TYPICAL MATERIAL BALANCE FOR A 90000 KG FFB/HR PALM OIL MILL [Assuming FFB Processed is all DXP (Tenera) oil palm] Sterilizer Condensate Oil Water Nos Total Loss (Oil to Nos)
% 0.89 93.32 5.79 100
Crude Oil Oil Water NOS Total
kg/hr 16963 8208 29549 36480
% 31 15 54 100
kg/hr 200.25 20997 1302.75 15000 9.76%
Fresh Fruit Bunches 90000 Composting Plant Sterilizer Condensate 22500 kg/hr
Sterilization Process
Steam Exhaust
Empty Bunch Oil Water Nos Total
Steam Input 24300 kg/hr Sterilized FFB 81000 kg/hr
10800 kg/hr Threshing Process
% 3.87 64.69 31.44 100
kg/hr 696.6 11644.2 5659.2 12000
Shredder Empty Bunches 18000 kg/hr
Steam Input 4500 kg/hr Screened Solids 2700 kg/hr
Sterilized Fruitlets 63000 kg/hr
To Boiler As Fuel Fibre + Kernel Loss 14850 kg/hr
Digestion Process
Diluted crude oil 57420 kg/hr
Digested Mash 70200 kg/hr
Undiluted crude oil 40950 kg/hr
Screening Process
Nut 14400 kg/hr
Pressing Process Dilution Water 16470 kg/hr
Screened Diluted Crude Oil 54720 kg/hr
Fibre + Shell + Kernel Loss 22860 kg/hr
Depericarping Process
Cracked Mixture 14400 kg/hr Nut Cracking Process
Light Shell & Dust + Kernel Loss 2700 kg/hr
Press Cake + Oil Loss 29250 kg/hr Water 10800 kg/hr Sludge 49050 kg/hr
Sand 490.5 kg/hr
Clarification Process
Dry Kernel 4770 kg/hr
Cracked Mixture 6930 kg/hr Shell + Kernel Losses 5310 kg/hr
Hydrocyclone Separation Process
Desanding Process
Clarified Oil 18270 kg/hr
Wet Kernel 1620 kg/hr
Pre-Cleaned Sludge 48560 kg/hr
Recycled Oil Sludge (L.P)
12600 kg/hr
Kernel Drying Process Vacuum Drying Process Production Oil 18000 kg/hr CPO Storage Tank
Purification Process
Centrifugal Separation Process- DECANTER
Purified Oil 18180 kg/hr Dirt & Water 90 kg/hr
Effluent (H.P) 32360 kg/hr
Production Kernel 4500 kg/hr Bulk Kernel Storage
Solid Waste 3600 kg/hr
To Effluent Treatment Plant Despatch Recycled Oil Sludge Oil Water Nos Total
% 30.7 61.8 7.5 100
kg/hr 3868 7787 945 8400
Sludge Oil Water NOS Total Effluent Oil Water Nos Total Loss (Oil to Nos) : 10.16%
% 3 12 85 100
kg/hr 1472 5886 41693 32700
% 0.71 95.48 3.81 100
kg/hr 230 30897 1233 23973
Shell + Kernel Loss 8010 kg/hr
Winnowing Separation Process
To Effluent Treatment Plant Hydrocyclone Waste 10800 kg/hr
Moisture 1890 kg/hr
Fresh fruit bunches Empty Bunches Liquid from EFB Press Potash (Bunch Ash) Fruitlets on bunch Fruitlets in Empty Bunch loss Digested Mesh (MPD) Press Cake Extraction CPO and Palm Kernel Wet Fibre & Nuts to depericarper Wet Fibre to Boiler Wet Nut Ex-Winnowing Cracked Mixture Kernel Shell Water for Hydrocyclone Clay for Claybath System Crude Oil diluted with water Clarified Crude Oil to Purifier Sludge to Decanter/ Separator
%/FFB Oil 100 25 25 0.75 8.3 0.25 0.5 66 24.25 2 0.735 64 23.52 26 1.56 38 21.96 25.75 1.55 12 1.08 13.75 0.47 12.5 5.5 7 80 5
F3 Water for Hydrocyclone 80 80kg 0 80 240 400 800 1,600 2,400 3,600 4,800 7,200 9,600 F4 Clay for Claybath system 5 5kg 5 15 25 50 100 150 225 300 450 600 G Crude oil diluated with water 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 6 G1 Clarified crude oil to Purifier 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, 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 Clean & dry CPO to stoarge tank 21.52 21.50 0.01 0.009 0 215 645 1,075 2,150 4,300 6,450 9,675 12,900 19,35 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 Solid waste fuel to boiler ( 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, 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 Boiler steam generation ( kg / ton FFB ) 660 660kg 660 1,980 3,300 6,600 13,200 19,800 29,700 39,600 59,400 79
L1 Turbine steam requirement 600 600kg 600 1,800 3,000 6,000 12,000 18,000 27,000 36,000 54,000 72,000 L2 Sterilisation steam requirement 540 540 kg 540 1,620 2,700 5,400 10,800 16,200 24,300 32,400 48,600 64,800 L3 Process heating steam requirement 120 120 kg 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400 M Wast water Effluent ( kg / ton FFB ) 1000 1000kg kg 1,000 3,000 5,000 10,000 20,000 30,000 45,000 60,000 90,0 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 Steriliser condensate 150 kg 150 450 750 1,500 3,000 4,500 6,750 9,000 13,500 18,000 M3 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 M5 From OTHERS & cleaning 100 kg 100 300 500 1,000 2,000 3,000 4,500 6,000 9,000 12,000 N Power generation ( kw / ton FFB / hr ) 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 PROCESS MASS FLOW AND LOSSES DURING PRODUCTION Based on
Water
Solid 48.5 18 7.4
6.25 0.664
37 1.121 35.88 10.9 15.2 10.82 3.6 0.76
7 0.212 6.79 14 0.84 13.29 6.48 12.53
Other
0 0.5 0 0 0 0 0 0 0 0 0 0 0
80
15,960 23,940 31,920 47,880 63,840 ,500 11,250 15,000 22,500 30,000 19,035 25,380 38,070 50,760 4,340 21,510 28,680
,300 6,450 9,675 12,900 19,350 25,800 90,000 120,000 00 63,000 84,000
600 12,900 19,350 25,800 38,700 51,600
10,125 13,500 20,250 27,000 9,800 29,700 39,600 59,400 79,200
5
00 36,000 54,000 72,000 24,300 32,400 48,600 64,800 400 7,200 10,800 14,400 000 30,000 45,000 60,000 90,000 120,000 ,500 66,000 3,500 18,000
