated by the circulation of the bacteria laden sludge into the mixing pond ofthe material from the last digester tank.

The acidification process will have an HRT of 1 day. Effluent from the mixing pond is pumped fromthe collecting sump and into the digesters with a total HRT of more than 20 days.

The discharge from the overflow of the final anaerobic tank is to be discharge into an open pit andpumped into the aerobic reactor tanks for the extended aeration process equipped with over poweredmechanical aerators.

The overflow of the aerobic reactor tank, operating in tandem with a total HRT of 4 days will bepumped to the clarifier tank for the removal of solids.

The sludge scum is to be held back and removed from the ample sized sludge clarification tank.

Sludge accumulated at the bottom of the clarifier, and drying bed, are to be removed by the autoprogrammed system provided for the sludge removal proc

Documents

SYNOPSIS by Wambeck