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TYPICAL MATERIAL BALANCE FOR A 90000 KG FFB/HR PALM OIL MILL

[Assuming FFB Processed is all DXP (Tenera) oil palm]

Sterilizer Condensate % kg/hr


Oil 0.89 200.25 Fresh Fruit Bunches
Water 93.32 20997 90000
Nos 5.79 1302.75 Composting Plant
Total 100 15000
Loss (Oil to Nos) 9.76% Sterilizer Condensate Sterilization Process Steam Input
22500 kg/hr 24300 kg/hr

Crude Oil % kg/hr Steam Exhaust Sterilized FFB


Oil 31 16963 10800 kg/hr 81000 kg/hr
Water 15 8208
NOS 54 29549 Threshing Process Shredder
Total 100 36480 Empty Bunches
18000 kg/hr

Steam Input Sterilized Fruitlets


4500 kg/hr 63000 kg/hr
Fibre + Kernel Loss
Screened Solids Digestion Process 14850
2700 kg/hr
Digested Mash
Diluted crude oil Undiluted crude oil 70200 kg/hr
57420 kg/hr 40950 kg/hr
Screening Process Pressing Process Depericarping Process
Dilution Water Press Cake + Oil Loss
Screened Diluted Crude Oil 16470 kg/hr 29250 kg/hr
54720 kg/hr

Sludge Sand
49050 kg/hr 490.5
Clarification Process Desanding Process

Clarified Oil Recycled Oil Sludge (L.P) Pre-Cleaned Sludge


18270 kg/hr 12600 kg/hr 48560

Vacuum Drying Process Purification Process Centrifugal Separation


Purified Oil Process- DECANTER
Production Oil 18180 kg/hr
18000 kg/hr Effluent (H.P) Solid Waste
Dirt & Water 32360 kg/hr 3600
CPO Storage Tank 90 kg/hr
To Effluent Treatment Plant

Recycled Oil Sludge % kg/hr Sludge


Oil 30.7 3868 Oil
Water 61.8 7787 Water
Nos 7.5 945 NOS
Total 100 8400 Total

Effluent
Oil
Water
Nos
Total
Loss (Oil to Nos) : 10.16%
Empty Bunch % kg/hr
Oil 3.87 696.6
Water 64.69 11644.2
Nos 31.44 5659.2
Total 100 12000

To Boiler As Fuel

Fibre + Shell + Kernel Loss


kg/hr 22860 kg/hr

Nut Cracked Mixture Light Shell & Dust + Kernel Loss Shell + Kernel Loss
14400 kg/hr 14400 kg/hr 2700 kg/hr 8010 kg/hr
Nut Cracking Process Winnowing Separation Process

Cracked Mixture
Water 6930 kg/hr
10800 kg/hr Shell + Kernel Losses
Dry Kernel 5310 kg/hr
kg/hr 4770 kg/hr Hydrocyclone Separation Process To Effluent Treatment Plant
Hydrocyclone Waste
Wet Kernel 10800 kg/hr
1620 kg/hr
kg/hr
Kernel Drying Process Moisture
1890 kg/hr
Production Kernel
4500 kg/hr
Bulk Kernel Storage
kg/hr

Despatch
% kg/hr
3 1472
12 5886
85 41693
100 32700

% kg/hr
0.71 230
95.48 30897
3.81 1233
100 23973
Nos) : 10.16%
%/FFB Oil
Fresh fruit bunches 100 25
Empty Bunches 25 0.75
Liquid from EFB Press 8.3 0.25
Potash (Bunch Ash) 0.5
Fruitlets on bunch 66 24.25
Fruitlets in Empty Bunch loss 2 0.735
Digested Mesh (MPD) 64 23.52
Press Cake 26 1.56
Extraction CPO and Palm Kernel 38 21.96
Wet Fibre & Nuts to depericarper 25.75 1.55
Wet Fibre to Boiler 12 1.08
Wet Nut Ex-Winnowing 13.75 0.47
Cracked Mixture 12.5
Kernel 5.5
Shell 7
Water for Hydrocyclone 80
Clay for Claybath System 5
Crude Oil diluted with water
Clarified Crude Oil to Purifier
Sludge to Decanter/ Separator

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
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 Other
48.5
18 6.25
7.4 0.664 0
0.5
37 7 0
1.121 0.212 0
35.88 6.79 0
10.9 14 0
15.2 0.84 0
10.82 13.29 0
3.6 6.48 0
0.76 12.53 0
0
0
0
80
5

40 15,960 23,940 31,920 47,880 63,840


0 7,500 11,250 15,000 22,500 30,000
90 19,035 25,380 38,070 50,760
5 14,340 21,510 28,680

0 4,300 6,450 9,675 12,900 19,350 25,800


000 90,000 120,000
2,000 63,000 84,000

200 21,600
0 8,600 12,900 19,350 25,800 38,700 51,600
750 10,125 13,500 20,250 27,000
0 19,800 29,700 39,600 59,400 79,200
,000 36,000 54,000 72,000
00 24,300 32,400 48,600 64,800
5,400 7,200 10,800 14,400
0,000 30,000 45,000 60,000 90,000 120,000
49,500 66,000
13,500 18,000

9,000 12,000
0 2,250 3,000