CHAPTER 3 TECHNICAL FEASIBILITY3.1 METHOD TO MAINTAIN SUSTAINBILITY 3.1.1 Tilting Sterilizer Sterilization is the most important unit process as it will determine the efficiency and the effectiveness of downstream milling process and also refining process. In this plant design project, tilting sterilizer is chosen to implement in the proposed plant due to its advantages. Tilting sterilizer is a type of horizontal sterilizer where it can be tilted into inclined position. The operation of tilting sterilizer is same like the conventional horizontal sterilizer during the sterilization process. The only difference is the use of conveyor to transfer the FFB and SFB into the sterilizer instead of using cages under inclined position. The working principle of tilting sterilizer is shown in Figure 11. During the time of cooking FFB, the tilting sterilizer is in horizontal position like the normal conventional method in cooking the FFB [28]. Once the steaming process is completed, the sterilizer is tilted in an inclined position allowing the SFB be poured out under gravity into the conveyor and send into a collection hopper. At the time it in the inclined position, new batch of FFB will fed into the sterilizer from the top. After filling in the FFB, the sterilizer is lowered to horizontal position and ready for steaming process. Figure 11: The operation of Tilting Sterilizer. Although the sterilization process of tilting sterilizer is similar to the conventional sterilizer, it offers a lot of advantages in term of steam consumption, minimum breakdown, safety and manpower. The steam consumption for a conventional sterilizer is around 272.6 kg steam/ton of FFB. However, the steam consumption of tilting sterilizer is 200 kg steam/ ton of FFB. The lesser steam consumption of tilting sterilizer will reduce the energy consumption of the proposed plant which in turn reduces the operating cost and maintenance cost for boiler and steam turbine in the power plant. Besides that, the used of tilting sterilizer will reduce the breakdown of sterilization station. In conventional method, cages are moving by using tractors and winches. Breakdown normally occurred in the sterilization station when transferring the cages. Times is spent to move the cages and it is very human dependable. Workplace accidents also occurred during the transferring of cages in and out the sterilizer. The steaming process is occurred in high temperature where workers tend to injure when monitoring the cooking process. Implementing the tilting sterilizer can help to increase the workplace safety and minimum the breakdown due to the automation system to filling in the FFB and discharge the SFB. Apart of that, the tilting sterilizer is easy to operate where the fully automated features only required 2-3 operators to operate the complete sterilization station. This also helps to reduce the manpower in our proposed mill. By implementing the tilting sterilizer in our proposed plant, the system can be lead to improvement in productivity and consistency in throughput. The proposed mill is able to run smoothly and achieve the target production capacity per day. The constant throughput can make sure other byproducts able to produce on time and maintain the income of the proposed mill throughout the year. Hence, tilting sterilizer is a technology that able to sustain the operation of the proposed palm oil mill. 3.1.2 Production of EFB Fiber Over the last decade, the interest to use biomass as a renewable resource has grown rapidly especially for energy and material applications. EFB is the largest amount of solid biomass generated from palm oil milling activities. Instead of applying the conventional methods to handle the EFB, the proposed mill will produce EFB dried fiber from EFB by undergo a series of machining steps to reduce it moisture content [24]. Figure 12 shows the EFB dried fiber after reduction of moisture content. Figure 12: The EFB dried fiber. The common methods to handle EFB in palm industries are by incinerating the EFB, mulching and dumping into landfills. These methods tend to produce environmental problems where burning the EFB in an incinerator will release dark smoke. Dark smoke will contains innumerable substances of unknown toxicity which caused the effects on the environment in the form of global warming, photochemical ozone or smog formation. Mulching is another common method used to dispose EFB in palm oil mills. Mulching will cause soil pollution as EFB contains high amount of oil residue where many palm oil mills did not carry out oil recovery of EFB. Hence, oil spill will occur on palm oil plantation. Indiscriminate dumping of EFB also causes the additional methane emission into the atmosphere. Methane is one of the greenhouse gases that contributed to global warming. The GWP value of methane is around 21. By introducing the EFB fiber production line, the proposed mill is able to handle the large volume of EFB via an eco-friendly way. The production process is pollution free and no hazard making it a long term solution to handle this solid biomass. On other hand, the market demand of replacement fiber for natural fiber makes EFB fiber a promising venture. The selling price up to RM 680/ton makes it able to increase the revenue of the proposed palm oil mill [24]. The plant is able to sustain in a long term period at the same time it can generate wealth from waste by utilizing the solid biomass. This proposed method is able to bring positive impacts toward people, profit and planet. 3.2 PRODUCT SPECIFICATIONS AND PROPERTIES 3.2.1 Crude Palm Oil In the proposed palm oil mill, the main product is CPO. According the MALAYSIAN STANDARD, the crude palm oil produced by every palm oil mill needs to meet the standards issued by MPOB. Crude palm oil is defined as the oil derived from freshly pulp of the fruit of Elaeis guineensis Jacq by mechanical expression [5]. In general, the standard requirements of palm oil can be divided into Identity Characteristic and Quality Characteristic. 3.2.1.1 Identity Characteristic Figure 13 shows the identity Characteristic of palm oil where the ranges given are not mandatory and are considered as guideline levels. Figure 13: Guideline identity characteristics for palm oil. 3 EFB Fiber . min 0. 133. It is normally sell to other company to produce palm kernel oil. max Color.2 Palm Kernel Palm kernel is the edible seed from oil palm tree.0 4. % max Moisture and Impurities.5 Standard Quality Grade 5.2 Quality Characteristic The color of crude palm oil shall be bright.2.35 mm max DOBI. oval between 1 and 2 cm long and have a shell that is as hard as stone.0 2.2. Characteristics Free fatty acid (as Special Quality Grade 2.3.3 3.25 2.2.1. At the time of shipment.8 0. clear and orange-red. crude palm oil shall be free from foreign and rancid odor. % max Peroxide value . Besides. Table 5:Quality requirements for crude palm oil. the crude palm oil shall conform to the requirement prescribed in Table 5. 3.0 palmitic). meq/kg max Anisidine value. Figure 14: Palm kernel.25 1.0 2. The kernels are brown.0 5. Figure 14 shows the palm kernel. Property Value Size Moisture Content Calorific 75-250 mm 17.1 Raw Material In palm oil milling process. A boiler is used for steam generation and it consists of two principal parts namely the furnace. the raw material is freshly pulp of the fruit from species Elaeis guineensis Jacq which also known as FFB.1 General Process Description In the proposed palm oil mill. This is to avoid the rise in free fatty acid during prolong storage. Water is used as boiler feed to generate steam. Table 6: Characteristic of EFB Fiber. the main products are CPO. the process also needs water and steam to produce CPO. The baler fiber will in the size between 100 Kg with dimension 510 mm X 760 mm X 510 mm [24]. the byproducts are palm kernel and EFB fiber. and the boiler itself which is a device responsible for the heat changes of water into steam [18]. The steam will used in power station to generate electricity by steam turbine. 3. The raw material need to process within 24 hours after harvesting. the mill also required diesel for vehicle usage such as tractors and showler.5% 18800 kJ 3. The EFB fiber will sell in baler form for local or oversea distribution. Furthermore. On the other hand.3. Meanwhile. Table 6 shows the characteristic of EFB fiber that produced in the proposed plant.2.2 Methods 3. CPO is produced from FFB by passing a series .3 PALM OIL MILLING PROCESS 3.EFB fiber is the green products from the proposed plant which able to replace the use of natural fiber.3.3. which usually provides heat through the burning of a fuel. Apart from that. diesel generator also used diesel to generate power for palm oil mill. 2 Fresh Fruit Reception The first stage to produce CPO is receiving FFBs. sterilizing and threshing of bunches to free the palm fruit. Meanwhile.3 FFB Loading Ramp . Figure 15: The truck passing through the weigh bridge and its weight was recorded. The initial weight of the truck will be determined. the palm kernel will undergo a separate process and used to produce dry kernel. 3.2. A sequence of processing steps had been established to extract high yield of good quality CPO.3. The crude oil will undergo further clarification and purification before store in the oil room. During the milling process. Hence. After sending the FFBs. digestion and pressing out the oil. The biomass include EFB. palm shell and mesocarp fiber. waste products will be formed which known as biomass. While the remaining biomass will be utilized for other used in the proposed mill. The dry kernel will be sent to another factory for further processed. EFB will undergo a series of pretreatment process to produce value added products which is also another by-product of the proposed mill known as EFB fiber. 3. Figure 15 shows the lorry carried the FFBs entering the mill by passing through the weigh bridge.2. the weight of the truck will be determined again.3. The overall palm oil processing included the receptions of FFBs.of mechanical processes. the quantity of the FFBs received can be calculated by subtracting the final weight of the lorry from its initial weight. 3. Figure 16 shows a typical loading ramp in palm oil mill. The conveyor will transfer the FFBs into the cages.3.Loading ramp hopper is the temporary place to store FFBs before processing. Figure 17: The tilting sterilizer in sterilization station. The automated feeder will transfer the FFBs into the sterilizer and transfer out the SFBs to threshing station.2. 3.5 Threshing .3. The sterilization process is running for 90 minutes at pressure of 50 psig.2. Although some stream goes out with the condensate where most of it is passed to atmosphere through a stream exhaust valve at the top of the sterilizer. It is a sliding platform made of mild steel where lorry unloading the FFBs.4 Sterilization Station Tilting sterilizer as shown in Figure 17 is used in the sterilization station. Figure 16: The loading ramp in palm oil mill. The stream usually enters sterilizer through a single pipe at the top of the vessel and a spreader plate is fitted running the whole length of the sterilizer. The steam consumption is 200 kg steam/ ton FFB [28]. The SFBs from the tilting sterilizer will flow to the thresher via auto feeder. This is carried out in the steam heated vessels provided with stirring arms and known as digester or kettles.6 Digestion Digestion process is carried out to reheat the stripped fruits so that the pericarp loosened from nuts. The stirring arms will stir and rub the fruits to loosen the pericarp from the nuts and at the same time breaking open as many of the oil cells as possible. 3. The effect of inadequate digestion is to increase the oil loss in press fiber and this is one way in which it may be detected. Then. A typical digesters used in palm oil milling process is shown in Figure 19. However. . It is essential for good digestion that the level of fruit in the digester kept as high as possible all the times at about 90°C.2. The digester is kept full since the digested fruit is drawn off continuously from the bottom of the vessel while freshly stripped fruit is added at an equal rate.3. Figure 18: Thresher used to detach sterilized fruitlets. The thresher will rotate to detach the fruitlets from the bunch. the results of poor digestion are noticeable if the press cake is examined when pieces of undigested pericarp will be found in the fiber and some of these pieces may even be still attached to nuts. The EFB will send to bunch crusher for crushing. This is to maximum the holding time and stirring effect per revolution. the sterilizer fruitlets will send to digester and EFB will send to EFB fiber production line. This is to make sure that 100% of stripping sterilized fruits from bunch. Figure 18 shows the typical thresher used in the palm oil mill. The digester has vertical rotating shaft which are attached to the stirring arms. 3.3. Figure 20: The batch type hydraulic press used in palm oil milling process. Then. The hydraulic pressure is gradually built up.2.7 Pressing After digestion process.3. Before pressing.Figure 19: The Digester used in palm oil milling process. 3. the fruits will be pressed by batch type hydraulic press to obtain oil.8 Screening . The maximum pressure is maintained for several minutes before it is released. the top plate is withdrawn and the sections of cake expelled by raising the ram. The screw press machine is shown in Figure 20.2. The nuts and fiber will be pushed out and for further processing. the cage is filled with digested fruit to ensure that the press cake formed is divided into conveniently sized portions. When the press cage is full with fruit. a heavy top plate is moved into place to close the top of the cage. The diluted mixture is passed through a screen to remove coarse fiber before send to clarification tank. The oil is dried in vacuum dryers. centrifuge. Because of the non-oily solids the mixture is very viscous. Oil from the top is skimmed off and purified in the centrifuge prior to drying in vacuum dryer. water. The addition of dilution water with temperature of 100 °C provides a barrier causing the heavy solids to fall to the bottom of the container while the lighter oil droplets flow through the watery mixture to the top when heat is applied to break the emulsion (oil suspended in water with the aid of gums and resins). . Vibrating screen is used to remove all fibrous material from crude oil and recycle them to the digester. fibrous material and ‘non-oily solids’. Figure 21: A Vibrating Screen used in palm oil milling process. Figure 22 to 25 show the oil clarifier. A settling time of 3 hours is acceptable. A typical vibrating screen used in palm oil mill is shown in Figure 21.2. The final crude palm oil is then cooled and stored.3. 3. cell debris. Hot water is therefore added to the press output mixture to thin it. cooled and sent to storage tanks. The lower layer from the clarification tank is sent to the centrifugal separator where the remaining oil is recovered.9 Clarifying and Drying of CPO The oil mixture is heated to 85-90◦C and allowed to separate in the clarification tank.The fluid coming out of the press is a mixture of palm oil. oil purifier and oil dryer used in clarification station. The lower layer is known as sludge which is the waste generates from this stage. Figure 22: Oil clarifier Figure 23: Centrifuge . There are two ways for separation of nut and fiber either by mechanical separation or air separation.10 Oil Storage CPO produced will store in storage tank before dispatching from the mill. Normally. the oil is transferred to oil room while the nut and the fiber will go further processing.025% and 0.Figure 24: Oil purifier Figure 25: Oil dryer 3. The storage tanks used in palm oil mill are shown in Figure 26. the storage tank needed to be lined with suitable protective coating to prevent iron contamination from the tank. 3. There are L-shape angles to increase the surface area and thus to increase efficiency of loosening fibers and nuts. The speed of rotation of ribbon is slightly higher than the others conveyor. Increasing the length of CBC will increase the separation time and thus improve the separation efficiency. At the same time.3.2. Hot water or low pressure steam heating coils will be used to prevent solidification and fractionation.3. The impurities and moisture is allowed below 0. Before the separation.11 Palm Kernel Processing After the pressing process. The quality of crude oil must be kept. the temperature of the storage will maintained at around 50 °C. air separation is chosen to separate the nut and fiber.2. In the proposed mill. . It is around 65 rpm.15%. CBC is used to loosen the nuts from the fibers. Figure 26: The oil storage tanks used to store CPO. Depericaping is the process which separates the nut and fiber. the FFA content must be below 3-5% while DOBI is need above 2.3. moisture of the fibers and the nuts are slightly removed. Besides that. Hence. dried kernels are transferred into kernel bunker for storage while the shell is keep at shell storage. the kernels are transferred into kernel silo for drying while the shells are transferred to shell line. broken kernels and shells. For nuts. The fibers are sucked up by air while the nuts drop down. There is shaking grate in the nut silo to control nut flow and ensure their retention time in silo. After that. they are easily separated. they are transferred into hydro cyclone to separate the whole kernels. For vertical column type air separator. Vertical air current is maintained absolutely parallel through whole height and cross section of the column in order to ensure the high efficiency in separation. The kernel bunker and shell storage place are shown in Figure 27. Then. the high velocity will affect the fibers going upward and the nuts will fall downward. dirt and shells. nuts are transferred into ripple mill to crack the nuts. The fibers are transferred to fiber cyclone. They are transferred into vibrating screen to separate the particles and oil. Lastly. whole kernels. good sterilization. partially cracked nuts. digestion and pressing process will ensure the fruit is cooked well. Then. such as stones.In addition. The nut is expected with presence a little bit of fibers. The fiber cyclone creates a momentum to remove moisture from fibers. After that. they are passed through the air lock or de-stoner to remove the big particles. The fiber is sucked by a fan through the open lower end of the column and is blown to fiber cyclone. the nuts are transferred into nut silo for drying purpose. There are un-cracked nuts. broken kernels. Stones will fall down and light particles are sucked to upper side. After the separation. Then. The fibers then are transferred by conveyor to boiler. they are passed through the winnowing system in order to blow out the small dirt and shell. they are transferred into polishing drum to loosen the kernel from the shell and then. the fibers and nuts are separated by air separator/air lock. The pericarp will easily be detached from the nuts and will also help the breakage of shell from kernel. It will distribute the nut evenly. Next. . The separated nuts drop conveyor. The strand fibers will in the size between 76-250 mm.3. the EFB baler fiber is then ready for market. Figure 28 shows the by-products. 3. the dried strand fibers will undergo the last process that is to be bailed into a more compact size like blocks using a bailing machine.12 EFB Fiber Production Firstly.5 %. the fibers were transferred into the Hammer Mill Machine in order to break the fibers into single strand fiber. Shredded EFB were being pressed in order to extract the liquor from the bunch. EFB baler fiber. After being bailed.2. . Next. Lastly.Figure 27: Kernel bunker and shell storage. Figure 28: The baler fiber produced from EFB. This process will reduced the moisture content of the fibers below 17. The crushed EFB were being shredded into a smaller size before it is being pressed in the EFB press machine. The baler fiber will in the size between 90-100 Kg with dimension 510 mm X 760 mm X 510 mm. The fibers were then undergoes a drying process by using a Rotary Dryer with dust remover system. the crushed EFB from threshing process were being transferred to EFB collection point. to transfer the heat energy to the water in the water circuit and convert it to steam. Firstly.13 Boiler Station Boiler is the closed vessel in which water or other fluid is heated under pressure.3.2. There are 2 types of efficient boiler. the hot water will flow down to mud drum which keeps the hot water. The flow of boiler house is shown in Figure 29. the water will flow in steam drum. Then. Normally. In this scenario. the water is pumped into the boiler. the water becomes steam and steam will flow into steam drum again. supply steam for generating electricity and to supply steam for other process units in the mill. After that. . the water tube boiler is used. the water will flows through tubes and the heat is transferred into water through glass tube. such as fire tube boiler and water tube boiler. At the same time. Then. The fluid is then circulated out of the boiler for use in various processes or heating applications. mesocarp fiber and palm shell are used as fuel for boiler and are transferred by conveyor.3. Figure 29: The flow of boiler house. The main functions of the boiler house are to convert chemical energy to heat energy. Ashes will take away into dust collector cone while smoke will be discharged through chimey. After that.14 Power Station In power station.3. However. The wet steam flows into superheater which converts the wet steam into dry steam at temperature of 250°C. 3. . the black smoke indicates heavy erratic firing or lack of secondary air. Heat energy of steam is converted to kinetic energy and finally is changed to electrical energy. The ashes are manually taken out by the operators through doors of furnace. The steam will generate the electricity in turbine at pressure of 31 and 32 bars. Light brown haze should be observed but white smoke is allowed because white indicates excess secondary air. So. After certain period of combustion. A steam turbine is a mechanical device that extracts thermal energy from pressurized and converts it into useful mechanical work. the blowers are used to clean the scaling of the boiler. the ashes are taken away by Induced Draft (ID) fans and pass through air lock which separates the ash and smoke.After complete combustion. ashes will stick to the boiler tubes and it will affect the heat transfer. Manual cleaning is also required. the steam will be stored in steam receiver for supplying to heating applications. steam turbine and diesel generator are used to generate electricity for operating all the motors and internal usage in the mill. the dry steam passes through the main steam stop valve and meet the water separator which separate the condensate because condensate will damage the turbine. After that. The main equipment used in power station is shown in Figure 30. Steam turbine plays an important role in power generation.2. .2. This system is reliable. 3. stable and capable of producing a final discharged with BOD less than 100mg/L. A typical effluent ponds system is shown in Figure 31. A2 Figure 31: Effluent ponds system.Figure 30: The steam turbine and diesel generator.15 POME Station Ponding system is the most common treatment method for POME.3. It is concluded by the bacteria is active and can functions well. factory hot sludge is pumped into effluent ponds. the upper solid is easily removed. The oxygen content is higher and do not lead side effect to the environment. The remaining waste water flow into polishing pond F1 and is pumped into clarifier. The cooling pond plays a role to cool down the sludge with combining the waste water from primary aerobic pond. They will change the dissolved solid into suspension solid. the effluent is pumped into the bio-tower that acts as filtration medium. The Biology Genesis activates the natural bacteria in pond and they function to build up the reaction.5. The retention time of this three ponds are 8 hours. The sludge is pumped into anaerobic pond A1. After 8 hours. Then. BOD is the amount of dissolved oxygen needed by aerobic biological organisms in a body of water to break down organic material present in a given water sample at certain temperature over a specific time period. Firstly. they will discharge into BC2. The plastic coils trap the solid and the remaining waste water will flow to bottom of bio-tower. The BOD is 3000 ppm that means quantity of oxygen is very low. the waste water flows into polishing pond F1 and discharge into trenches or flat bed. Then.Effluent ponds play an important role in all factories. The temperature is around 53°C and pH is 4. waste water from anaerobic pond BC2 will discharge A3. Then. There is the bypass between pond F1 and pond F2 in order to avoid overflow of the effluent. The sludge or waste water will be managed before they go into river or into ground. The waste water flows into settling pond which separates the solid by their size. . the sludge A1 will discharge into anaerobic pond A2 while the sludge from B1 and C1 will discharge and combine into anaerobic pond BC1. The flat beds play role to filter the contaminant. So. The BOD of output of the effluent must be kept below 100 ppm which is standardized by Department of Environment. The clarifier separates the solid and liquid by momentum. the combined sludge will go into primary aerobic pond A4. A5 and BC3. The color of pond is greenish and the bubbles on the surface of pond can be observed. Finally. At the same time. The BOD of primary aerobic pond will decrease. B1 and C1. Sludge from A1 is discharged into anaerobic pond A2 and A3. The flow chart of raw water treatment plant is shown in Figure 32. flocculation and filtration. coagulation.3. the tests of pH. Overflow raw water pond is used to store the overflow raw water. 4 basic steps involved in water clarification are pH adjustment. pH of raw water is needed to be neutralized. Raw water is required as boiler feed and others process in palm oil mill. This process is called as charge neutralization . Normally. the raw water is dosed alum as coagulant (aluminium sulphate) to clog the dissolved solid into suspended solid. Soda (sodium carbonate) is dosed into raw water to increase the pH.16 Raw Water Treatment Station Figure 32: Flow chart of raw water treatment plant. the total hardness and turbidity of raw water are carried in treatment plant. After that.2.3. 3 and sand filter No. For daily usage. The clarifier used in water treatment plant is shown in Figure 33. Clean water will flows into concrete holding pond. Then. the water can is pumped to overhead water tank No. The analysis of pH. the water is pumped into earth pond or drinking pond and to sand filter No. turbidity and chlorine content are carried out to ensure the quality of water produced. 1 for storage. The sand filter used in raw waste treatment system is shown in Figure 34. Lastly. Then. There are line for factory usage and line for daily usage. the water is pumped into sand filter No. piping system in this line is made by stainless steel in order to prevent rusting and corrosion occurs. 2 for removal sand.process. The solids are sedimentated at the bottom of the clarifier. After that. For factory usage. 4. then will lead the breakage of piping system in factory. . Figure 33: The water clarifier. the water flows into clarifier. In the line for factory. the clean water is pumped to overhead water tank No. the chlorine is not dosed in water because the chlorine will precipitate and oxidize the pipes. Normally. the total hardness. 2. chlorine is added into water because chlorine can kill bacteria. 1 and No. The drain valve is opened to discharge the suspended solid out to drainage system until the water is looked clean. Polymer as flocculant is added into raw water when the water is too dirty and very yellowish color. Figure 34: The sand filter. . The equipment for wastewater treatment plant and raw water treatment plant is not included in this study. the by-products are palm kernel and EFB fiber. Fruit Loading Ramp Quantity Specification 1 Model . A series of mechanical processes is used to produce those products.6 kW . [9] No Machinery FRUIT RECEPTION 1.05 kW Dimension .12 door X 15 ton = 180 ton Power . The costs of the wastewater treatment plant and raw water treatment plant will be estimated using Lang formula in the economic feasibility part. Table 7:The main equipment and its specification. Meanwhile. The Table 7 shows the quantity of the main equipment required in the proposed plant and the specification of the respective equipment.Electronic Weighbridge Capacity .0.3 m (H) 1 Type . The FFB being processed for each batch is 30 ton with total of 8 batches will be processed to achieve design capacity of 240 ton FFB/day.2 m (L) X 3 m (W) X 0.4 EQUIPMENT SIZING AND SPECIFICATION In the proposed palm oil mill.40 ton Power . The selection of equipment is based on the capacity per batch of FFB will be processed. the main product is CPO. Road Weighbridge 2.3.5.Avery Berkel J 311 Type .Vertical sliding gate Capacity . 60 Type .30 ton / hour Power .STERILIZATION STATION 3.15 kW Dimension .2 m Inlet & Outlet Door – 1.30 ton / hour Power . Bunch Crusher .5 m Diameter .2.Besteel Size 30 T Type .23 kW Shell Length – 7. Tilting Sterilizer 1 Model .2 m 1 Model .Double Deck Bunch Crusher Capacity .5.5 kW Length .5 m Plate Thickness – 0.KH-7.015 m THRESHING STATION 4.Rotary Drum Capacity .10 ton / hour Power .18.219 m (L) X 0.9 m (W) X 1.264 m (H) 5.CB Thresher Type .8 m Diameter .3. Thresher 1 Model .Pressure Vessel Capacity . 3 m PRESSING STATION 7.1.CB Vertical Digester Type .2. Screw Press 2 Model . Digester 2 Model .20 ton / hour Power .CB Screw Press Type .Twin Press Capacity .3500 L Height – 3.DIGESTION STATION 6.5 kW Dimension .7 m (W) x 0.18.29.8 Kw Volume .20 ton / hour Power .78 m (H) .Unjacketed Capacity .32 m (L) x 0.1 m Diameter . 000 L Height .8 m .1 m 9.4 m Diameter .Xb 6000L Separator Type .15 ton / hour Power .LST1-12 Type . Sand Trap Tank 1 Model .1.2.1. Hot Water Tank 1 Model .Storage Tank Capacity .12.CLARIFICATION STATION 8.AMKCO Double Deck Vibratory Separator Type .6000 L 10.86 kW Diameter .Vibro Energy Capacity .2. Vibrating Screen Separator 2 Model .Cylindrical conical bottom Capacity . 6.2 m (H) 12.12000L Dimension .4.KDE-S-12000L Type .4 m (W) x 1.8 m (L) x 2.95 m .2 m Diameter .Cylindrical conical bottom Volume .Rectangular Storage Tank Volume .4.000 L Height .IY-CXGC Type . Crude Oil Tank 1 Model .120. Continuous Settling Tank 1 Model .11. AMKCO Single Deck Vibratory Type . Sludge Separator 1 Model .Cylindrical conical bottom Volume .30000 L .VEN 30 Type .15 ton / hour Power .13.Cylindrical conical bottom Volume .000 L 14.25.6 kW 15.ZG-25.Vibro Energy Capacity . Sludge Oil Tank 1 Model .1. Pure Oil Tank 1 Model .000L Type . DY-CG-002 Buffer Tank Type .3000 L 17.XG Sludge Tank . Sludge Drain Tank 1 Model .Cylindrical Volume .16. Sludge Buffer Tank 1 Model . 6 ton / hour Power . Oil Purifier 2 Type .7.000 L Model .Steel tank rectangular section Volume .Electromotor Capacity .18.18.5 kW .Alfa Laval Purifier MFPX 307 Type . Oil Storage Tank 1 1 Model .19.11 kW Model.CFL-Y Oil Tank Type .Storage Tank Volume .Vacuum Pump Capacity .15 ton / hour Power . Vacuum Oil Dryer OIL STORAGE TANK 20.PT Vacuum Dryer Type .1000000 L . T-S1000 Oil Tank Type .DG Cake Breaker Conveyor 21. Cake Breaker Conveyor 1 Model .500000 L DEPERICARPING STATION 22.Storage Tank Volume . .CPO Daily Storage Tank 1 Model . 12 ton / hour Power .DG D06 . Depericarper Vertical Column 1 Model .8m (W) 23. Nut Polishing Drum 1 Model .Induced Draught Capacity . unjacketed model screw Capacity .DG DP012 Type .12 ton / hour Power .11 kW Dimension . Type .11 kW Dimension .8m (L) X 0.22m (L) X 0.Semi scroll.8m (W) X 4m (H) 24. 7.Rotary without roller sprocket Capacity .5m (L) X 3.5m (W) X 4m (H) .49 kW Dimension .5m Model .1m Length . Fan (Suction).Induced Draught(Fiber Cylone). Pneumatic Fiber Transport System (Including Ducting. Airlock) 1 Type .6 ton / hour Power .6 ton / hour Power .25. Fan.8.5 kW Diameter . Fiber Cylone.DG Palm Oil Pneumatic System Type . Airlock(Rotary) Capacity . 6 ton / hour Power .Cylindrical Storage Tank Capacity .VG-8T Type .30000L Diameter . Nut Silo 1 Model .6m 27.Ripple Mill Capacity .KERNEL STATION 26.11 kW Ripple Mill . 1 Model .TCK05605 Type .2.5m Length . Discharge Pump.11 kW 29. Conical Separation Tank.30000L .28. Pump.Circular section with conical bottom Capacity .BC30 Type .6 ton / hour Power . Claybath (Including Mixer and Clay Solution Tank.DG Claybath System Capacity . Kernel Silo 1 Model . Vibrating Screen) 1 Model . BOILER STATION 30. Boiler 1 Model - Takuma N 600 Type - Water Tube Boiler Capacity - 36 ton / hour Working Pressure - 22 bars Temperature - 260°C POWER STATION 31. Steam Turbine 1 Model - W-1350C Type - Non-Condensing (Back-pressure) Capacity - 28 ton / hour Output Power - 1200 kW Speed - 5400 rpm 32. Back Pressure Vessel 1 Model - BEITE 012 Type - Pressure Vessel Capacity - 12000L Working design Pressure : 3.5 kg/cm² 33. Diesel Engine Set 1 Model - Komatsu SAA6D125-P400 Output Power - 450 kW Dimension - 3.3 (L) x 1.12 (W) x 1.79 (H) 34. Fuel Tank 1 Model - Fuel Oil Double Wall AST - ULC S602 Type - Cylindrical Fuel Tank Capacity - 20000L Diameter - 1.94 m Length - 4.5 m EFB STATION 35. EFB Shredder Machine 1 Model - SE/BCE-1 L Capacity - 6 ton / hour Power - 75 kW Dimension - 3.1m (L) X 2.2m (W) X 1.3m 36. 1 Model - SE/SSP 50 Capacity - 6 ton / hour Power - 45 kW Dimension - 3.8m (L) X 2m (W) X 1.25m (H) EFB Fiber Press 37. Hammer Mill Machine 1 Model - YTH-7.100 Capacity - 6 ton / hour Power - 75 kW Dimension - 1.145m (L) X 1.07m (W) X 1.35m (H) 38. Rotary Dryer 1 Model - BN30 Type - Rotary Capacity - 6 ton / hour Power - 30 kW Dimension - 5.5m (L) X 3.5 (W) X 3m (H) 1m (W) X 5.SHBA2-200 Capacity .39. Baler Machine 1 Model .6m (L) X 5.7.15 baler / hour Power .35 kW Dimension .1m (H) . palm shell and mesocarp fiber will used as boiler fuel to generate electricity for internal usage. Palm shells are used as boiler fuel in steam power plant due to its high calorie value and low content of ash and sulphur [7]. Figure 35: bulk physical and chemical characteristics of palm shell. Mesocarp fiber is another waste product from palm oil milling process. As the EFB will be utilized to produce EFB fiber. mesocarp fiber and EFB. dumped in landfills and sell to plantation for mulching. Figure 35 shows the bulk physical and chemical characteristics of palm shell. the old disposal methods of EFB are burning in incinerator.3. In conventional method.5 WASTE PRODUCTS A large amount of biomass is produced at palm oil mills during the processing of FFB. 5 % of palm shell will be produced. all the palm shell produced will be used to generate energy in our proposed plant. For every one ton of FFB processed. Those biomass included palm shell. Meanwhile. Mesocarp fiber is contained in the oval shaped palm fruit which consists of yellowish red oily flesh . Therefore. the waste products in this proposed mill are palm shell and mesocarp fiber. Palm shells are the shell factions left after the nut has been removed in the palm oil mill. Figure 36: The mesocarp fiber on the fresh oil palm fruit.6. Therefore. FFBs are cooked using steam as the heating medium in a sterilization process. the mesocarp fiber is mixed with kernel shell and being utilized as a medium of boiler fuel to generate electricity for the proposed mill. Being the first process in the mill. 3. . Since palm oil mill is self-sufficient in energy.mesocarp and single seed Palm Kernel Nut.1 Continuous and Conventional Sterilization In order to maximize the production of CPO in a palm oil mill. A lot of steam is used in this part of the mill that accounts thirty to sixty percent of the total process steam supplied from the boiler. Figure 36 shows the mesocarp fiber on the fresh oil palm fruit. various technologies have been developed by the people in the industry. Mesocarp fibre contains less than 6% oil residue with calorific value of 19000kJ/kg [7]. the type of sterilizer technology chose greatly affects steam and power consumption of the sterilization process. sterilization is a crucial part of the whole processes since it influences the quantity and the quality of CPO produced later.6 TECHNOLOGY AND ALTERNATIVE ROUTES FOR PRODUCING CRUDE PALM OIL 3. The mesocarp fiber is then separated from Palm Kernel Nut by cyclone separator. there are many types of innovation and improvement of conventional type sterilizers such as cage material handling using indexing system. as opposed to a vertical sterilizer. palm oil mill owners usually choose one of these technologies to be implemented. From this batch type process. This involves the discharge of condensate and air in the pressure vessel. the sterilization process of fresh fruit bunches is carried out in cylindrical pressure vessels that lies horizontally or vertically. The most common type of sterilizer used is the horizontal sterilizer fitted with two quick opening doors [11]. and various other equipment are needed for handling these cages. empty fruit bunch. It is vital to ensure that the sterilizer operates correctly so that it will produce minimum oil loss and generate proper oil extraction rate. Thus. To comply with the amount of FFB processed per day. tippers. the cylindrical vessel sterilizer has fairly good disposition because the oil palm fresh fruit bunches placed in cages with a low stacking height are more uniformly spread out in this position across the length of the elongated vessel.With the growing demand for energy efficiency at palm oil mills. The concept of conventional sterilization is shown in Figure 37. the selection of sterilizer is based mainly on its relevance to steam and power consumption because this will affect the overall energy efficiency of the palm oil extraction process. In a conventional sterilization. With horizontal position. Oil losses that correspond from sterilizing process are oil losses in condensate. time and steam usage can be saved. conveyors. fasten pressure built and evenly distributed steam. Basically sterilizers are design to operate continuously or in batches. when pressurized steam is injected into the interior of the horizontally positioned cylindrical vessel. un-striped bunch and partly striped bunch. Fruit cages are used to transfer the bunches in and out of sterilizers. transfer carriages and tractors. Vertical Sterilizer and Tilting Sterilizer. Currently. including overhead cranes. The introduction of a three peak cycle process in the sterilization process allows a synchronized integration. The conventional and continuous type processes are described to select most economical sterilizer technology. CMC Systems. the steam can reach out to different directions and corners of the contents within . After that they are filled with steam under pressure as a batch process. The concept of continuous sterilization process is shown in Figure 38. A significant advantage of continuous sterilization over batch sterilization is that it renders the palm oil milling process a continuous operation from start to finish. Due to the low stacking height of the fruit bunches in the cages. when the received crops are less in capacity. condensate drains out freely from the fruit bunch stack facilitating heat penetration. Batch process however arrests the oil quality deterioration due to enzymatic activity. This will result in the increment of FFA content in the fruits and leads to poor quality of CPO. The continuous sterilizer was introduced as an alternative to pressure vessels and batch process of sterilization and offer advantage in terms of use of unpressurised heating cabin and steady steam demand for the sterilization process [12]. Initially. making it cost-effective to automate the bunch handling operations. Continuous type sterilization process is also famously adopted in palm oil mill due to its much beneficial factors if compared to batch sterilization. It also eliminates the use of . Generally. the process is carried out in a heating cabin operating with steam at atmospheric pressure. Figure 37: Concept of Conventional Sterilization Process. The splitting of the fruit bunches facilitates steam penetration into inner layers of the fruit bunch.the cages thereby helping treatment of the fruit bunches. the fruit bunches are split using a mechanical splitter machine before it is transported by scraper conveyor within the heating cabin to expose the material to steam. Considerable space and a system of rails are required to facilitate the fitting of the cages and the charging and discharging of the sterilizers. In current technology. the fruit bunches will be bulked and processed the next day. and simplifies mill operation. overhead cranes. the process significantly improves strippability of bunches as researched by Sivasothy. Figure 38: Concept of Continuous Sterilization Process. However. palm oil mills are made safer for operators. transfer carriages and tractors and thereby facilitates the design and construction of mills having significantly smaller footprints than conventional mills The process leads to improvements in the design of mills. . Mills using the process can be more easily supervised and automated. the continuous sterilizer suffers a significant disadvantage in terms of high steam consumption.sterilizer cages. The use of conveyors in place of cages also minimizes spillage of fruits and oil making mills cleaner. reduces the number of process operators. lowers the operating and maintenance costs. tippers. Although the new process is carried out using steam at low or atmospheric pressure. rail tracks. A plus point is that avoiding fluctuations in the steam flow to the sterilization process provides a considerable advantage in maintaining overall process steam pressures and temperatures in the mill. By avoiding the use of pressure vessels for sterilization and cages and cranes for the handling of bunches. Then. FFBs will be loaded through a loading ramp hopper to feeding point. It consists of bogies.1 Horizontal Double-Door Sterilizer with Wire Rope Winch System for Cage Movement One of an outdated technology of a conventional palm oil mill is the usage of wire rope winch system for cage movement.6. The system is specially design for palm oil mill horizontal line pull for position in between sterilizer rail track line.6.3. Figure 39 to 41 show the typical equipment in conventional sterilization station. The process of marshaling is facilitated by arranging 7 cages in train order.2. wire rope and hook. The conventional system is still considered impractical due to the facts . The wire rope winch system is used to transport the fruit cages from the loading area. Figure 39 to 41: The conventional sterilization station with the used of winch system and horizontal sterilizer.2 Common Batch Sterilizers 3. In the reception area of a palm oil mill. winch. once again the train of fruit cages will be winched into the tippler to be rotated for unloading purposes. An intermediate between the loading area and the sterilizer is the cage transfer carriage which acts as lane changer for the cages. guide bollard. After fed with FFB. After sterilization process. rail track system and fruit cages transfer carriage. The train of cages runs out at the further end of the arches by means of wire rope attached to hydraulic capstans [23]. It is a human dependable system since operators need to manually handle the rope between the fruit cages and the winch system during an operation. they are fed into the fruit cages which act as holder of FFB to be sterilized inside a long horizontal sterilizer. the fruit cages will be transported using the system to pull them along a rail track system into the sterilizer. bulldozers.2 Horizontal Double-Door Sterilizer with Indexing System for Cage Movement A better way to replace the wire rope winch system is the usage an auto-cage transporter known as the indexing system [11]. it is easier to monitor via an automation system with remote console panel . It is a cage material handling that eliminates the need and use of tractors. Furthermore. capstans and winches that have been applied in a conventional system. install and uninstall chain from cages.that the sterilizer uses horizontal technology which posed greater impacts towards the workers safety and health. Some of the work activities require operators to perform the works manually such as closing and open the sterilizer door.2. The so called twin cage indexer system is only suited for long horizontal double door sterilizer installed in a palm oil mill. Besides that.6. Figure 42: Indexing system for cage movement. working in confined space. On top of the sterilization process. 3. An advantage of the indexing system is it improves working conditions and safety for operators as well as reducing manual handling of the cages. a platform is installed providing a good view of the production area. bumper-to-bumper cage movement for single cage and/or twin cage movement. The system is less maintenance. Figure 42 shows the indexing system for cage movement. leading to improvement in productivity and consistency in throughput. and replace packing of sterilizer door. it is a much efficient material handling system for the sterilization process to perform synchronization and control of equipment from fruit reception to sterilizer station and to threshing and press station. Continuous Systems for Cage Movement Another method for the movement of fruit cages is the CMC system. As the building footprint is small.2. the system provides ease of operation. Figure 43: CMC system for cage material handling. Modular. the CMC system is only for horizontal sterilizer with single door in sterilizer station. If compared to the indexing system.3 Horizontal Single-Door Sterilizer with Compact. In terms of control. . Figure 43 shows the CMC system that implemented in the sterilization station. continuous run material handling system for the sterilization process to perform synchronization and control of flow of FFB from loading ramp to sterilizer station and then to threshing and press station. This leads to significant improvement in productivity and enhanced throughput. the system has low maintenance cost due to the reduced wear and tear by good and precise cage movement. thus the CMC system is compact. The CMC system is actually derived the cage movement from the indexing system. manual operation to operate via push buttons and by-pass operation to operate via local panels. Using a single touch control on push buttons. The indexer movement is based on twin cage. the indexing system use auto mode to move the hydraulic cylinder on indexer. It is also for owner looking for an enhanced automated material handling and steam management process controlled in a smaller foot print area [11].control. modular. Moreover.6. 3. Similar to the indexing system. ease of monitoring. Less cage movement operation is needed too due to its smaller footprint area. CMC system also improves the working conditions.6. FFB is fed into the vertical sterilizer using the robust scrapper bar conveyers at control of a push button. Figure 44 shows a typical vertical sterilizer. It is designed to sterilize FFB at superior steam efficiency of 60 minutes cooking (for 30 tons FFB) gives a greater preservation of FFB quality. the vertical sterilizer enables a “one way traffic” operation of a palm oil mill [19]. . This is due to the loading of FFBs from the top of the sterilizer and discharged at the bottom. 3. Its handling system moves away completely from the conventional fruit cages doublehandling arrangement.4 Vertical Sterilizer Modern batch-type sterilization. Figure 44: Vertical Sterilizer. Then it is directly transported to the stripping station for the separation of fruitlets and bunches. work safety for operators. Akin to the indexing system. The control mechanism is in the same way as that in indexing system except there is no by-pass operation. a platform on top of the sterilization process is also installed to view the production area. One of the important benefits is the CMC system is an automated process of continuous flow and integration of material handling to sterilization process. All these handling is completed using only maximum two operators.2. low maintenance cost and ease of operation. which eventually minimized the total POME. capstans. cantilever bridges. These produce a very low construction cost because of less machinery and reduced down-time. bollards.5 Tilting Sterilizer Of all the batch type sterilizers. However it needs a water filling system and auger discharge making a delay for the process. To top that. rail tracks. EFB press. air removal and condensate drainage from the fruit bunch stack is restricted and this impedes heat penetration.2. Furthermore there is still dead space during its operation which reduces the capacity and throughput. Simple design with fewer moving parts. tipper. winches. only 2 to 3 operators are . a high strength liquid waste generated during milling process. A very good reason to install the tilting sterilizer in a new palm oil mill is that it needs only 30% of the space occupied by horizontal sterilizer.Operation cost saving is proven to be halved compares to conventional cages system. the steam consumption is low with minimal heat loss. A disadvantage of using the vertical position sterilizer is that the oil loss is high due to the compacted fruits at the bottom. The design requires higher steam pressure with multiple-peak cycles and a longer sterilization time for effective heat treatment of the fruit bunches resulting in higher steam consumption. EFB splitter and SFB post heating cooker. the tilting sterilizer completely diminished the usage of FFB cages.6. Small space is also needed as a requirement to install the sterilizer in the sterilization area of a palm oil mill. overhead-cranes. An award winning equipment developed to improve many issues in palm oil mill is what makes this sterilizer the most efficient way of sterilization process [28]. cage indexer system. This is the type of sterilizer that will be implemented in the proposed mill. 3. due to considerable stacking height and resulting fruit bunch compression in the vertical vessel. It is also a relatively greener technology due to it approximately 40% savings in steam consumption compares to conventional horizontal sterilization technology. transfer carriages. hoists. However. Other than that. the most up-to-date technology is the tilting sterilizer. Capital investment for vertical sterilization system is so far the lowest amongst the other sterilization system available in the market. pushers and tractors. The less amount of steam used resulted in relatively reduced condensate produced. Figure 45 shows a typical tilting sterilizer. In terms of clean working environment. Steam consumption also reduced by half of conventional system with the achievement of the shortest steaming time in industry of 45-50 minutes. Higher quality oil extraction can be obtained in comparison with other sterilizers along with the oil recovery in condensate recovered. an automatic operation with safety interlocks is applied in the system. As the name implies the tilted position allows FFB to slide and roll down during filling making sure that minimum damage of FFB. Besides that.needed to operate a multiple sterilizer station that results in lower operation and maintenance costs in conjunction with much fewer moving parts. lower power consumption by the lesser machinery than conventional system. no oil drips. it has a minimum dead space by compaction of fruits inside the sterilizer during an operation. Furthermore. . the tilting sterilizer minimizes oil loss oil loss in Empty Fruit Bunches. As of the energy efficiency. Figure 45: A tilting sterilizer. Moreover the sterilizer itself is easier and safer to operate than the conventional horizontal sterilizers due to the fact that direct loading through the conveyer from the FFB loading area. and condensate is directly used for dilution. 1 Process Operation Chart Process operation chart is the simple graphic representation that gives an overall view for the entire process. It also shows the chronological sequence for all activities.1 Process Operation Chart of EFB Fiber Production EFB Shredding Pressing Hammering Drying Dried Strand Fiber Bailing EFB BALER FIBER Liquor .7. 3.1.7. It includes the points where materials are produced and the sequence of inspection for all operations.7 PROCESS FLOW SHEET 3.3. 2 Process Operation Chart of Palm Oil Milling Processes FFB Sterilization of Fresh Fruit Bunches Threshing/Strip ping EFB Fruit Digestion Pulp Pressing Screening Depericarping Clarifying Fiber Drying Purifying Cracking Separation I Drying Winnowing Separation I Separation CPO Sludge Drying Kernel Shell .1.3.7. 000 kg per day.2. The palm kernel and EFB produced from every one ton of FFB be processed are 5. For one day production. the material balance for the overall processes is included.240 kg shredded EFB/day Hammering 42. This is a batch process where 8 batch of CPO will produce per day.2 Process Block Diagram of Palm Oil Milling Processes 18.7. In the proposed mill. the total feed in of EFB into EFB fiber production line is 52. The process units is based on one day production where the amount of FFBs be processed per batch is 30 ton. the plant capacity is 240 ton FFB/day. In process block diagram. 3. For every ton of FFB be processed.000 kg dried strand fiber/day Bailing 240 Baler Fibers/day (100 kg each) 3.7.560 kg Liquor/day 42.800 kg. The block diagram of CPO and EFB fiber are based on one day production.1 Process Block Diagram of EFB Fiber Production 52. It represents the main processing section in terms of functional blocks. The detailed calculation of mass balance will show in the following part.7.800 kg/day EFB Shredding 52.240 kg single strand fiber/day Drying 24.3. 21% of CPO will produced.6% and 22% respectively.800 kg shredded EFB/day Pressing 10.2 Process Block Diagram Process block diagram is the flow diagram that gives an overview of the process structure with process units.2.240 kg Moisture/day . The total feed in of FFBs is 240. 440 kg Mixture/day Light Shell Winnowing and Dust/day 28.000kg Diluted Oil/day 168.440 kg Kernel/day 2.472 kg Effluent/day 3.600 kg Sludge /day 51.400 kg Production oil/day 74.800 kg Wet Nuts/day Drying 2.000 kg Settled Oil/day 120 kg Dirt Purifying and Water/day 50.472 kg Condensate/day Sterilization of Fresh Fruit 211.200 kg Fiber/day 13.200 kg Sterilized FFB/day Threshing/Stripping 9.3 Process Flow Diagram 46.000 kg Dilution Water/day Depericarping 21.280 kg Moisture/day 35.000 kg Digested Fruitlets/day 42.400 kg Water/day Drying 170.000 kg Sludge/day Separation II 26.000 kg FFB/day 48.800 kg EFB/day 158.480 kg Shell/day 15.328 kg Exhaust Steam/day 52.240.880 kg Oil/day 480 kg Drying Moisture/day Separation I 96.080 kg Shell and Kernel/day 12.600 kg Wet Kernel/day Separation 26.160 kg Moisture/day .520 kg Cracked 7.520 kg Dry Nuts/day Cracking 35.000 kg Steam/day at 50 Psig 68.7.400 kg Sterilized Fruitlets/day Fruit Digestion 84.600 Kg Oil + Water (Recycle Oil)/day Clarifying 96.600 kg Steam/day 8.000 kg Press Cake/day Pulp Pressing 50.400 kg Water/day 600 kg Sand/day 84.400 kg sludge/day 37.000 kg Crude Oil/day Screening 126. It shows the process route and process conditions of each station. Figure 46: Process flow diagram of Palm Oil Milling Processes. The flow diagram of process plants is based on ISO 106298. Table 8:The description of process flow diagram.The process flow diagram is the central to the design task. The stream 28 to stream 40 is the process routes for palm kernel production.7. The stream 1 to stream 27 is the process routes for CPO production.1 Process Flow Diagram of Palm Oil Milling Processes Figure 46 is the process flow diagram for CPO and palm kernel production. There a total of 40 streams in the production line. It indicates the general flow of plant processes and equipment. Table 8 shows the detailed description of the process condition in each stream with the used of equipment. 3.3. . 696 psi Temperature=32°C Time=30 minutes Pressure= 14.3.696 psi Temperature= 90 °C Pressure=14.7.696 psi Temperature=32 °C Pressure= 14.696 psi Temperature=32 °C Pressure= 14.3.2 Conveyor 5 Digestion Digester 6 Pressing Screw Press 7 Separating Nut and Depericarper & Nut Fiber Polishing drum 8 Screening Sand Trap Tank 9 Screening Vibrating Screen Separator` 10 Sand Disposal Sand Trap Tank 11 Recycle Sterilized Conveyor 12 Fruitlets Storing CPO Crude Oil Tank 13 Clarification Continuous Settling Tank 14 Storing Pure Oil Pure Oil Tank 15 Purification Purifier 16 Storing Purified Oil Holding Tank Process Condition Pressure=50psig Temperature=150 °C Time=90 minutes Pressure= 14.696 psi Temperature=90 °C Time=30 minutes Pressure= 14.696 psi .2 Pressure= 14.7.Stream Process 1 Sterilization Equipment Tilting Sterilizer 2 Threshing Thresher 3 4 EFB fiber production Transferring Fruitlet Refer section 3.696 psi Temperature=90 °C Pressure=14.696 psi Temperature=100 °C Time=30 minutes Pressure= 14.696 psi Temperature= 60 °C Time=120 minutes Pressure=14.696 psi Temperature=32 °C Time=60 minutes Pressure= 14.696 psi Temperature=32 °C Time=30 minutes Refer section 3.696 psi Temperature=100 °C Pressure= 14.696 psi Temperature= 90 °C Time=120 minutes Pressure=14.696 psi Temperature=32 °C Time=30 minutes Pressure= 14. Removing Sludge Sludge Separator 24. Burning Fiber Boiler 31.696 psi Temperature= 70 °C Pressure=14.696 psi Temperature= 70 °C Pressure=14.696 psi Temperature= 70 °C Pressure=14. Cracking Ripple Mill 32. Remove Impurity Pneumatic Fiber 29. From Fiber Nut Drying & System Nut Silo Storing 30.696 psi Temperature= 90 °C Pressure=14. Sludge Clarifying Recycle Continuous Settling 26.696 psi Temperature= 70 °C Pressure=14.17 Removing Sludge To POME Pond 18 Drying Vacuum Dryer 19 Storing CPO CPO Tank 20 Dispatch CPO Shipment Truck 21 Sludge Separation I Sludge Buffer Tank 22 Sludge Separation II Sludge Drain Tank 23.696 psi Temperature= 40 °C Time=60 minutes Pressure=14. Oil Removing Sludge to Tank To Sludge Pit 27.696 psi Temperature= 90 °C Time=60 minutes Pressure=14. Recycling Oil From Sludge Oil Tank 25.696 psi Temperature= 70 °C Pressure=14.696 psi .696 psi Temperature= 40 °C Time=60 minutes Pressure=14.696 psi Temperature= 70 °C Pressure=14.696 psi Temperature= 50 °C Time=30 minutes Pressure=14. Sludge Pit Discharge Sludge To POME Pond 28.696 psi Temperature= 70 °C Pressure=14. Winnowing Winnowing Column 33.696 psi Temperature= 30 °C Pressure=14.696 psi Temperature= 40 °C Pressure=14. Purifying Fiber Fiber Cylone Temperature= 70 °C Pressure=14.696 psi Temperature= 40 °C Time=60 minutes Pressure=30 psi Temperature=180 °C Pressure=14. 696 psi Temperature= 40 °C Pressure=14. Table 9 shows the detailed description of the process condition in each stream with the used of equipment.696 psi Temperature= 80 °C Time =60 minutes Pressure=30 psi Temperature=180 °C Pressure=14. Burning Shell Boiler 39. Kernel Drying Kernel Dryer Track 38. There a total of 40 streams in the production line.2 Process Flow Diagram of EFB Fiber Production Figure 47 is the process flow diagram for CPO and palm kernel production. . Dispatch Kernel Shipment Truck Temperature= 40 °C Pressure=30 psi Temperature=180 °C Pressure=14.34. Separating Shell and Claybath Kernel 36.696 psi Temperature= 40 °C Pressure=14. Storing Shell Shell Bunker 37. Burning Fiber Boiler 35.696 psi Temperature= 40 °C Time=60 minutes Pressure=14. The stream 1 to stream 10 is the process routes for EFB fiber production.696 psi Temperature= 40 °C 3.3. Storing Kernel Kernel Silo 40.7. 696 psi Temperature=32 °C Pressure= 14.696 psi Temperature=32 °C Time=60 minutes Pressure= 14.696 psi Temperature=32 °C Machine 4 Pressing EFB EFB Fiber Press Machine 5 Removing Liquor To POME Pond 6 Hammering Hammer Mill Machine 7 Drying Rotary Drying 8 Baling Baling Machine 9 Storing To EFB Fiber store 10 Dispatch EFB Fiber Shipment Truck .696 psi Temperature=32 °C 2 conveyor Transfer EFB to Conveyor Pressure= 14.Figure 46: Process flow diagram of EFB Fiber Production. Stream Process 1 Transfer EFB to Equipment Conveyor Process Condition Pressure= 14.696 psi Temperature=32 °C Time=60 minutes Pressure= 14.696 psi Temperature=32 °C 3 Collection Point Shredding EFB EFB Shredder Pressure= 14.696 psi Temperature=100 °C Time=120 minutes Pressure= 14.696 psi Temperature=32 °C Time=60 minutes Pressure= 14.696 psi Temperature=32 °C Pressure= 14.696 psi Temperature=32 °C Time=60 minutes Pressure= 14. Table 9:The description of process flow diagram. palm kernel and EFB fiber production.30PM 3PM 10. The amount of FFB being processed is 30 ton per batch. 8 batches of palm kernel and EFB fiber will be produced.8 PROCESS SCHEDULING 3.30AM 11PM 6. the plant capacity is 240 ton FFB/hours.30AM 1AM 8.30PM 5PM 12.30AM 7PM 2.30PM 1PM 8. PRODUCTIO BATCH 1 BATCH 2 BATCH 3 BATCH 4 BATCH 5 BATCH 6 BATCH 7 BATCH 8 N CPO 9AM 11AM 1PM 3PM 5PM 7PM 9PM 11PM - - - - - - - - PALM 6.30AM 9PM 4. At the same time. Table 10 shows the time for each batch of the CPO.30AM 3AM KERNEL - - - - - - - - EFB FIBER 7PM 11AM 9PM 1PM 11PM 3PM 1AM 5PM 3AM 7PM 5AM 9PM 7AM 11PM 9AM 1AM - - - - - - - - 5PM 7PM 9PM 11PM 1AM 3AM 5AM 7AM . a total of 8 batch FFBs will be processed.8. Table 10: Processing Time.1 Process Scheduling Description In the proposed mill.3. 3.2 Process Scheduling of CPO Production TIME PROCESS 8 9 10 11 12 13 14 15 16 17 18 BATCH 1 STERILIZATION THRESHING DIGESTION PRESSING SCREENING CLARIFICATION PURIFICATION DRYING STORAGE BATCH 2 STERILIZATION THRESHING DIGESTION PRESSING SCREENING CLARIFICATION PURIFICATION DRYING STORAGE BATCH 3 STERILIZATION THRESHING DIGESTION PRESSING SCREENING 19 20 21 22 23 24 1 2 3 4 5 6 7 .8. CLARIFICATION PURIFICATION DRYING STORAGE BATCH 4 STERILIZATION THRESHING DIGESTION PRESSING SCREENING CLARIFICATION PURIFICATION DRYING STORAGE BATCH 5 STERILIZATION THRESHING DIGESTION PRESSING SCREENING CLARIFICATION PURIFICATION DRYING STORAGE BATCH 6 STERILIZATION THRESHING DIGESTION PRESSING SCREENING . CLARIFICATION PURIFICATION DRYING STORAGE BATCH 7 STERILIZATION THRESHING DIGESTION PRESSING SCREENING CLARIFICATION PURIFICATION DRYING STORAGE BATCH 8 STERILIZATION THRESHING DIGESTION PRESSING SCREENING CLARIFICATION PURIFICATION DRYING STORAGE 3.3 Process Scheduling of Palm Kernel Production TIME 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 .8. PROCESS BATCH 1 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 2 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 3 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 4 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 5 . DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 6 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 7 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING BATCH 8 DEPERICAPING NUT DRYING CRACKING WINNOWING SEPARATION KERNEL DRYING 3.4 Process Scheduling of EFB Fiber Production .8. TIME PROCESS 8 9 10 11 12 13 14 15 16 17 18 BATCH 1 SHREDDING PRESSING HAMMERING DRYING BALING BATCH 2 SHREDDING PRESSING HAMMERING DRYING BALING BATCH 3 SHREDDING PRESSING HAMMERING DRYING BALING BATCH 4 SHREDDING PRESSING HAMMERING DRYING BALING BATCH 5 SHREDDING PRESSING HAMMERING 19 20 21 22 23 24 1 2 3 4 5 6 7 . DRYING BALING BATCH 6 SHREDDING PRESSING HAMMERING DRYING BALING BATCH 7 SHREDDING PRESSING HAMMERING DRYING BALING BATCH 8 SHREDDING PRESSING HAMMERING DRYING BALING . 9.25% of mesocarp fiber. The steam loss that occurred from this process was 3. This process also generated 88% of SFB and 28.200 kg SFB/day . 5.472 kg 8.1 Law of Conservation of Mass The mass balance calculation was made based on the law of conservation of mass. 19. [24] and [26].2 Material Balance of Palm Oil Milling Process 3. 3. The sterilization process was carried out for 90 minutes under temperature of 150°C.47 % for one ton of FFB be processed.328 kg Exhaust Condensate/day Steam/day 211.3.3% of shell and 5. The capacity of the proposed palm oil mill was 240 ton FFB/day. For every one ton of FFB processed in the mills. [7]. The mass balance was calculated based on the law of mass balance by with the formula as follow: Minput=Moutput Where Minput = Mass input (kg).000 kg Steam/day at 50 psig Sterilizatio n 68. All material balance data are based on [4].9. Calculation: 240.2.9. Moutput = Mass output (kg) The basis of mass balance was set at one day. a total of 200 kg steam was required for tilting sterilizer.6% palm kernel were produced.9 MATERIAL BALANCE 3. For every one ton of FFB processed. 22 % of empty fruit bunch.000kg FFB/day 48.1 Sterilization Station The first stage to produce crude palm oil was to cook the FFB by using steam at pressure of 50 psig.53% of condensate. 400 kg Sterilized Fruitlets/day .200 kg SFB/day Non Solid Exhaust steam = 240.000 kg/day 3. the cooked FFB were fed into a stripper drum to dislodge the fruitlets.200 kg SFB/day + 8328 kg Exhaust Steam/day + 68.472 kg condensate/day Total mass output = 211.800 kg EFB/day 158. The amount of fruitlets obtained was 75% of SFB. The quantity of EFB was accounted 22% of every one ton processed FFB.2.9.2 Threshing Station In this process.000 kg FFB x 28.472 kg condensate/day = 288. A waste product was generated in this station which known as EFB.Mass input Solid FFB = 240. 000 kg FFB/day or 240 ton FFB/day Non-solid Steam = 200 kg steam ×240 ton FFB /day=48.47% = 8.328 kg Exhaust Steam/day Condensate = 240.000 kg FFB/day x 3.000 kg/day Mass output Solid SFB = 240.000 kg FFB/day + 48.53% = 68.000 kg steam/day ton Total mass input = 240.200 kg SFB/day Threshing 52.000 kg steam/day = 288. Calculation: 211.000 kg FFB/day x 88% = 211. 52.2.800 kg EFB/day Sterilized Fruitlets = 211.Mass input Solid SFB = 211.800 kg EFB/day = 158. This is carried out in the steam heated vessels provided with stirring arms and known as digester.200 kg SFB/day . the amount of steam required was 6.000 kg Digested Fruitlets/day .400 kg Sterilized Fruitlets/day Mass input Solid Digestion 168.600 kg Steam/day 158.800 kg EFB/day + 158. Calculation: 9.200 kg SFB/day Total mass input = 211.9.000 kg FFB/day x 22% = 52.400 kg sterilized fruitlets/day Total mass output = 52. In this process.1% of the amount of the feed.200 kg/day 3.200kg/day Mass output Solid EFB = 240.400 kg Sterilizer fruitlets/day = 211.3 Digestion Station Digestion process is carried out to reheat the sterilized fruitlets and separated it from nuts. 2.Sterilized fruitlets = 158.1% =9.000 kg Crude oil/day .600 kg steam/day Total mass input = 158. the remaining solid residual will send to a separation process for recovery mesocarp fiber. Approximately 50% of crude oil will produced from the digested fruitlets.400 kg Sterilized Fruitlets/day Non-solid Steam = 158.4 Pressing Station Screw press was used to compress the digested fruitlets to squeeze out the oil.000 kg Digested Fruitlets/day Total mass input = 168.000 kg/day Mass output Solid Digested Fruitlets = 168.000 kg/day 3.000 kg Press cake/day Mass input Solid Digested fruitlets = 168.000 kg Digested Fruitlets/day Pressing 84.600 kg steam/day= 168.000 kg/day 84.9. palm kernel and palm shell.400 kg Sterilized Fruitlets/day + 9. Calculation: 168.000 kg Digested Fruitlets/day Total mass output = 168.400 kg Sterilized Fruitlets/day x 6. Mass output Solid Press cake = 168.5 Screening Station For every one ton of FFB processed.000 kg dilution water/day Total mass input = 84.000 kg Digested Fruitlets/day x 50%= 84.000 kg crude oil/day= 168.000 kg Press cake/day Non-solid Crude oil = 168.000 kg Diluted Oil/day Mass input Non-solid Crude oil = 84.000 kg Dilution Water/day 84. Calculation: 42.000kg/day 3.000 kg/day Mass output Non-solid .000 kg Crude oil/day Screening 126.000 kg Crude oil/day x 50% = 42.000 kg crude oil/day Total mass output= 84.9.000 kg Press cake/day+ 84.2.000 kg Crude oil/day Dilution water = 84.000 kg Crude oil/day + 42.000 kg dilution water/day = 126. dilution water is added in the ratio of 1:2 to the crude oil.000 kg Digested Fruitlets/day x 50%= 84. Both of them will flow in the crude oil tank.9.400 kg Sludge/day Non-solid Diluted Oil =126.600 kg Recycle Oil/day=147. After 1-3 hours. The sludge will undergo separation process I to remove sand.600kg/day .000 kg Diluted oil /day x 0.000 kg diluted oil/day Total mass output = 126.000 kg/day 3.600 kg Recycle Oil/day Total mass input = 126.000 kg Diluted oil /day Recycle Oil=126.Diluted oil= 126. The amount of sand removed is 0.000 kg Sludge/day Separation II Mass input 74. Calculation: 126. The remaining amount of sludge is discharge to sludge pit.000 kg Diluted oil /day Clarification 51.171:1. 45.2.000 kg Settled oil/day 21.62 % of the sludge.01 % of settled oil will be produced and the remaining is sludge.171 = 21.600 kg Recycle Oil/day 96. Then.600 kg Sludge/day Separation I 600 kg Sand/day 96.5% of the sludge.000 kg Diluted oil /day+21.6 Clarification Station The ratio of recycle oil to diluted oil is 0. the sludge will undergo separation process II to recover oil where its amount is 22. 76.6% of sludge will produced from the amount of diluted oil. 6%) kg sludge/day x 0.000 x 76.000 kg Settled oil/day Recycle Oil=126.000 kg Diluted oil /day x 0.000 kg Diluted oil /day x 40.600 kg Recycle Oil/day Total mass output = 600kg sand/day + 74. Calculation: 51.600 kg Recycle Oil/day= 147.9.000 kg Settled Oil/day Purification 120 kg Dirt and Water/day 50.7 Purification Station The settled oil will then undergo purification to produce oil.6%) kg sludge/day x 77% =74.400 kg sludge/day+51.235% of dirt and water is removed.62% = 600kg sand/day Sludge = (126.000 kg/day Mass output Solid Dirt and water = 51.2.600 kg/day 3.880 kg Oil/day Mass input Non-solid Settled Oil = 51.400 kg sludge/day Non-solid Settled Oil = 126.000kg Settled oil/day + 21.235%= 120 kg Dirt and Water/day . 0.Mass output Solid Sand from separation I = (126.5% = 51.000 kg Settled Oil/day x 0.000 x 76.000 kg Settled Oil/day Total mass input = 51.171 = 21. In this process. The production oil produced is 21% for every one ton of FFB been processed.880 kg Oil/day x 0.2.000 kg FFB/day x 21% = 50. Calculation: 50.880 kg Oil/day Mass input Drying 480 kg moisture/day 50.235) %= 50.400 kg production oil/day + 480kg moisture/day =50.880 kg/day . Non-solid Oil= 51.94% moisture of its content before produce the production oil.880 kg Oil/day Total mass input = 50.400 kg production oil/day Non-solid Oil=50.400 kg production oil/day Moisture = 50.000kg/day 3.000 kg Settled Oil/day x (100-0.880 kg Oil/day Total mass output = 120 kg Dirt and Water/day+50.8 Oil Drying Station The purified oil will undergo drying process with the removed of 0.880 kg/day Mass output Non-solid Production Oil = 240.880 kg Oil/day=51.9.94% = 480kg moisture/day Total mass output = 50. 200 kg Mesocarp Fiber/day Mass input Solid Press cake = 84.000 kg FFB/day x 19.9. Around 19.000 kg Press Cake/day Depericarping 37.1 Depericarping Station In this stage.25% = 46.000 kg Press cake/day x 45% = 37.25% of mesocarp fiber will formed from every one ton of FFB to be processed.3.3. From the depericarping process.800 kg Wet Nuts/day .800 kg Wet Nuts/day 46. press cake from pressing process will undergo depericarping process to separate mesocarp fibers and nuts.200 kg Mesocarp fiber/day Wet nuts = 84.3 Material Balance of Palm Kernel Production 3. Calculation: 84.000 kg Press cake/day Total mass input = 84.000 kg/day Mass output Solid Mesocarp fiber = 240.9. 45% of press cake is wet nuts. 9.2 Silo Drying Station The wet nuts will undergo drying process to produce dry nuts.200 kg Mesocarp fiber/day+37.800 kg Wet Nuts/day x (100-6. 6.800 kg Wet Nuts/day Total mass input = 37.800 kg Wet Nuts/day x 6. Total mass output = 46.520 kg Dry Nuts/day Non-solid Moisture = 37. Calculation: 37.280 kg Moisture/day .3.03% = 2.03) % = 35.03% of moisture will formed from the amount of feed.800 kg Wet Nuts/day = 84. During the process.800 kg Wet Nuts/day Drying 35.520 kg Dry Nuts/day 2.000kg/day 3.800 kg/day Mass output Solid Dry nuts = 37.280 kg Moisture/day Mass input Solid Wet nuts = 37. Calculation: .520 kg Cracker Mixture/day Mass input Solid Dry nuts = 35. the palm shell and kernel mixture will undergo further separation process. Calculation: 35.800kg/day 3. Then.4 Winnowing station In this station.520 kg/day 3.9.3.520 kg Dry Nuts/day + 2.9.520 kg Cracker Mixture/day Total mass output = 35. Total mass output = 35.94 % of shells and dust are removed from cracked mixture. Around 20.280 kg Moisture/day = 37. shells and dust are drawn to the boiler using pneumatic separation which known as winnowing.3.3 Nut Cracking Station Palm nuts that had been dried in the silo dryer station were fed to this station to encounter a breakdown process.520 kg Dry Nuts/day Cracking 35.520 kg/day Mass output Solid Cracked mixture = 35.520 kg Dry Nuts/day Total mass input =35. 520 kg/day 3.520 kg Cracker Mixture/day x (100-20.080 kg Shell and Kernel/day 7.440 kg Light Shell and Dust/day Mass input Solid Cracker mixture = 35. separation of kernels from their shells occurred based on the specific gravity.9.94) % = 28.080 kg Shell and Kernel/day Total mass output = 7.520 kg/day Mass output Solid Light shell and dust = 35.520 kg Cracker Mixture/day Winnowing 28.520 kg Cracker Mixture/day Total mass input = 35. Calculation: 26.400 kg water/day Separation . The core of the kernels would move upwards the hydrocyclone. 5. while the shells would fall under the hydrocyclone.94:1 to kernel and shell mixture in this process which then discharge to effluent pond. Water is added in the ratio of 0.94% = 7.440 kg Light Shell and Dust/day + 28.5 Hydrocyclone Station In the hydrocyclone.35.520 kg Cracker Mixture/day x 20. For every one ton of FFB processed in the mills.440 kg Light Shell and Dust/day Shell and Kernel mixture = 35.3.080 kg Shell and Kernel/day = 35.2% palm shell was produced. 000 kg FFB/day x 5.080 kg Shell and Kernel/day 26.3.400 kg water/day 12.480 kg Palm Shell/day Wet Kernel = = 28.080 kg Shell and Kernel/day x 0.080 kg Shell and Kernel/day Non-solid Water input = 28.080 kg Shell and Kernel/day +26.600 kg Wet Kernel/day 28.15.480 kg Palm Shell/day Mass input Solid Shell and Kernel mixture = 28.600 kg Wet Kernel/day+26.480 kg/day Mass output Solid Palm Shell = 240.480 kg Palm Shell/day=15.480 kg/day 3.2 % = 12.480 kg Palm Shell/day+15.080 kg Shell and Kernel/day-12.600 kg Wet Kernel/day Non-solid Water output = 26.400 kg water/day Total mass output = 12.9.94 = 26.400 kg water/day=54.6 Kernel Drying Station .400 kg water/day Total mass input = 28.400 kg water/day= 54. 5.600 kg Wet Kernel/day Total mass input = 15.160kg moisture/day Total mass output = 13.600 kg Wet Kernel/day x 13.600kg/day Mass output Solid Dry Kernel = 240.000 kg FFB/day x 5.600kg/day .440 kg Dry Kernel/day Non-solid Moisture = 15.160 kg Moisture/day Mass input Solid Wet Kernel = 15. Calculation: 15.6% = 13.84% contained in the kernels was evaporated.84% = 2.440 kg Dry Kernel/day+2. For every one ton of FFB processed in the mills. In this process.Kernels from the hydrocyclone were fed into a kernel dryer.160kg moisture/day= 15. the water content as much as 13.600 kg Wet Kernel/day Drying 13.440 kg Dry Kernel/day 2.6% palm kernel was produced. 000 kg FFB/day x 22% = 54. The EFB will transfer to EFB collection point and undergo shredding process to produce shredded EFB. Calculation: 54.800 kg/day 3.1 EFB Shredding Station The amount of EFB produced is 22% for every one ton of FFB to be processed.9.3.800 kg EFB/day Total mass input =54.2 Pressing Station 54.800 kg shredded EFB/day Total mass output = 54.4.9.4 Material Balance of EFB Fiber Production 3.4.800 kg EFB/day Shredding Mass input Solid EFB = 240.9.800 kg shredded EFB/day .800 kg/day Mass output Solid Shredded EFB = 54. 560 kg Liquor/day Total mass output = 44.800 kg shredded EFB/day Mass input Pressing 42.800 kg shredded EFB/day x 19.560 kg Liquor/day=44.9.240 kg shredded EFB/day+10.800kg/day Mass output Solid Shredded EFB = 54.4.800kg/day 3.3%. Calculation: 54.800 kg shredded EFB/day Total mass input = 54.240 kg shredded EFB/day Non-solid Liquor=54.240 kg single strand fiber/day . Calculation: 42. The moisture content of EFB will remove around 19.240 kg shredded EFB/day Hammering 42.240 kg shredded EFB/day 10.3% = 10.3 Hammering Station The fibers were transferred into the Hammer Mill Machine in order to break the fibers into single strand fiber.Shredded EFB were being pressed in order to extract the liquor from the bunch.560 kg Liquor/day=54.800 kg shredded EFB/day-10.560 kg Liquor/day Solid Shredded EFB = 54. 4.Mass input Solid Shredded EFB=42.2%.240kg/day 3.000 kg dried strand fiber/day . Calculation: 42. This process will remove the moisture content of the fibers around 43.240 kg shredded EFB/day Total mass input = 42.4 Drying Station The fibers were then undergoes a drying process by using a Rotary Dryer with dust remover system.240 kg Moisture/day Mass input Solid Single stand fiber = 42.240 kg Single strand fiber/day Total mass output = 42.240kg/day Mass output Solid Single stand fiber = 42.240 kg Single strand fiber/day Drying 18.9.240 kg Single strand fiber/day 24. 2% = 18. The baler fiber will in the size 100 Kg with dimension 510 mm X 760 mm X 510 mm.240 kg moisture/day Total mass output = 24. Total mass input = 42.240 kg/day Mass output Solid Dried strand fiber = 42.2) %= 24.9.4.000 kg dried strand fiber/day Total mass input = 24.240 kg Single strand fiber/day-(100-43.000 kg dried strand Baling 240 Baler Fibers (100 kg each) fiber/day Mass input Solid Dried stand fiber = 24. Calculation: 24.000 kg dried strand fiber/day Non-solid Moisture = 42.000 kg dried strand fiber/day+18.240 kg moisture/day=42.5 Bailing Station The dried single strand fiber will bailed into baler fiber.240 kg/day 3.000kg/day Mass output Solid Baler fiber = 24.000 kg dried strand fiber/day/100kg = 240 baler fiber .240 kg Single strand fiber/day x 43. Total mass output = 24.000 kg/day .