1ST YEAR INTEGRATED PROJECT

(CHEMICAL ENGINEERING PROGRAM)

SEMESTER I 2021/2022

PRODUCTION OF MARGARINE FROM PALM OIL

LECTURER :

KKPK1113: PROF. MADYA. DR. MASLI IRWAN ROSLI

: TS. DR. MOHD SHAIFUL BON SAJAB

KKPK1123: PROF. MADYA TS. DR. WAN NOR ROSLAM WAN ISAHAK

: DR. NORASHIKIN MD SALEH

KKPK1133: PROF. DATO’ IR. DR. WAN RAMLI WAN DAUD

: DR. DARMAN NORDIN

GROUP : 2-10

TITLE : PRODUCTION OF MARGARINE FROM PALM OIL

MEMBERS : NUR AINA'A ZAFIRAH BINTI BAROM (A190554)

VIKNISH A/L ARUMUGAM (A181472)

NUR HIJANAH BINTI MOHAMAD ZAHID (A190612)

MUHAMMAD HARRAZ BIN ZAKARIA (A189655)

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DECLARATION

We hereby declare the work in this project is our own except for quotations and
summaries which have been duly acknowledged.

23 JUN 2022 NUR AINA’A ZAFIRAH

BINTI BAROM
A190554

VIKNISH A/L
ARUMUGAM
A181472

NUR HIJANAH BINTI

MOHAMAD ZAHID
A190612

MUHAMMAD HARRAZ
BIN ZAKARIA
A189655
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ACKNOWLEDGEMENT

First, we would like to thank the supreme power the almighty God who is the main
guidance throughout this project and the main reason we get to do our project
successfully.

We would like to thank our Lecturers Prof. Madya Dr. Masli Irwan Rosli, Ts.
Dr. Mohd Shaiful Sajab, Prof. Madya Ts. Dr. Wan Nor Roslam Wan Isahak, Dr.
Norasyikin Md Saleh, Prof. Dato’ Ir. Dr. Wan Ramli Wan Daud, Prof Jamaliah Md.
Jahim, Dr. Darman Nordin and Dr. Peer Mohamed for providing us guidance
throughout this research. We were extremely grateful for what our supervisor taught us
especially in literature view’s writing and also taught us to present the research work as
clearly as possible.

We were also grateful to our parents for their love, prayers, caring and sacrifices
for educating and preparing us for our future and always support us in what we were
doing. We also would like to express our special thanks to our dearest course mate and
seniors for helping and giving us extra helps in completing our integrated project
indirectly. Not to forget, to thank our very own group mates for giving good cooperation
and hard work to complete this group project report. Without their support and
motivations to us, we could not be able to complete this integrated project right on time.
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ABSTRACT

Margarine is a butter-like spread that many consumers use daily. Although it is derived
from the palm oil, through a process called hydrogenation these liquid oils become the
loved spread. To meet modern health concerns, trans fat free margarine is also created
through another process called enzyme interesterification. Palm oil prevents butter and
margarine from oxidation. Oil oxidation is a chemical reaction involving oxygen that
degrades the quality of oil contributing to off flavour and smell

In Chapter II, the physical chemistry for raw materials to produce the margarine
from palm oil has been and the product itself which is margarine. Margarine was
initially prepared from a single hydrogenated palm oil with a chemical formula
C15 H29 O5 . The hydrogenation process, which involves transforming oil into semi-solid
form, is the most notable of the seven steps required in manufacturing margarine from
palm oil before it is distributed for commercialization and physical condition of is
margarine.

The process flow diagram of production margarine from palm oil is presented
in Chapter III. In this chapter, the detailed for each process were presented such as the
temperature, pressure and vapour fraction for each stream and the equipment used in
each process. The process equipment includes storage drum, bleacher reactor,
deodorization reactor, mixer and vessel reactor for hydrogenation process, with
conveyor, pump and chiller.

In Chapter IV, we are focusing more on calculation of material balance in each

unit operation. Material balance is a method of analysing physical systems using the
principle of mass conservation. Mass flows that were previously unknown can be
identified by measuring for material entering and leaving a system. The results of our
calculation have proved that input and output in each unit operation are balanced.
Besides, the calculation of material balance for reacting system is focusing on where
the reaction takes place which in our production is at hydrogenation process in vessel
reactor.
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TABLE OF CONTENTS

Page

DECLARATION ii
ACKNOWLEDGEMENT iii
ABSTRACT iv
TABLE OF CONTENTS v
LIST OF TABLES vii
LIST OF ILLUSTRATIONS viii

CHAPTER I INTRODUCTION
1.1 Introduction 1
1.2 Usage of Margarine 2
1.3 Price of Palm Oil and Margarine 3
1.4 List of Companies in The World Producing Margarine
from Palm Oil 5
1.5 Supply and Demand Of MArgarine From Palm Oil 6
1.6 Plant Capacity 7

CHAPTER II PROCESS DESCRIPTION

2.1 Physical and Chemical Properties 9
2.2 Process Block Diagram 11
2.3 Process Description 12
2.4 Process Flow Diagram 15

CHAPTER III SAFETY AND ENVIRONMENTAL ISSUES

3.1 Safety Issues of Raw Materials 17
3.2 List of Action Required To Handle These Risky Materials 20
3.3 Physical and Chemical Properties of waste 22
3.4 Waste Treatment Methods 23
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CHAPTER IV MATERIAL BALANCE

4.1 Introduction 25
4.2 Degree of Freedom 25
4.3 Material Balance 25
4.3.1 Material Balance in Palm Oil Storage Drum, V-
101 26
4.3.2 Material Balance in Packed Bed Reactor, R-101 27
4.3.3 Material Balance in Flash Distillation Column 1, V-
102 29
4.3.4 Material Balance in CB-101 Conveyer 31
4.3.5 Material Balance in Flash Distillation Column 3,
V-103 32

4.3.6 Material Balance in M-101 A/B Mixer 33

4.4 Energy Balance 34
4.6.1 Energy Balance in Palm Oil Storage Drum, V-
101 36
4.6.2 Energy Balnce in Fluid Distillation Column 1, V-
102 38
4.6.3 Energy Balnce in CB-101 Conveyer 39
4.6.4 Energy Balnce in Fluid Distillation Column 3,
V-103 40
4.6.5 Energy Balnce in A/B Mixer, M-101 42

CONCLUSION 44

REFERENCES 45
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LIST OF TABLES

Table No. Page

Table 1.3.1 Prices and packaging sizes for each selected product in
Malaysia and Indonesia 3

Table 1.3.2 Prices and packaging sizes for each selected product in
USA and Turkey 4

Table 1.4 List of producer companies in Malaysia 5

Table 2.1.1 Physical and chemical properties of palm oil 9

Table 2.1.2 Physical and chemical properties of margarine 9

Table 2.1.3 Physical and chemical properties of water 10

Table 2.3 Process description of margarine from palm oil 12

Table 2.4 Stream Table 16

Table 3.1 Safety Issues of Raw Materials 17

Table 3.2 List of Action Required to Handle These Risky Materials 20

Table 3.3 Physical and Chemical Properties of Waste 22

Table 3.4 Waste Treatment Methods 23

Table 4.4 Degree of Freedom 25

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LIST OF ILLUSTRATIONS

Figure No. Page

Figure 1.1 a) The general chemical structure of palm oil;

(b) The chemical structure of fatty acids in palm oil Error!
Bookmark not defined.

Figure 1.5 Global supply demand curve of palm oiled margarine 7

Figure 2.4 Process block diagram of palm margarine production 11

Figure 2.4 Process flow diagram of margarine production from palm

oil 15

Figure 4.3.1 Palm Oil Storage Drum, V-101 26

Figure 4.3.2 Packed Bed Reactor, R-101 27

Figure 4.3.3 Flash Distillation Column 1,V-102 29

Figure 4.3.4 CB-101 Conveyer 31

Figure 4.3.5 Flash Distillation Column 3, V-103 32

Figure 4.3.6 M-101 A/B Mixer 33

Figure 4.4.1 Packed Bed Reactor, R-101 36

Figure 4.4.2 Flash Distillation Column 1, V-102 38

Figure 4.4.3 Conveyer CB-101 39

Figure 4.4.4 Flash Distillation Column 1, V-103 40

Figure 4.4.5 Mixer A/B, M-101 42

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CHAPTER I

INTRODUCTION

1.1 INTRODUCTION

Margarine is a water-in-fat emulsion and butter substitute originally made from animal
fats and high in trans-fat, which associated with coronary diseases such as coronary
heart disease and arterial plaque. It leads to the production of margarine using vegetable
oils as this trans-free margarine is currently required in many developed countries.

Palm oil is a tropical oil which is naturally semi-solid and do not require
hydrogenation, becomes the choice for trans-free margarine formulations. It also further
modified by fractionation, interesterification, hydrogenation and blending.

The palm oil contains equal quantities of saturated and unsaturated fatty acids
as it is important for polymorphic stability. It is rich in palmitic acid(C16H32O2) which
is 44 percentage and crystallizes in the β' form which is recommendable in production
of margarines. It also contains approximately 5% stearic acid (C 18H36O2), and trace
amounts of myristic acid (C14H28O2). The unsaturated fatty acids are approximately
40% oleic acid (C18H34O2) and 10% polyunsaturated linoleic acid (C18H32O2) and
linolenic acid (C18H30O2).

Palm oil stops margarine from oil oxidation which degrades the quality of oil
and contributes to off flavor and smell involving oxygen. It provides consistency,
texture ad structure which stabilizes the firmness, spread ability, smoothness and proper
melt-down of the margarine product.
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Figure 1.1 a) The general chemical structure of palm oil; (b) The chemical structure
of fatty acids in palm oil

1.2 USAGE OF MARGARINE

Palm oil-based margarine has become such a staple in the diets most individual today.
The consideration of manufacturing palm margarine as an ideal ingredient has affect a
widely use of it by people living in Malaysia today. Thus, studies also proves that palm
oil can provide health benefits to human especially to those who concerned about the
cholesterol level. Palm margarine which is devoid of trans fats and cholesterol free can
keeps us away from the risks that trans-fat imposes on our health. As we know that high
level fats taken can contribute to a heart disease, high cholesterol, and diabetes. The
good of palm oil in margarine which is rich in vitamin E that can reduce risk of getting
heart disease and prevent free radical skin.

The sheer wealth of palm margarine suppliers proves the benefits associated
with this type of margarine in the country today. The absent of hydrogenation process
in palm oil are extremely beneficial to not create a solid and creating trans fatty acids.
Widely documented that this trans fatty acids are bad for human heart. This palm oil-
based margarine is a lot healthier because of the presence of palm oil instead of others.
Without ignoring that this margarine is a great component for cooking, it is also filled
with healthier nutrients with the benefits of good taste. However, the manufacturing
process of palm oil comes with one con that the packing process has to go through some
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difficulties. Readily available that palm margarines are at competitive prices. It is worth
to the whole world when it is getting inclined to the healthier option which is highly
beneficial to our health ground. It is a spread used for flavoring, baking and cooking.
used as a topping for many foods, such as bread, crackers, baked goods, vegetables, and
snacks and it is also useful as an ingredient in a variety of baked goods.

To wrap it up, palm oil-based margarine is not extremely the best, instead they
have provided us a better array benefits of health as well. The new diet staple of palm
oil has surprised us today. Thus, the beta-carotene in palm oil also helps to balance our
hormonal levels.

1.3 PRICE OF PALM OIL AND MARGARINE

The price of palm oil-based margarine varies with each product produced by companies
in Malaysia. For comparison, the price of the brand margarine was collected. The name
of the brand are Planta, Seri Pelangi Margarine, Daisy Margarine, Adela, and Krimwell
Margarine. The price of palm oil-based margarine in other countries were also collected
to compare the margarine price in Malaysia with the other country. The average price
of margarine sized 1000g in Malaysia is RM 12.40. The selected countries are
Indonesia, United State of America (USA), and Singapore. The brand and price of each
product with their packaging sizes will be shown in Table 1.1 and 1.2 respectively.

Table 1.3.1 Prices and packaging sizes for each selected product in Malaysia and
Indonesia

Country Product Name Size Price

Planta 1000g RM16.50
Seri Pelangi Margarine 1000g RM7.19
Daisy Margarine 1000g RM14.50
Adela 480g RM11.03
Malaysia
Krimwell 1000g RM13.00
Blue Band 200g Rp8.475
Sania Royale 200g Rp5.200
Royal Palmia 200g Rp5.500
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forVITA 200g Rp5.000

Rose Brand 200g Rp6.487
Indonesia

Table 1.3.2 Prices and packaging sizes for each selected product in USA and Turkey
Country Product Name Packaging Size Price
Imperial Margarine 16 oz $0.87
Blue Bonnet 16 oz $1.17
USA Hill Country Fare 15 oz $1.96
Land O Lakes 15 oz $2.04
I Can’t Believe It’s 15 oz $3.07
Not Butter!
Blue Band 250g $4.35
Naturel Soft Margarine 500g $3.75
Singapore MeadowLea 500g $3.35
Margarine
Planta Multi-Purpose 480g $3.95
Margarine
Daisy Margarine 480g $3.30

The price of palm oil-based margarine also depends on palm oil price. Between
other edible oils, palm oil has the advantage of cheaper in price. For example, during
21 September 2021, the price of crude palm oil was US$1230 per MT while the price
of soybean oil was US$1391, giving crude palm oil US$161 price advantage against
soybean oil. However, palm oil has its own disadvantage. The export price of palm oil
might be high, causing other type of oil to be cheaper.
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1.4 LIST OF COMPANIES IN THE WORLD PRODUCING MARGARINE FROM

PALM OIL

There are companies within Malaysia and other countries which are investing in the
production of margarine from palm oil. It can be shown in Table 1.4.

Table 1.4 List of producer companies in Malaysia

Companies Information Plant Capacity
Per Day Per Year

Delima Oil Products Sdn 750 tonnes 266,250

Bhd (DOPSB) began in tonnes
Kuala Lumpur in year
2000. This company
produces margarine
products branded Adela
and Seri Pelangi.

900 tonnes 319,500

Planta multi-purpose tonnes
margarine is produced by
DCH Contract
Manufacturing Sdn. Bhd.
in Selangor.
DCH CONTRACT
MANUFACTURING

Lam Soon is a household 700 tonnes 255,500

name in Southeast Asia tonnes
and this company
produce daisy Margarine
which is cholesterol free
and rich with vitamins.
LAM SOON

Moi Foods is part of the 800 tonnes 284,000

Mewah Group which has tonnes
over 60 years of
experience in the edible
oils and fats industry,
marketed to more than
120 countries around the
world.

Source: Panjiva,2022
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1.5 SUPPLY AND DEMAND OF MARGERINE FROM PALM OIL

The market for supplements is well on its path of gaining enhanced momentum in the
backdrop of rising demands from healthy conscious consumers. The margarine from
palm oil plays role as an essential component of a healthy, balanced diet, having
beneficial effects on development and in mitigating a range of pathological conditions.
The palm oiled margarine is most used for preventing heart attack, and contains Vitamin
A, and tocopherol and tocotrienol antioxidants. However, their global supply from all
the traditional sources of these nutrients is insufficient to satisfy human nutritional
requirements.

The global palm oiled market is growing fast. The volume of the palm
oiled margarine market in 2018 was around 7000 kilotons and it is expected to reach
approximately is 9870 kilotons/year by 2025 with an expected CAGR of around 7.7%
during the forecast period. Due to the high demand of palm oiled in global market, there
is also increase in number of producers. The global production and supply of palm oiled
is anticipated to reach a market volume of 8600 kilotons by 2025, at a CAGR of 5.4%
from 2018 to 2025 (Ciech, 2019). The graph below shows the supply and demand of
palm oiled margarine from year 2018 to 2025. Based on the line graph, we can conclude
that the supply and demand for palm oiled margarine is gradually went up from year
2018 to 2025. The demand for palm oiled margarine exceeds the supply of it so future
marketing shows positive indication (Grand New Research 2020).
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Figure 1.5 Global supply demand curve of palm oiled margarine

Source : Ciech, 2019

1.6 PLANT CAPACITY

The processing time is 355 days a year and will run continuously 24 hours a day. The
10 remaining days are for purposes of rest and maintenance. Our plant capacity
4281.69kg/hour to ease the estimate. The increasing demand of margarine from palm
oil in the coming years is expected due to usage of it in various sector especially the use
of margarine in cooking and baking industry as topping agent. Based on the data
analysis above, a gross value of plant capacity can be calculated by assuming that this
plant can achieve 3% of the global demand. This assumption is the key for the
organization which need to make an investment decision based on what level of
capacity is to be selected and when it is to be provided.

From Figure 4.1, palm oiled margarine demand in 2025 is 9870

kilotonne/year and palm oiled margarine in 2025 is at 8600 kilotonne/year. Therefore,
in 2025, the production rate of palm oiled margarine can be calculated as,
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Demand-Supply = 9870 kilotonne/year – 8654 kilotonne/year

= 1216 kilotonne/year

Production per year = 355 days × 24 hours

= 8520 hours

Plant capacity = 0.03 × 1216 kilotonne/year

= 36.48 kilotonne/year

= (36.48 × 10^6) kg × 8520 hours

= 4281.69 kg/hour
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CHAPTER II

PROCESS DESCRIPTION

2.1 PHYSICAL AND CHEMICAL PROPERTIES

Table 2.1.1 Physical and chemical properties of palm oil

Properties Description

Colour Yellowish in solid, white in liquid

pH Neutral
Solubility Insoluble
Fatty acids 50% saturated fatty acids
40% monounsaturated fatty acids
10% polyunsaturated fatty acids
Boiling point 300 C / 572 F
Melting point 35 C / 95 F (at saturated fat 52%)
Smoke point 235 °C
Flash point 615 ˚F

Table 2.1.2 Physical and chemical properties of margarine

Properties Description

Colour Yellow
Type of fat Unsaturated fat (double bond)

Conditions at room Solid

temperature
pH Neutral
Melting point 34◦C / 93 ◦F
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Freezing point 10–20 °C at room temperature

Smoke point 410-430°F (210-221°C)
Flash point 600°F (315°C)
Fire point 700°F (371°C)

Table 2.1.3 Physical and chemical properties of water

Properties Description

Hydrogen pressure 103 kPa

Formula H2O
Texture Colourless, Tasteless

Density Solid:
0.9167 g/ml at 0 °C
Liquid:
0.961893 g/mL at 95 °C
0.9970474 g/mL at 25 °C
0.9998396 g/mL at 0 °C

Boiling point 99.98 °C (211.96 °F; 373.13 K)

Melting point 0.00 °C (32.00 °F; 273.15 K)

Specific Heat Capacity 4.2 joules per gram at 25°C

Viscosity 0.89 cP(centi-poise)
Acidity 13.995 pKa
Basicity 13.995 pKb
Molecule of water formed by the covalent bond of hydrogen and oxygen atoms
 11

2.2 PROCESS BLOCK DIAGRAM

Figure 2.1 illustrates the nine processes involved in producing margarine from palm oil
before it is disseminated for marketing, the most prominent of which is hydrogenation,
that involves converting oil into semi-solid form, and is the physical condition of
margarine.

Figure 2.2 Process Block Diagram of Palm Margarine Production

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2.3 PROCESS DESCRIPTION

Table 2.3 depicted each stage of margarine manufacture from palm oil, from
hydrogenation to the final stage before packing and marketing.

Table 2.3 Process description of margarine from palm oil

Zones
Hydrogenation (zone 1)
Emulsion preparation
(zone 2)
Pasteurization (zone 3)
Explanations
To make margarine, palm oils and fats are extracted first, for example
by crushing seeds, and then refined. Palm oil is stabilised via
hydrogenation, which converts it from a liquid to a solid or semi-
solid state. This is accomplished by connecting a hydrogen atom to
the double bonds of fatty acid chains. At room temperature,
hydrogenated palm oil is solid and white in appearance. In a reactor,
the oil is heated and treated with hydrogen and a nickel catalyst. The
catalyst is removed after hydrogenation, and the oil is cooled in a
heat exchanger to produce refined bleached deodorised and
hydrogenated palm oil. When hydrogen is added to unsaturated
bonds (alkenic double C=C bonds), saturated C-C bonds form, thus
raising the melting point of the oil and "hardening" it. This is because
van der Waals forces between saturated molecules are stronger than
unsaturated molecules.
Transferring various oils and fats, or fat mixes, to the emulsion tank
creates the emulsion. High melting fats or fat blends are usually put
first, followed by lesser melting fats and liquid oil. The emulsifier
and other oil-soluble minor components are added to the fat mix to
finish the fat phase preparation. The water phase is introduced after
all the fat phase components have been well combined, and the
emulsion is generated by vigorous but controlled mixing. Different
techniques for measuring the different ingredients for the emulsion
can be utilised, two of which are batch-based flow meter system and
weighing tank system. The flow meter system is based on batch-wise
emulsion preparation, in which mass flow meter measure the various
phases and components as they are transported from phase
preparation tanks to the emulsion tank. The flow meter system based
on batch-wise emulsion preparation is similar to the weighing tank
system. The ingredients and phases are directly added to the emulsion
tank, which is positioned on load cells that control the amount of
ingredients and phases fed to the tank.
Each tank serves as a preparation and buffer tank (emulsion tank),
thus one tank will feed the crystallisation line while the other
prepares a new batch, and vice versa. The system is called the flip-
flop system. A solution in which the emulsion is made in one tank
and then moved to a buffer tank from which the crystallisation line is
supplied is also an option. The premix/buffer system is the name for
this system.
Before entering the crystallization line, the emulsion is generally
continuously pumped via a plate heat exchanger (PHE), a low
pressure scraped surface heat exchanger (SSHE), or a high pressure
SSHE for pasteurization. In-line pasteurization is handled using a
skid-mounted pasteurization equipment. The emulsion is pasteurised
using a pump that transports it through a wire mesh filter to a plate
heat exchanger. The passage of hot water via the plate heat exchanger
is aided by another pump. Following the creation of the emulsion at
45-55°C, a typical pasteurisation process will involve a heating and
holding sequence of the emulsion at 75-85°C for 16 seconds,
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followed by a cooling phase to 45-55°C. The melting point of the fat

phase determines the final temperature: the greater the melting point,
the higher the temperature. Heating the emulsion prevents bacteria
and other microorganisms from growing and increases the emulsion's
stability.

Chilling, crystallization, A high-pressure piston pump (HPP) transports the emulsion to

and kneading (zone 4) the crystallisation line. The crystallisation line for margarine and
similar products is generally made up of a high-pressure SSHE
that is cooled with ammonia or Freon-type cooling medium. To
provide extra kneading intensity and duration for the
manufacturing of plastic goods, pin rotor machine(s) and/or
intermediate crystallizers are frequently placed in the line. The
final step in the crystallisation line is a resting tube, which is only
included if the product is packed. On the inside surface of the
chilling tube, the heated emulsion is supercooled and solidified.
The rotating scrapers efficiently scrape the emulsion off, chilling
and kneading the emulsion at the same time. When the fat in an
emulsion crystallises, it forms a three-dimensional network that
traps the water droplets and liquid oil, resulting in semi-solid
products with plastic characteristics. The features of the final
margarine and spread products are heavily influenced by the
crystallisation process, processing conditions, and processing
parameters. It's critical to identify the features of the products
that will be made on the line while constructing a crystallisation
line. Because the variety of products of interest as well as raw
materials may change over time, the line's flexibility as well as
individually configurable processing parameters are required to
ensure the investment's long-term viability. After cooling in the
high-pressure SSHE, the product is kneaded for a specific
amount of time and with a particular intensity in the pin rotor
machine and/or intermediate crystallizers to aid in the promotion
of the three-dimensional network, which is the plastic structure
on a macroscopic level. If the product is to be supplied as a
wrapped product, it will pass through the high-pressure SSHE
once more before settling in the resting tube.
Packing, filling, and A packed product must obviously have a harder texture than a filled
remelting (zone 5) product, and if this texture is not ideal, the product will be redirected
to the remelting system, melted, and returned to the buffer tank for
reprocessing. There are several remelting systems available, however
the most utilised are PHE or low pressure SSHE.
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At the start of the process, 2092.4 kg/h of palm oil is mixed with 50 kg/h of recycled
palm oil in a drum vessel (V-101). The mixture is then pumped into a packed bed reactor
by a feed pump (P-101). The mixture mixes with compressed hydrogen from a
compressor (C-101). Palm oil and hydrogen will react to form hydrogenated palm oil
via a process known as hydrogenation, with a conversion rate of around 97.24 percent
for palm oil and 92 percent for hydrogen respectively and the remainder being unreacted
hydrogen. A reboiler (E-101) is used to obtain the desired temperature (110-140 ̊C) for
the mixture to react. The hydrogenated palm oil is passed through a flash separator (V-
102) to separate the hydrogen gas and hydrogenated palm oil mixture from the
unreacted palm oil where 15 percent of conversion rate occur. Unreacted hydrogen gas
is returned into the compressor (C-101). The two liquids of hydrogenated palm oil and
unreacted palm oil are cooled down using a heat exchanger (E-102) that uses cooling
water at normal ambient temperature before being delivered to the next equipment (30-
35 ̊C). At room temperature, the hydrogenated palm oil changed its phase from liquid
to solid and was transferred to the bleacher tank (V103) temperature, while the
unreacted palm oil was recycled back to V-101. Conveyor filtration (CB-101) also aids
in the separation of unreacted palm oil from hydrogenated palm oil. The mid product is
sent to a bleacher tank (V-103) for decolorization. The decolorize mid product is fed
into a mixer (R-102) and combined with a secret ingredient. The combined margarine
is subsequently transported into a chiller tank (TK-101) to be cooled using a conveyor
belt (CB-102) and an elevator solid margarine (EL-101).
 15

V-101 PALM OIL STORAGE DRUM R-101 PACKED BED REACTOR V-104 BLEACHED TANK CB-102 CONVEYER

P-101 PALM OIL FEED PUMP V-102 FLASH DISTILLATION COLUMN 1 E-101 REBOILER EL-101 ELEVATOR SOLID MARGARINE

C-101 A/B HYDROGEN GAS COMPRESSOR V-103 FLASH DISTILLATION COLUMN 3 E-102 HEAT EXCHANGER M-101 MIXER

TK-101 CHILLER TANK CB-101 CONVEYER

2.4 PROCESS FLOW DIAGRAM (PFD) PRODUCTION OF MARGARINE PALM OIL BASED FAKULTI KEJURUTERAAN DAN ALAM
BINA (FKAB)

JABATAN KEJURUTERAAN KIMIA DAN

PROSES (JKKP)

TITLE;

PROCESS FLOW DIAGRAM OF

PRODUCTION MARGARINE

FROM PALM OIL

LECTURERS;

DR. PEER MOHAMED

PROF MADYA DR MASLI IRWAN BIN ROSLI

TS DR MOHD SHAIFUL BIN SAJAB

DR NOORASHIKIN MD SALEH

GROUP 2-10
1. NUR AINA’A ZAFIRAH BINTI
BAROM (A190554)
2. VIKNISH A/L ARUMUGAM (A181472)
3. NUR HIJANAH BINTI MOHAMAD
ZAHID (A190612)
4. MUHAMMAD HARRAZ BIN
ZAKARIA (A189655)

SYMBOLS;

1) OUTPUT
2) INPUT
3) STREAM LABEL
 16

Table 2.4 Stream Table

STREAM NUMBER 1 2 3 4 5 6 7 8

TEMPERATURE (℃) 30.0 30.0 31.1 13.5 75.3 110.0 110.0 38.5

PRESSURE (bar) 1.9 2.0 25.0 24.3 25.0 20.0 2.1 1.7

VAPOR FRACTION 0 1.0 0 1.0 1.0 1.0 0.9 0

MASS FLOW (Kg/h) 2092.4 2060.0 2142.4 82.4 2060.0 70.0 4120.0 4050.0

COMPONENT FLOWMOLES (Kg/h)

PALM OIL 2092.4 0 2142.4 0 0 0 59.08 50.0

HYDROGEN 0 2060.0 0 82.4 2060.0 70.0 824.0 0

SECRET 0 0 0 0 0 0 0 0
INGREDIENT

HYDROGENATED 0 0 0 0 0 0 3978.5 4000.0

PALM OIL

STREAM NUMBER 9 10 11 12 13 14 15 16

TEMPERATURE (℃) 31.1 30.0 31.1 30.0 31.0 30.0 30.0 5.0

PRESSURE (bar) 1.6 1.1 1.5 1.9 1.5 1.7 1.3 1.0

VAPOR FRACTION 0 0 0 0 0 0 0 0

MASS FLOW (Kg/h) 50.0 4000.0 5.0 4005.0 276.7 4281.7 4281.7 4281.7

COMPONENT FLOWRATES (Kg/h)

PALM OIL 50.0 0 0 0 0 0 0 0

HYDROGEN 0 0 0 0 0 0 0 0

SECRET INGREDIENT

POTASSIUM 0 0 0 0 110.7 0 0 0
SORBATE

SODDIUM 0 0 0 0 83.0 0 0 0
CHLORIDE
 17

WATER 0 0 0 0 27.7 0 0 0

LACTIC ACID 0 0 0 0 55.3 0 0 0

HYDROGENATAED 0 4000.0 0 0 0 0 0 0
PALM OIL

BLEACHER 0 0 5.0 0 0 0 0 0

HYDROGENATED 0 0 0 4005.0 0 0 0 0
BLEACHED PALM
OIL

MIXED
HYDROGENATED
BLEACHED PALM
OIL WITH SECRET
0 0 0 0 0 4281.7 4281.7 0
INGREDIENT

MARGARINE 0 0 0 0 0 0 0 4281.7
 18

CHAPTER III

SAFETY AND ENVIRONMENTAL ISSUES

3.1 SAFETY ISSUES OF RAW MATERIALS

Raw material Flammability Toxicity Corrosivity Explosive

Palm Oil Flammable if get Contains no Prolonged or repeated Contains gas under
on fire or heat substances known skin contact may cause pressure; may
to be hazardous to drying, cracking, or explode if heated.
the environment. irritation. Sensitive
Contains no individuals may
substances known experience dermatitis
to be not after long exposure of
degradable in oil on skin
waste treatment This product is not
facilities. expected to cause
reproductive or
developmental effects.

Hydrogen Extremely No known No known effects Contains gas under

flammable gas. toxicological from this product pressure; may
effects from this explode if heated.
product.

Potassium Not Flammable Slight toxicity may Causes skin and eyes Not explosive as
Sorbate causes irritation if irritation. inflammable
make any contact. material
 19

Bleacher The product is Very toxic to Any contact to skin Containers can burst
not flammable. aquatic life causes severe burns. violently or explode
Extinguish with Symptoms following when heated, due to
alcohol- resistant overexposure may excessive pressure
foam, carbon include the following: build-up
dioxide, dry Pain or irritation.
powder or water Redness. Blistering
fog. Use fire- may occur.
extinguishing Any contact to eyes
media suitable may causes serious
for the eye damage.
surrounding fire. Symptoms following
overexposure may
include the following:
Pain. Profuse watering
of the eyes. Redness
Lactic Acid Not flammable Toxic fumes Eye: Causes eye Not explosive
possible in cases of burns. Causes redness
fire and pain. May cause
chemical
conjunctivitis and
corneal damage.

Skin: Causes skin

burns. Causes redness
and pain.
Sodium Not flammable Not toxic Not causes any Unexplosive
Chloride irritation

Margarinated As with most Not available Mild iriitant and Fine dust dispersed
palm oil organic solids, possible to causes in air in sufficient
fire is possible a surface inflammation concentrations, and
elevated especially prolonged in the presence of an
temperatures or contact with oily skin. ignision sources is a
by contact with potential dust
an ignition explosion hazard.
sources.

Table 3.1 Safety issues of raw materials


3.2 LIST OF ACTION REQUIRE TO HANDLE THESE RISKY MATERIALS
Material Handling
PALM OIL Keep away from sparks, flame,
and heat.
Keep in a tightly closed container.
Dissipate static electricity during
transfer by grounding and bonding
containers and equipment before
moving to keep the material from
any explosion or fire
HYDROGEN Hydrogen cylinders supplying the
process must be connected through
approved gas manifold.
Hydrogen detection- Detection of
hydrogen must be provided in all
areas to avoid any hazardous since
hydrogen gas in odorless and
colorless.
Avoids flammable areas.
20
Storage
Can be stored in mild steel.
Store in a segregated and approved
area.
Must be stored in a warm place
(30° - 45°C)
Storing as liquid is suitable as it
reduces the energy density of the
gas.
Can also be stored underground in
large quantities.
Can be stored in salt domes,
caverns, and gas and oil fields that
are no longer in use
 21

POTASSIUM SORBATE Avoid all personal contact, Use polyethylene or polypropylene

including inhalation. container.
Wear protective clothing when risk Store in original containers.
of exposure occurs. Keep containers securely sealed.
Empty containers may contain
residual dust which has the
potential to accumulate following
settling. Such dusts may explode in
the presence of an appropriate
ignition source.
Do not cut, drill, grind or weld
such containers.
Ensure such activity is not
performed near full, partially
empty or empty containers without
appropriate workplace safety
authorization or permit.

Table 3.2 List of Action Required

 22

3.3 PHYSICAL AND CHEMICAL PROPERTIES OF WASTE

Waste Chemical Properties Physical Properties

Water Universal solvent, Can conduct

Water has positive electric, Density
and negative end
max at 4℃, Low
viscosity
Boiling point = 100°C
Melting point = 0°C
Hydrogen Hydrogen gas usually Nontoxic,
did not react with other at
room temperature Non-
because large amount of metallic,
energy required to break
the bond between Odourless
hydrogen atoms.
,
Tasteless,
Colourles
s,

Highly combustible
Melting point = -
259.2K
Boiling point = -252.76K
Stearic Acid Stearic acid is insoluble Molar mass =
in water and soluble in 284.484 g·mol−1
ethanol
White solid
appearance
Pungent, oily smell
Melting point =
69.3 °C Boiling
point = 361 °C
 23

Oleic acid Oleic acid is insoluble in Molar mass =

water and soluble in 282.468 g·mol−1
ethanol
Colorless oily
liquid
appearance
Lard-like odor
Melting point = 13 to
14 °C Boiling point =
360 °C

Linoleic acid Oleic acid is insoluble in Molar mass =

water but many organic 280.452 g·mol−1
solvents.
Colorless oil
appearance
Melting point = −5
°C Boiling point =
230 °C

Table 3.3 Physical and Chemical Properties of Waste

 24

3.4 WASTE TREATMENT METHODS

Waste Products Treatment

Water To minimise total wastewater Chemical Oxygen Demand (COD) and improve water
quality, aerobic and anaerobic treatment are utilised.
To manage margarine wastewater suspension, toxic organics, and inorganics, the up
flow anaerobic reactor and aerobic biological reaction tank complicated combination
technique is employed.

Stearic acid Return any unused component of the material to the manufacturer or supplier for
recycling or approved use.
The material's impact on air quality, potential migration in air, soil, or water,
effects on animal, aquatic, and plant life, and compliance with environmental and
public health requirements must all be considered in the final disposal of the chemical.
If practicable or reasonable, utilise a chemical product with a lower inherent risk of
occupational harm, injury, toxicity, or contamination of the environment.
Consult the appropriate local waste disposal expert about waste disposal.
Do not empty into drains.

Linoleic acid SRP: Criteria for land treatment or burial (sanitary landfill) disposal practices are
subject to significant revision. Prior to implementing land disposal of waste residue
(including waste sludge)
Consult with environmental regulatory agencies for guidance on acceptable
disposal practices.
Do not empty into drains.
Hazardous Substances Data Bank (HSDB)

Hydrogen gas Return unused goods to source in original cylinder. Please do not discharge into any
regions.
Where there is a danger of an explosive combination forming with air, waste gas
should be recycled.
Flared with a flashback arrestor and an appropriate burner. Return the cylinder to the
vendor. Before installing a regulator, never break
a hydrogen cylinder valve to remove dust or dirt from fittings. While this approach
may be acceptable for other gases, it poses a risk of self-ignition with hydrogen
(HYDROGEN GAS SAFETY).

Table 3.4 Waste Treatment Methods

 25

CHAPTER IV

MATERIAL BALANCES

4.1.1 INTRODUCTION

Material balances are important for process management, especially in regulating

product yields. When changes are made to the process, the material balances must be
recalculated. Because of the growing cost of energy, businesses are looking for ways to
decrease energy consumption during processing, and energy balances are used to assess
the numerous phases of a process, as well as the complete process and even the full
production system from raw material to end product. The law of mass conversation
states that when actions in a closed system occur, the system's mass remains constant.

4.1.2 DEGREE OF FREEDOM ANALYSIS

To calculate the material balance, degree of freedom is calculated.

Table 4.1 Degree of freedom in each unit process

System V-101 R-101 V-102 B-101 V-103 M-101
Number of 1 2 4 2 1 6
variables
Number of 0 0 0 0 0 0
independent
equations
Sum of mass 0 1 0 0 1 1
fraction
Conversions 0 2 2 0 0 0
Basis 1 5 2 2 0 5
Degree of 0 0 0 0 0 0
freedom
 26

4.1.3 MATERIAL BALANCE

4.1.3.1 Material Balance in Palm Oil Storage Drum, V-101

Figure 4.3.1 Palm Oil Storage Drum, V-101

Stream Stream 1 Stream 3 Stream 9

Mass flowrate Mass flowrate Mass flowrate
(kgh-1) (kgh-1) (kgh-1)
Palm oil 2092.4 2142.4 50.0
Total 2092.4 2142.4 50.0

The Material Balance (Check)

Σ𝐹𝑖𝑛 = Σ𝐹𝑜𝑢𝑡

F1 + F9 = F3

(2092.4 + 50) = 2142.4

2142.4 kgh-1 = 2142.4 kgh-1 (Balanced)

 27

4.1.3.2 Material Balance in Packed Bed Reactor, R-101

Figure 4.3.2 Packed Bed Reactor, R-101

Stream Stream 3 Stream 4 Stream 5 Stream 7

Mass flowrate Mass flowrate Mass flowrate Mass flowrate
(kgh-1) (kgh-1) (kgh-1) (kgh-1)
Palm oil 2142.4 0 0 59.08
Hydrogen 0 82.4 2060 824.00
Hydrogenated 0 0 0 3978.52
palm oil

Total 2142.4 82.4 2060 4120

Assumption:

 No accumulation
 Conversion of palm oil (X = 0.9724)
 Conversion of hydrogen (X = 0.92)
 Reactive process system
 F7MUH1 = F4 MUH2
 28

Conversion rate of palm oil

palm oil input to reactor − palm oil output to reactor

0.9724 =
palm oil input to reactor

2142.4 − x
0.9724 =
2142.4

x =59.0808

Since F7 = 4120 kgh-1

F7MUPO = 59.0808

MUPO = 0.01434

Conversion rate of hydrogen

hydrogen input to reactor − hydrogen output to reactor

0.92 =
hydrogen input to reactor

2060 − x
0.92 =
2060

x = 164.8

Since x = F7MUH1 + F7MUH2 and UH1 = UH2,

164.8
UH1 =
2

= 82.4

UH1 = UH2 = 82.4

Since F7 = 4120 kgh-1

MUH1 = 0.02
 29

F7MHPO = 2142.4(0.9724) + 2060(0.92)

= 3978.46976

Since F7 = 4120 kgh-1

F7MHPO = 3978.46976

MHPO = 0.96566

The Material Balance (Check)

Σ𝐹𝑖𝑛 = Σ𝐹𝑜𝑢𝑡

F3 + F5 = F4 + F7

2142.4(1) + 2060(1) = 4120(0.01434 + 0.96566 + 0.02) + 82.4(1)

4202.4 kgh-1 = 4202.4 kgh-1 (Balanced)

4.1.3.3 Material Balance in Flash Distillation Column 1, V-102

Figure 4.3.3 Flash Distillation Column 1, V-102

 30

Stream Stream 6 Stream 7 Stream 8

Mass flowrate Mass flowrate Mass flowrate
(kgh-1) (kgh-1) (kgh-1)
Unreacted palm oil 0 59.0808 50
Hydrogenated palm 0 3978.5192 4000
oil
Unreacted hydrogen 70 82.4 0
Total 70 4120 4050

Assumption:

 Conversion of unreacted palm oil (X = 0.15)

 Conversion of hydrogen (X = 0.15)

Conversion rate of unreacted palm oil

unreacted palm oil input to separator – unreacted palm oil output to separator
0.15 = unreacted palm oil input to separator

4120(0.01434) − F8 MUPO
0.15 =
4120(0.01434)

F8MUPO = 59.08

Since F8MUPO = 59.08 kgh-1

4050(MUPO) = 59.08

MUPO = 0.0124

Conversion rate of hydrogen

hydrogen input to separator – hydrogen output to separator

0.15 =
hydrogen input to separator

0.2(4120) − F6 MUH3
0.15 =
0.2(4120)

F6MUH3 = 70 kgh-1

Since F6 = 70 kgh-1

MUH3 = 1

To find mass flowrate of hydrogenated palm oil

 31

F8MHPO = 0.96566(4120) + 0.15(4120 × 0.01434) + 0.15(4120 × 0.2)

F8MHPO = 4000 kgh-1

Since F8 = 4050 kgh-1

4000
MHPO = = 0.9876
4050

The Material Balance (Check)

Σ𝐹𝑖𝑛 = Σ𝐹𝑜𝑢𝑡

F7 = F6 + F8

4120(0.01434 + 0.96566 + 0.02000) = 4050(0.98760 + 0.01240) + 70(1)

4120 kgh-1 = 4120 kgh-1 (Balanced)

4.1.3.4 Material Balance in CB-101 Conveyer

Figure 4.3.4 CB-101 Conveyer

Stream Stream 8 Stream 9 Stream 10

Mass flowrate Mass flowrate Mass flowrate
(kgh-1) (kgh-1) (kgh-1)
Unreacted palm oil 50 50 0
Hydrogenated palm 4000 0 4000
oil
Total 4050 50 4000
 32

The Material Balance (Check)

Σ𝐹𝑖𝑛 = Σ𝐹𝑜𝑢𝑡

F8 = F9 + F10

4050(0.0124) + 4050(0.9876) = 50(1) + 4000(1)

4050 kgh-1 = 4050 kgh-1 (Balanced)

4.1.3.5 Material Balance in Flash Distillation Column 3, V-103

Figure 4.3.5 Flash Distillation Column 3, V-103

Stream Stream 10 Stream 11 Stream 12

Mass flowrate Mass flowrate Mass flowrate
(kgh-1) (kgh-1) (kgh-1)
Hydrogenated palm 4000 0 0
oil
Bleacher 0 5 0
Hydrogenated 0 0 4005
bleached palm oil
Total 4000 5 4005
 33

The Material Balance (Check)

Σ𝐹𝑖𝑛 = Σ𝐹𝑜𝑢𝑡

F10 + F11 = F12

4000(1) + 5(1) = 4005(1)

4005 kgh-1 = 4005 kgh-1 (Balanced)

4.1.3.6 Material Balance in M-101 A/B Mixer

Figure 4.3.6 M-101 A/B Mixer

Stream Stream 12 Stream 13 Stream 14

Mass flowrate Mass flowrate Mass flowrate
(kgh-1) (kgh-1) (kgh-1)
Hydrogenated 4005 0 0
bleached palm oil
Potassium sorbate 0 110.68 0
Sodium chloride 0 83.00 0
Water 0 27.67 0
Lactic acid 0 55.34 0
Mixed 0 0 4281.69
hydrogenated
bleached palm oil
with secret
ingredient
Total 4005.00 276.69 4281.69
 34

The Material Balance (Check)

Σ𝐹𝑖𝑛 = Σ𝐹𝑜𝑢𝑡

F12 + F13 = F14

4005(1) + 276.69(0.4) + 276.69(0.3) + 276.69(0.1) + 276.69(0.2) = 4281.69(1)

4281.69 kgh-1 = 4281.69 kgh-1 (Balanced)

4.4 ENERGY BALANCE

Energy balance is a systemic presentation of energy flows and transformation in a

system. Theoretical basis for and energy balance is the first law of thermodynamics
which states that energy cannot be created or destroyed, but just can be modified in
form. Energy balance determines the heat is either being released and absorbed during
the reactions. If heat is being released the reaction is exothermic while if the heat is
being absorbed, the reaction is endothermic. In order to prove the First Law of
Thermodynamics, or Energy Conservation at very in outlet of a system or component,
it is important to do the energy balance for each component.

Assumption:

1. Assume that there is no kinetic energy, potential energy and work

done by the system and it is a steady flow process.

2. Reference temperature is 27°C.

Enthalpy change in each component is important in order to determine the

overall heat change. The enthalpy change of a component is given by:

𝑇2
∆𝐻 = ∫ 𝐶𝑝 𝑑𝑇
𝑇1
 35

Where Cp = the heat capacity of the component

T1 = reference temperature

T2 = inlet or outlet temperature

The heat capacity, Cp is given by this equation, Cp = a + bT + cT2 + dT3 + eT4, where
the unit of Cp is J/kg°C and temperature, T is in unit Celcius. Table 4.6 shows the
specific heat values of carbohydrates, agorose, impurities, water and bleach that lead to
the calculation of the heat capacity, Cp.

Table 4.4 Specific heat values of the component

Component Specific heat capacity, Cp (kJ/kg°C)

Palm oil 1.875

Hydrogen 14.2

Potassium sorbate 3.07

Sodium chloride 0.86

Water 4.2

Lactic acid 2.06

Hydrogenated palm oil 5.709

Bleacher 3.802
 36

Hydrogenated bleached palm oil 7.45

Mixed hydrogenated bleached palm oil 1.26

with secret ingredient

4.4.1 ENERGY BALANCE CALCULATIONS

Packed Bed Reactor, R-101

Figure 4.4.1 below shows reactor which involves reaction of palm oil and hydrogen.
Table 4.4.1 shows the enthalpy change of each inlet and outlet streams.

F3 F7

F5

F4

Figure 4.4.1 Packed Bed Reactor, R-101

 37

Table 4.4.1 Enthalpy change of reactor R-101

Enthalpies Stream 3 Stream 4 Stream 5 Stream 7

(kJ/kg) (kJ/kg) (kJ/kg) (kJ/kg)

Palm oil -7.6875 0 0 155.625

Hydrogen 0 -191.7 -685.86 1178.6

Hydrogenated 0 0 0 473.847
palm oil

Q = F7∆H7 + F4∆H4 – F3∆H3 – F5∆H5

= [2865561.015 + (-15796.08)] – [(-16469.7) + (-1412871.6)]

= 4279106.235 kJ/hr

= 1188.641 kW
 38

Fluid Distillation Column 1, V-102

Figure 4.4.2 below shows distillation column which involves distillation palm oil,
hydrogen, and hydrogenated palm oil. Table 4.4.2 shows the enthalpy change of each
inlet and outlet streams.

F7 F8
V-102

F6

Figure 4.4.2 Flash Distillation Column 1, V-102

Table 4.4.2 Enthalpy change of flash distillation column V-102

Enthalpies Stream 6 (kJ/kg) Stream 7 (kJ/kg) Stream 8 (kJ/kg)

Palm oil 0 -155.625 21.5625

Hydrogenated palm 0 -473.847 65.65

oil

Hydrogen 1178.6 -1178.6 0

 39

Q = F6∆H6 + F8∆H8 – F7∆H7

= 83502 + 353210.625 – (-2865561.015)

= 3301273.64 kJ/hr

= 917.020 kW

Conveyer, CB-101

Figure 4.4.3 below shows conveyer involves conveying palm oil and hydrogenated
palm oil. Table 4.4.3 shows the enthalpy change of each inlet and outlet streams.

F8

CB-101
F10

F9

Figure 4.4.3 Conveyer CB-101

Table 4.4.3 Enthalpy change of conveyer CB-101

Enthalpies Stream 8 (kJ/kg) Stream 9 (kJ/kg) Stream 10 (kJ/kg)

Palm oil -21.5625 7.6875 0

Hydrogenated palm -65.65 0 17.127

oil
 40

Q = F10∆H10 + F9∆H9 – F8∆H8

= 68508 + 384.375 – (-263678.125)

= 332570.5 kJ/hr

= 92.381 kW

Fluid Distillation Column 3, V-103

Figure 4.4.4 below shows distillation column which involves distillation of

hydrogenated palm oil and bleacher. Table 4.4.4 shows the enthalpy change of each
inlet and outlet streams.

F11

V-103
F10

F12

Figure 4.4.4 Flash Distillation Column 1, V-103

 41

Table 4.4.4 Enthalpy change of flash distillation column V-103

Enthalpies Stream 10 (kJ/kg) Stream 11 (kJ/kg) Stream 12 (kJ/kg)

Hydrogenated palm -17.127 0 0

oil

Bleacher 0 -15.59 0

Hydrogenated 0 0 22.35
bleached palm oil

Q = F12∆H12 – F11∆H11 – F10∆H10

= 89511.75 – (-77.95) – (-68508)

= 158097.7 kJ/hr

= 43.916 kW
 42

A/B Mixer, M-101

Figure 4.4.5 below shows mixer which involves mixing of potassium sorbate, sodium
chloride, lactic acid, water and hydrogenated bleached palm oil. Table 4.4.5 shows the
enthalpy change of each inlet and outlet streams.

F13

F12
M-101

F14

Figure 4.4.5 Mixer A/B, M-101

 43

Table 4.4.5 Enthalpy change of mixer M-101

Enthalpies Stream 12 (kJ/kg) Stream 13 (kJ/kg) Stream 14 (kJ/kg)

Hydrogenated -22.35 0 0
bleached palm oil

Potassium sorbate 0 -12.28 0

Sodium chloride 0 -3.44 0

Water 0 -16.8 0

Lactic acid 0 -8.24 0

Mixed 0 0 3.78
hydrogenated
bleached palm oil
with secret
ingredient

Q = F14∆H14 – F12∆H12 – F13∆H13

= 16184.826 – [-89511.75 + (-2565.948)]

= 108262.524 kJ/hr

= 30.073 kW
 44

CONCLUSION

Margarine is made up mainly from vegetable oil (palm oil) that had undergoes the
process of hydrogenation. The aim of this project is to produce 1216 kilotonne/year of
margarine.

In this margarine process, there is no difficulties in manufacturing process and

most importantly the raw material of hydrogen recycles back fed into the vessel. It will
save a lot of cost to purchase a new raw material. Also, the production of margarine
there is no waste produce (eco-friendly) to the environment. There is no cost to calculate
how many values to treat the waste. The production of margarines also high and easily
to get the raw material and can be compared the cost among supplier to minimize the
cost.

By calculating the mass balance for each material, the output mass flowrate we
got through our plant design is 4281.69 kg/hour. The input and output of the material
balance calculation for this plant design is balanced. Based on the data analysis, a gross
value of plant capacity can be calculated by assuming that this plant can achieve 3% of
the global demand. Thus, the conclusion can be made that this project is viable and
feasible to run.

Margarine has less environment effects and the production of margarine does
not cause any damages to air, water, land, soil, forests, as long as not toxic chemical is
used. However, the production of margarine has its wastes such as alkali, bleach, and
water that may contain salts, colouring matters, and soluble carbohydrates. Therefore,
the right treatment must be done carefully so that the wastes are not harmful to the
environment and human health.

The energy balances of the plant equipment are calculated. The reactions that
involved in our plant are endothermic. The energy for packed bed reactor and fluid
distillation column 1 are 1188.641 kW and 917.020 kW while energy for conveyor is
92.381 kW. The energy for fluid distillation column 3 and A/B mixer are 43.916 kW
and 30.073 kW.
 45

REFERENCES

Akinola, F. F., Oguntibeju, O. O., Adisa, A. W., & Owojuyigbe, O. S. (2010). Physico-
chemical properties of palm oil from different palm oil local factories in Nigeria.
Journal of Food, Agriculture and Environment, 8(3-4 PART 1), 264–269.

Arasu, N. (2015, June 23). MARGARINE USING PALM OIL. Retrieved from
https://prezi.com/bpeko8zl6n6f/margarine-using-palm-oil/

Ferdous Alam, A. S. A., Er, A. C., & Begum, H. (2015). Malaysian oil palm industry:
Prospect and problem. Journal of Food, Agriculture and Environment, 13(2), 143–
148.

Hydrogen Fuel Cell Engines and Related Technologies. (2001). Module 1: Hydrogen
Properties. Hydrogen Fuel Cell Engines, 41.
http://www1.eere.energy.gov/hydrogenandfuelcells/tech_validation/pdfs/fcm01r0
.pdf

Ismail, N. U. R. H., Rosnani, W. A. N., Isa, A. W. G., Lida, N., & Mat, H. (2020).
Product Texture.

Material, S. (1899). 4 . Material and Energy Balance. 79–101.

Nagoya University. (2007). Chemical Modification of Oil and Fats. 19–24.

Network, B. (2020). INDUSTRIALLY-PRODUCED TRANS-FATTY ACIDS ( iTFA ) IN

PAKISTAN. June.

Turton, R., Bailie, R., Whiting, W., Shaeiwitz, J., & Bhattacharyya, D. (2018).
Analysis, synthesis, and design of chemical processes. Boston: Prentice Hall.
Dolipski, M; Giza, T; Sobota, P; Osadnik, J. (1992)
https://www.osti.gov/etdeweb/biblio/5468050

K Mehra. Material and Energy Balance for Distillation Process

https://www.chemengghelp.com/mb-hb-distillation-process/
 46

APPENDIX B

Packed Bed Reactor, R-101

𝑄 = 𝐹7 ∆𝐻7 + 𝐹4 ∆𝐻4 − 𝐹3 ∆𝐻3 − 𝐹5 ∆𝐻5

Stream 3,

∆𝐻3 = 1.875(27 − 31.1)

= −7.6875𝑘𝐽/𝑘𝑔

Stream 4,

∆𝐻4 = 14.2(13.5 − 27)

= −191.7𝑘𝐽/𝑘𝑔

Stream 5,

∆𝐻5 = 14.2(27 − 75.3)

= −685.86𝑘𝐽/𝑘𝑔

Stream 7,

∆𝐻7𝑃𝑂 = 1.875(110 − 27)

= 155.625𝑘𝐽/𝑘𝑔

∆𝐻7𝐻 = 14.2(110 − 27)

= 1178.6𝑘𝐽/𝑘𝑔

∆𝐻7𝐻𝑃𝑂 = 5.709(110 − 27)

 47

= 473.847𝑘𝐽/𝑘𝑔

𝑄𝑜𝑣𝑒𝑟𝑎𝑙𝑙 = [ 59.08(155.625) + 824(1178.6) + 3978.5(473.847)] +

[82.4(−191.7)] − [2142.4(−7.6875)] −
[2060(−685.86)]

= 2865561.015 + (−15796.08) − [(−16469.7) + (−1412871.6)]

= 4279106.235𝑘𝐽/ℎ𝑟

Fluid Distillation Column I, V-102

𝑄 = 𝐹6 ∆𝐻6 + 𝐹8 ∆𝐻8 − 𝐹7 ∆𝐻7

Stream 6,

∆𝐻6𝐻 = 14.2(110 − 27)

= 1178.6 𝑘𝐽/𝑘𝑔

Stream 7,

∆𝐻7𝑃𝑂 = 1.875(27 − 110)

= −155.625 𝑘𝐽/𝑘𝑔

∆𝐻7𝐻 = 14.2(27 − 110)

= −1178.6 𝑘𝐽/𝑘𝑔

∆𝐻7𝐻𝑃𝑂 = 5.704(27 − 110)

= −473.847 𝑘𝐽/𝑘𝑔

Stream 8,
 48

∆𝐻8𝑃𝑜 = 1.875(38.5 − 27)

= 21.5625 𝑘𝐽/𝑘𝑔

∆𝐻8𝐻𝑃𝑂 = 5.709 (38.5 − 27)

= 65.65 𝑘𝐽/𝑘𝑔

𝑄𝑜𝑣𝑒𝑟𝑎𝑙𝑙 = [70(11.78.6) + (4050)(21.5625 + 65.65) − (59.08)(−155.625)

+ (824)(−1178.6)
+ (3978.5)(−473.847)

= 82502 + 353210.625 − (−2865561.015)

= 3301273.64 𝑘𝐽/ℎ𝑟

Conveyer, CB-101

𝑄 = 𝐹10 ∆𝐻10 + 𝐹9 ∆𝐻9 − 𝐹8 ∆𝐻8

Stream 8,

∆𝐻8𝑃𝑂 = 1.875(27 − 38.5)

= −21.5625 𝑘𝐽/𝑘𝑔

∆𝐻8𝐻𝑃𝑂 = 5.709 (27 − 38.5)

= −65.65 kJ/kg
 49

Stream 9,

∆𝐻9𝑃𝑂 = 1.875(31.1 − 27)

= 7.6873 𝑘𝐽/𝑘𝑔

Stream 10,

∆𝐻10𝑃𝑂 = 5.759(30 − 27)

= 17.127 𝑘𝐽/𝑘𝑔

𝑄𝑜𝑣𝑒𝑟𝑎𝑙𝑙 = [ (4000)(17.127) + (50)(7.6875) − (4000)(−65.65) +

(50)(−21.5625)]

= 68508 + 384.375 − (−263678.125)

= 332570.5 𝑘𝐽/ℎ𝑟
 50

Fluid Distillation Column 3, V-103

𝑄 = 𝐹12 ∆𝐻12 − 𝐹11 ∆𝐻11 − 𝐹10 ∆𝐻10

Stream 10,

∆𝐻10𝐻𝑃𝑂 = 5.709(27 − 30)

= −17.127 𝑘𝐽/𝑘𝑔

Stream 11,

∆𝐻11𝐵 = 3.802(27 − 31.1)

= −15.59 𝑘𝐽/𝑘𝑔

Stream 12,

∆𝐻12𝐻𝑃𝑂𝐵 = 7.45(30 − 27)

= 22.35 𝑘𝐽/𝑘𝑔

𝑄𝑜𝑣𝑒𝑟𝑎𝑙𝑙 = [(4005)(22.35) − (5)(−15.59) − (4000)(−17.127)]

= 158097.7 𝑘𝐽/ℎ𝑟
 51

A/B Mixer, M-101

𝑄 = 𝐹14 ∆𝐻14 − 𝐹12 ∆𝐻12 − 𝐹13 ∆𝐻13

Stream 12,

∆𝐻12𝐻𝐵𝑃𝑂 = 7.45(27 − 30)

= −22.35𝑘𝐽/𝑘𝑔

Stream 13,

∆𝐻13𝑃𝑆 = 3.07927 − 31)

= −12.28 𝑘𝐽/𝑘𝑔

∆𝐻13𝑁𝑎𝐶𝑙 = 0.86 (27 − 31)

= −3.44 𝑘𝐽/𝑘𝑔

∆𝐻13𝐻20 = 4.2(27 − 31)

= −16.8 𝑘𝐽/𝑘𝑔

∆𝐻13𝐿𝐴 = 2.06(27 − 31)

= −8.24 𝑘𝐽/𝑘𝑔

Stream 14,

∆𝐻14𝐻𝐵𝑃𝑂𝑆𝐼 = 1.26(30 − 27)

= 3.78 𝑘𝐽/𝑘𝑔

𝑄𝑜𝑣𝑒𝑟𝑎𝑙𝑙 = [(3.78)(4281.7) − (−22.35)(4005)] − [(110.7)(−12.28) +

(83)(−3.44) +

(−16.8)(27.7) + (−8.24)(55.3)]
= 108262.524 𝑘𝐽/ℎ𝑟