CHAPTER 3 TECHNICAL FEASIBILITY3.1 METHOD TO MAINTAIN SUSTAINBILITY3.1.1 Tilting SterilizerSterilization 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 FiberOver 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 PROPERTIES3.2.1 Crude Palm OilIn 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.3.2.1.2 Quality Characteristic The color of crude palm oil shall be bright, clear and orange-red. Besides, crude palm oil shall be free from foreign and rancid odor. At the time of shipment, the crude palm oil shall conform to the requirement prescribed in Table 5. Table 5:Quality requirements for crude palm oil.CharacteristicsSpecial Quality GradeStandard Quality Grade

Free fatty acid (aspalmitic), % max2.55.0

Moisture and Impurities, % max0.250.25

Peroxide value , meq/kg max1.02.0

Anisidine value, max4.05.0

Color, 133.35 mm max--

DOBI, min2.82.3

3.2.2 Palm KernelPalm kernel is the edible seed from oil palm tree. The kernels are brown, oval between 1 and 2 cm long and have a shell that is as hard as stone. Figure 14 shows the palm kernel. It is normally sell to other company to produce palm kernel oil.

Figure 14: Palm kernel.3.2.3 EFB FiberEFB fiber is the green products from the proposed plant which able to replace the use of natural fiber. Table 6 shows the characteristic of EFB fiber that produced in the proposed plant. The EFB fiber will sell in baler form for local or oversea distribution. The baler fiber will in the size between 100 Kg with dimension 510 mm X 760 mm X 510 mm [24]. Table 6: Characteristic of EFB Fiber.PropertyValue

Size75-250 mm

Moisture Content17.5%

Calorific18800 kJ

3.3 PALM OIL MILLING PROCESS3.3.1 Raw MaterialIn palm oil milling process, the raw material is freshly pulp of the fruit from species Elaeis guineensis Jacq which also known as FFB. The raw material need to process within 24 hours after harvesting. This is to avoid the rise in free fatty acid during prolong storage. Apart from that, the process also needs water and steam to produce CPO. Water is used as boiler feed to generate steam. A boiler is used for steam generation and it consists of two principal parts namely the furnace, which usually provides heat through the burning of a fuel, 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. On the other hand, diesel generator also used diesel to generate power for palm oil mill. Furthermore, the mill also required diesel for vehicle usage such as tractors and showler.3.3.2 Methods3.3.2.1 General Process DescriptionIn the proposed palm oil mill, the main products are CPO. Meanwhile, the by-products are palm kernel and EFB fiber. CPO is produced from FFB by passing a series of mechanical processes. A sequence of processing steps had been established to extract high yield of good quality CPO. Meanwhile, the palm kernel will undergo a separate process and used to produce dry kernel. The dry kernel will be sent to another factory for further processed. During the milling process, waste products will be formed which known as biomass. The biomass include EFB, palm shell and mesocarp fiber. 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. While the remaining biomass will be utilized for other used in the proposed mill. The overall palm oil processing included the receptions of FFBs, sterilizing and threshing of bunches to free the palm fruit, digestion and pressing out the oil. The crude oil will undergo further clarification and purification before store in the oil room. 3.3.2.2 Fresh Fruit ReceptionThe first stage to produce CPO is receiving FFBs. Figure 15 shows the lorry carried the FFBs entering the mill by passing through the weigh bridge. The initial weight of the truck will be determined. After sending the FFBs, the weight of the truck will be determined again. Hence, the quantity of the FFBs received can be calculated by subtracting the final weight of the lorry from its initial weight.

Figure 15: The truck passing through the weigh bridge and its weight was recorded.3.3.2.3 FFB Loading RampLoading ramp hopper is the temporary place to store FFBs before processing. Figure 16 shows a typical loading ramp in palm oil mill. It is a sliding platform made of mild steel where lorry unloading the FFBs. The conveyor will transfer the FFBs into the cages.

Figure 16: The loading ramp in palm oil mill.3.3.2.4 Sterilization Station Tilting sterilizer as shown in Figure 17 is used in the sterilization station. The automated feeder will transfer the FFBs into the sterilizer and transfer out the SFBs to threshing station. The sterilization process is running for 90 minutes at pressure of 50 psig. The steam consumption is 200 kg steam/ ton FFB [28]. 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. 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.

Figure 17: The tilting sterilizer in sterilization station.3.3.2.5 ThreshingThe SFBs from the tilting sterilizer will flow to the thresher via auto feeder. The thresher will rotate to detach the fruitlets from the bunch. Figure 18 shows the typical thresher used in the palm oil mill. The EFB will send to bunch crusher for crushing. This is to make sure that 100% of stripping sterilized fruits from bunch. Then, the sterilizer fruitlets will send to digester and EFB will send to EFB fiber production line.

Figure 18: Thresher used to detach sterilized fruitlets.3.3.2.6 DigestionDigestion process is carried out to reheat the stripped fruits so that the pericarp loosened from nuts. This is carried out in the steam heated vessels provided with stirring arms and known as digester or kettles. The digester has vertical rotating shaft which are attached to the stirring arms. A typical digesters used in palm oil milling process is shown in Figure 19. 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. 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. It is essential for good digestion that the level of fruit in the digester kept as high as possible all the times at about 90C. This is to maximum the holding time and stirring effect per revolution. 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. However, 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.

Figure 19: The Digester used in palm oil milling process.3.3.2.7 PressingAfter digestion process, the fruits will be pressed by batch type hydraulic press to obtain oil. The screw press machine is shown in Figure 20. The nuts and fiber will be pushed out and for further processing. Before pressing, 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 hydraulic pressure is gradually built up. The maximum pressure is maintained for several minutes before it is released. Then, the top plate is withdrawn and the sections of cake expelled by raising the ram.

Figure 20: The batch type hydraulic press used in palm oil milling process.3.3.2.8 Screening The fluid coming out of the press is a mixture of palm oil, water, cell debris, fibrous material and non-oily solids. Because of the non-oily solids the mixture is very viscous. Hot water is therefore added to the press output mixture to thin it. 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). The diluted mixture is passed through a screen to remove coarse fiber before send to clarification tank. Vibrating screen is used to remove all fibrous material from crude oil and recycle them to the digester. A typical vibrating screen used in palm oil mill is shown in Figure 21.

Figure 21: A Vibrating Screen used in palm oil milling process. 3.3.2.9 Clarifying and Drying of CPO The oil mixture is heated to 85-90C and allowed to separate in the clarification tank. A settling time of 3 hours is acceptable. Oil from the top is skimmed off and purified in the centrifuge prior to drying in vacuum dryer. The final crude palm oil is then cooled and stored. The lower layer from the clarification tank is sent to the centrifugal separator where the remaining oil is recovered. The lower layer is known as sludge which is the waste generates from this stage. The oil is dried in vacuum dryers, cooled and sent to storage tanks. Figure 22 to 25 show the oil clarifier, centrifuge, oil purifier and oil dryer used in clarification station. Figure 22: Oil clarifier Figure 23: Centrifuge

Figure 24: Oil purifier Figure 25: Oil dryer3.3.2.10 Oil StorageCPO produced will store in storage tank before dispatching from the mill. The storage tanks used in palm oil mill are shown in Figure 26. Normally, the temperature of the storage will maintained at around 50 C. Hot water or low pressure steam heating coils will be used to prevent solidification and fractionation. Besides that, the storage tank needed to be lined with suitable protective coating to prevent iron contamination from the tank. The quality of crude oil must be kept. Hence, the FFA content must be below 3-5% while DOBI is need above 2.3. The impurities and moisture is allowed below 0.025% and 0.15%.

Figure 26: The oil storage tanks used to store CPO.3.3.2.11 Palm Kernel ProcessingAfter the pressing process, the oil is transferred to oil room while the nut and the fiber will go further processing. Depericaping is the process which separates the nut and fiber. There are two ways for separation of nut and fiber either by mechanical separation or air separation. In the proposed mill, air separation is chosen to separate the nut and fiber. Before the separation, CBC is used to loosen the nuts from the fibers. At the same time, moisture of the fibers and the nuts are slightly removed. 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. It is around 65 rpm. Increasing the length of CBC will increase the separation time and thus improve the separation efficiency. In addition, good sterilization, digestion and pressing process will ensure the fruit is cooked well. The pericarp will easily be detached from the nuts and will also help the breakage of shell from kernel. Then, the fibers and nuts are separated by air separator/air lock. The fibers are sucked up by air while the nuts drop down. The fibers are transferred to fiber cyclone. The fiber cyclone creates a momentum to remove moisture from fibers. The fibers then are transferred by conveyor to boiler.For vertical column type air separator, the high velocity will affect the fibers going upward and the nuts will fall downward. 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 fiber is sucked by a fan through the open lower end of the column and is blown to fiber cyclone. The separated nuts drop conveyor. The nut is expected with presence a little bit of fibers. For nuts, they are transferred into polishing drum to loosen the kernel from the shell and then, they are easily separated. After that, the nuts are transferred into nut silo for drying purpose. There is shaking grate in the nut silo to control nut flow and ensure their retention time in silo. It will distribute the nut evenly. Then, nuts are transferred into ripple mill to crack the nuts. There are un-cracked nuts, partially cracked nuts, whole kernels, broken kernels, dirt and shells. Then, they are passed through the winnowing system in order to blow out the small dirt and shell. Next, they are passed through the air lock or de-stoner to remove the big particles, such as stones. Stones will fall down and light particles are sucked to upper side. They are transferred into vibrating screen to separate the particles and oil. After that, they are transferred into hydro cyclone to separate the whole kernels, broken kernels and shells. After the separation, the kernels are transferred into kernel silo for drying while the shells are transferred to shell line. Lastly, dried kernels are transferred into kernel bunker for storage while the shell is keep at shell storage. The kernel bunker and shell storage place are shown in Figure 27.

Figure 27: Kernel bunker and shell storage.3.3.2.12 EFB Fiber ProductionFirstly, the crushed EFB from threshing process were being transferred to EFB collection point. The crushed EFB were being shredded into a smaller size before it is being pressed in the EFB press machine. Shredded EFB were being pressed in order to extract the liquor from the bunch. Next, the fibers were transferred into the Hammer Mill Machine in order to break the fibers into single strand fiber. The strand fibers will in the size between 76-250 mm. The fibers were then undergoes a drying process by using a Rotary Dryer with dust remover system. This process will reduced the moisture content of the fibers below 17.5 %. Lastly, 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. The baler fiber will in the size between 90-100 Kg with dimension 510 mm X 760 mm X 510 mm. After being bailed, the EFB baler fiber is then ready for market. Figure 28 shows the by-products, EFB baler fiber.

Figure 28: The baler fiber produced from EFB.3.3.2.13 Boiler StationBoiler is the closed vessel in which water or other fluid is heated under pressure. The fluid is then circulated out of the boiler for use in various processes or heating applications. The main functions of the boiler house are to convert chemical energy to heat energy, to transfer the heat energy to the water in the water circuit and convert it to steam, supply steam for generating electricity and to supply steam for other process units in the mill.There are 2 types of efficient boiler, such as fire tube boiler and water tube boiler. In this scenario, the water tube boiler is used. The flow of boiler house is shown in Figure 29. Normally, mesocarp fiber and palm shell are used as fuel for boiler and are transferred by conveyor. At the same time, the water is pumped into the boiler. Firstly, the water will flow in steam drum. After that, the hot water will flow down to mud drum which keeps the hot water. Then, the water will flows through tubes and the heat is transferred into water through glass tube. Then, the water becomes steam and steam will flow into steam drum again.

Figure 29: The flow of boiler house. After complete combustion, the ashes are taken away by Induced Draft (ID) fans and pass through air lock which separates the ash and smoke. Ashes will take away into dust collector cone while smoke will be discharged through chimey. Light brown haze should be observed but white smoke is allowed because white indicates excess secondary air. However, the black smoke indicates heavy erratic firing or lack of secondary air. The ashes are manually taken out by the operators through doors of furnace. After certain period of combustion, ashes will stick to the boiler tubes and it will affect the heat transfer. So, the blowers are used to clean the scaling of the boiler. Manual cleaning is also required. The wet steam flows into superheater which converts the wet steam into dry steam at temperature of 250C. After that, 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. The steam will generate the electricity in turbine at pressure of 31 and 32 bars. After that, the steam will be stored in steam receiver for supplying to heating applications.3.3.2.14 Power StationIn power station, steam turbine and diesel generator are used to generate electricity for operating all the motors and internal usage in the mill. Steam turbine plays an important role in power generation. A steam turbine is a mechanical device that extracts thermal energy from pressurized and converts it into useful mechanical work. Heat energy of steam is converted to kinetic energy and finally is changed to electrical energy. The main equipment used in power station is shown in Figure 30.

Figure 30: The steam turbine and diesel generator.3.3.2.15 POME StationPonding system is the most common treatment method for POME. This system is reliable, 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.Effluent ponds play an important role in all factories. The sludge or waste water will be managed before they go into river or into ground. Firstly, factory hot sludge is pumped into effluent ponds. The temperature is around 53C and pH is 4.5. The BOD is 3000 ppm that means quantity of oxygen is very low. BOD is the amount ofdissolved oxygenneeded 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. The cooling pond plays a role to cool down the sludge with combining the waste water from primary aerobic pond. The sludge is pumped into anaerobic pond A1, B1 and C1. The retention time of this three ponds are 8 hours. After 8 hours, 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 Biology Genesis activates the natural bacteria in pond and they function to build up the reaction. They will change the dissolved solid into suspension solid. So, the upper solid is easily removed. Then, they will discharge into BC2. Sludge from A1 is discharged into anaerobic pond A2 and A3. At the same time, waste water from anaerobic pond BC2 will discharge A3. Then, the combined sludge will go into primary aerobic pond A4, A5 and BC3. The BOD of primary aerobic pond will decrease. Then, the effluent is pumped into the bio-tower that acts as filtration medium. The plastic coils trap the solid and the remaining waste water will flow to bottom of bio-tower. The remaining waste water flow into polishing pond F1 and is pumped into clarifier. The clarifier separates the solid and liquid by momentum. There is the bypass between pond F1 and pond F2 in order to avoid overflow of the effluent. The waste water flows into settling pond which separates the solid by their size. Finally, the waste water flows into polishing pond F1 and discharge into trenches or flat bed. The flat beds play role to filter the contaminant. The BOD of output of the effluent must be kept below 100 ppm which is standardized by Department of Environment. The oxygen content is higher and do not lead side effect to the environment. The color of pond is greenish and the bubbles on the surface of pond can be observed. It is concluded by the bacteria is active and can functions well.

3.3.2.16 Raw Water Treatment Station

Figure 32: Flow chart of raw water treatment plant.Raw water is required as boiler feed and others process in palm oil mill. 4 basic steps involved in water clarification are pH adjustment, coagulation, flocculation and filtration. The flow chart of raw water treatment plant is shown in Figure 32. pH of raw water is needed to be neutralized. Overflow raw water pond is used to store the overflow raw water. Normally, the tests of pH, the total hardness and turbidity of raw water are carried in treatment plant. Soda (sodium carbonate) is dosed into raw water to increase the pH. After that, the raw water is dosed alum as coagulant (aluminium sulphate) to clog the dissolved solid into suspended solid. This process is called as charge neutralization process. Polymer as flocculant is added into raw water when the water is too dirty and very yellowish color. Then, the water flows into clarifier. The solids are sedimentated at the bottom of the clarifier. The clarifier used in water treatment plant is shown in Figure 33. The drain valve is opened to discharge the suspended solid out to drainage system until the water is looked clean. Clean water will flows into concrete holding pond. There are line for factory usage and line for daily usage. For factory usage, the water is pumped into sand filter No. 1 and No. 2 for removal sand. Then, the water can is pumped to overhead water tank No. 1 for storage.

Figure 33: The water clarifier. In the line for factory, the chlorine is not dosed in water because the chlorine will precipitate and oxidize the pipes, then will lead the breakage of piping system in factory. For daily usage, the water is pumped into earth pond or drinking pond and to sand filter No.3 and sand filter No. 4. The sand filter used in raw waste treatment system is shown in Figure 34. After that, chlorine is added into water because chlorine can kill bacteria. Lastly, the clean water is pumped to overhead water tank No. 2. Normally, piping system in this line is made by stainless steel in order to prevent rusting and corrosion occurs. The analysis of pH, the total hardness, turbidity and chlorine content are carried out to ensure the quality of water produced.

Figure 34: The sand filter.

3.4 EQUIPMENT SIZING AND SPECIFICATIONIn the proposed palm oil mill, the main product is CPO. Meanwhile, the by-products are palm kernel and EFB fiber. A series of mechanical processes is used to produce those products. The Table 7 shows the quantity of the main equipment required in the proposed plant and the specification of the respective equipment. The selection of equipment is based on the capacity per batch of FFB will be processed. 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. The equipment for wastewater treatment plant and raw water treatment plant is not included in this study. 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. [9]NoMachineryQuantitySpecification

FRUIT RECEPTION

1.Road Weighbridge

1 Model - Avery Berkel J 311 Type - Electronic Weighbridge Capacity - 40 ton Power - 0.05 kW Dimension - 2 m (L) X 3 m (W) X 0.3 m (H)

2. Fruit Loading Ramp

1 Type - Vertical sliding gate Capacity - 12 door X 15 ton = 180 ton Power - 5.6 kW

STERILIZATION STATION

3. Tilting Sterilizer

1 Model - Besteel Size 30 T Type - Pressure Vessel Capacity - 30 ton / hour Power - 23 kW Shell Length 7.8 m Diameter - 3.2 m Inlet & Outlet Door 1.5 m Plate Thickness 0.015 m

THRESHING STATION

4.Thresher

1 Model - CB Thresher Type - Rotary Drum Capacity - 30 ton / hour Power - 18.5 kW Length - 5.5 m Diameter - 2 m

5.Bunch Crusher

1 Model - KH-7.60 Type - Double Deck Bunch Crusher Capacity - 10 ton / hour Power - 15 kW Dimension - 2.219 m (L) X 0.9 m (W) X 1.264 m (H)

DIGESTION STATION

6.Digester

2 Model - CB Vertical Digester Type - Unjacketed Capacity - 20 ton / hour Power - 29.8 Kw Volume - 3500 L Height 3.1 m Diameter - 1.3 m

PRESSING STATION

7.Screw Press

2 Model - CB Screw Press Type - Twin Press Capacity - 20 ton / hour Power - 18.5 kW Dimension - 2.32 m (L) x 0.7 m (W) x 0.78 m (H)

CLARIFICATION STATION

8.Vibrating Screen Separator

2 Model - AMKCO Double Deck Vibratory Separator Type - Vibro Energy Capacity - 15 ton / hour Power - 1.86 kW Diameter - 2.1 m

9.Hot Water Tank

1 Model - Xb 6000L Separator Type - Storage Tank Capacity - 6000 L

10.Sand Trap Tank

1 Model - LST1-12 Type - Cylindrical conical bottom Capacity - 12,000 L Height - 2.4 m Diameter - 1.8 m

11.Crude Oil Tank

1 Model - KDE-S-12000L Type - Rectangular Storage Tank Volume - 12000L Dimension - 4.8 m (L) x 2.4 m (W) x 1.2 m (H)

12.Continuous Settling Tank

1 Model - IY-CXGC Type - Cylindrical conical bottom Volume - 120,000 L Height - 6.2 m Diameter - 4.95 m

13.Pure Oil Tank

1 Model - ZG-25,000L Type - Cylindrical conical bottom Volume - 25,000 L

14.Sludge Separator

1 Model - AMKCO Single Deck Vibratory Type - Vibro Energy Capacity - 15 ton / hour Power - 1.6 kW

15.Sludge Oil Tank

1 Model - VEN 30 Type - Cylindrical conical bottom Volume - 30000 L

16.Sludge Buffer Tank

1 Model - DY-CG-002 Buffer Tank Type - Cylindrical Volume - 3000 L

17.Sludge Drain Tank

1 Model - XG Sludge Tank Type - Steel tank rectangular section Volume - 18,000 L

18.Oil Purifier

2 Model - Alfa Laval Purifier MFPX 307 Type - Electromotor Capacity - 6 ton / hour Power - 7.5 kW

19.Vacuum Oil Dryer

1 Model - PT Vacuum Dryer Type - Vacuum Pump Capacity - 15 ton / hour Power - 11 kW

OIL STORAGE TANK

20.Oil Storage Tank

1 Model- CFL-Y Oil Tank Type - Storage Tank Volume - 1000000 L

21.CPO Daily Storage Tank

1 Model - T-S1000 Oil Tank Type - Storage Tank Volume - 500000 L

DEPERICARPING STATION

22.Cake Breaker Conveyor

1 Model - DG Cake Breaker Conveyor Type - Semi scroll, unjacketed model screw Capacity - 12 ton / hour Power - 11 kW Dimension - 22m (L) X 0.8m (W)

23.Depericarper Vertical Column

1 Model - DG DP012 Type - Induced Draught Capacity - 12 ton / hour Power - 11 kW Dimension - 8m (L) X 0.8m (W) X 4m (H)

24.Nut Polishing Drum

1 Model - DG D06 Type - Rotary without roller sprocket Capacity - 6 ton / hour Power - 7.5 kW Diameter - 1m Length - 5m

25.Pneumatic Fiber Transport System(Including Ducting, Fiber Cylone, Fan, Airlock)

1 Model - DG Palm Oil Pneumatic System Type - Induced Draught(Fiber Cylone), Fan (Suction), Airlock(Rotary) Capacity - 6 ton / hour Power - 49 kW Dimension - 8.5m (L) X 3.5m (W) X 4m (H)

KERNEL STATION

26.Nut Silo

1 Model - TCK05605 Type - Cylindrical Storage Tank Capacity - 30000L Diameter - 2.5m Length - 6m

27.Ripple Mill

1 Model - VG-8T Type - Ripple Mill Capacity - 6 ton / hour Power - 11 kW

28.Claybath (Including Mixer and Clay Solution Tank, Conical Separation Tank, Pump, Discharge Pump, Vibrating Screen)

1 Model - DG Claybath System Capacity - 6 ton / hour Power - 11 kW

29.Kernel Silo

1 Model - BC30 Type - Circular section with conical bottom Capacity - 30000L

BOILER STATION

30.Boiler

1 Model - Takuma N 600 Type - Water Tube Boiler Capacity - 36 ton / hour Working Pressure - 22 bars Temperature - 260C

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/cm

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.EFB Fiber Press

1 Model - SE/SSP 50 Capacity - 6 ton / hour Power - 45 kW Dimension - 3.8m (L) X 2m (W) X 1.25m (H)

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)

39.Baler Machine

1 Model - SHBA2-200 Capacity - 15 baler / hour Power - 35 kW Dimension - 7.6m (L) X 5.1m (W) X 5.1m (H)

3.5 WASTE PRODUCTSA large amount of biomass is produced at palm oil mills during the processing of FFB. Those biomass included palm shell, mesocarp fiber and EFB. In conventional method, palm shell and mesocarp fiber will used as boiler fuel to generate electricity for internal usage. Meanwhile, the old disposal methods of EFB are burning in incinerator, dumped in landfills and sell to plantation for mulching. As the EFB will be utilized to produce EFB fiber, 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 35 shows the bulk physical and chemical characteristics of palm shell. For every one ton of FFB processed, 5 % of palm shell will be produced. 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]. Therefore, all the palm shell produced will be used to generate energy in our proposed plant.

Figure 35: bulk physical and chemical characteristics of palm shell.Mesocarp fiber is another waste product from palm oil milling process. Mesocarp fiber is contained in the oval shaped palm fruit which consists of yellowish red oily flesh mesocarp and single seed Palm Kernel Nut. The mesocarp fiber is then separated from Palm Kernel Nut by cyclone separator. Mesocarp fibre contains less than 6% oil residue with calorific value of 19000kJ/kg [7]. Figure 36 shows the mesocarp fiber on the fresh oil palm fruit. Since palm oil mill is self-sufficient in energy, the mesocarp fiber is mixed with kernel shell and being utilized as a medium of boiler fuel to generate electricity for the proposed mill.

Figure 36: The mesocarp fiber on the fresh oil palm fruit.3.6 TECHNOLOGY AND ALTERNATIVE ROUTES FOR PRODUCING CRUDE PALM OIL 3.6.1 Continuous and Conventional SterilizationIn order to maximize the production of CPO in a palm oil mill, various technologies have been developed by the people in the industry. Being the first process in the mill, sterilization is a crucial part of the whole processes since it influences the quantity and the quality of CPO produced later. FFBs are cooked using steam as the heating medium in a sterilization process. 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. Therefore, the type of sterilizer technology chose greatly affects steam and power consumption of the sterilization process. With the growing demand for energy efficiency at palm oil mills, 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. It is vital to ensure that the sterilizer operates correctly so that it will produce minimum oil loss and generate proper oil extraction rate. Oil losses that correspond from sterilizing process are oil losses in condensate, empty fruit bunch, un-striped bunch and partly striped bunch. Basically sterilizers are design to operate continuously or in batches. The conventional and continuous type processes are described to select most economical sterilizer technology. In a conventional sterilization, the sterilization process of fresh fruit bunches is carried out in cylindrical pressure vessels that lies horizontally or vertically. The concept of conventional sterilization is shown in Figure 37. After that they are filled with steam under pressure as a batch process. The most common type of sterilizer used is the horizontal sterilizer fitted with two quick opening doors [11]. Fruit cages are used to transfer the bunches in and out of sterilizers, and various other equipment are needed for handling these cages, including overhead cranes, tippers, conveyors, transfer carriages and tractors.Currently, there are many types of innovation and improvement of conventional type sterilizers such as cage material handling using indexing system, CMC Systems, Vertical Sterilizer and Tilting Sterilizer. To comply with the amount of FFB processed per day, palm oil mill owners usually choose one of these technologies to be implemented. The introduction of a three peak cycle process in the sterilization process allows a synchronized integration. This involves the discharge of condensate and air in the pressure vessel, fasten pressure built and evenly distributed steam. From this batch type process, time and steam usage can be saved. With horizontal position, 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, as opposed to a vertical sterilizer. Thus, when pressurized steam is injected into the interior of the horizontally positioned cylindrical vessel, the steam can reach out to different directions and corners of the contents within the cages thereby helping treatment of the fruit bunches. Due to the low stacking height of the fruit bunches in the cages, condensate drains out freely from the fruit bunch stack facilitating heat penetration. Batch process however arrests the oil quality deterioration due to enzymatic activity. Considerable space and a system of rails are required to facilitate the fitting of the cages and the charging and discharging of the sterilizers. Generally, when the received crops are less in capacity, the fruit bunches will be bulked and processed the next day. This will result in the increment of FFA content in the fruits and leads to poor quality of CPO.

Figure 37: Concept of Conventional Sterilization Process.Continuous type sterilization process is also famously adopted in palm oil mill due to its much beneficial factors if compared to batch sterilization. The concept of continuous sterilization process is shown in Figure 38. 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]. In current technology, the process is carried out in a heating cabin operating with steam at atmospheric pressure. Initially, 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. The splitting of the fruit bunches facilitates steam penetration into inner layers of the fruit bunch. 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, making it cost-effective to automate the bunch handling operations. It also eliminates the use of sterilizer cages, rail tracks, overhead cranes, tippers, 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, reduces the number of process operators, lowers the operating and maintenance costs, and simplifies mill operation. Mills using the process can be more easily supervised and automated. By avoiding the use of pressure vessels for sterilization and cages and cranes for the handling of bunches, palm oil mills are made safer for operators. The use of conveyors in place of cages also minimizes spillage of fruits and oil making mills cleaner. Although the new process is carried out using steam at low or atmospheric pressure, the process significantly improves strippability of bunches as researched by Sivasothy. 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. However, the continuous sterilizer suffers a significant disadvantage in terms of high steam consumption.

Figure 38: Concept of Continuous Sterilization Process.

3.6.2 Common Batch Sterilizers 3.6.2.1 Horizontal Double-Door Sterilizer with Wire Rope Winch System for Cage MovementOne of an outdated technology of a conventional palm oil mill is the usage of wire rope winch system for cage movement. In the reception area of a palm oil mill, FFBs will be loaded through a loading ramp hopper to feeding point. Then, they are fed into the fruit cages which act as holder of FFB to be sterilized inside a long horizontal sterilizer. The wire rope winch system is used to transport the fruit cages from the loading area. 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. After fed with FFB, the fruit cages will be transported using the system to pull them along a rail track system into the sterilizer. The process of marshaling is facilitated by arranging 7 cages in train order. The train of cages runs out at the further end of the arches by means of wire rope attached to hydraulic capstans [23]. An intermediate between the loading area and the sterilizer is the cage transfer carriage which acts as lane changer for the cages. Figure 39 to 41 show the typical equipment in conventional sterilization station. Figure 39 to 41: The conventional sterilization station with the used of winch system and horizontal sterilizer. After sterilization process, once again the train of fruit cages will be winched into the tippler to be rotated for unloading purposes. The system is specially design for palm oil mill horizontal line pull for position in between sterilizer rail track line. It consists of bogies, winch, wire rope and hook, guide bollard, rail track system and fruit cages transfer carriage. The conventional system is still considered impractical due to the facts 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, install and uninstall chain from cages, working in confined space, and replace packing of sterilizer door.3.6.2.2 Horizontal Double-Door Sterilizer with Indexing System for Cage MovementA better way to replace the wire rope winch system is the usage an auto-cage transporter known as the indexing system [11]. It is a cage material handling that eliminates the need and use of tractors, bulldozers, capstans and winches that have been applied in a conventional system. The so called twin cage indexer system is only suited for long horizontal double door sterilizer installed in a palm oil mill. The system is less maintenance, bumper-to-bumper cage movement for single cage and/or twin cage movement. Figure 42 shows the indexing system for cage movement. Furthermore, 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, leading to improvement in productivity and consistency in throughput.

Figure 42: Indexing system for cage movement.On top of the sterilization process, a platform is installed providing a good view of the production area. An advantage of the indexing system is it improves working conditions and safety for operators as well as reducing manual handling of the cages. Besides that, it is easier to monitor via an automation system with remote console panel control. Moreover, the system has low maintenance cost due to the reduced wear and tear by good and precise cage movement. Using a single touch control on push buttons, the system provides ease of operation. In terms of control, the indexing system use auto mode to move the hydraulic cylinder on indexer, manual operation to operate via push buttons and by-pass operation to operate via local panels.3.6.2.3 Horizontal Single-Door Sterilizer with Compact, Modular, Continuous Systems for Cage MovementAnother method for the movement of fruit cages is the CMC system. If compared to the indexing system, the CMC system is only for horizontal sterilizer with single door in sterilizer station. It is also for owner looking for an enhanced automated material handling and steam management process controlled in a smaller foot print area [11]. Figure 43 shows the CMC system that implemented in the sterilization station. The CMC system is actually derived the cage movement from the indexing system. The indexer movement is based on twin cage. As the building footprint is small, thus the CMC system is compact, modular, 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.

Figure 43: CMC system for cage material handling.Similar to the indexing system, 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. Less cage movement operation is needed too due to its smaller footprint area. Akin to the indexing system, CMC system also improves the working conditions, work safety for operators, ease of monitoring, low maintenance cost and ease of operation. The control mechanism is in the same way as that in indexing system except there is no by-pass operation.3.6.2.4 Vertical SterilizerModern batch-type sterilization, the vertical sterilizer enables a one way traffic operation of a palm oil mill [19]. Figure 44 shows a typical vertical sterilizer. This is due to the loading of FFBs from the top of the sterilizer and discharged at the bottom. Then it is directly transported to the stripping station for the separation of fruitlets and bunches. Its handling system moves away completely from the conventional fruit cages double-handling arrangement. 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. FFB is fed into the vertical sterilizer using the robust scrapper bar conveyers at control of a push button. All these handling is completed using only maximum two operators.

Figure 44: Vertical Sterilizer.Operation cost saving is proven to be halved compares to conventional cages system. Capital investment for vertical sterilization system is so far the lowest amongst the other sterilization system available in the market. It is also a relatively greener technology due to it approximately 40% savings in steam consumption compares to conventional horizontal sterilization technology. The less amount of steam used resulted in relatively reduced condensate produced; which eventually minimized the total POME, a high strength liquid waste generated during milling process. Other than that, the steam consumption is low with minimal heat loss. Small space is also needed as a requirement to install the sterilizer in the sterilization area of a palm oil mill. However it needs a water filling system and auger discharge making a delay for the process. A disadvantage of using the vertical position sterilizer is that the oil loss is high due to the compacted fruits at the bottom. Furthermore there is still dead space during its operation which reduces the capacity and throughput. However, due to considerable stacking height and resulting fruit bunch compression in the vertical vessel, air removal and condensate drainage from the fruit bunch stack is restricted and this impedes heat penetration. 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.3.6.2.5 Tilting SterilizerOf all the batch type sterilizers, the most up-to-date technology is the tilting sterilizer. 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]. This is the type of sterilizer that will be implemented in the proposed mill. Figure 45 shows a typical tilting sterilizer. 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. Simple design with fewer moving parts, the tilting sterilizer completely diminished the usage of FFB cages, rail tracks, transfer carriages, capstans, bollards, winches, overhead-cranes, hoists, cage indexer system, cantilever bridges, tipper, pushers and tractors, EFB press, EFB splitter and SFB post heating cooker. These produce a very low construction cost because of less machinery and reduced down-time. To top that, only 2 to 3 operators are needed to operate a multiple sterilizer station that results in lower operation and maintenance costs in conjunction with much fewer moving parts. Steam consumption also reduced by half of conventional system with the achievement of the shortest steaming time in industry of 45-50 minutes. Furthermore, it has a minimum dead space by compaction of fruits inside the sterilizer during an operation. Besides that, the tilting sterilizer minimizes oil loss oil loss in Empty Fruit Bunches, no oil drips, and condensate is directly used for dilution. Higher quality oil extraction can be obtained in comparison with other sterilizers along with the oil recovery in condensate recovered. As of the energy efficiency, lower power consumption by the lesser machinery than conventional system. 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. In terms of clean working environment, 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.

Figure 45: A tilting sterilizer.

3.7 PROCESS FLOW SHEET3.7.1 Process Operation ChartProcess operation chart is the simple graphic representation that gives an overall view for the entire process. It includes the points where materials are produced and the sequence of inspection for all operations. It also shows the chronological sequence for all activities.3.7.1.1 Process Operation Chart of EFB Fiber ProductionEFB

Shredding

Liquor

Pressing

Hammering

EFB BALER FIBERBailingDried Strand FiberDrying

3.7.1.2 Process Operation Chart of Palm Oil Milling ProcessesFFB

Sterilization of Fresh Fruit Bunches

Threshing/Stripping

EFB

Fruit Digestion

Pulp Pressing

Fiber

DepericarpingScreening

DryingClarifying

CrackingSeparation IPurifying

WinnowingDrying

Shell

SeparationSeparation ICPO

DryingSludge

Kernel

3.7.2 Process Block DiagramProcess block diagram is the flow diagram that gives an overview of the process structure with process units. It represents the main processing section in terms of functional blocks. In process block diagram, the material balance for the overall processes is included. In the proposed mill, the plant capacity is 240 ton FFB/day. This is a batch process where 8 batch of CPO will produce per day. For every ton of FFB be processed, 21% of CPO will produced. The palm kernel and EFB produced from every one ton of FFB be processed are 5.6% and 22% respectively.The process units is based on one day production where the amount of FFBs be processed per batch is 30 ton. The block diagram of CPO and EFB fiber are based on one day production. For one day production, the total feed in of EFB into EFB fiber production line is 52,800 kg. The total feed in of FFBs is 240,000 kg per day. The detailed calculation of mass balance will show in the following part. 3.7.2.1 Process Block Diagram of EFB Fiber Production52,800 kg/day EFB

52,800 kg shredded EFB/day10,560 kg Liquor/dayPressingShredding

42,240 kg shredded EFB/day

42,240 kg single strand fiber/dayBailing 18,240 kg Moisture/dayDryingHammering

24,000 kg dried strand fiber/day240 Baler Fibers/day (100 kg each)

3.7.2.2 Process Block Diagram of Palm Oil Milling Processes48,000 kg Steam/day at 50 Psig240,000 kg FFB/daySeparationDryingCrackingScreeningPulp PressingFruit DigestionThreshing/Stripping

8,328 kg Exhaust Steam/day68,472 kg Condensate/daySterilization of Fresh Fruit Bunches

211,200 kg Sterilized FFB/day

52,800 kg EFB/day

158,400 kg Sterilized Fruitlets/day9,600 kg Steam/day

84,000 kg Crude Oil/day168,000 kg Digested Fruitlets/day

84,000 kg Press Cake/day

42,000 kg Dilution Water/day46,200 kg Fiber/dayDepericarping

21,600 Kg Oil + Water (Recycle Oil)/day126,000kg Diluted Oil/day37,800 kg Wet Nuts/day

96,600 kg Sludge /day2,280 kg Moisture/dayDryingClarifying

51,000 kg Settled Oil/day35,520 kg Dry Nuts/day

120 kg Dirt and Water/day96,000 kg Sludge/daySeparation IPurifying

50,880 kg Oil/day7,440 kg Light Shell and Dust/day 35,520 kg Cracked Mixture/daySeparation II

480 kg Moisture/dayWinnowingDrying

600 kg Sand/day50,400 kg Production oil/day26,400 kg Water/day28,080 kg Shell and Kernel/day12,480 kg Shell/day26,400 kg Water/day

74,400 kg sludge/day15,600 kg Wet Kernel/day

2,160 kg Moisture/day

170,472 kg Effluent/day

13,440 kg Kernel/day

3.7.3 Process Flow DiagramThe process flow diagram is the central to the design task. It indicates the general flow of plant processes and equipment. It shows the process route and process conditions of each station. The flow diagram of process plants is based on ISO 106298.3.7.3.1 Process Flow Diagram of Palm Oil Milling ProcessesFigure 46 is the process flow diagram for CPO and palm kernel production. There a total of 40 streams in the production line. The stream 1 to stream 27 is the process routes for CPO production. The stream 28 to stream 40 is the process routes for palm kernel production. Table 8 shows the detailed description of the process condition in each stream with the used of equipment.

Figure 46: Process flow diagram of Palm Oil Milling Processes.

Table 8:The description of process flow diagram. Stream ProcessEquipmentProcess Condition

1SterilizationTilting Sterilizer Pressure=50psig Temperature=150 C Time=90 minutes

2ThreshingThresher Pressure= 14.696 psi Temperature=32 C Time=30 minutes

3EFB fiber production Refer section 3.7.3.2Refer section 3.7.3.2

4Transferring FruitletConveyor Pressure= 14.696 psi Temperature=32 C

5DigestionDigester Pressure= 14.696 psi Temperature=90 C Time=30 minutes

6PressingScrew Press Pressure= 14.696 psi Temperature=32 C Time=30 minutes

7Separating Nut and FiberDepericarper & Nut Polishing drum Pressure= 14.696 psi Temperature=32 C Time=60 minutes

8ScreeningSand Trap Tank

Pressure= 14.696 psi Temperature=100 C Time=30 minutes

9ScreeningVibrating Screen Separator` Pressure= 14.696 psi Temperature=32C Time=30 minutes

10Sand Disposal Sand Trap Tank Pressure= 14.696 psi Temperature=100 C

11Recycle Sterilized FruitletsConveyor Pressure= 14.696 psi Temperature=32 C

12Storing CPOCrude Oil Tank Pressure= 14.696 psi Temperature=90 C

13ClarificationContinuous Settling Tank Pressure=14.696 psi Temperature= 90 C Time=120 minutes

14Storing Pure OilPure Oil Tank Pressure=14.696 psi Temperature= 90 C

15PurificationPurifier Pressure=14.696 psi Temperature= 60 C Time=120 minutes

16Storing Purified OilHolding Tank Pressure=14.696 psi Temperature= 70 C

17Removing SludgeTo POME Pond Pressure=14.696 psi Temperature= 70 C

18DryingVacuum Dryer Pressure=14.696 psi Temperature= 90 C Time=60 minutes

19Storing CPOCPO Tank Pressure=14.696 psi Temperature= 50 C Time=30 minutes

20Dispatch CPOShipment Truck Pressure=14.696 psi Temperature= 30 C

21Sludge Separation ISludge Buffer Tank Pressure=14.696 psi Temperature= 70 C

22Sludge Separation IISludge Drain Tank Pressure=14.696 psi Temperature= 70 C

23.Removing SludgeSludge Separator Pressure=14.696 psi Temperature= 70 C

24.Recycling Oil From SludgeSludge Oil Tank Pressure=14.696 psi Temperature= 70 C

25.Clarifying Recycle OilContinuous Settling Tank Pressure=14.696 psi Temperature= 90 C

26.Removing Sludge to Sludge PitTo Sludge Pit Pressure=14.696 psi Temperature= 70 C

27.Discharge SludgeTo POME Pond Pressure=14.696 psi Temperature= 70 C

28.Remove Impurity From Fiber Pneumatic Fiber System Pressure=14.696 psi Temperature= 40 C

29.Nut Drying & StoringNut Silo Pressure=14.696 psi Temperature= 40 C Time=60 minutes

30.Burning FiberBoiler Pressure=30 psi Temperature=180 C

31.CrackingRipple Mill Pressure=14.696 psi Temperature= 40 C Time=60 minutes

32.WinnowingWinnowing Column Pressure=14.696 psi Temperature= 40 C Time=60 minutes

33.Purifying FiberFiber Cylone Pressure=14.696 psi Temperature= 40 C

34.Burning FiberBoiler Pressure=30 psi Temperature=180 C

35.Separating Shell and KernelClaybath Pressure=14.696 psi Temperature= 40 C Time=60 minutes

36.Storing ShellShell Bunker Pressure=14.696 psi Temperature= 40 C

37.Kernel DryingKernel Dryer Track Pressure=14.696 psi Temperature= 80 C Time =60 minutes

38.Burning ShellBoiler Pressure=30 psi Temperature=180 C

39.Storing KernelKernel Silo Pressure=14.696 psi Temperature= 40 C

40.Dispatch KernelShipment Truck Pressure=14.696 psi Temperature= 40 C

3.7.3.2 Process Flow Diagram of EFB Fiber ProductionFigure 47 is the process flow diagram for CPO and palm kernel production. There a total of 40 streams in the production line. The stream 1 to stream 10 is the process routes for EFB fiber production. Table 9 shows the detailed description of the process condition in each stream with the used of equipment.

Figure 46: Process flow diagram of EFB Fiber Production.

Table 9:The description of process flow diagram. Stream ProcessEquipmentProcess Condition

1Transfer EFB to conveyorConveyor Pressure= 14.696 psi Temperature=32 C

2Transfer EFB to Collection PointConveyor Pressure= 14.696 psi Temperature=32 C

3Shredding EFB EFB Shredder Machine Pressure= 14.696 psi Temperature=32 C Time=60 minutes

4Pressing EFBEFB Fiber Press Machine Pressure= 14.696 psi Temperature=32 C Time=60 minutes

5Removing LiquorTo POME Pond Pressure= 14.696 psi Temperature=32 C

6HammeringHammer Mill Machine Pressure= 14.696 psi Temperature=32 C Time=60 minutes

7DryingRotary Drying Pressure= 14.696 psi Temperature=100 C Time=120 minutes

8BalingBaling Machine Pressure= 14.696 psi Temperature=32 C Time=60 minutes

9StoringTo EFB Fiber store Pressure= 14.696 psi Temperature=32 C

10Dispatch EFB FiberShipment Truck Pressure= 14.696 psi Temperature=32 C

3.8 PROCESS SCHEDULING3.8.1 Process Scheduling DescriptionIn the proposed mill, the plant capacity is 240 ton FFB/hours, a total of 8 batch FFBs will be processed. The amount of FFB being processed is 30 ton per batch. At the same time, 8 batches of palm kernel and EFB fiber will be produced. Table 10 shows the time for each batch of the CPO, palm kernel and EFB fiber production. Table 10: Processing Time.PRODUCTIONBATCH 1BATCH 2BATCH 3BATCH 4BATCH 5BATCH 6BATCH 7BATCH 8

CPO9AM-6.30PM11AM-8.30PM1PM-10.30PM3PM-12.30AM5PM-2.30AM7PM-4.30AM9PM-6.30AM11PM-8.30AM

PALM KERNEL1PM-7PM3PM-9PM5PM-11PM7PM-1AM9PM-3AM11PM-5AM1AM-7AM3AM-9AM

EFB FIBER11AM-5PM1PM-7PM3PM-9PM5PM-11PM7PM-1AM9PM-3AM11PM-5AM1AM-7AM

3.8.2 Process Scheduling of CPO ProductionTIME891011121314151617181920212223241234567

PROCESS

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

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

3.8.3 Process Scheduling of Palm Kernel ProductionTIME891011121314151617181920212223241234567

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

3.8.4 Process Scheduling of EFB Fiber ProductionTIME891011121314151617181920212223241234567

PROCESS

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

DRYING

BALING

BATCH 6

SHREDDING

PRESSING

HAMMERING

DRYING

BALING

BATCH 7

SHREDDING

PRESSING

HAMMERING

DRYING

BALING

BATCH 8

SHREDDING

PRESSING

HAMMERING

DRYING

BALING

3.9 MATERIAL BALANCE3.9.1 Law of Conservation of MassThe mass balance calculation was made based on the law of conservation of mass. The capacity of the proposed palm oil mill was 240 ton FFB/day. For every one ton of FFB processed in the mills, 22 % of empty fruit bunch, 19.25% of mesocarp fiber, 5.3% of shell and 5.6% palm kernel were produced. All material balance data are based on [4], [7], [24] and [26]. The mass balance was calculated based on the law of mass balance by with the formula as follow:Minput=MoutputWhere Minput = Mass input (kg), Moutput = Mass output (kg)The basis of mass balance was set at one day.3.9.2 Material Balance of Palm Oil Milling Process3.9.2.1 Sterilization StationThe first stage to produce crude palm oil was to cook the FFB by using steam at pressure of 50 psig. The sterilization process was carried out for 90 minutes under temperature of 150C. For every one ton of FFB processed, a total of 200 kg steam was required for tilting sterilizer. The steam loss that occurred from this process was 3.47 % for one ton of FFB be processed. This process also generated 88% of SFB and 28.53% of condensate. 48,000 kg Steam/day at 50 psig

Calculation:Sterilization

240,000kg FFB/day211,200 kg SFB/day

68,472 kg Condensate/day

8,328 kg Exhaust Steam/day

Mass input SolidFFB = 240, 000 kg FFB/day or 240 ton FFB/day Non-solidSteam = steam/day Total mass input = 240,000 kg FFB/day + 48,000 kg steam/day = 288,000 kg/dayMass output SolidSFB = 240,000 kg FFB/day x 88% = 211,200 kg SFB/day Non SolidExhaust steam = 240,000 kg FFB/day x 3.47% = 8,328 kg Exhaust Steam/dayCondensate = 240,000 kg FFB x 28.53% = 68,472 kg condensate/day Total mass output = 211,200 kg SFB/day + 8328 kg Exhaust Steam/day + 68,472 kg condensate/day = 288,000 kg/day3.9.2.2 Threshing StationIn this process, the cooked FFB were fed into a stripper drum to dislodge the fruitlets. The amount of fruitlets obtained was 75% of SFB. A waste product was generated in this station which known as EFB. The quantity of EFB was accounted 22% of every one ton processed FFB. Calculation:158,400 kg Sterilized Fruitlets/day

211,200 kg SFB/day52,800 kg EFB/dayThreshing

Mass input SolidSFB = 211,200 kg SFB/day Total mass input = 211,200kg/dayMass output SolidEFB = 240,000 kg FFB/day x 22% = 52,800 kg EFB/daySterilized Fruitlets = 211,200 kg SFB/day - 52,800 kg EFB/day = 158,400 kg sterilized fruitlets/day Total mass output = 52,800 kg EFB/day + 158,400 kg Sterilizer fruitlets/day = 211,200 kg/day3.9.2.3 Digestion StationDigestion process is carried out to reheat the sterilized fruitlets and separated it from nuts. This is carried out in the steam heated vessels provided with stirring arms and known as digester. In this process, the amount of steam required was 6.1% of the amount of the feed. Calculation: 9,600 kg Steam/dayDigestion

158,400 kg Sterilized Fruitlets/day

168,000 kg Digested Fruitlets/day

Mass input SolidSterilized fruitlets = 158,400 kg Sterilized Fruitlets/day Non-solidSteam = 158,400 kg Sterilized Fruitlets/day x 6.1% =9,600 kg steam/day Total mass input = 158,400 kg Sterilized Fruitlets/day + 9,600 kg steam/day= 168,000 kg/dayMass output SolidDigested Fruitlets = 168,000 kg Digested Fruitlets/day Total mass output = 168,000 kg/day3.9.2.4 Pressing StationScrew press was used to compress the digested fruitlets to squeeze out the oil. Approximately 50% of crude oil will produced from the digested fruitlets, the remaining solid residual will send to a separation process for recovery mesocarp fiber, palm kernel and palm shell. Calculation: Pressing

84,000 kg Crude oil/day

168,000 kg Digested Fruitlets/day

84,000 kg Press cake/day

Mass input SolidDigested fruitlets = 168,000 kg Digested Fruitlets/day Total mass input = 168,000 kg/dayMass output SolidPress cake = 168,000 kg Digested Fruitlets/day x 50%= 84,000 kg Press cake/day Non-solidCrude oil = 168,000 kg Digested Fruitlets/day x 50%= 84,000 kg crude oil/day Total mass output= 84,000 kg Press cake/day+ 84,000 kg crude oil/day= 168,000kg/day3.9.2.5 Screening StationFor every one ton of FFB processed, dilution water is added in the ratio of 1:2 to the crude oil. Calculation: 42,000 kg Dilution Water/day

Screening

126,000 kg Diluted Oil/day

84,000 kg Crude oil/day

Mass input Non-solidCrude oil = 84,000 kg Crude oil/dayDilution water = 84,000 kg Crude oil/day x 50% = 42,000 kg dilution water/day Total mass input = 84,000 kg Crude oil/day + 42,000 kg dilution water/day = 126,000 kg/dayMass output Non-solidDiluted oil= 126,000 kg diluted oil/day Total mass output = 126,000 kg/day3.9.2.6 Clarification StationThe ratio of recycle oil to diluted oil is 0.171:1. Both of them will flow in the crude oil tank. After 1-3 hours, 45.01 % of settled oil will be produced and the remaining is sludge. 76.6% of sludge will produced from the amount of diluted oil. The sludge will undergo separation process I to remove sand. The amount of sand removed is 0.62 % of the sludge. Then, the sludge will undergo separation process II to recover oil where its amount is 22.5% of the sludge. The remaining amount of sludge is discharge to sludge pit. Calculation: 21,600 kg Recycle Oil/day126,000 kg Diluted oil /day

96,600 kg Sludge/dayClarification

600 kg Sand/daySeparation I51,000 kg Settled oil/day

96,000 kg Sludge/day

Separation II

74,400 kg Sludge/day

Mass input Non-solidDiluted Oil =126,000 kg Diluted oil /dayRecycle Oil=126,000 kg Diluted oil /day x 0.171 = 21,600 kg Recycle Oil/day Total mass input = 126,000 kg Diluted oil /day+21,600 kg Recycle Oil/day=147,600kg/dayMass output SolidSand from separation I = (126,000 x 76.6%) kg sludge/day x 0.62% = 600kg sand/daySludge = (126,000 x 76.6%) kg sludge/day x 77% =74,400 kg sludge/day Non-solidSettled Oil = 126,000 kg Diluted oil /day x 40.5% = 51,000 kg Settled oil/dayRecycle Oil=126,000 kg Diluted oil /day x 0.171 = 21,600 kg Recycle Oil/day Total mass output = 600kg sand/day + 74,400 kg sludge/day+51,000kg Settled oil/day + 21,600 kg Recycle Oil/day= 147,600 kg/day3.9.2.7 Purification StationThe settled oil will then undergo purification to produce oil. In this process, 0.235% of dirt and water is removed. Calculation: Purification

51,000 kg Settled Oil/day120 kg Dirt and Water/day

50,880 kg Oil/day

Mass input Non-solidSettled Oil = 51,000 kg Settled Oil/day Total mass input = 51,000 kg/dayMass output SolidDirt and water = 51,000 kg Settled Oil/day x 0.235%= 120 kg Dirt and Water/day Non-solidOil= 51,000 kg Settled Oil/day x (100-0.235) %= 50,880 kg Oil/day Total mass output = 120 kg Dirt and Water/day+50,880 kg Oil/day=51,000kg/day3.9.2.8 Oil Drying StationThe purified oil will undergo drying process with the removed of 0.94% moisture of its content before produce the production oil. The production oil produced is 21% for every one ton of FFB been processed.Calculation: 480 kg moisture/day50,880 kg Oil/day

Drying

50,400 kg production oil/day

Mass input Non-solidOil=50,880 kg Oil/day Total mass input = 50,880 kg/dayMass output Non-solidProduction Oil = 240,000 kg FFB/day x 21% = 50,400 kg production oil/dayMoisture = 50,880 kg Oil/day x 0.94% = 480kg moisture/day Total mass output = 50,400 kg production oil/day + 480kg moisture/day =50,880 kg/day

3.9.3 Material Balance of Palm Kernel Production3.9.3.1 Depericarping StationIn this stage, press cake from pressing process will undergo depericarping process to separate mesocarp fibers and nuts. Around 19.25% of mesocarp fiber will formed from every one ton of FFB to be processed. From the depericarping process, 45% of press cake is wet nuts.Calculation: Depericarping

37,800 kg Wet Nuts/day

84,000 kg Press Cake/day

46,200 kg Mesocarp Fiber/day

Mass input SolidPress cake = 84,000 kg Press cake/day Total mass input = 84,000 kg/dayMass output SolidMesocarp fiber = 240,000 kg FFB/day x 19.25% = 46,200 kg Mesocarp fiber/dayWet nuts = 84,000 kg Press cake/day x 45% = 37,800 kg Wet Nuts/day Total mass output = 46,200 kg Mesocarp fiber/day+37,800 kg Wet Nuts/day = 84,000kg/day

3.9.3.2 Silo Drying StationThe wet nuts will undergo drying process to produce dry nuts. During the process, 6.03% of moisture will formed from the amount of feed.Calculation: Drying

35,520 kg Dry Nuts/day37,800 kg Wet Nuts/day

2,280 kg Moisture/day

Mass input SolidWet nuts = 37,800 kg Wet Nuts/day Total mass input = 37,800 kg/dayMass output SolidDry nuts = 37,800 kg Wet Nuts/day x (100-6.03) % = 35,520 kg Dry Nuts/day Non-solidMoisture = 37,800 kg Wet Nuts/day x 6.03% = 2,280 kg Moisture/day Total mass output = 35,520 kg Dry Nuts/day + 2,280 kg Moisture/day = 37,800kg/day3.9.3.3 Nut Cracking StationPalm nuts that had been dried in the silo dryer station were fed to this station to encounter a breakdown process. Calculation: 35,520 kg Cracker Mixture/dayCracking35,520 kg Dry Nuts/day

Mass input Solid Dry nuts = 35,520 kg Dry Nuts/day Total mass input =35,520 kg/dayMass output SolidCracked mixture = 35,520 kg Cracker Mixture/day Total mass output = 35,520 kg/day3.9.3.4 Winnowing stationIn this station, shells and dust are drawn to the boiler using pneumatic separation which known as winnowing. Around 20.94 % of shells and dust are removed from cracked mixture. Then, the palm shell and kernel mixture will undergo further separation process. Calculation: 28,080 kg Shell and Kernel/day35,520 kg Cracker Mixture/day

Winnowing

7,440 kg Light Shell and Dust/day

Mass input SolidCracker mixture = 35,520 kg Cracker Mixture/day Total mass input = 35,520 kg/dayMass output SolidLight shell and dust = 35,520 kg Cracker Mixture/day x 20.94% = 7,440 kg Light Shell and Dust/day Shell and Kernel mixture = 35,520 kg Cracker Mixture/day x (100-20.94) % = 28,080 kg Shell and Kernel/day Total mass output = 7,440 kg Light Shell and Dust/day + 28,080 kg Shell and Kernel/day = 35,520 kg/day3.9.3.5 Hydrocyclone StationIn the hydrocyclone, separation of kernels from their shells occurred based on the specific gravity. The core of the kernels would move upwards the hydrocyclone, while the shells would fall under the hydrocyclone. Water is added in the ratio of 0.94:1 to kernel and shell mixture in this process which then discharge to effluent pond. For every one ton of FFB processed in the mills, 5.2% palm shell was produced.Calculation: 26,400 kg water/day

Separation

28,080 kg Shell and Kernel/day

15,600 kg Wet Kernel/day

26,400 kg water/day

12,480 kg Palm Shell/day

Mass input SolidShell and Kernel mixture = 28,080 kg Shell and Kernel/day Non-solidWater input = 28,080 kg Shell and Kernel/day x 0.94 = 26,400 kg water/day Total mass input = 28,080 kg Shell and Kernel/day +26,400 kg water/day= 54,480 kg/dayMass output SolidPalm Shell = 240,000 kg FFB/day x 5.2 % = 12,480 kg Palm Shell/dayWet Kernel = = 28,080 kg Shell and Kernel/day-12,480 kg Palm Shell/day=15,600 kg Wet Kernel/day Non-solidWater output = 26,400 kg water/day Total mass output = 12,480 kg Palm Shell/day+15,600 kg Wet Kernel/day+26,400 kg water/day=54,480 kg/day3.9.3.6 Kernel Drying StationKernels from the hydrocyclone were fed into a kernel dryer. In this process, the water content as much as 13.84% contained in the kernels was evaporated. For every one ton of FFB processed in the mills, 5.6% palm kernel was produced.Calculation: 13,440 kg Dry Kernel/day15,600 kg Wet Kernel/day

Drying

2,160 kg Moisture/day

Mass input SolidWet Kernel = 15,600 kg Wet Kernel/day Total mass input = 15,600kg/dayMass output SolidDry Kernel = 240,000 kg FFB/day x 5.6% = 13,440 kg Dry Kernel/day Non-solidMoisture = 15,600 kg Wet Kernel/day x 13.84% = 2,160kg moisture/day Total mass output = 13,440 kg Dry Kernel/day+2,160kg moisture/day= 15,600kg/day

3.9.4 Material Balance of EFB Fiber Production3.9.4.1 EFB Shredding StationThe amount of EFB produced is 22% for every one ton of FFB to be processed. The EFB will transfer to EFB collection point and undergo shredding process to produce shredded EFB.Calculation:54,800 kg shredded EFB/day54,800 kg EFB/dayShredding

Mass input SolidEFB = 240,000 kg FFB/day x 22% = 54,800 kg EFB/day Total mass input =54,800 kg/dayMass output SolidShredded EFB = 54,800 kg shredded EFB/day Total mass output = 54,800 kg/day3.9.4.2 Pressing StationShredded EFB were being pressed in order to extract the liquor from the bunch. The moisture content of EFB will remove around 19.3%.Calculation:42,240 kg shredded EFB/day54,800 kg shredded EFB/dayPressing

10,560 kgLiquor/day

Mass input SolidShredded EFB = 54,800 kg shredded EFB/day Total mass input = 54,800kg/dayMass output SolidShredded EFB = 54,800 kg shredded EFB/day-10,560 kg Liquor/day=44,240 kg shredded EFB/day Non-solidLiquor=54,800 kg shredded EFB/day x 19.3% = 10,560 kg Liquor/day Total mass output = 44,240 kg shredded EFB/day+10,560 kg Liquor/day=54,800kg/day3.9.4.3 Hammering Station The fibers were transferred into the Hammer Mill Machine in order to break the fibers into single strand fiber.Calculation:42,240 kg single strand fiber/day42,240 kg shredded EFB/dayHammering

Mass input SolidShredded EFB=42,240 kg shredded EFB/day Total mass input = 42,240kg/dayMass output SolidSingle stand fiber = 42,240 kg Single strand fiber/day Total mass output = 42,240kg/day3.9.4.4 Drying StationThe fibers were then undergoes a drying process by using a Rotary Dryer with dust remover system. This process will remove the moisture content of the fibers around 43.2%. Calculation:Drying

24,000 kg dried strand fiber/day42,240 kg Single strand fiber/day

18,240 kg Moisture/day

Mass input SolidSingle stand fiber = 42,240 kg Single strand fiber/day Total mass input = 42,240 kg/dayMass output SolidDried strand fiber = 42,240 kg Single strand fiber/day-(100-43.2) %= 24,000 kg dried strand fiber/day Non-solidMoisture = 42,240 kg Single strand fiber/day x 43.2% = 18,240 kg moisture/day Total mass output = 24,000 kg dried strand fiber/day+18,240 kg moisture/day=42,240 kg/day3.9.4.5 Bailing StationThe dried single strand fiber will bailed into baler fiber. The baler fiber will in the size 100 Kg with dimension 510 mm X 760 mm X 510 mm.Calculation:Baling

24,000 kg dried strand fiber/day

240 Baler Fibers (100 kg each)

Mass input SolidDried stand fiber = 24,000 kg dried strand fiber/day Total mass input = 24,000kg/dayMass output SolidBaler fiber = 24,000 kg dried strand fiber/day/100kg = 240 baler fiber Total mass output = 24,000 kg/day