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INTRODUCTION cases the estate worker’s quarters also use
the RE generated by the mill, so RE is not
ost of the mill engineers, in something new for the palm oil industry.
particular the mechanical The palm oil mills also have diesel operated
engineers, may be quite familiar power plants as a back-up for use during
with the engineering thermodynamics non-processing hours for security lighting,
associated with the biomass fired boilers office equipment, workshop operation
that they operate daily in a palm oil mill. The and domestic consumption. The diesel
heat content in the biomass fuel expressed generator set load is considerably low
usually as the calorific value is transferred compared to the full load demand during
to the water in a boiler to generate the steam processing hours that may vary from 1 to
which in turn operates the steam turbine 1.5 MW in a mill capable of processing 60 t
wheels when undergoing an approximate fresh fruit bunches (FFB) per hour (usually
isentropic expansion. As the alternator called 60 tph mill).
is coupled to the turbine shaft through a
gear box, it can generate electricity that is The RE is also known as green energy.
sufficient to operate all the mill machinery Many people seem to be confused with
as well as the domestic supplies if worker’s the term RE. When the by-products of
quarters is located nearby. the processing operation like the biomass
are burnt, it still produces identical
As the energy produced is from carbon dioxide (CO2) that the fossil fuels
biomass, the mill operation is completely produces when combusted. It is exactly
powered by renewable energy (RE). the same molecule having one carbon
Palm oil mills had been (say for the past atom combined with two oxygen atoms. It
100 years) and still are processing fruit certainly does not exhibit green colour and
bunches using the self-generated RE. The its greenhouse gas (GHG) impact on the
staff and worker’s quarters and in some environment will remain exactly the same
as that being generated by other means.
* Malaysian Palm Oil Board, It will be helpful to emphasis this because
6 Persiaran Institusi, Bandar Baru Bangi, some non-technical decision-makers
43000 Kajang, Selangor, Malaysia.
E-mail: nravi@mpob.gov.my
seem to think that the CO2 released by the
combustion of biomass and fossil fuel have available rather than its heat content. Some
different molecular structure! of the salient points associated with palm
oil biomass-based power generation as
The biomass has heat energy which compared to conventional power stations
we do not feel when we touch them. The are discussed in this article.
heat value of a biomass can be easily
ascertained using calorimeters. There are POWER PLANTS IN POWER
many types of calorimeters known as STATIONS vs. PALM OIL MILLS
solution calorimeter, differential scanning
calorimeter (DSC), titration calorimeter, There is a vast difference between the heat
gas calorimeter and reaction calorimeter content of palm oil biomass and the fossil
for different applications. But generally for fuel that is used in power plants belonging
evaluating the calorific values of biomass to the Tenaga National Berhad (TNB) or
a bomb calorimeter is used. In a bomb Independent Power Plants (IPP). Although
calorimeter made of a steel chamber, a the palm oil mill power plant (POMPP) may
small sample of the fuel is combusted in look like a toy when compared to the TNB
an atmosphere of oxygen at high pressure. or IPP, the fundamental principles of power
The steel chamber is immersed in another generation remains very much the same
closed chamber containing water so that the except perhaps the palm oil mill managers
heat can be absorbed by the water during have a much wider scope of responsibilities
the complete combustion of the sample of than just operating the power plant.
the fuel. During the combustion process,
the chamber pressure and temperature As I had the opportunity to work in both
may reach very high values and as such the Lembaga Letrik Negara (LLN) now
the chamber must be able to withstand the renamed as TNB thermal power stations
required conditions. and the palm oil mills, I may be in a position
to draw some comparisons between the
The calorific values of raw biomass is two systems based on my specific scope of
very much lower than that of fossil fuels work. This is purely a subjective discourse
like coal as for example, the moisture based on my experience with events that
content of empty fruit bunches (EFB) can took place about half a century back in time
be as high as 70% and that of fibre which at LLN and the current experience in the
has about 40% moisture. Reduction of the palm oil mills. Some of the comparative
moisture content of 15 t of EFB from 70% responsibilities of a mill manager and a
to 30% by drying would entail evaporation station superintendent are given in Table 1.
of 6 t of water per hour at atmospheric
pressure. As the enthalpy of evaporation Mill Manager’s Responsibilities
(latent heat) at atmospheric pressure is 2258
kJ kg-1, the drying of EFB to make it a usable As can be seen in Table 1, the mill
fuel will need approximately 13.5 MJ of managers have a number of additional
heat per hour! This factor alone will make responsibilities compared to their
EFB one of the worst fuels in the world. counterparts in power plants. The palm oil
The cost of transportation of the water in millers use the steam not only for power
the EFB will not make it financially viable generation but for processing the crop as
if we consider transporting the EFB from well. The operational system comprises an
several mills to a central power station assortment of processing stages before the
for grid connected power generation. The final product is ready for shipping. Most of
relevant authorities or investors, who want the miller’s time and energy are focussed
to venture into power generation using on refining the processing techniques
EFB, should consider these crucial issues as the product quality is an important
as they may only focus on the mass of EFB target for marketability of the products.
It is possible that about 90% of all millers’ so based on the attitude of the mill owners
attention will be directed towards product or top management. It is not difficult for
quality, process losses, environment issues, a thermodynamist to fathom the criminal
sustainability issues and social welfare. As waste of steam in certain stages of the pro-
a consequence, the efficient utilisation of cess line. The areas that offer great oppor-
steam and power generation aspect of the tunities to save the wasted steam and use it
milling operation in a palm oil mill takes for the benefit of humanity are still awaiting
the backstage leading to the pathetic abuse the right opportunity for the right Malay-
of energy in palm oil mills. sian investor to coordinate with our com-
petent steam engineers and set up energy
THERMODYNAMICS APPLIED TO saving systems before someone from some
PROCESS OPERATIONS remote corner of the earth start selling the
product to Malaysia.
Energy Wastage
Application of Thermodynamics
As mentioned earlier, the steam utilisa-
tion segment of a palm oil mill is a grossly Application of engineering thermody-
under-explored area and is likely to remain namics in a palm oil mill are seen in the
POMPP, sterilisation station and other heat in tapping this large potential of energy. If
exchange equipment like kernel silo heater, a mechanical engineer from overseas visit
oil tanks, process water tanks, sludge oil our palm oil mills and observe a substantial
storage tanks, crude palm oil storage tanks, amount of steam blowing out of steam
etc. This clearly indicates that the mill engi- traps, leaky seam joints, isolating valves
neers should be fairly well-versed with en- and relief valves he will certainly have a
gineering thermodynamics associated with bad impression of the professionalism of
steam, a very interesting part of mechanical the engineers operating the mills. Most
engineering. Currently the mill engineers of these leaks can be easily prevented by
are expected to process whatever crop con- tightening the nuts on the flange coupling
taminated with stones, sand and other and yet these are not attended resulting in
trash that accompany them are brought unnecessary waste of steam.
to the mill and try to extract more oil than
what the fruit bunches contain. The de- Lack of Preventive Maintenance
mand for increasing the oil extraction rate
(OER) of the mill by the mill owners or the Our observation of the maintenance
top management is exerting an unreason- work carried out on steam traps in palm
able pressure on the mill personnel as OER oil mills are as follows. None of the mills
is solely dependent on the oil content of the we visited had a routine maintenance pro-
bunches that is clearly under the jurisdic- gramme associated with steam traps. Most
tion of the plantation managers. of the steam traps were never overhauled
ever since the mills were commissioned.
Steam Leakage Common sense dictates that any mechani-
cal machinery must be maintained on a rou-
The mill engineers should also try to tine basis at least once a year, if we want the
improve processing techniques associated machinery to perform efficiently. If the mill
with steam by applying the thermodynamic personnel have no time to carry out this one
principles wherever it is required. A me- day job they may outsource experts to carry
chanical engineer with sound knowledge out this job. It is worth the while as a lot of
of thermodynamics will not allow steam to steam can be saved, bearing in mind that to
blow out of steam joints or the steam traps. produce steam which itself is a GHG the bi-
When the MPOB code of practice (CoP) au- omass combustion involved for its produc-
ditors audit the mills, a common sight in al- tion also releases CO2, which also is a GHG.
most all mills is the free issuance of steam
from steam traps. When the auditors query Energy Wastage Evaluation
on whether the steam traps are working,
the answer is always “yes” based on the Even the exhaust steam released from the
considerable amount of steam visibly seen steriliser that is responsible for causing so
blowing out of the steam traps! This cer- much of noise pollution reaching perhaps
tainly is a sad state of affairs as the engi- 200 decibels can be effectively curtailed. For
neers do not seem to know how to diagnose this, the exhaust may be re-routed through
the defect in a faulty steam trap. They do the condensate line or discharged into an
not even realise the fact that the function of open chamber from where its enthalpy of
a steam trap is to trap the steam and allow condensation could be recovered for prod-
it to blow out freely. uct drying operations. The blown out steam
from the sterilisers still has a sizable quanti-
Apart from the steam trap losses a ty of heat that is currently discharged func-
significant amount of heat is wasted from tioning literally as a device meant for dis-
the leaky steam pipe joints in palm oil mills trict heating, which we can do without as
and this will paint a poor picture of our mill we are already blessed with an abundant
engineers who do not seem to be interested supply of sun’s heat throughout the year.
Let us now make some quantitative oil industry will be left out for the local
analysis of the heat lost in the steam exhaust industry management to handle.
in a 60 tph mill steriliser with an operating
cycle spanning 90 min ( door close pressure But a specialised body is yet to evolve
cook and door open time) similar to the for addressing such issues either in
home pressure cooker. For the purpose of Malaysia or Indonesia who are the major
simplification, the calculation is based on producers of palm oil. Most developing
an hourly data as shown in Table 2. countries find it easy to copy systems
prevailing in developed nations as then
This is a criminal waste of steam that no we do not have to re-invent the wheels.
one seem to worry about. This is indeed a That is fine but the question arises as to
steam engineer’s dilemma. The reasons are why the developed nations should make
easy to find. The progressive thinking of efforts to develop something that they do
the human race and their genuine concern not need. In such cases, we have to take the
on diminishing fuel reserves, conservation initiative and move forward. Based on the
of energy, global warming leading to current discussion, the palm oil industry in
adverse GHG impact on environment Malaysia must establish a centre to address
are in place. There are also a number of the important issues related to upgrading
successfully established mechanisms for milling operation so that they are on par
monitoring and enforcing the major well with other food processing industries from
known and popular energy guzzlers and all angles including efficient and profitable
pollution generators like power stations use of resources.
and transport industry. However, the odd
ones like the non-efficient steam generation MASTERING MONGANA REPORT,
and its usage in palm oil mills, being not A COMPETENT MILLER BORN?
widely established, may not appear in the
global energy abuse radar screen. In such A palm oil miller’s encyclopedia is the
situations, the monitoring mechanisms Mongana Report, a very useful report
must necessarily evolve locally as global that was published in 1955 (it is now
bodies will only look at common issues the property of MPOB, a gift from Lever
such as sustainability and environmental Brothers). This magnificent report is the
impact but steam wastage and its efficient outcome of a research project conducted
utilisation in specific applications like palm by a team of scientists from the Institute for
Note: FFB - fresh fruit bunch. tpm – total productive maintenance. tph – tonne per hour.
stem from the miller’s poor knowledge of eration coupled with low specific steam
thermodynamics. The sterilisers of all palm consumption.
oil mills are fitted with pressure gauges
that generally give a satisfactory reading of There are many options available in this
three bar if the boiler capacity is sufficient area. Boilers may opt for medium pressures
to cater for the mill. When anyone taking like 50 bar or even higher with high super
a quick look at the steam table and see the heat of say 500°C so that the Rankine work
saturation temperature corresponding to done by the turbine exceeds 10 MW in a
this pressure as 143.6°C, he has good rea- 60 tph mill. This is possible and at higher
son to be satisfied as the optimum required superheat temperatures the specific steam
temperature is 130°C. If a thermometer had temperatures can drop to even 5 kg steam
-1
been installed on the sterilisers the engi- per kWh compared to the 25 kg kWh in
neers would have realised that something the conventional non-condensing turbines
was not right. The temperature shown currently used in palm oil mills.
corresponds to a much lower steam pres-
sure as the air content in the steriliser has There will be some changes in the design
reduced the effective steam pressure and of the turbines as the single Curtis wheel
its corresponding saturation temperature will be replaced by a six stage reaction
according to Dalton’s Law of Partial Pres- turbine. Adequate steam bleeding points
sures. The mills must find an effective way also will be needed with steam re-heating if
to reduce the air contained in a steriliser so necessary, to shift the superheat state point
that the sterilisation temperature remains towards far right so that after the isentropic
above 130°C. expansion the exhaust state point is out of
the wet region. There are many ways to
THE STEAM TURBINE achieve the industries’ objectives.
Note: ∆ T - temperature rise. FFB – fresh fruit bunch. CPO – crude palm oil. tph – tonne per hour.
Palm Oil Mill Heat Balance waste compared to its costly transportation
to the dumping site. The system of steam
The turbine exhaust steam is admitted exhausting to the atmosphere as chosen at
to a steam receiver drum having a diameter that time was the cheapest way to dispose
of about 2 m and a length of about 6 m it. Noise pollution from factories was not
having a volume of 18.84 m3. However, an unusual phenomena or a Department of
considerable variations can be seen in Environment (DOE) issue at that time. Now
different mills. The 40 t of steam exhausting requirements have changed but the millers
form the turbine at 4 bara will have a are not ready yet to responding fast enough
specific volume of 0.4623 m3 kg-1 occupying to the new requirements.
a volume of 18.49 m3. The steam receiver
volume is just sufficient to receive the Palm oil mills in Malaysia are slow to
exhaust steam form the turbine when the embark on projects that will improve the
mill is processing 60 tph of crop. When there efficient utilisation of heat. A good example
is a mill breakdown and the mill throughput
drops to half there will be a corresponding
drop in generator load. But if the mill
continues to operate the sterilisation station
at full capacity, the steam pressure will drop
resulting temperature drops in all stages of
processing ending up in process loss.