CHAPTER ONE

INTRODUCTION

1.1BACKGROUND

Palm trees are one of the major plant crops produce in Ghana. It has a lot of uses from the roots through to
the stem, leaves and the fruits. The major product obtain from the palm tree is oil. The oil which is obtained is
mainly from the palm fruits. At the matured stage, the palm tree produces fruits which are contain in bunches.
The bunches are harvested and transported to an oil extraction mill for the oil to be extracted from the fruits

At the extraction mill, oil extracted from the freshy fruit (mesocarp) is called Crude palm oil and oil
extracted from the kernel is called palm kernel oil. In other to produce a crude palm oil, the harvested bunches
go through a number of processes and equipments as indicated in the flow chart below.

Figure 1.1 (process flow chart for production of

oil)

From figure 1.1, the fruits from the digester are

transported to the press where the digestered
fruits are pressed to separate the liquor from the
pressed cake. This project will look at
designing a pulp press for the process.

1.2 OBJECTIVES

1.2.1 MAIN OBJECTIVE

 The main objective of this project is to design a motorized hydraulically operated press for extracting
crude palm oil from palm fruits.

1.2.2 SPECIFIC OBJECTIVES

 Design a motorized hydraulic press with a capacity of about 8,700 kg/hr.

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  The equipment should be able to withstand high operating pressure.

 The materials of construction should be non corrosive and ductile to prevent easy wearing out.

 The equipment should be operated in a continuous process

1.3 SCOPE

This project will focus on the design of a motorized hydraulic pulp press with a specified cage capacity of
about 9,400 kg/hr. The materials for the construction and sizing of the various parts of the equipment will be
looked at.

Also, the operation mechanism in terms of applied pressure and stress, and the energy demand of the
equipment will be of great interest.

CHAPTER TWO
LITERATURE REVIEW

2.1 MAIN TYPES OF PULP PRESS

There are two distinct types of pulp press based on the methods of extracting oil from the digested material.
The mechanical press which uses the ‘dry’ method and the hydraulic press which uses hot water to leach out
the oil (‘wet’ method).

In the ‘dry’ method the objective of the extraction stage is to squeeze the oil out of a mixture of oil, moisture,
fiber and nuts by applying mechanical pressure on the digested mash. There are a large number of different

2
types of presses but the principle of operation is similar for each. The presses may be designed for batch
(small amounts of material operated upon for a time period) or continuous operations.

2.2 BATCH PRESS

In batch presses, material is placed in a heavy metal ‘cage’ and a metal plunger is used to press the material.
The main differences in batch press designs are

a) The method used to move the plunger and apply the pressure

b) The amount of pressure in the press, and

c) The size of the cage. (cornish, 1991)

The plunger can be moved manually or by a motor.

Different designs use either a screw thread (spindle press) or a hydraulic system (hydraulic press) to move the
plunger. Higher pressures may be attained using the hydraulic system. Spindle press screw threads are made
from hard steel and held by softer steel nuts so that the nuts wear out faster than the screw. These are easier
and cheaper to replace than the screw.

The pressure should be increased gradually to allow time for the oil to escape. Heavy plates’ are inserted into
the raw material to prevent trapped oil at the centre of material with great depth.

Hydraulic presses are faster than spindle screw types and powered presses are faster than manual types. Some
types of manual press require considerable effort to operate and do not alleviate. (Afr. J. Environ. Sci.
Technol, 2009)

2.3 CONTINUOUS SYSTEMS

These consist of a cylindrical perforated cage through which runs a closely fitting screw. Digested fruit is
continuously conveyed through the cage towards an outlet restricted by a cone, which creates the pressure to
expel the oil through the cage perforations (drilled holes). Oil-bearing cells that are not ruptured in the
digester will remain unopened if a hydraulic or centrifugal extraction system is employed. Screw presses, due
to the turbulence and kneading action exerted on the fruit mass in the press cage can effectively break open
the unopened oil cells and release more oil. These presses act as an additional digester and are efficient in oil
extraction.

Moderate metal wear occurs during the pressing operation. The rate of wear depends on the type of press,
method of pressing, nut-to-fiber ratio, etc. Below are some examples of pulp pressers.

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Figure 2.1 Hydraulic Press (manual)

Figure 2.2 Manual Vertical Press

Figure 2.3 Motorized horizontal screw Press

(source: www.malysiapalmproject.com)

CHAPTER THREE
MATERIAL AND ENERGY BALANCE

3.1 MATERIAL BALANCE;

Pulp, 1 = 8,593.2 kg/hr

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 0.21 w/w oil T1 =110oC
0.08 w/w water
0.71 w/w solids

PULP PRESS
Boiled water, 2 = 740.37kg/hr Pressed Liquor, 3 = 4,387.77 kg/hr
T2 = 100oC 0.4 w/w oil T3 = 95oC
0.5 w/w water
0.1 w/w solids

Pressed Cake, 4 = 4,946 kg/hr

0.01 w/w oil T4 = 90oC
0.09 w/w water
0.9 w/w solids
(Ind. Proc. and the Environ. Hnd bk 3, Resh. Juaben, 2012)

Overall material balance:

Material input = material output

1 + 2 = 3 + 4 ……………………………………………….. (3.1)

1 = 8,593.2 kg/hr

2 = 740.37 kg/hr

8,593.2 + 740. 37 = 3 + 4

9,333.57 = 3 + 4 ………………………………………………. (3.2)

Oil component balance:

0.21 (8,593.2) = 0.4 3 + 0.01 4

1,804.57 = 0.4 3 + 0.01 4 ………………………………….. (3.3)

Solving equation (3.2) and equation (3.3) simultaneously,

0.01 3 = 93.34 – 1,804.57 + 0.4 4

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0.39 3 = 1711.23
0.39 0.39

3 = 4,387.77kg/hr

1804.57 = 0.4(4387.77) + 0.01 4

1804.57 = 1755.11 + 0.01 4

4 = 4,946.00 kg/hr

3.2 ENERGY BALANCE

Since the press is an open system, the open system energy balance equation is used, and is give as;

∆ + ∆Ėk + ∆ĖP = - s ……………………………………… (3.4)

The work done Ws, is determined by,

P = 2π/60 x Motor speed x Torque ………………………………….. (3.5)

Pinput = 22.0kW

Speed = 1750rpm

Torque, T = force x Distance

Force = 1 x acceleration due to gravity

Force = 8,593.2kg 9.81m 1hr

hr s2 3,600s

Force = 23.42 kgm/s3

Distance cooked fruits travel in the unit = 7.02m

Torque = 23.42 x 7.02 = 164.41 kgm2/s3 (Nm/s)

From equation (5) by substitution,

P = 2π/60 x 1750 x 164.41 = 30141.83 J/s

Therefore the work done on the unit, W = 30.1418kW

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For the change in enthalpy;

∆ = Ĥ- Ĥ ………….…………………………………. (3.6)

Ĥ= 1 1 + 2 2……………………………………………..… (3.7)

Ĥ= 3 3 + 4 4 ………………………………………….…… (3.8)

For enthalpy of the boiled water,

Ĥ2L = 419.10 kJ/kg at 100oC (from steam tables)

2 2 = 740.37 kg 419.10 kJ 1hr

hr kg 3600s

2 2= 86.19 kJ/s

For enthalpy of the pulp,

1 1= 1 pulp dT

Cppulp = 0.6987kJ/kg.K

1 1 = 1 dT
.

1 1 = 8,593.2kg 0.6987kJ (110-25)+273.15K 1hr

hr kg.K 3600s

1 1= 597.32 kJ/s

Substituting into equation (3.7)

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 Ĥ = 597.32 + 86.19 = 683.51 kJ/s

For enthalpy of the pressed cake,

4 4 = 4 cake dT

Cpcake = 0.9664kJ/kg.K

4 4 = 4 dT
.

4 4= 4946kg 0.9664kJ (90 - 25) + 273.15K 1hr

hr kg.K 3600s

4 4= 448.97 kJ/s

For enthalpy of the pressed Liquor,

3 3= 3 dT
liquor

Cpliquor = XoilCpoil + XH2OCpH2O + XsolidsCpsolids ………………… (3.9)

Xoil = mass fraction of palm oil = 0.4

XH2O = mass fraction of water = 0.5

Xsolids = mass fraction of solids (pulp) in the liquor = 0.1

From tables,

Cppalm oil = 1.6694 kJ/kg.K

CpH2O = 4.23 kJ/kg.K at 95oC

Cpsolids = 0.6987kJ/kg.K

Substituting into equation (3.9)

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Cpliquor = (0.40 x 1.6694) + (0.50 x 4.23) + (0.1 × 0.6987) = kJ/kg.K

Therefore the heat capacity of the pressed liquor is 2.8526kJ/kg.K

3 3 = 3 dT
.

3 3= 4387.77kg 2.8526kJ (95-25) + 273.15k 1hr

Hr kg.K 3600s

3 3= 1193.071 kJ/s

Substituting into equation (3.8)

Ĥ = 1193.071 + 448.97 = 1642.041 kJ/s

Substituting into equation (3.6),

∆ = 1642.041 – 683.51 = 958.531 kJ/s

Since there is no rise and fall of material in the unit ∆EP = 0

Since change in kinetic energy is negligible, ∆EK = 0

Substituting calculated values of ∆ and s into equation (3.4),

= 958.531 + 30.1418 = 988.673 kJ/s

Therefore the energy loss by the screw press, = 988.673 kW

CHAPTER FOUR
DESIGN AND CONSTRUCTION

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4.1 CONTRUCTION
The various parts of the motorized hydraulic press is listed in the table below;

Table 4.1: Parts of a Motorized Hydraulically Operated Palm Oil Press

S/N PARTS
1 Hydraulic tank
2 Hydraulic tank support
3 Ram support The construction of the various
4 Pressure hose separate components of the press is
5 Angle bar discussed below;
6 Frame
7 Ram rod (piston)
8 Piston palisade Frame: Weight of the electric
9 Pressing plate motor, the valve, the hydraulic
10 Cage pump, the hydraulic ram and its
11 Collector supports, hydraulic tank is
12 Hydraulic pump considered in designing the frame.
13 Electric motor U-channel mild steel is used for the
14 2-way Valve frame for strength and rigidity due
15 Spout to the load of the component parts
and pressing pressure. The frame is of triangular shape. Sub-supports like that for electric motor, ram and
hydraulic tank are welded to the main frame to provide support for the various components. 25.5 inch angle
bar of thickness 0.867 m is used to fabricate rectangular seats for the electric motor and the hydraulic tank.
Two cylindrical pipes of 7.820m length, 1.020 m diameter and 1.156m thickness is used to support the ram

Collector: The collector is a cylinder of diameter 11.220m, height 2.210 mm and thickness 0.85m with one
end closed for collecting the oil from the cage during pressing

Spout: This was cut from a galvanized pipe of diameter and thickness 40 and 2 mm respectively. This was
connected to the opening in the collector by welding.

Cage: This is made from sheet metal of thickness of 0.85m. Thickness of 0.85m is used to withstand the
internal pressure that is built up due to the pressing pressure. The extraction cuts on the cage were perforated
round staggered of diameter of 0.85m throughout the circumference of the cage. It is made of two halves,
joined with hinges. The diameter of the press cage is 6.8m with a height of 11.05m
Pressing Plates: The pressing plate is a steady steel disc of 0.136m thickness. Cut to circular shape of
diameter 6.46m. Welded to the center is a nut for attachment to the ram.

Lock pins: These are made from mild steel rod of diameter 0.17m. They are made in form of a “Tee” shape
by welding. These are locks for the cage before loading the digested palm pulp into cage for pressing.

Hydraulic Tank: 0.034m thick mild steel sheet is used for the hydraulic tank of size 3.4 x 2.72 x 5.1 m. A
neck is welded to the top, through which the hydraulic fluid can be poured into the tank. An outlet pipe of
0.34m in diameter is welded to the bottom to serve as inlet to the pump. Also a diameter 0.289m bolt and nut
is weld to the bottom for draining should there be the need for the tank to be dismantled.

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Connecting Hoses: The connecting hoses are pressure hoses in order to withstand the pump pressure and ram
pressure.

2-way Valve: The valve required in order for the machine to perform effectively is a two way valve. This is to
enable the fluid to move to the upper and lower chamber of the ram. The 2-way valve pumps the hydraulic oil
to and from the hydraulic tank. It also controls the flow of the fluid pressure. The valve controls the down
movement of the ram during pressing operation and up movement after the pressing operation. It is controlled
by the lever of the control valve

Hydraulic Pump: Hydraulic pumps are positive displacement pumps that pumps fluid to create a non-
pulsating pumping action. Hydraulic pumps are able to pump at high pressures and excel at pumping high
viscosity liquids efficiently. The pump capacity is 30.6 kW. Pump pulley diameter is 2.125m. The hydraulic
ram is controlled by a hydraulic pump.

Electric Motor: Electric motor is the one of common device for rotating equipment and it is useful for
smooth operation and makes our process faster and more efficient. 7.5 Hp motor capacity and Speed of 1750
rpm is considered proper and suitable for the load, speed and the whole system. Motor pulley diameter is 1.9m

Hydraulic Ram: A 510psi (3516.45KN/m2) capacity hydraulic ram is used for the palm oil press. The
diameter of the ram is 4.25m.

4.2 ENGINEERING DRAWING

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Figure 4.1 Diagram of the Motorized Hydraulically Operated Palm Oil Press (numbering of the diagram is
based on the arrangement of the parts on table 4.1)

Figure 4.2 Orthographic Drawing of the Motorized Hydraulically Operated Palm Oil Press

4.3 DESIGN CALCULATIONS

Determination of Hydraulic Pressure of the Palm Oil Press:

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The diameter of the ram is given as 4.25m. The diameter of the press cage is 6.8m; hence in order to produce
the required pressure on the fruit, the hydraulic pressure (Ph) must be:

Ph =

(Asiedu, 1989)

Ph =

= 3516.45 × m2

The Power Drive Mechanism

Proper calculation is done to avoid overload, and motor burn due to wrong estimation of the load. The power
transmission of the machine is by pulley and belt arrangement as shown in Figure 3.3. The speed of the pump
depends on:
i. The speed of the electric motor.
ii. The diameter of the pulleys.

Figure 3.3 Arrangement of the pulleys (source: Khurmi and Gupta 2006)

The selected motor of 7.5 hp delivers at speed of 1750 rpm which was connected to the hydraulic pump
pulleys. A diameter of the motor shaft pulley of 1.190m is selected. The pump speed is calculated as follows:

Np = (khurmi and Gupta, 2006)

Np =

Np = = 980 rpm

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Where:

Nm = speed of electric motor

Np = speed of the pump

Dm = diameter of motor pulley

Dp = diameter of pump pulley

Belt Analysis

Determination of Centre Distance: the centre distance, X, between two adjacent pulleys is given as:

X= + Dm

X= + 1.190

X= + 1.190

= 1.6575 + 1.190

X = 2.8475m

Determination of Belt Length (Lb):

Lb =

Or

Lb = (dm + dp) + 2X + (khurmi and Gupta, 2006)

Lb = (2.125 + 1.190) + 2 2.8475 +

Lb =

= 5.20455 + 4.5695 + 0.9648

Lb = 10.73886m

Where:

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Lb = Length of belt

d1 = diameter of motor pulley (smaller pulley)

d2 = diameter of pump pulley (larger pulley)

X = distance between the centers of two pulley

Belt speed:

V = ωɤm

ω= (khurmi and Gupta, 2006)

ω = 183.28 rad/s

But

V = ωɤm\

V=

V = 183.28 × 0.595

V = 109.0516m/s

Where:

V = Belt speed in m/s

ω = angular speed of electric motor

ɤm = radius of the electric motor pulley

N = speed of electric motor

Mass per Unit Length of Belt:

M = ρgA

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ρ = 981kg/m3

g = 9.81m/s2

A = cross sectional area of the belt

Figure 3.4: Cross Sectional Area of the Belt

Tan 20o = X/0.008

0.008tan20 = X

X = 0.00291m

But ,

A = ½ (0.00618 + 0.012) 0.008

A = 7.212 × 10-5m2

Then mass per unit length

M = 980 ×9.81 × 7.272 × 10-5

M = 0.699kg/m

Where:

ρ = density of belt material

g = acceleration due to gravity

A = Area of the belt

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Centrifugal Tension of belt

Tc = MV2

Tc = 0.699 × (109.0516)2

Tc = 8312.6834 N

Where:

Tc = centrifugal tension of belt

M = mass per unit length of belt in kg/m

V = belt speed

Angle of wrap (Ɵ):

Angle of wrap for the electric motor pulley

Ɵm = 180 - 2α

Angle of wrap for the hydraulic pump pulley

Ɵp = 180 + 2α

But

Sin α =

Therefore:

Ɵp = 180 + 2sin-1

= 180 + 2sin-1

= 180 + 2sin-10.1642

Ɵp = 198.86o

Ɵp = 198.86o × = 3.47 rad

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Ɵm = 180 – 2sin-1

Ɵm = 180 – 2sin -1

= 180 – 2sin-1 0.1642

Ɵm = 161.18o × = 2.81 rad

Where:

α1 = angle total

R = radius of hydraulic pump pulley

r = radius of electric motor pulley

X = center distance between the pulleys

Torque Transmitted by Motor (Tt):

Tt =

Tt = 164.41 N-m

Torque Exerted on the Driving Pulley

Driving Tension on the Driving Belt

This is given by:

= (khurmi and Gupta, 2006)

Where:

T1 =?

T2 =?

Tc = 8312.6834 N

θ = 30o

μ = 0.268

Ɵm = 2.81 rad

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 =

T1 – 8312.6834 = 18.36T2 – 152620.86

T1 – 18.36T2 = -144308.18

Torque supplied is given by:

Tt = (T1 - T2) r1

164.41 = (T1 – T2) × 0.595

T1 – T2 = 276.319

T1 = 276.319 + T2

(276.319 + T2) – 18.36T2 = - 144308.18

17.36T2 = 144031.87

T2 = 8296.7667N

T1 = 276.319 + 8296.7667

T1 = 8573.086 N

Where:

T1 = tension in the tight side of the belt in Newtons

T2 = tension in the slack side of the belt in Newtons

Tc = centrifugal tension of belt

𝞵 = coefficient of friction between the belt and the pulley

α1 = angle of wrap of the smaller pulley

θ = groove angle of the pulley

Coefficient Friction (μ):

μ =0.268 (khurmi and Gupta, 2006)

19
Where:

μ = coefficient of friction between the belt and pulley (based on belt material).

Power Transmitted by Electric Motor:

1Hp = 0.746KW

7.5Hp = (7.5 × 0.746) kW = 5.595kW

Power Transmitted by the Belt:

Pb = (T1 – T2) V watts

Pb = (8573.086 – 8296.7667)109.051

Pb = 30132.895 W

Where: V = peripheral velocity of the belt in m/s

Stress built up in the Cage:

The cylindrical cage is subjected to two types of tensile stresses, namely

1) Circumferential stress

2) Longitudinal stress

Circumferential Stress

The results of the internal pressure in the cylinder have the tendency to split up the cylinder into troughs.

Height of the cage H = 11.05m

Diameter of the cage D = 6.8m

Thickness of the cage t = 0.17m

Total pressure along the diameter of the cage =?

The stress, σ;

σ = intensity of stress × area = σdL

circumferencial stress in the shell

σc = =
20
Hoop stress = σn =

Where: P = 3516.45N/m2, t = 0.085m, σn = 3516.45/0.085

σn = 41370 KN/m2

Hoop stress = tensile stress across the diameter:

σc = σnd/2t (khurmi 2008)

σc = (41370 × 6.8) / (2 × 0.085) = 281316/0.17

σc = 1654800KN/m2

Longitudinal stress = ½ circumferential stress

= ½ x1654800
= 827400 KN/m2

Hydraulic Tank Capacity:

Vt = length x width x height = L x W x H

Where: L = 3.4m, W = 2.805m, H = 5.1m

Vt = 3.4 x 2.805 x 5.1 = 48.639m3

Where: Vt = volume of tank

Volume of the Cage:

The area Ac = πr2
Therefore, Volume of the cage is given by:
Vc = πr2h

Where: diameter (d) = 6.8m, r = d/2 = 3.4, π = 3.142

Height of the cage (h) = 11.05m
Ac = 3.142 × (3.4) = 36.322m2
VC = 3.142 x (3.4)2 x 11.05
= 401.353m3

Area of the Pressing Plates

The area of the plate is given by, Ap = πr2
Where: r = d/2
The diameter of pressing plate = 6.63m,
Radius r = 6.63/2 = 3.315
Area = 3.14 × (3.315)2 = 34.506 m²

Pressure on the Cage, Cp:

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The force exerted on the cage walls is given as:
Force = Ram pressure x Area of pressing plate
The ram pressure = 3516.45KN/m2
Force, F = Pressure x Area
= 3516.45 x 34.506
= 121338.62KN

CP = 121338.62/36.322
Cp = 3340.637KN/m2

CHAPTER FIVE
DISCUSSION AND CONCLUSION
22
5.1 DISCUSSION

The 7.5hp electric motor transmits power and rotary movement to the pump pulley, this causes the hydraulic
oil from the tank to be sucked via the hose into the pump. The oil passes through the pressure hose into the
ram through the valve inlet channel to the upper chamber of the ram thereby building up pressure for pushing
down the ram. The ram moves down when the lever on the valve is gently pressed downwards. This requires
little or no effort at all. After the pressing is complete the lever is pushed up again to return to its position.
This causes the hydraulic oil to enter the ram through the lower nozzle thereby pushing the ram up. This
upward movement expels the fluid in the upper chamber of the ram back to the tank.

5.2 RECOMMENDATIONS

To enhance equipment performance, it is recommended that,

 The hydraulic oil tank is filled to attain the required level to avoid the suction of air.

 The connections are well checked to avoid leakage. This will avoid loss of pressure that will affect the
pressing pressure of the ram piston.

5.3 CONCLUSION

The design of a motorized hydraulic operated palm oil press has been reported. The equipment is design using
materials that can withstand the operating pressure and will also not easily wear out. The volume of the cage
is 401.353m2 with a cage pressure of 3340.637KN/m2.The equipment is therefore appropriate to process about
8,593.2Kg/hr of digestered palm fruits.

5.4 REFERENCES

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1. Cornish EH (1991). Materials and the Designer, Cambridge University Press, Cambridge, pp. 28-29.
ISBN 052138506.
2. African Journal of Environmental Science and Technology Vol. 3(11), pp. 387-398, November 2009.
3. Industrial Process and the Environment, Crude Palm Oil Industry (Hand Book No.3)
4. Research on the Juaben Oil Mill Plant, Report (2012)
5. New Delhi-110055, pp. 509-556.
6. Muthurajah RN (2002). Palm Oil Factory Hand Book, Palm Oil Research

7. Khurmi R.S and J.K Gupta, 2006. A Textbook for Machine Design. First Multicolor Edition. Eurasis
publishing house New Delhi, 509-556.

8. Khurmi R.S 2008. Strength of materials. McGraw-Hill, S Chand & Company Lt. New Delhi, India.

9. Gupta, S.K. (Ed.). 2012. Technological Innovations in Major World Oil Crops. Volume 1:165-20
http:// rd.springer.com/chapter/10.1007/978-1-4614-0356-2_7.
10. Asiedu, J.J. 1989. Processing of Tropical Crops. Macmillan Publ.: London, UK.

11. Design and Fabrication of Motorized Hydraulically Operated Palm Oil Press.
P. A. Azodo, M. Eng.1, A. B. Hassan, Ph.D. J. Ezenwa, B.Eng. and P.U. Ogban, B.Eng.
12. http://www.akamaiuniversity.us/PJST.htm

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