14 cm

PALM OIL MILL

POCKETBOOK
Engineering & Processing Division
MPOB
8 cm
 EDITORIAL COMMITTEE

Datuk Dr. Ahmad Kushairi Din

Dr. Ahmad Parveez Ghulam Kadir
Dr. Astimar Abdul Aziz
Rohaya Mohamed Halim
Rusnani Abd Majid
Dr. Andrew Yap Kian Chung
Nu’man Abdul Hadi
Che Rahmat Che Mat

i
 FOREWORD

This Palm Oil Mill Pocketbook is published to provide guidelines on use of

data related to palm oil mill processing. It is hoped that the pocketbook is
useful as a quick reference to mill operators and engineers in their daily tasks.
Detailed information on specific topics pertaining to palm oil milling process
are found in a number of publications by the Malaysian Palm Oil Board
(MPOB).

Datuk Dr. Ahmad Kushairi Din

Director General
Malaysian Palm Oil Board (MPOB)
ii
 PREFACE

Palm oil mill design and operation involve multiple engineering calculations
requiring numerous data and formulas. This first edition of the Palm Oil Mill
Pocketbook provides a quick reference containing guidelines on palm oil milling
process handy for palm oil mill engineers. This pocketbook covers palm oil milling
processes, equipment and machineries operations, products properties, wastes/by-
products and characterisation of palm oil. For quick calculations of the palm oil
parameters and properties, conversion factors are also included.

iii
 Table of Content
Page Page
EDITORIAL COMMITTEE i EQUIPMENT AND MACHINERIES (cont.)
FOREWARD ii ▪ Sizing Steam Pipes 16
PREFACE iii ▪ Key Machinery Data 17
PROCESS 1 ▪ Starting Current – Squirrel Motors 18
▪ Palm Oil Mill Process Flow 2 ▪ Motor Speeds 19
▪ Approximate Milling Products 3 ▪ Sizing of Steam Distribution Pipe 20
▪ Typical Mass Balance for Palm Oil Mill 4 ▪ Calculation of Thresher Capacity 21
▪ Typical Sterilisation Cycle (3 Peaks) 5 ▪ Sizing of Fruits Elevator 22
▪ Oil Losses during Processing 6 ▪ Sizing of De-pericarper Fan 23
▪ Composition of Press Cake 7 ▪ Sizing of Separation Column 24
▪ Lifting Velocities 8 ▪ Sizing of De-stoner 25
▪ Sizing of Tanks at Clarification Station 26
EQUIPMENT AND MACHINERIES 9
PROPERTIES 27
▪ Calculation of Motor Amps 10
▪ Power Factor Improvement 11 ▪ Characteristics of Malaysian Planting
▪ Water / Pumping Data 12 Materials 28
▪ Water / Pumping - Brake Horse Power 13 ▪ Bulk Densities of Palm Products 29
▪ Compressed Air Pipe Line 14 ▪ Guideline for CPO Quality 30
▪ Pipe Capacity 15
iv
 Table of Content

Page
PROPERTIES (cont.)
▪ Fatty Acid Composition of CPO and PKO 31 Abbreviations:
▪ Density, Viscosity and Specific Heat of CPO 32 CPO = Crude palm oil
▪ Composition of Palm Kernel 33
DOE = Department of
▪ Composition of Palm Fruit 34 Environment (Malaysia)
▪ Characteristics of Palm Oil Mill Effluent 35
EFB = Empty fruit bunch
▪ Calorific Value of Various Oil Palm Biomass 36
FFB = Fresh fruit bunch
GENERAL INFORMATION 37 KER = Kernel extraction rate
▪ Limit of Effluent Discharge and Smoke NOS = Non oily solid
Emission 38 OER = Oil extraction rate
▪ Guidelines for Biogas Trapping and Methane PK = Palm kernel
Avoidance Facility 39 PKC = Palm kernel cake
▪ Production Cost for Palm Oil Mill (Estimated) 40
PKO = Palm kernel oil

CONVERSION OF UNIT 41 POM = Palm oil mill

▪ Typical Unit Conversion 42 POME = Palm oil mill effluent

v
PROCESS

1
 Palm Oil Mill Process Flow
Fresh Fruit Bunch (FFB)

Steam Sterilisation Condensate

Stripping Empty Fruit Bunch (EFB)

Fibrous Material
Sterilised Fruitlets
Steam Digestion

Water Crude Oil Press Cake

Pressing

Oil Screening Nut/Fibre Separation Fibre

Clarification Nut Drying

Desanding Purification Dirt Nut Cracking

Separation Drying Dry Separation Dry Shell

Waste water Wet Separation Wet Shell

Sludge
Crude Palm Oil
Kernel Drying Kernel
2
 Approximate Milling Products
* Percentage to FFB 20-23%
100%
FFB Steam

12-20% 60-80% 20-23%

Steriliser Fruitlet EFB
Condensate

5-11%
29-31% 60-65%
Hydrocyclone Water
Press Cake Diluted Crude Oil

4-8%
Washing 12-14% 14-15% 40-50% 19-21%
Water Nut Mesocarp Fibre Sludge Crude
Palm Oil

2-3% 6-8% 5-6%

Kernel Loss Shell Kernel

55 – 65%
Mill Effluent
3
 Typical Mass Balance for Palm Oil Mill

100 kg loss moisture

FFB 1000 kg Sterilisation Oil in condensate

1.5 kg
Sterilised FFB 898.5 kg
Water 155.8 kg
Stripping EFB Non-oil solid 71.4 kg
232.8 kg Oil 5.6 kg
Fruitlets 665.7 kg
Dilution water
137 kg Pressing
Crude oil Mesocarp fibre
Fibre Water 73.9 kg
Water 266 kg Depericarping Non-oil solid 97 kg
Sludge 179.7 kg Oil 8.8 kg
Non-oil solid 24 kg Clarification
294 kg
Oil 4 kg Water 14.7 kg
Shell
Nut Cracking Non-oil solid 57 kg
72.8 kg Oil 1.1 kg

Kernel Water 13.4 kg

Crude Palm Oil 225 kg
Non-oil solid 19.8 kg
67.2 kg
Oil 34 kg
4
 Typical Sterilisation Cycle (3 Peaks)

Table 1: Valve opening sequence

Time a
Step Inlet Outlet Exhaust
(minute)
S1 –De-aeration O O X 8
S2 – 1st peak O X X 18
S3 – De-aeration X O O 4
S4 – 2nd peak O X X 18
S5 – De-aeration X O O 2
S6 – 3rd peak
O X X 56
(Holding/Cooking)
Figure 1: Typical plot of 3-peaks sterilisation cycle S7 – Final blow X O O 2
Total time a 108
Note: ‘O’ means valve opened, ‘X’ means valve closed
Cycle Time = (Number of Steriliser) x (Capacity of Steriliser) a
Example of sterilisation cycle for illustration purpose

Mill Throughput

Cycle Time Cycle Time : Duration for one sterilisation cycle (from S1 to S7)
Interval Time = Interval Time : Duration between cycle
Number of Steriliser Idle Time : Duration when sterilisation is halted
Final Blow-off : Duration of steam exhaustion
Steriliser Time = Cycle Time - Interval Time Steam Built-up: Duration from zero to 40-50 psi

Cooking Time = Steriliser Time – Final Blow-off Time 5

 Oil Losses during Processing

Product Oil in product (%) Oil loss as % FFB

Empty fruit bunch 1.90 - 2.86 0.42 - 0.61
Steriliser condensate 0.07 - 0.64 0.10 - 0.47
Mesocarp fibre 4.00 - 6.20 0.45 - 0.76
Nuts 0.53 - 0.92 0.07 - 0.12
Sludge 0.72 - 1.00 0.32 - 0.60
Source: Corley RHV and Tinker PB (2016) The Oil Palm. Wiley Blackwell: 5th Edition

6
 Composition of Press Cake

Component % Component %

Fibre/nut 1.0 - 1.2 Oil in fibre (wet) < 5.0

Broken nut / total nut < 10 Oil loss in fibre (NOS) 7.0 - 9.5

Free broken kernel < 1.0 Moisture in fibre < 4.5

Cracked nuts < 7.5 Shell to kernel ratio 1.0 - 1.2

Free shell < 1.0 Moisture in kernel < 21

Note : NOS = Non oily solid

7
 Lifting Velocities

Component Lifting (m/s) Component Lifting (m/s)

Fine fibre <2 Small nut 16
Dry fibre 4 Large nut 24 - 28
Wet fibre 6 Average nut 20 - 24
Small shell 10 Small kernel 14
Large shell 16 Large kernel 20
Average shell 12 - 14 Average kernel 18

8
EQUIPMENT AND
MACHINERIES

9
 Calculation of Motor Amps

Given brake horse power (BHP), power factors, volts & efficiency

Calculate the current / phase of :

Single Phase Motor

Amps = BHP x 746 x 100

Volts x Efficiency x Power factor
3 Phase Motor

Amps = BHP x 746 x 100

Volts x Efficiency x Power factor x 1.73

10
 Power Factor Improvement
Multipliers to Determine Capacitor Kilovars Required for Power Factor Correction

Original Power Desired Power Factor

Factor 0.80 0.85 0.90 0.95 1.0

0.55 0.769 0.899 1.035 1.490 1.519

0.60 0.583 0.713 0.849 1.004 1.333

0.65 0.419 0.549 0.685 0.840 1.169

0.70 0.270 0.400 0.536 0.691 1.020

0.75 0.132 0.262 0.398 0.553 0.882

0.80 0 0.130 0.266 0.421 0.750

0.85 - 0 0.136 0.291 0.620

0.90 - - 0 0.155 0.484

Source: www.eaton.com
11
 Water / Pumping Data

(1) Velocity of water, V (ft / sec) = Gallons / min

(2 x D2)
(D = Pipe ID in inches)

(2) Weight of water (lbs) = D2 x L

(D = Pipe ID in inches, L = Pipe length in yards)

(3) Water hose power (WHP) = G x H

3,300
(G = Flow rate in gallons /min, H = Head in feet)

12
 Water / Pumping – Brake Horse Power (BHP)

BHP – Power required to drive the pump

BHP = WHP x 100 or 100 x G X H

E 3,300 E

Where, G = Gallons per minute

H = Total head of water in feet
E = Efficiency of the pump

Efficiency of the pump, E = WHP x 100

BHP

13
 Compressed Air Pipe Lines

Flow Capacity (L/s)

Applied Pressure (bar)

14
 Pipe Capacity

Pipe Diameter
Flow Velocity (m/s)

Flow Rate (m3/s) 15

 Sizing Steam Pipes
Velocity 25 m/s

Pipe Diameter (mm)

Pipe Diameter (mm)

Max. Capacity (kg/h)

Pressure (bar) 16
 Key Machinery Data
RPM & Size

Machinery RPM a Other Details a

Digester 25 L = 22 ft (6.7 m)

Thresher 19 L ≈ 22 ft (6.7 m)

Press cake conveyor 55 -

Clarifier stirrer 6 -

Nut polishing drum 15 6.0 m (L) x 2.16 m (D)

a RPM = round per minute, L = length, D = diameter
17
 Starting Current - Squirrel Cage Motors

Starting Torque % Starting Current %

Method of Starting
Full Load Torque Full Load Current
(1) Direct 100 - 175 450 - 750
(2) Star-delta 3-phase 33 - 55 150 - 250

(3) Series parallel- 2 phase 25 - 35 100 - 200

(4) Auto transformer 20 - 80 100 - 400

18
 Motor Speeds
(4 pole motors, frequency 50 cycles/sec)

Motor Speeds at Different Horse Power Ratings

Horse Power RPM a

1 to 5 1415
6 to 14 1425
15 to 40 1440
41 to 100 1460
a RPM = round per minute

19
 Sizing of Steam Distribution Pipe
(from Engine Room to Steriliser Station)

Mean = 0.4785 m3/kg

= 0.235 m (~10 inches) 20

Calculation of Thresher Capacity

21
 Sizing of Fruit Elevator

= 0.0087 m3 (8.7 L) per bucket = 1.83 kW

Assuming a service factor of 3,
Power required = 1.83 kW x 3 = 5.5 kW
22
 Sizing of De-pericarper Fan
Data available:
Mill capacity = 45 t/h
Mesocarp fibre to FFB = 19 %
Air density at 27°C = 1.1777 kg/m3
Air to fibre ratio = 4:1

Fibre production rate = Mill capacity x Fibre to FFB

= 45 t/h x 0.19 x 1,000 kg/t
= 8,550 kg/h

Air required = Fibre produced x ratio Volume of air required = Air required ÷ Air density
= 8,550 kg/h x 4 = 34,200 kg/h ÷ 1.777 kg/m3
= 34,200 kg/h = 29,040 m3/h

To determine the fan capacity, allowing 25% extra air losses and leakages, the minimum air volume
required hence fan capacity preferred to be:

Fan Capacity = Volume of air required x 125%

= 29,040 m3/h x 1.25
= 36,300 m3/h 23
 Sizing of Separating Column

Data available:
De-pericarp fan capacity = 24,000 m3/h Fan efficiency = 70 %
Separating velocity of nut = 8 – 12 m/s Service factor = 1.3
Average for 10 m/s = 36,000 m/h Pressure loss = 0.3

Calculation:
Column sectional area = fan capacity ÷ separating velocity
= 24,000 m3/hr ÷ 36,000 m/h = 0.816 m2
Length x width = L2 = 0.816 m2 L = 903 mm

Conveying trunk sizing at velocity= 25 m/s = 90,000 m/h

= 24,000 m3/hr ÷ 90,000 m/h = 0.266 m2
π r2 = 0.266 m2 r = 291 mm

Power = (fan capacity x pressure loss x service factor) ÷ (311 x fan efficiency)
= (24,000 m3/h) (0.3) (1.3) ÷ (311 x 0.7) = 42.99 kW Power = 43 kW

24
 Sizing of De-stoner
Data available:
Mill capacity = 30 t/h, Nut to FFB ratio = 12 %, Air to nut = 5:1, Separating velocity = 16 m/s, Service
factor = 1.3, Fan efficiency = 70%, Nut conveying velocity = 25 m/s, Air density = 1.777kg/m3 , Pressure
loss = 0.3

Fan capacity:
Nut production rate = 30 t/h x 12 % = 3,600 kg/h
Air required = (3,600 kg/hr) (5) ÷ (1.777 kg/m3) = 10,129 m3/h
Fan capacity = 125% of air required (air loss 25%) = 12,662 m3/h

Separating Column Size

Separating velocity = 16 m/s = 57,600 m/h
Column size = 12,662 m3/h ÷ 57,600 m/h = 0.2198 m2
Length x width = L2 = 0.2198 m2 L = 469 mm

Duct size:
Conveying velocity = 25 m/s = 90,000 m/h
Duct area = 12,662 m3/h ÷ 90,000 m/h = 0.1407 m2
π r2 = 0.1407, r2 = 0.04471, r = 211 mm

Power = (fan capacity x pressure loss x service factor) ÷ (311 x fan efficiency)
= (12,662 m3/h) (0.3) (1.3) ÷ (311) (0.7) = 22.68 kW Power = 23 kW 25
 Sizing of Tanks at Clarification Station
Assumption:
Mill capacity = 30 t/h,

Dilute crude oil = 65 % to FFB = (30 t/h) (0.65) = 19.5 t/h ≈ 20 t/h

Clarifier tank capacity:

Assume oil density = 860.7 kg/m3, 3 hours retention time & 1.3 service factor

Clarifier capacity = (20 t/h) (3 h) (1.3) ÷ (0.8607 t/m3) = 90.62 m3 ≈ 91 m3

Pure oil & sludge tank capacity:

Assume oil & sludge density = 860.7 kg/m3 & 1 hour retention time

Pure oil tank capacity = 40 % of crude oil = (20 t/h) (0.4) (1 h) ÷ (0.8607 t/m3) = 9.29 m3 ≈ 10 m3

Sludge tank capacity = 50 % of FFB = (20 t/h) (0.5) (1 h) ÷ (0.8607 t/m3)= 11.62 m3 ≈ 12 m3
26
PROPERTIES

27
 Characteristics of Malaysian Planting Material

Parameter Mean Parameter Mean

Mean fruit weight (g) 9.39 Oil / dry mesocarp (%) 76.87

Mean nut weight (g) 2.14 Oil / wet mesocarp (%) 47.29

Fruit / bunch (%) 65.71 Oil / bunch (%) 24.07

Mesocarp / fruit (%) 77.27 Kernel / bunch (%) 6.20

Kernel / fruit (%) 9.39 *OER [oil / bunch x (0.855)] (%) 20.56

Shell / fruit (%) 13.34

*OER = Oil extraction rate

28
 Bulk Densities of Palm Products

Component lb/ft3 kg/m3

Fresh fruit bunches 27 - 32 432 - 513
Fresh loose fruits 38 - 40 609 - 641
Sterilised & stripped bunch 40 - 44 641 - 705
Press cake, pc ex-press 29 - 31 465 - 497
PC entering de-pericarper 22 - 23 352 - 368
Nut 41 - 44 657 - 705
Dry kernel 39 - 40 625 - 641
Cyclone fibre 7-9 112 - 144
Ground cyclone fibre 11 - 12 176 - 192
Empty fruit bunch 19 - 21 304 - 336
29
 Guideline for CPO Quality

Parameter Mean value Parameter Mean value

Free fatty acids (%)a 3.2 (5.00 max.) Carotene (mg/L) 500 - 700

Moisture & dirts

0.2 (0.25 max.) Sterols (mg/L) 250 - 620
(%)a

DOBIa (2.3 min.) Vitamin E (mg/L) 600 - 1000

Iron (mg/L)b 4.8 (10 max.) Phospholipids (mg/L) 20 - 80

Peroxide value
Copper (mg/L)b 0.12 (0.5 max) 0.7
(meq/kg)
Anisidine value
Iodine value 52 4.7 30
(meq/kg)
a Traditional limit for trading purpose is shown in bracket
 Fatty Acid Composition of CPO and PKO
Composition (%)
Fatty acid
CPO PKO
Caproic (C6) - 0.1 - 0.5
Caprylic (C8) - 3.4 - 5.9
Capric (C10) - 3.3 - 4.4
Lauric (C12) 0.1 - 1.0 46.3 - 51.1
Myristic (C14) 0.9 - 1.5 14.3 - 16.8
Palmitic (C16) 41.8 - 46.8 6.6 - 8.9
Palmitoleic (C16:1) 0.1 - 0.3 -
Stearic (C18) 4.2 - 5.1 1.6 - 2.6
Oleic (C18:1) 37.3 - 40.8 13.2 - 16.4
Linoleic (C18:2) 9.1 - 11.0 2.2 - 3.4
Linolenic (C18:3) 0 - 0.6 -
Arachidic (C18:2) 0.2 - 0.7 -
31
 Density, Viscosity and Specific Heat of CPO

Temperature (oC) Apparent Kinematic Specific heat Specific heat

density viscosity (k.cal / kg oC) (k.J / kg oC)
(g/mL) (centipoise)

45 0.893 28.7 0.483 2.02

50 0.889 23.7 0.486 2.03
55 0.886 19.9 0.49 2.05
60 0.883 16.9 0.494 2.07
65 0.879 14.6 0.497 2.08
70 0.876 12.7 0.501 2.10
75 0.873 11.2 0.504 2.11
100 - 6.7 0.522 2.19

32
 Composition of Palm Kernel

Component Percentage (%)

Oil content 49.0

Protein (N x 6.25) 8.3

Crude fibre 8.1

Moisture content 6.5

Ash content 2.0

Carbohydrate content 26.1

33
 Composition of Palm Fruit

Component Moisture content Ash content Volatile matter content

(%) (%) (%)

Empty fruit bunch 67.00 4.60 87.04

Mesocarp fibre 37.09 6.10 84.91
Nuts 12.67 4.05 84.00
Palm shell 12.00 3.00 83.45
Palm kernel 6.31 1.49 78.20
Analysis based on dry basis

34
 Characteristics of Palm Oil Mill Effluent

Constituent Range (mg/L) Constituent Range (mg/L)

pH 3.3 – 5.7 (no unit) Phosphorus (P) 109 – 136
BOD 18,225 – 23,900 Potassium (K) 1,696 – 2,043
COD 45,818 – 54,861 Magnesium (Mg) 279 – 296
Suspended solid 24,846 – 30,920 Calcium (Ca) 282 – 290
Total solid 46,304 – 63,192 Iron (Fe) 65 – 67
Ammonical nitrogen 77 – 101 Manganese (Mn) 2.67 – 2.93
Total nitrogen 670 – 780 Copper (Cu) 0.80 – 0.90
Volatile fatty acid 1,057 – 1,073 Zinc (Zn) 1.24 – 2.72
Oil & grease 5,614 – 8,812 Nickel (Ni) 0.10 – 2.70
Source: Malaysian Palm Oil Board, 2017
35
 Calorific Value of Various Oil Palm Biomass

Component Gross Calorific Component Gross Calorific

Value (MJ/kg) a Value (MJ/kg) a

Empty fruit bunch 18.88 Spikelets 19.79

Mesocarp fibre 19.06 Oil palm fronds 15.72

Palm shell 20.09 Oil palm leaflets 15.72

Palm kernel cake 18.89 Oil palm trunks 17.47

a Calorific value based on dry basis

36
GENERAL INFORMATION

37
 Limit of Effluent Discharge and Smoke Emission
(DOEa Standard)
Parameter Max. limit Parameter Max. limit

BODb 100 mg/L Particulate matterc 400 mg/m3

Suspended solid 400 mg/L Carbon monoxide 1000 mg/m3

Oil & grease 50 mg/L Opacity 40 % black

(Ringlemann Chart
Ammonical nitrogen 150 mg/L No. 2 )
Total nitrogen 200 mg/L

pH 5-9
a Department of Environment (Malaysia)
b Sabah (critical areas): 20 mg/L; Sarawak (until March 2018): 50 mg/L
c 150 mg/m3 for new boiler effective June 2014; 150 mg/m3 for all mills effective June 2019

38
 Guidelines for Biogas Trapping and Methane Avoidance Facility

1. Mandatory installation of biogas a. New mills applying for new

capturing or methane avoidance license
facility (effective January 2014)
b. Existing mills applying for
throughput expansion
2. Example of biogas trapping a. Digester tank
facility
b. Covered lagoon

3. Example of methane avoidance a. Aerobic composting

facility
b. POME evaporation

39
 Production Cost for Palm Oil Mill (Estimated)
Particulars Mill Capacity (t/h)
20 30 45 60
Operation cost (RM/mt)
Water and power 6.30 5.30 4.00 3.20
Effluent treatment 0.30 0.35 0.45 0.50
Upkeep machinery & building 14.20 14.90 15.30 15.70
Laboratory 0.90 0.70 0.50 0.30
Storage 1.50 1.20 1.00 0.70
Dispatch 9.30 10.00 10.80 11.50
Overhead cost (RM/mt)
Supervision (executive & staff) 6.50 5.50 4.00 3.00
Office & administration 4.00 3.00 2.00 1.00
Labor recruitment 7.00 6.00 3.00 1.50
Other cost (RM/mt)
Depreciation 9.30 10.20 11.50 12.70
TOTAL (RM / mt) 59.30 57.15 52.55 50.10 40
CONVERSION OF UNIT

41
 Typical Unit Conversion

1 inch = 2.54 cm 1 ft = 0.3048 m 1 yard = 3 ft

1 mile = 1.609 km 1 n mile = 1852 m 1 acre = 4047 m2

1 barrel = 159 litres 1 lb = 0.454 kg 1 acre = 0.4 ha

1 US gal = 3.785 litres 1 tonne = 1000 kg 1 micron = 1/1000 mm

1 bar = 14.5 psi 1 poise = 0.1 NS/m2 1 kW = 1.34 Hp

1 bar = 14.5 lb/in2 1 bar = 100 kPa 1 calorie = 4.2 Joules

°C to °F: T(°F) = T(°C) × 1.8 + 32

°F to °C: T(°C) = (T(°F) - 32) / 1.8

42