Engineering Bulletin #102 front cover - Malaysian Palm Oil ...palmoilis.mpob.gov.my/publications/POEB/poeb115.pdf · MALAYSIAN PALM OIL BOARD KEMENTERIAN PERUSAHAAN PERLADANGAN DAN

PALM OIL ENGINEERING BULLETIN NO. 115 1

Engineering Bulletin #102

front cover

LEMBAGA MINYAK SAWIT MALAYSIAMALAYSIAN PALM OIL BOARD

KEMENTERIAN PERUSAHAAN PERLADANGAN DAN KOMODITI MALAYSIAMINISTRY OF PLANTATION INDUSTRIES AND COMMODITIES, MALAYSIA

Website: www.mpob.gov.my

ISSUE NO. 115 (Apr. - June 2015)

PALM OIL ENGINEERING BULLETIN NO. 1152

Ad(Inside Front)

Modipalm Engineering Sdn Bhd


EDITORIAL BOARD

ChairpersonDatuk Dr Choo Yuen May

MembersDr Ahmad Kushairi Din

Dr Lim Weng SoonAb Aziz Md Yusof

SecretaryIr N Ravi Menon

Malaysian Palm Oil BoardMinistry of Plantation Industries and Commodities,

Malaysia6 Persiaran Institusi, Bandar Baru Bangi,

43000 Kajang, Selangor, Malaysia.Tel: 603-8769 4400Fax: 603-8925 9446

Website: www.mpob.gov.my

© Malaysian Palm Oil Board, 2015All rights reserved.

No part of this publication may be reproduced, stored in a retrieval system, in any form or by any means, electronic,

mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher.

Products and services advertised in thisPalm Oil Engineering Bulletin do not

connote endorsement by MPOB.

Editorial

see page 2

CONTENTS

Editorial

TRAINING AND SEMINARSMPOB Training Programme 2015

MPOB Conferences and Seminars 2015

FEATURE ARTICLESDiesel Power Plant

Palm Oil Mill Innovation for Improved Efficiency, Based on Creativity and Profitability

TITBITS Special Dishes Using Exclusively Palm Oil

DATASHEET Approximate Diesel Consumption at Partial Engine Loads

1

7

11

8

W

19

47

53

ith the new business op-portunities associated with biogas-based grid con-

nected power generation creeping to share the territory hitherto occupied by the steam and diesel power plants, the mill power plant operation may have to undergo some changes in terms of addi-tional capacity building of its engineers. One such adjustment that is deemed to be worth considering is the new skill that will be needed to accommodate the impending changes. It is possible that eventually the palm oil mills may have to focus more on power generation than processing oil palm fruit bunches like the sugar industry.

Currently the mill engineers are not well-trained to manage all issues likely to come up while operating power plants equipped with the conventional internal combustion engines (ICE). It is therefore prudent for the mill management to con-sider a one-week training programme for their engineers in an established work-shop to sharpen their skill in the proper monitoring, operation and maintenance of a diesel generator set. Once the engi-neers become proficient the knowledge can be passed on to the engine drivers. Almost all palm oil mills in Malaysia op-erate diesel generating sets and the mill engineers are quite familiar with its op-eration and maintenance. The gas and diesel engines have many common op-erational features and as such it will not be difficult for them to acquire the extra knowledge to operate gas engines.

One of the problems associated with diesel engine had been the exhaust gas temperature (EGT) which should be monitored all the time as damage to engine is inevitable if the temperature is left undetected. A remote gauge to measure this temperature is not installed on most diesel engines, a vital mistake considering its effectiveness in saving a hefty amount of money to rectify the damage resulting from an overheated


from page 1

CALL FOR ARTICLESPersonnel of the palm oil mills are invited to send in articles of relevance to the palm oil industry in Malaysia for publication in Palm Oil Engineering Bulletin. By sharing your expertise you will be helping the industry and the nation as a whole. The topics of interest are:

1. Plant modifications done in your mill that resulted in improvements in milling operation or main-tenance.

2. Innovations done in your mill that produced improvements in the operation of the mill and that you are willing to share them with others.

3. Any special work done in your mill that directly resulted in improvements in OER and product quality.

Please submit your article to us and we shall be pleased to publish them in Palm Oil Engineering Bulletin. Feel proud to have your articles published in this Bulletin that is circulated throughout the industry and MPOB offices worldwide.

engine. If the engineer has undergone sufficient training he will be able to save a lot of cost for the company. Secondly this training will assist in the capacity building of the engineer making their value to move upwards.

Another change that will help the industry is for the mills to take full charge of the maintenance of the estate fleet of vehicles. All the maintenance can fall under

the mill engineers instead of being managed by the planters. So the special training for the engineers to get fully involved in diesel vehicle maintenance will allow the planters to focus on agricultural activities. This is a win-win situation that can also strengthen the inter-estate mill relationship. In addition, the proposed training for the engineers will hopefully benefit the plantation industry as a whole.


AdBosch Rexroth Sdn Bhd

Linear Motion Technology Industrial Hydraulic Controls Assembly Technology Electric Drives and Controls Industrial Hydraulic Cylinders

Product Groups Transmission Units Power Units, Manifolds, and Hydraulic Accessories Pneumatics Mobile Controls Compact Hydraulics Mobile Electronics Pumps and Motors Large Hydraulic Drives Wind Turbine Gearboxes

Hydraulics Electric Drives and Controls

Linear Motion and Assembly Technology

Pneumatics Drive Technology

Service and Training

The Drive & Control Company

Bosch Rexroth Sdn. Bhd. 11, Jalan Astaka U8/82, Bukit Jelutong, 40150, Shah Alam, Selangor Tel: 03-7844 8000 Fax: 03-7845 4800 www.boschrexroth.com.my E-mail : [email protected]

Hydraulic System for Palm Oil Mill Applications

SALES & SERVICE PARTNERS Malaysia Gerex Automation (M) Sdn Bhd (Johor) Gismann Hidromech Engineering (Melaka / Negri Sembilan) Millivest Sdn Bhd (Sabah - Sandakan) Utama Parts Trading Sdn Bhd (Sarawak – Bintulu)

Indonesia Pt. Technindo Contromatra (Medan) Pt. Agrindo Putra Lestari (Jakarta)

INDEXER, CONTINOUS STERILIZER, FFB CONVEYOR DRIVE, WINCHES, COMPOSITE MIXER, TILTING STERILIZER, TIPPER & MOVING TIPPER, MOVING FLOOR & MOVING GRATE FOR BOILER, TIPPING PLATFORM, CHAIN TENSIONER, LOADING RAMP, TRANSFER CARRIAGE & OTHERS

Prai Branch : Tel : 04-390 4100 Fax : 04-390 2141


AdSM Cyclo (M) Sdn Bhd (Relax)

(1st half)

MALAYSIA SM-Cyclo (Malaysia) Sdh. BhdKuala Lumpur (Head o�ce)No.7C, Jalan Anggerik Mokara 31/56Kota Kemuning, Seksyen 3140460 Shah Alam, Selangor, MalaysiaTel: 03-5121 0455Fax: 03-5121 0578E-mail: [email protected]

Sabah & Sarawak1st Floor, MDLD 7151, Bandar Sri Perdana Phase 3, 91100 Lahad Datu, SabahHp: 019-380 2909Hp: 019-335 0455

PenangNo. 2945, 1st Floor Jalan Prai, Taman Inderawasih 13600 Prai, Penang Hp: 019-470 3737Hp: 019-650 2909

Johor24-02, Jalan Ros Merah 2/17Taman Johor Jaya 81100 JB JohorHP: 019-238 6101

SINGAPORE Sumitomo (SHI) Cyclo Drive AsiaPaci�c Pte. Ltd. (Asia Paci�c Headquarters) 15 Kwong Min Road, Singapore 628718 Tel: +65 6591 7800Fax: +65 6863 4238Email: [email protected]

THAILAND SM-Cyclo (Thailand) Co. Ltd.195 Empire Tower Unit 2103-421th Floor South Sathorn RoadYannawa, Bangkok 10120, ThailandTel: +66 2670 0998Fax: +66 2670 0999Email: [email protected]

PHILIPPINESSumitomo (SHI) Cyclo Drive Asia Paci�c Pte. Ltd. (Branch O�ce)B2b Building, Granville Industrial Complex,Governor’s Drive, Carmona Cavite, Philippines 4116 Tel: +632 584 4291/(6346) 430 3591Fax: +632 584 4922Email: [email protected]

INDONESIAPT SM-Cyclo IndonesiaFactory & WarehouseJalan Sungkai Blok F 25 No. 09K, Delta Silicon 5, Lippo Cikarang Bekasi 17530Ph: +62-21-2961 2100Fax: +62-21-2961 2211Email: [email protected]

www.sumitomodrive.com


AdMackenzie Industries Sdn Bhd





SINGAPORE Sumitomo (SHI) Cyclo Drive AsiaPaci�c Pte. Ltd. (Asia Paci�c Headquarters) 15 Kwong Min Road, Singapore 628718 Tel: +65 6591 7800Fax: +65 6863 4238Email: [email protected]

THAILAND SM-Cyclo (Thailand) Co. Ltd.195 Empire Tower Unit 2103-421th Floor South Sathorn RoadYannawa, Bangkok 10120, ThailandTel: +66 2670 0998Fax: +66 2670 0999Email: [email protected]

PHILIPPINESSumitomo (SHI) Cyclo Drive Asia Paci�c Pte. Ltd. (Branch O�ce)B2b Building, Granville Industrial Complex,Governor’s Drive, Carmona Cavite, Philippines 4116 Tel: +632 584 4291/(6346) 430 3591Fax: +632 584 4922Email: [email protected]




AdArachem (M) Sdn Bhd


A1.2 Kursus Operator Mekanisasi Ladang (KOML)Tahap 2 Apr (5 month) PLASMA Keratong, Pahang

Tahap 3 Okt (5 month) PLASMA Keratong, Pahang

A1.3 Kursus Pengurusan dan Penyelenggaraan Nurseri SawitBil. 4: Wilayah Utara 25 – 26 Ogos Sungai Petani, KedahBil. 5: Wilayah Tengah 20 – 21 Okt Puteri Resort Ayer Keroh,

Melaka2 PALM OIL

A2.1 Diploma in Palm Oil Milling Technology & Management (DIPOM)Semester III 8 – 17 Jun

MPOB HQExamination 7 – 8 Sep

A2.2 The 29th MPOB Oil Palm Products Surveying Course 26 – 30 Oct Shah Alam, Selangor

A2.3 The 28th MPOB Oil Palm Products Surveying Examination Dec* *

Training & Seminars

MPOB TRAINING PROGRAMME 2015

CODE NO. TITLE DATE VENUE

A COURSES 1 OIL PALM

A1.1 Kursus Kemahiran Menggred Buah SawitWilayah Utara 4 – 6 Ogos Legend Inn Hotel,

Taiping, PerakWilayah Tengah 17 – 19 Ogos Melang Inn Hotel, Kuala Pilah,

Negeri SembilanWilayah Sabah 8 – 10 Sept MB Hotel, Tawau, SabahWilayah Timur 20 – 22 Okt Kuala Terengganu, TerengganuWilayah Sarawak 27 – 29 Okt RH Hotel, Sibu, SarawakWilayah Selatan 3 – 5 Nov Segamat, Johor


Training & Seminars

For enquiry or further information, please contact:

HRD & Conference Management UnitTel. No. : 03-8769 4400 ext. 4865, 4860, 4867Fax No. : 03-8925 7549E-mail : [email protected]’s website : www.mpob.gov.my

All information are correct as at press time.

Note: *To be confirmed.

A2.4 Kursus Penyelia Kilang Sawit

Peperiksaan

21 – 25 Sep

23 NovPLASMA, Lahad Datu, Sabah

A2.5 Kursus Pengendali Makmal Kilang Sawit 8 – 16 Jun MPOB HQ

A2.6 Kursus Asas Rawatan Tertiari Efluen SawitWilayah SemenanjungWilayah SabahWilayah Sarawak

3 – 5 Nov11 – 13 Mei19 – 21 Okt

PLASMA Keratong, PahangSabah

Sarawak

A2.7 Margarine Course * MPOB HQA2.8 Kursus Drebar Enjin 2 – 6 Nov PLASMA Lahad Datu, SabahA2.9 Kursus Penyelia Bengkel Kilang Sawit 8 – 16 Nov MPOB HQ

B MPOB CONFERENCES AND SEMINARSB1.1 PIPOC 2015 6 – 8 Oct KLCC, Kuala Lumpur


AdJasa Aman Engineering Sdn Bhd

Designed In The USA with over 70 years of total steam turbine experience

• Installation In Palm Oil, Steel, Sugar, Paper, Rice & Bagasse Industries

• Complete Packaged Systems with Steam Turbine, Gearbox, Generator, Lube System And Controls

• API Compliance

• Supply To All Major OEM, EPC & end user

Jasa Aman Engineering SDN BHDJasa Aman Sales and Services SDN BHD 39/39A, Jalan 23, Taman Bukit Kuchai, Batu 8, Jalan 47100 Puchong, Selangor Darul Ehsan, MalaysiaTel: +603-8075 6521, 8075 6750 Fax: +603-8070 2436, 8075 6485Email: [email protected] Web: www.jasaaman.com


AdSKF Malaysia

Sdn Bhd

SKF offers a total solution to the Palm Oil IndustrySKF Explorer Spherical Roller Bearings Bearing

Heater

Sealing Solutions

Lubricants & Lubrication Systems

Microlog

Plummer Block Housings

Power Transmission Products

SKF Explorer Spherical Roller Thrust Bearings

The SKF 360˚ Solution helps you get more out of your plant machinery and equipment investment! Contact us to find out more.

SKF Malaysia Sdn. Bhd. (13872-K)432, Jalan Sultan Azlan Shah, 51200 Kuala Lumpur.Tel: +603-4047 3333 Fax: +603-4043 9381Website: www.skf.com.my


Feature Article

A

Diesel Power Plant

N Ravi Menon* and Hasliyanti Alias*

INTRODUCTION

lmost all palm oil mills have stand by diesel electricity generator sets (DGS). There are alternating views

by mill managers on what criteria to adopt when choosing the capacities of these DGS. It is quite obvious that the mill managers did not spend enough time to analyse the requirements in more details when requesting for diesel sets for their mills. The selection of a steam power plant is relatively simple compared to DGS. Let us look at the mill requirements when the mill is not in operation. In the daytime, electricity is needed for the operation of office equipment, office and mill lighting. In the night time, the security lighting and domestic load will add on to the load. After midnight, the domestic load will drop until early morning.

SELECTION CRITERIA FOR DGS

It will be a good exercise for all palm oil mills to record hourly loads as accurately as possible for a full year so that it can cover the periods of low crop, normal crop and

peak crop. This exercise will help the new engineers to gain considerable knowledge on how to scientifically rate the DGS they want for their mills. Currently some of the mills have assorted inventory of DGS with improper ratings. It is useful to enter the data in a table to enable them to make a good decision. Samples of the data needed are shown in Table 1. The figures given are not actual readings and not to be used for real assessments as they are only examples. Based on the figures compiled in Table 1, we can easily size the steam turbine require-ment with sufficient provision for 10% ad-ditional load as it is normal for such expan-sion. If a single turbo alternator is using a 1250 kW, it would be a good choice. How-ever, it is prudent to choose two units so that in case of a major breakdown the mill can still satisfy part of the process require-ment. In this case, two 700 kW would be a good choice. The selection is very much a subjective issue. There are many options to choose from based on specific requirements.

Now for the DGS although many mill managers may select two units of say 250 kW or slightly different combinations, the reason being that the two units it can sup-ply at least half the electrical load in case the turbo alternator breaks down. This does not

* Malaysian Palm Oil Board, 6 Persiaran Institusi, Bandar Baru Bangi, 43000 Kajang, Selangor, Malaysia. E-mail: [email protected]


Feature Article

TABLE 1. DATA NEEDED FOR DIESEL GENERATOR SET SELECTION FOR A 60 TPH MILL

No Electric load demand by kW % to total

Time(hr)

a Mill: 60 tph@ 18 kW t-1 1 080 95 20 Based on maximum load (B) 1 135

b Only nut station operation 25% 270 23.8 Off-daysc Non- processing: base load:

(4 hr)40 3.5 4 am-8 am

d Off-day: maintenance load 40 3.5 7 am-3 pme Compound lighting 10 0.9 7 pm-7 amf Mill lighting 5 0.45 7 pm-7 amg Office lighting/air conditioner 15 1.3 8 am-5 pmh Domestic load- say 120

personnel40, 20 3.5/1.7 7 pm-11 pm

TOTAL LOAD (approximate)A Day: 7 am- 7 pm 1 080B Evening: 7 pm- 12 pm (40kw)

(maximum) 1 135 a+ e+f+h+1 080+10+5+40 =

1 135C Night: 12 pm- 7 am (20kw) 1 115 a+ e+f+h+1 080+10+5+20 =1 115D Maintenance day 40 dE Non-processing hours 40F Public holidays (Evening+

night)40

Note: tph – tonne per hour.

seem to be a good selection criteria when we consider the breakdown of a single turbo alternator as then the entire process steam will have to issue out of a pressure reducing valve without any work output by the steam. It will be better to have addi-tional steam turbine (third unit) as standby than too many DGS.

In this case, the DG’S capacity can be re-duced to a single unit of 80 kW that can op-erate between 52 kW to 56 kW. This is all we need. No additional units are required. The best efficiency for a DGS is at about 65% to 70% loading. If the unit is well maintained, it will last for a long time. Since the DGS are not operated while the steam power plan is in operational, there is ample time to main-tain it in good condition. The diesel con-

sumption also will drop to 3 kWh per litre diesel at the optimum load of 65% to 75%. A suggested selection is shown in Table 2.

DGS COMPONENTS

Apart from the engine, the associated other components that make up the whole plant are some additional equipment also used for improving the quality of exhaust gases to comply with the Department of Environ-ment’s (DOE) requirements:• air intake system comprising air filter,

ducting and turbo-chargers.• fuel supply system comprising diesel

storage tank, flow meter, pipe work, pumps, strainers, day tanks and float level indicator. The fuel pump with common rail and fuel injection nozzles.


Feature Article

TABLE 2. A SIMPLE METHOD FOR THE SELECTION OF BOILERS AND POWER PLANT

Type of electric generators No Maximum load

Steam turbo alternators 700 kW 2 1 135 kW Normal operation for 60 tphSteam turbo alternators 700 kW 1 700 kW Stand by unitDiesel generator set 80 kW 1 80 kW Back-up – non-processing and off-days hoursBoiler 20 tph 2 40 tph Capable of generating up to 1 500 kWBoiler 20 tph 1 20 tph Capable of generating 750 kW / 40 tph FFB

Note: FFB – fresh fruit bunch. tph – tonne per hour.

• exhaust system with turbo-charger, si-lencers and ducts.

• cooling systems comprising water circu-lating pumps, radiators, cooling towers, water treatment system and pipes.

• lubricating system comprising lubricant circulating pump, oil tanks, oil filters, oil purifiers and air compressor.

• the dedicated alternator.• armoured feeder cables to control panel

bus bar.• electric control panel with relevant instru-

mentation and synchroniser.• noise insulation system for the whole en-

gine so that the noise levels comply with the DOE’s set limits.

• warning signs for visitors to use ear plugs, safety shoes and helmets.

FUEL CONSUMPTION

Diesel consumption may be roughly taken as 0.304 kg per kWh or 0.42 litre per kWh (at a diesel specific gravity of 0.73kg per litre). For a 75 kW cummins engine, it is given as 0.37 litre per kWh. The specific fuel con-sumption for different capacities and frac-tional loads are given in the Datasheet of this bulletin. If the palm oil mill generator sets in Malaysia consume more diesel than say 0.5 litre per kWh, the mill engineers are advised to conduct an investigation to rule out the possibility of diesel leakage from submerged pipe joints as I personally ex-perienced such a catastrophe in one of the mills.

THERMODYNAMIC FUNDAMENTALS

There is a distinct possibility for some mill engineers to forget the basic fundamentals related to diesel engines and that should not be the case. There are many areas of mill operations where the mill engineers will get the thrill of intellectual interaction with thermodynamics especially with wet steam. When we deal with steam we get an oppor-tunity to remember and experience the ap-plication of the two laws of thermodynam-ics, the impact of Dalton’s law of partial pressures during sterilisation process and the Rankine cycle during power genera-tion. In a palm oil mill, the engineers have a great opportunity to work with all the facets of mechanical engineering, generous amount of electrical engineering, control systems, civil engineering, accountancy, hu-man resource management, environmental protection and sustainability issues. A good combination of this proportion is not of-fered by most other industries.

THE AIR STANDARD CYCLE FOR DIESEL PLANT

The diesel cycle was created by Rudolph Diesel in 1892 and in the original engine powdered coal was blasted using com-pressed air and using hot bulb, the fuel was ignited unlike spark plug ignited petrol en-gines operating on Otto cycle. The cycle used was called Diesel cycle comprising an isentropic compression followed by a


Feature Article

reversible constant pressure heating, isen-tropic expansion during which the work was done and a reversible constant volume cooling (Figure 1). In this case, the ignition took place when the piston reached the top dead center (TDC) but now the diesel engines have undergone changes from the original concept of firing only during the constant pressure combustion.

Contrary to popular belief the diesel engines do not operate on diesel cycles anymore. The cycle is a combination of diesel and Otto cycle as shown in Figure 2. The engine based on this cycle called dual combustion cycle was invented by Ackroyd-Stuart in 1888. It is rather unfortunate that despite the fact that he formulated the dual combustion cycle four years before Diesel presented his diesel cycle his name never came to the fore front but faded away from history. In this cycle, the firing takes place during the constant volume operation indicated by 2 to 3 as well as during the constant pressure operation represented by 3 to 4. In this cycle there is a compression ratio v1 /v2, an expansion ratio v3 /v2 as well as a pressure ratio p3 /p2.

Heat supplied is given by the equation Hinput = min{ cv (T3 – T2) + cp (T4 –T3)}

Heat rejected by exhaust gases = mex { cv (T5- T4)}

Where,

cp and cv are specific heats at constant pressure and constant volumes respectively;

minin and mex are masses of fuel air mixture injected at inlet and exhaust gases respectively.

Two-stroke internal combustion engines are mechanically simple compared to their four-stroke engines but are more complex in thermodynamic and aerodynamic terms, according to Society of Automotive Engineers (SAE) definitions. In a two-stroke engine, the four fundamental operations of the engine comprising air intake, compression, ignition and exhaust occur in one revolution of the crank shaft i.e. 360 mechanical degrees, while in a four-stroke engine these operations are done in two complete revolutions or 720 mechanical degrees. In a two-stroke engine, more than one function occurs at any given time during the engine’s operation. The advantages and disadvantages of the two stroke engines are given in Table 3.

• air intake takes place when the piston ap-proaches the bottom dead center (BDC) through the ports provided in the cylin-der wall with or without valves. All two-stroke diesel engines need either an artifi-cial aspiration system like a mechanically

Figure 2. Dual combustion cycle (replaced diesel cycle).

Figure 1. Diesel cycle (1892).

P


Feature Article

TABLE 3. THE ADVANTAGES AND DISADVANTAGES OF TWO-STROKE ENGINES

POSITIVE NEGATIVE INTERESTINGDo not have valves, simplifying their construction.

Two-stroke engines don’t live as long as four-stroke engines. The lack of a dedicated lubrication system means that the parts of a two-stroke engine wear-out faster. Two-stroke engines require a mix of oil in with the gas to lubricate the crankshaft, connecting rod and cylinder walls.

The following comments are from Columnist Michael Harrison of Deep Science:• Most of what is written on

advantages and disadvantages of two-stroke vs four-stroke are not actually correct.

• The comparisons are often made based on unequal basis. A two-stroke motor cycle engine that mixes the lubricant with the fuel cannot be compared with a four-stroke power plant prime mover.

• It should be compared to a unit equal in size any large Caterpillar, or Detroit two-stroke they have conventional oil sumps, oil pumps and full pressure fed lubrication systems and they are also two-stroke.

• The ports of two-stroke is claimed to be inefficient in scavenging exhaust gases compared to the valves of four-stroke engines but the same valve system can be incorporated in two stroke engines. The emission quality of some two-stroke engines are as good as four-stroke engines like Surrich/Orbital two-stroke design that Mercury outboards are using - this is as clean burning as four-stroke.

Fires every revolution (four-stroke engines fire once every two revolution). This gives two-stroke engines a significant power boost.

Two-stroke oil can be expensive. Mixing ratio is about 1:40 ( burning about 2 lit/1000 km).

Two-stroke engines are lighter and cost less to manufacture.

Cannot use fuel efficiently, gets less km per lit.

Two-stroke engines have the potential for about twice the power in the same size because there are twice as many power strokes per revolution.

Two-stroke engines produce more pollution from:• The combustion of the oil in the

gas. • The oil makes all two-stroke

engines smoky to some extent, and a badly worn two-stroke engine can emit more oily smoke.

• Each time a new mix of air/fuel is loaded into the combustion chamber, part of it leaks out through the exhaust port.

driven motor or a turbo-charger to charge the cylinder with air. During the aspira-tion phase, the residual exhaust gas of the previous charge is also expelled out.

• as the piston rises, the intake charge of air is compressed. Fuel is injected near the TDC to initiate the combustion as the compressed air temperature would be high enough to ignite the fuel. The high compression of the air is accomplished by the downward movement of the piston. As the piston moves downward in the

cylinder it will reach a point where the exhaust port is opened to expel the high pressure combustion gases. Currently the concept has undergone some changes as now the cylinder wall body ports have given way to poppet valves and im-proved exhaust gas evacuation. As the piston moves downward, the air intake ports will be exposed in the cylinder wall and the cycle will start again.

• the scavenging ports are symmetrically set to open from 45o before BDC to 45o


after BDC whereas the exhaust port settings being based on maximum exhaust gas evacuation does not have to be symmetrical. A single camshaft operates the poppet-type exhaust valves with the special injector systems using three lobes: two for exhaust valves (either two valves on the smallest engines or four valves on the largest; and the third for the injector system).

There are hardly any major variations in the operational features of most of the engines. The discharge ports can either open at 45o or before the piston reaches the TDC. The scavenging ports are set to open at any point from 45o before BDC to same angle after BDC to keep it symmetrical. The exhaust valves are set to allow maximum air intake. According to Caterpillar’s Electro-Motive Diesel known widely as EMD, it uses the following specifications for its two-stroke engine operation system.

The power stroke begins at 0o TDC. Fuel injection will start 4o before TDC 356o

in order to ensure that fuel injection is completed by the time the piston reaches the TDC or slightly after. This is followed by the fuel ignition and exhaust gas expulsion when the exhaust valves are opened causing a reduction of combustion gas pressure and temperature. The duration of the power stroke is about 103o.

• the scavenging will begin 32o later or at 135o (103+ 32), or 45o before the BDC having a duration of 90o ending at 225o (135 + 90). The delay of 32o is for the scavenging ports to open and another 16o delay after the scavenging ports are closed (thereby initiating the compression stroke), maximises scavenging effectiveness, thereby maximising engine power output, while minimising engine fuel consumption.

• towards the end of scavenging, all products of combustion have been forced out of the cylinder, and only

‘charge air’ remains (scavenging may be accomplished by Roots blowers, for charge air induction at slightly above ambient, or EMD’s proprietary turbo-compressor which acts as a blower during start-up, and as a turbo-charger under normal operational conditions and for charge air induction at significantly above ambient, and which turbocharging provides a 50% maximum rated power increase over Roots-blown engines of the same displacement).

• the compression stroke begins 16o later at 241o (225+16), to begin the compression stroke having a duration of 119o. By then the piston will be at 360o (241+119).

• in present day engines with electronic fuel injection systems, the electronically-controlled unit injector is used. But they are actuated mechanically, the amount of fuel fed into the plunger-type injector pump is under the control of the Engine Control Unit replacing the Woodward governor or similar units or conventional unit injectors specific to General Motors (GM) two-stroke engines.

• the same procedure is followed by the GM/EMD 567 and the GM/Detroit Diesel 6-71 engines as they were designed and developed by the same team of engineers. Turbocharging provisions were an optional extra in some of the EMD and Detroit Diesel engines that employed turbocharging like for hybrid turbo-compressor system with inter cooling. For conventional units, Roots blowers were used for scavenging as a hybrid turbo-compressor would elevate the cost of the engines.

Some of the performance characteristics of EGT 6 truck are given in Table 4. The negative temperature at zero throttle opening shows that the drop in temperature of the exhaust at inlet was faster than the gas turbine outlet as the gas picked up heat from residual heat from the turbine casing.

Feature Article


TABLE 4. SHOWS THE PERFORMANCE OF A ‘POWER STROKE OF EGT 6 TRUCK’

At gas turbine inlet At gas turbine outlet ∆T TPS MPH

RPM Turbine-in temp (F)

Turbine-in temp (0C)

Turbine-out temp

(F)

Turbine-out temp

(0C)

Temperature difference in-out (F)

Throttle position sensor

(%)

Miles (hr)

3 900 950 510 720 382 128 (230) 22 55.73 800 1 060 571 740 393 178 (270) 57 532 500 1 030 554 760 404 150(270) 60 53.82 500 660 349 540 282 67 (120) 0 44.42 400 980 527 750 399 128 (230) 55 52.41 700 1 040 560 800 427 133 (240) 48 54.1650

(Idle) 690 366 705 374 -8 (-15) 0 65.8

Fuel savings in terms of efficiency, the diesel engines fair better than gas engines mainly due to the higher calorific value of the diesel oil (7% higher) but some diesel engine manufacturer’s claim of 30% increase in efficiency needs verification.

DIESEL ENGINE IMPORTANT MAINTENANCE TIPS

As diesel engine works on the principle of compressing the air that is drawn into the cylinder during the suction stroke so that the compressed air temperature is sufficient to ignite the fuel injected into it at close to the TDC, there is no need for any electrical components like the spark plugs or induc-tion coil.

In diesel engines, the cylinder walls are thicker than petrol engines due to the high compression ratio. The temperature is also high resulting in additional demand for an efficient cooling system that has to be closely monitored. Abnormal temperature rise should be avoided in order to ensure prolonged engine life and to prevent engine getting seized or gasket get damaged. Gas-ket must be replaced as a set.

IMPORTANT TIPS ON BASIC DIESEL ENGINE MAINTENANCE

Sometimes the gas engines will get overheated due to poor coolant performance or continuous overloading of the engine. In such instances, the mill engineers seldom have a clue as to how the problem can be resolved. The right thing to do is to give it a break for a few minutes and restart when the temperature comes back to normal. The use of a fan will be of great help and as such it is prudent to have a fan permanently stationed near the gas engine. This may even prevent the occurrence of overheating. Overheating of a diesel engine should never be allowed even for short periods.

If a temperature rise is observed on a diesel engine, take any precaution that can prevent such occurrence as once it happens there is a good possibility for the cylinder gaskets to be damaged. Now let us look at some of the measures that would help the preventions of such catastrophe. The use of fan can be tried out but if the tempera-ture rise cannot be arrested check the cooler tubes to remove any scales. If that does not bring the desired results, the best solution

Feature Article


would be renewal of cooler tubes with big-ger tubes or add another cooler in series or parallel based on the available space. This should solve the problem amicably.

In order to safeguard the engine parts, it is usual to have filters on the run line to separate any dirt accumulated in the cool-ant while it circulates through the engine cooling circuit. Some engine manufactur-ers also provide coolant purification system so that the possibility of damage to engine parts by the coolant contaminants is effec-tively eliminated. Some of the coolant fil-ters carry out multiple functions specially designed to protect the engines but they all add to the cost.

It is not a common practice in palm oil mills to assign an engineer or artisan to monitor the condition of the diesel engine and this weakness has been responsible for many costly engine breakdowns. If the mill engineers had been marine engineers before joining palm oil mills, they would have known how to maintain diesel power plants. Regular check on all the bolts and nuts to ensure the recommended torque is the starting point as over a period of time we can expect the nuts to work itself loose setting in motion a series of problems culminating in overheating and damage

of gaskets. When this happens immediate attention should be given to change as a set to prevent further damage to the engine.

Great care must be directed to the condition of the oil filter. In palm oil mills, additional care will be needed and as such it is advisable to implement more than the manufacturer’s recommendation based on the operating hours as the environment in the palm oil mill is very dusty and a shorter period would be more appropriate.

Ensure that the diesel fuel storage is done according to prescribed methods. It must be enclosed in a concrete tank having a volume equivalent to the storage tank so that in case of a leak through a leak or otherwise the escaping diesel oil can be contained without getting it into the monsoon drain. The day tank also must have the same provision. Both the storage tank and the day tank must have level indicators with identification signage and statement on the tank capacity. It is preferable to install a flow meter or a remote flow recorder close to the engine with isolating valves and a filter.

Ensure that all spare parts used for the engine are original parts. Imitation parts can damage the engine.

Feature Article


Feature Article

* MECC Engineering Sdn Bhd 1, Jalan Setia Nusantara U13/19A, Eco-Park, Setia Alam, 40170 Shah Alam, Selangor, Malaysia. E-mail: [email protected]

C

Palm Oil Mill Innovation for Improved Efficiency,Based on Creativity and Profitability

Krishna Moorthy Palanisamy*

‘THE DREAM MILL’

an life for palm oil mill managers and engineers be (ever) made ‘easy’? Actually, yes with a

solution that is both easy and simple. Just picture this managers and engineers focusing on mill processes and production matters rather than tending to persistent mill utility issues. This will lead to enriching their daily working life and enhancing the core business of their company.

The current technological innovations and developments have no doubt given some boost to the palm oil mill operations. But new technologies have also emerged in recent times that can be profitably employed to re-engineer the design of existing palm oil extraction processes to achieve the desired results.

With The Dream Mill, mill managers and engineers can spend valuable time (a key

scarce resource) focusing on mill processes and production: • optimal process parameters• extraction efficiencies• product qualities• product losses• process energy efficiencies• production scheduling

Instead of concentrating on regular daily chores involving non-productive processing issues such as: • poor quality crop • inadequate process steam• high oil losses• black boiler stack emissions related to

Department of Environment (DOE) is-sues

• insufficient power • insufficient labour• machinery break down• fuel shortage

The crude palm oil extraction process prevalent in the palm oil mills today was originally expounded in the Mongana Report (Congo Palm, 1955). As this process technology still appears to be remaining stagnant, it needs radical changes befitting


Feature Article

the current technological development that is taking place around the palm oil industry. Palm oil mills appear to be in a world of its own unaffected by the development of numerous technologies that can be adopted for its own improvements.

New innovative technologies involving process steam utilisation are incorporated to surpass the initial performance levels of certain processes. The source of long-stand-ing mill performance issues can be traced to inefficient deaeration together with inad-equate steam pressures in the sterilisation process. The proposed technologies provide the impetus for a new paradigm for the de-velopment of a modern palm oil mill design criteria.

Today, new drop-in-place technologies that have compelling ease of use, cost and carbon advantages are available to revamp existing mills. These innovative methods and systems are engineered to address the issues of inefficient deaeration and batch effects of sterilisation because these are the root of the causes and large fluctuations in steam demand and frequent blow off from the steriliser and steam receiver relief valves. Once these drawbacks are resolved, sterilisation in the horizontal steriliser can regain its superior performance.

The steam optimisation technologies of-fer several benefits for the boilers as well as sterilisers. Firstly, as the steam demand is successfully reduced, it can be met satisfac-torily by existing over-stretched steam boil-ers and consumption of less amount of fuel. Secondly, the constancy of process steam demand allows for a stable boiler operation enabling compliance with regulatory boiler stack emission limits. Thirdly, the boiler plant maintenance issues and downtime are reduced.

The fourth significant advantage of the new technologies is that having boilers ren-dered a near steady-state operation; they become amenable for full automation of their operation. Automation can now fa-

cilitate control of the boiler plant including furnace draft and fuel feed systems.

The above mentioned advantages can re-lieve mill engineers of the major problems they encounter in their daily work at their mills — high count of unstripped and over-ripe bunches, inconsistent process tem-peratures due to fluctuating process steam pressure, inability of the turbo alternators to cope up with the process steam demand, black smoke emission from boiler stack, or lack of boiler fuel especially during low-crop seasons. Other pressing issues such as increasing environmental concerns and regulations, and skilled manpower shortag-es affecting boiler plant operation can now also be effectively addressed.

Relieved from being bogged down by mill utility issues, mill managers and engi-neers are now free to devote more time on process performance issues like quality of the finished products, product losses and extraction efficiencies

With the new technologies in place, the mill engineers have more time to attend to their core business activities as they are fi-nally relieved of disruptive utility chores.

It is estimated that The Dream Mill could slice up to two fifths of its energy demand with the new design.

‘AIR-VOID’

The ‘Air-Void’ system is a drop-in-place ret-rofit equipment designed for the deaeration of sterilisers air — a very innovative and scientific operational system incorporating sound thermodynamic principles to ensure maximum thermal efficiency. Heat transfer from the steam to the bunches had always been a persistent problem faced by the fresh fruit bunch (FFB) processing industry from the infancy of the industry itself. The air oc-cupying the large vacant space within the steriliser is a very bad conductor of heat that initially forms an insulation layer be-tween the FFB and the steam until through


Feature Article

diffusion heat transfer could be established but the air pockets within the bunch may still be present as it is continuously released by the bunches when they are subjected to heating. The deaeration of the steriliser is a very important operation as without which the steriliser temperature will remain far below the saturation temperature of the in-put steam due to the lower partial pressure of the steam in air/steam mixture. Until now this problem still remains unresolved despite the availability solutions overcome it. The important factor is to recognise that inefficient deaeration is the main weakness of the existing system.

The steam management and boiler op-erational issues at palm oil mills continue to remain problematic and have yet to be satisfactorily resolved. The root cause can be traced to the inefficient method of air re-moval at the steriliser station.

The Air-Void technology has been creat-ed specifically to solve the above-mentioned problem of inefficient air removal that is both serious and still prevalent in palm oil mills. The steam management system has hardly seen any significant improvement and the technology have remained stagnant for many decades. Research activities of the industry seem to have been mainly centred on downstream applications.

The effective evacuation of trapped air in the steriliser vessel at the onset of the steri-lisation process is critical to ensure achiev-ing the right heat treatment of palm fruits. However, many palm oil mills operating conventional horizontal sterilisers employ air release methods that are not efficient. At present, the trapped air is released through diffusion by using multiple steam pulses, during which the steriliser vessel experi-ences fluctuating steam pressures. This invariably leads to the excessive process steam consumption and a long process time to meet contemporary sterilisation require-ments. A further consequence is the reduced throughput of the sterilisation station.

By addressing the issue of inefficient re-sidual air removal that is the basis of inef-ficient steam usage at the steriliser station, the following attendant problems can be resolved:

Wasteful steam usage at the mill

Inefficient residual air removal method employed during the sterilisation cycle re-sults in wasteful steam consumption and highly fluctuating steam demand at the steriliser station, a common problem plagu-ing palm oil mills today. This leads to fre-quent large draw-down of live steam from the boiler through the make-up valves by-passing the non-condensing steam turbine to meet the rising steam demand, and steam blow off during low steam demand peri-ods. This gives rise to further steam loss at the mill increasing boiler load and consum-ing large amount of fuel to raise the steam.

Boiler operational woes

The widely fluctuating steam demands required by the sterilisation heating cy-cles tend to exert onerous load demand on the boilers. The resulting instability of the boiler operation can result in ‘black smoke’ emission from the boiler stack, a clear non-compliance operation not lightly taken by the regulatory bodies. Added to this are re-lated boiler plant maintenance issues and prolonged boiler downtime hours.

Insufficient and inconsistent process steam pressures

The above two problems usually co-exist throughout all the mill operations affect-ing process efficiencies in each stations. The excessive and fluctuating steam demand of the sterilisation process causes varying pressure in the back pressure vessel, which in turn leads to inconsistent process steam pressure across the mill.

The Air-Void solves the above prob-lems by allowing quick and efficient air


Feature Article

removal from the steriliser vessel through a novel steam flushing method right at the very start of the sterilisation cycle. The air-removal phase ensures that the steriliser at-mosphere is almost void of air. The results are dramatic; adequate thermal treatment with:● a shorter time for sterilisation, ● lower temperature process steam, and ● a lower steam consumption.

The above three outcomes translate into drastic improvements in process steam management and equipment capacities.

Fitting conventional horizontal sterilis-ers with the innovative fast-acting Air-Void offers several advantages and contributes to overall improved process efficiencies and performance as elaborated below:

Easy, seamless and relatively inexpensive integration

Seamless integration with existing conventional horizontal sterilisers, making expensive infrastructure investments is unnecessary. It is a viable solution for palm oil mills of all sizes.

Speedy solution

A swift drop-in-place retrofit solution that precisely fits the application without the need for any field engineering or fab-rication. Existing steam connections can be used without modification so that commis-sioning is quickly and easily carried out.

Enables compliance with DOE regulations

Assists compliance with strict envi-ronmental legislation for steam boilers by avoiding boiler load swings and furnace combustion upsets which lead to ‘black smoke’ from the boiler stacks at the mill.

Environmental legislations demand ever-stricter efficiency and control of emis-sions from industrial boilers and other power plant processes. For example, the DOE in Malaysia has recently introduced stricter stack particulate emission lim-its requiring operators to carry out online continuous monitoring of their emission parameters, whilst other countries’ legisla-tions are equally onerous.

Maintains operation of existing boilers at design parameters

Maintains the operation of existing boil-ers at design load factors that brings about improved fuel feeding and boiler draft con-trol. These are the pre-requisites for clean combustion and reduced stack emissions, which lead to dramatic cost savings.

Enables boiler automation

Boiler controls become amenable for full automation once boilers are rendered near-steady-state operation. Automation can now facilitate control of the boiler plant in-cluding furnace draft and fuel feed systems.

CONCLUSION

The Air-Void is a drop-in-place retrofit so-lution that addresses critical steam man-agement issues present in today’s palm oil mills that is affordable, quick and easy to implement. It tweaks the performance of existing horizontal sterilisers to unprece-dented levels of efficiency and productivity. It makes the horizontal steriliser far superi-or in terms of steam usage when compared with other types of sterilisers, for example, the vertical steriliser and the continuous steriliser.



AdBiotech International Asia Sdn Bhd

Total Solution in Biogas

w w w.bio -tec.net

Biotec International S.C. (HQ)Rue Louis de Geer, 6 B-1348Louvain-La-Neuve, Belgiume: [email protected]

Biotec International Asia Sdn Bhd C-10-2, Setia Walk,Persiaran Wawasan,47610 Puchong, Selangor, MalaysiaT: 603 5879 1410 F: 603 5891 0461e: [email protected]

Finca Yambo, km 3, La Buitrera,Cali, Colombiae: [email protected]

RSPORoundtable on Sustainable Palm Oil

Biotec was established in Belgium since 1984.

1. Biogas - Biodigester 2. Composting 3. Ferti-irrigation

To-date, we have developed our own technologies for

Certi�ed members of

R&D Center


AdRPS Traders Sdn Bhd


AdTurbokraft Sdn Bhd

N0. 45, JALAN BULAN U5/167, SEKSYEN U5, BANDAR PINGGIRAN SUBANG, 40150, SHAH ALAM, SELANGOR, MALAYSIA. Tel : +603 7847 1795 Fax :+603 7847 1901 Email : [email protected] / [email protected]

TURBOKRAFT SDN. BHD.

STEAM TURBINE SOLUTION AND SERVICES

“Bringing Energy and the Environment into Harmony”

Dresser-Rand has extensive experience in biomass-to-energy

initiatives around the world and in providing power generation

from fuels as diverse as:

❚ Animal waste ❚ Sewage digester gas

❚ Mine gas ❚ Coke oven gas

❚ Landfill gas ❚ Agri-crop waste

❚ Clinical waste ❚ Sewage sludge

❚ Wood ❚ Processed wood waste

❚ Forest residue ❚ Solid waste

❚ Food waste ❚ Used-vehicle tires

With many years of experience in mechanical drive and power plant system,

Turbokraft are able to provide professional services and solution such as :

❚ EPCC Solution for Power Plant ❚ Power Plant Equipment

❚ Maintenance, Repair & Overhaul ❚ Fabrication & Packaging

❚ Troubleshooting ❚ Spare Parts

❚ Dynamic Balancing Facilities


AdCL Advance Engineering Sdn Bhd

N0. 45, JALAN BULAN U5/167, SEKSYEN U5, BANDAR PINGGIRAN SUBANG, 40150, SHAH ALAM, SELANGOR, MALAYSIA. Tel : +603 7847 1795 Fax :+603 7847 1901 Email : [email protected] / [email protected]

TURBOKRAFT SDN. BHD.

STEAM TURBINE SOLUTION AND SERVICES

“Bringing Energy and the Environment into Harmony”

Dresser-Rand has extensive experience in biomass-to-energy

initiatives around the world and in providing power generation

from fuels as diverse as:

❚ Animal waste ❚ Sewage digester gas

❚ Mine gas ❚ Coke oven gas

❚ Landfill gas ❚ Agri-crop waste

❚ Clinical waste ❚ Sewage sludge

❚ Wood ❚ Processed wood waste

❚ Forest residue ❚ Solid waste

❚ Food waste ❚ Used-vehicle tires

With many years of experience in mechanical drive and power plant system,

Turbokraft are able to provide professional services and solution such as :

❚ EPCC Solution for Power Plant ❚ Power Plant Equipment

❚ Maintenance, Repair & Overhaul ❚ Fabrication & Packaging

❚ Troubleshooting ❚ Spare Parts

❚ Dynamic Balancing Facilities


AdJeffcon Eng. Sdn Bhd


AdPMT Industries. Sdn Bhd


AdRWT Tanks Sdn Bhd

RWT Tanks Sdn Bhd, the Malaysian registered company authorized to distribute and installs Permastore® tank since 1991. More than 650 tanks have been successfully installed by RWT in Malaysia, Indonesia, Brunei and Vietnam over the past 23 years. The applications of tanks used include portable water, sewage sludge, industrial waste water and biogas. Permastore® and RWT have been working together for more than20 years. We can confidently solve all your requirements for biogas storage.

Double Membrance Cover

Fixed Roof System

Features and Benefits of Glass-Fused-to-Steel

RWT TANKS SDN. BHD 15-3, Jalan Medan Putra 1, Medan Putra Business Centre, 52200 Kepong, Kuala Lumpur, Malaysia.

Tel: +603 6275 6887 Fax: +603 6277 2955 URL: www.rwt.com.my Email:[email protected]

FEATURE BENEFIT TO THE CUSTOMER Modular Design Site fabrication is not required simplifying

Factory applied coating Consistent quality not dependent on site conditions

Strong adhesion Strength of steel with corrosion resistance of glass

Abrasion & UV resistance Ensuring long term aesthetics and reduced maintenance costs

Lifetime coating, re-application not required

Reduced operational costs and downtime, improving the return on capital investment

Corrosion allowance not required

Reduced capital expenditure

Potable water compliant Versatility at no extra cost


AdSzetech Engineering Sdn Bhd

(Page 1 of centrefold)


AdMuar Ban Lee Engineering Sdn Bhd



AdMuar Ban Lee Engineering Sdn Bhd



AdLeesonmech Engineering Sdn Bhd



AdLeesonmech Engineering Sdn Bhd

(Facing Page 4 of centrefold)


AdSM Cyclo (M) Sdn Bhd

(Hansen)

Complete and Powerful Solutions for Palm Oil Industry

SINGAPORE Sumitomo (SHI) Cyclo Drive Asia Paci�c Pte. Ltd.(Asia Paci�c Headquarters) 15 Kwong Min Road, Singapore 628718 Tel: +65 6591 7800Fax: +65 6863 4238Email: [email protected]

THAILAND SM-Cyclo (Thailand) Co. Ltd.195 Empire Tower Unit 2103-421th Floor South Sathorn RoadYannawa, Bangkok 10120, ThailandTel: (66) 2670 0998Fax: (66) 2670 0999Email: [email protected]

BELGIUM (World Headquarter)Hansen Industrial Transmissions NV Leonardo da Vincilaan 12650 Edegem - AntwerpBelgium

W H Y H A N S E N I N D U S T R I A L G E A R B O X E S ?

Gear drives matched to the application For proven reliability under the most severe conditions

Superior designFor maximum sti�ness of all components under load

Carburised and ground gearingFor strength, torque capacity, surface durability and low noise

Continuous oil circulation through bearingsFor long trouble-free working life

Unique Oil-LockTM system For maintenance-free sealing

Drywell on vertical down shafts For prevention of oil leakage

Re�ned internal housing For simple and complete oil drainage

Inspection cover above the oil level For easy inspection and service on the spot

Optimal micro-gear geometry, no tip-to-root interferenceFor smooth gear meshing, reduced friction losses and low noise

In-depth engineering support and complete documentationFor one-stop-shopping

Local stocks & service capability For reduced downtimes

(a subsidiary of Sumitomo Heavy Industries, Ltd.)








AdGlobal Green Synergy Sdn Bhd


AdMaster Links Industries Sdn Bhd


AdTotal Drive Transmission Sdn Bhd

东大机械有限公司

TOTAL DRIVE TRANSMISSIONS SDN BHD (299888-A)No. 1, Jalan Anggerik Mokara 31/48, Kota Kemuning, Seksyen 31, 40460 Shah Alam, Selangor D.E.

Tel: (03) 5122 6030 (Hunting Line) Fax: (03) 5122 6090Email: [email protected] Website: www.totaldrive.com.my

Empty Bunch Conveyor

Nut Elevator

FFB Conveyor Hydrocyclone Drum Bottom Cross Conveyor

Geared Motor & GearboxGeared Motor & Gearbox

Thresher Drum


AdT Energy Industries Sdn Bhd

BioGasclean - the best H2S removal system with lowest operating costs

BioGasclean is the leading supplier of gas cleaning systems to the biogas industry. The company is supplying clean gas to engines with a capacity above 350 MW. BioGasclean has more than 90 references in SE Asia and over 50 installations at palm oil mills.

Biogas from POME contains typically 2,500 to 3,500 ppm H2S and has to be reduced to 100-200 ppm to meet the engine manufacturers specifications. BioGasclean can guarantee this gas quality with a 100% biological H2S remov-al process.

BioGasclean has compared to other gas clean-ing systems the lowest operating costs and the highest availability. The downtime for maintenance is limited to less than one week per year, as the packing media can be cleaned inside the tank with BioGasclean’s unique QSR® cleaning system.

Contact BioGasclean if you want to learn more!

BioGasclean Asia Co., Ltd.2/22 Iyara Tower 7th FloorChan Road, Soi 2, Kwaeng ThungwatdornKhet Sathorn, Bangkok,10120, ThailandTel. (+66) (0)2-286-1157www.biogasclean.com


AdPerkin Elmer Sdn Bhd

See what advanced solutions can do for you. At PerkinElmer, we think about the needs of your lab today and tomorrow. Optimize your laboratory’s potential. Let us show you how.

INNOVATIVE SOLUTIONS FOR YOUR LABORATORY

PinAAcle™ 900AASpectrophotometer

Optima™ 8x00 Series ICP-OESNexION® 300 ICP-MSAAnalyst™ 200

AxION® 2 TOF MSwith AxION DSA System

Flexar™ SQ300MS Clarus® SQ8 GC/MS TurboMatrix™ Headspace &Thermal Desorption

®

0008 AMD0006 ATS0058 CSDO/SNHC II seireS 0042

Spotlight™ 400 FTIR Imaging System

LAMBDA™ 1050 UV/Vis/NIRSpectrophotometer

Frontier™ FTMIR / NIRSpectrophotometer

Spectrum Two™

FTIR Spectrometer

Atomic AbsorptionICP Optical EmissionICP Mass SpectrometrySample Digestion

Gas ChromatographyGC Mass SpectrometryLiquid ChromatographyHeadspace and Thermal Desorption

DSCTGADMA/TMASimultaneous TGA/DTACHNS/O and N2 Analyzers

High-speed FT-IR ImagingFT-IR, FT-NIP & FT-FIRSpectroscopyRaman SpectroscopyUV / VIS and UV / Vis / NIRSpectrophotometersFluorescence Spectroscopy

Atomic Spectroscopy

Chromatography

Molecular Spectroscopy

Thermal and Elemental Analysis

Perkin Elmer Sdn. Bhd. ( Instruments & Life Sciences )#2.01 Level 2, Wisma Academy, Lot 4A, Jalan 19/1, 46300 Petaling Jaya, Selangor, Malaysia.Tel : 03-79491118 Fax : 03-79491119

Visit us at www.perkinelmer.com


Ad(4 pages continues) Pg 1

YKL Engineering Sdn Bhd











Journal of Oil Palm Research

AVAILABLE ON-LINE

http://j

opr.mpob.gov.m

y

Vol. 24 April 2012

1

2007 Survey on Quality Parameters and Properties of Palm and Palm Kernel Fatty Acid DistillatesRM 20 (within Malaysia)/USD10 (outside Malaysia)

MPOBTECHNOLOGY

No. 33 • July 2010

2007 SURVEY ON QUALITY PARAMETERS AND PROPERTIES OF PALM AND PALM KERNEL FATTY

ACID DISTILLATES FROM LOCAL REFINERIES

by

BONNIE TAY YEN PING; TANG THIN SUE and MOHTAR YUSOF

i

Proof No: Date:Done By: Zack

OILPA L MB U L L E T I NNUMBER 63 HALF ANNUALLY NOVEMBER 2011

MPOBthe one stop

shopping centre for oil palm/palm oil

publications

Visit us at http://www.mpob.gov.my/

en/publications for the latest titles

MALAYSIAN PALM OIL BOARD6, Persiaran Institusi, Bandar Baru Bangi, 43000 Kajang, Selangor, Malaysia

Tel: 603-8769 4400Fax: 603-8922 3564

E-mail: [email protected]


Titbits

Special Dishes Using Exclusively Palm Oil

I n Africa, the crude palm oil extracted by manual methods has been one of the staple diets of the native people for perhaps thousands of years. The crude oil extracted by our present day palm oil mills will not suitable for their consumption. They did not use the oil for frying but was

added to their rice or pounded yam (called garri). The ‘Banga’, a soup of Nigeria requires the crude oil to have a free fatty acid (FFA) exceeding 10% while the Sierra Leone ‘Palaver’ soup needed FFA above 20%. Thus, the FFA is not after all a bad quality for the oil.

The Wonderful Dish Called ‘Palm Oil Chop’ of Africa

History

The Caucasians who worked in Africa acquired a taste for this wonderful dish and they wanted to continue to have the dish even after returning home and this set in motion a healthy trade of processed and canned mesocarp to Europe until that generation of expatriates faded into oblivion probably to-gether with the trade. After a long spell of frozen trade the production was re-established by a small company in Malaysia operated by an expatriate and the trade continued until the plant was closed when the expat passed away.

The ingredients and preparation of global dish is shown in Table 1.

TABLE 1.Ingredients Qty Preparation

Non-vegetariansBeef/mutton/chicken /fish/sotong (2cm to 5 cm cubes) VegetariansYam/soyabean meal maker (2cm to 5 cm cubes)

1 kg Season with salt and cover with 1 cm height of water; boil until the meat is tender and most of the water has evaporated

Fresh red peppers 2 Grind well and add to the cooked meatTomatoes 3Large onions 3Mesocarp puree * or virgin palm oil (home-made) 4 tbs Add to the meat and cook uncovered for

5 min to prevent burning

Note: * Mesocarp puree/oil: In the palm oil mill, the sterilised fruits can be obtained from the cages or from the thresher drum and after shaving off the mesocarp followed by grinding in a blender and filtration the oil cells can be obtained. Others who have access to fruits: If fruits are used about four fruits, should be adequate others pressure cook fresh fruit for four whistles and proceed as above. If no fruits are available, use commercial palm oil but will not match the taste when full crude oil is used.


AdEita Electric Sdn Bhd


AdMaster Jaya Environmental Sdn Bhd


Ad(Facing)

Customcraft (M) Sdn Bhd


Ad(Facing)

Customcraft (M) Sdn Bhd


Ad HSS Industrial Products Sdn Bhd

HSS INDUSTRIAL PRODUCTS SDN. BHD.Address | Lot 64, Batu 4 ½ Jalan Bukit Pasir, 84300 Muar, Johor Darul Takzim, Malaysia. Tel +606 953 2553 (HL) | Fax +606 953 1378Email [email protected] | Website www.hssip.com

For more information, please contact :Mr S.S Hon +6012 631 3662

Ms K.L Hon +6017 653 9991

NO AUGERNO WATERSterilization Cycle < 100 Mins

SELF-DISCHARGEVERTICAL STERILIZER

Turning Point of Palm Oil Mill Industry


Datasheet

APPROXIMATE DIESEL CONSUMPTION AT PARTIAL ENGINE LOADS

Generator size (kW) ¼ load (gal hr-1) ½ load (gal hr-1) ¾ load (gal hr-1) Full load (gal hr-1)

20 0.6 0.9 1.3 1.6

30 1.3 1.8 2.4 2.9

40 1.6 2.3 3.2 4.0

60 1.8 2.9 3.8 4.8

75 2.4 3.4 4.6 6.1

100 2.6 4.1 5.8 7.4

125 3.1 5.0 7.1 9.1

135 3.3 5.4 7.6 9.8

150 3.6 5.9 8.4 10.9

175 4.1 6.8 9.7 12.7

200 4.7 7.7 11.0 14.4

230 5.3 8.8 12.5 16.6

250 5.7 9.5 13.6 18.0

300 6.8 11.3 16.1 21.5

350 7.9 13.1 18.7 25.1

400 8.9 14.9 21.3 28.6

500 11.0 18.5 26.4 35.7

600 13.2 22.0 31.5 42.8

750 16.3 27.4 39.3 53.4

1 000 21.6 36.4 52.1 71.1

1 250 26.9 45.3 65.0 88.8

1 500 32.2 54.3 77.8 106.5

1 750 37.5 63.2 90.7 124.2

2 000 42.8 72.2 103.5 141.9

2 250 48.1 81.1 116.4 159.6

Source: diesel servive and supply/Diesel_Fuel_Concumption


AdUMS Corp Sdn Bhd


AdSew Euro-drive Sdn Bhd


AdSawipac Sdn Bhd


AdOkutech Sdn Bhd

OKUMA BOILERS

BIOMASS FIRED BOILERS

PALM OIL MILLS POWER GENERATION

BOILER REHABILITATION TURN KEY PROJECTS

INDUSTRIAL PACKAGE BOILER (GAS/OIL FIRED) BOILER AUXILIARY EQUIPMENT

THE HIGHEST TECHNOLOGY

IN BOILER DESIGN

No. 6, Jalan USJ 1/33, 47600 Subang Jaya, Selangor Darul Ehsan, Malaysia. Website : www.okutech.com Tel : 603-8023 5877 Email : [email protected] Fax : 603-8023 1194


AdApex Uniparts Sdn Bhd

(2 facing pages)


AdApex Uniparts Sdn Bhd

(2 facing pages)


AdTaner Industrial Technology Sdn Bhd


MPO

B P

ALM

OIL

EN

GIN

EERI

NG

BU

LLET

IN -

FULL

PA

GE

ADVERTISEMENTue to the increased cost of printing, the advertisement rate is RM 700 per issue for an A4 size page of black and white, whereas the cost for colour is RM 900. One year of complimentary Vendor’s List advertisement for every one page A4-size colour or black & white advertisement. Advertisers are required to submit to us either their own black and white or colour artwork in CD. Cheque should be made payable to the ‘Malaysian Palm Oil Board’. If you have any queries, please contact the following at MPOB.

Tel: 03-87694400 Fax: 03-89262971

Dr. Lim Weng Soon ext: 4406 • Ir. N. Ravi Menon ext: 4467 • Lim Soo Chin ext: 4676 E-mail: [email protected]

Advertising Schedule for MPOB Palm Oil Engineering Bulletin

Issue Quarter Deadline forRegistration

Deadline forSubmission of Artwork

116 Jul - Sept 2015 30 Jul 2015 30 Aug 2015117 Oct - Dec 2015 31 Oct 2015 29 Nov 2015118 Jan - Mar 2016 30 Jan 2016 27 Feb 2016119 Apr - Jun 2016 30 Apr 2016 31 May 2016

REPLY-SLIP

Dr. Lim Weng Soon/Ir. N. Ravi MenonEngineering and Processing Division Palm Oil Engineering BulletinMPOB6, Persiaran InstitusiBandar Baru Bangi43000 Kajang, Selangor

PALM OIL ENGINEERING BULLETIN ADVERTISEMENT – FULL PAGE ADVERTISEMENT

1. We confirm our intention to advertise in the MPOB Palm Oil Engineering Bulletin.

Company:

Address:

E-mail: Tel. No.: Fax No.: Contact Person: Issue No.:

2. The artwork is attached/will be sent on for your further action.

3. Please find enclosed *crossed cheque No.: for RM ( ) being payment for the advertisement fee.

4. Thank you.

(Signature and Date) (Company stamp)

D#

* Made payable to ‘MALAYSIAN PALM OIL BOARD’.

Advertisement Reply Form received on/after 1 April 2015 will be subjected to 6% Goods and Services Tax (GST) as imposed by the Malaysian Government.


#

MPO

B PA

LM O

IL E

NG

INEE

RIN

G B

ULL

ETIN

- V

END

OR

’S L

IST

ollowing a decision by the Editorial Board to further increase the role of Palm Oil Engineering Bulletin to serve the industry better, a new addition called Palm Oil Mill Vendor’s List has been introduced similar to Telekom Yellow Pages to assist mill engineers to know where to source materials or services pertaining to the industry. In order to make this useful, we need the co-operation of the mill engineers/managers to persuade their vendors to advertise in the Vendor’s List for a nominal fee of RM 100/year. If you have any queries, please contact the following at MPOB.

Tel: 03-87694400 Fax: 03-89262971

Ir. Ravi Menon ext. 4467 or e-mail: [email protected] Ms. Lim Soo Chin ext. 4676 or e-mail: [email protected]

REPLY SLIP

Dr. Lim Weng Soon/Ir. N. Ravi MenonEngineering and Processing Division Palm Oil Engineering Bulletin AdvertisementMPOB, 6, Persiaran Institusi, Bandar Baru Bangi, 43000 Kajang, Selangor, Malaysia.

We wish to advertise in the MPOB Palm Oil Engineering Bulletin Vendor’s List

Company: Issue No.:

Contact Person: H/P:

Address:

E-mail: Tel: Fax:

Please find enclosed a crossed cheque No.: Bank:

for RM: (Ringgit Malaysia)

drawn in favour of MALAYSIAN PALM OIL BOARD

Please select the headings from the list given below (not more than five headings) under which you wish to advertise.

Air filters/dryersAir separatorsBearings/belts/bushesBiomass/bio-compost/productsBoiler spares/control/othersBoiler suppliers Bunch crushersCastingsCivil engineering Cleaning - generalCondition monitoringConsultancy services/certificationControl/automation/sparesConveyors/chains/elevators/beltsDiesel eng./services/sparesDynamic balancing Electric motors/systemsExpansion jointsFabrication works Fans

Signature:

Name:

Date: Company stamp

ADVERTISEMENT

F

Filter press/materialsFluid control system/couplingsGaskets/packing materials/sealsGear boxesHardware Hydraulic systems/services/spares Laboratory analysisLaboratory equipmentLubricantsMill machinery/sparesMiscellaneousNut crackersOil recovery systemsPalm kernel oil crushing plantPower plantPollution control/safety systemsPressure vesselsPumps/services PurifiersScrew press/parts

ScrubbersSludge separators/decantersSteam turbines/generator/sparesSterilizer/partsStorage silosVacuum pumpsValves/seatsWaste water treatment Water treatmentWeighing machines/sparesWelding equipmentsWheel loaders/spares

Advertisement Reply Form received on/after 1 April 2015 will be subjected to 6% Goods and Services Tax (GST) as imposed by the Malaysian Government.


From:

Address:

Question/Comment:

Signed: Date:

(We have enclosed this form to assist you in sending to us any questions or comments)

#


ChairmanThe Editorial BoardPalm Oil Engineering Bulletin Malaysian Palm Oil Board P. O. Box 1062050720 Kuala LumpurMalaysia

STAMP


ww

w.r

enol

dmal

aysi

a.co

m

Stro

nge

r in

co

nve

yor

chai

n

than

eve

r b

efor

e

Repu

tati

on,

Expe

rien

ce,

Exce

llen

ce

•U

nri

valle

d ap

plic

atio

n

expe

rien

ce

•Fl

exib

ility

to

mee

t yo

ur

nee

ds

•Su

peri

or d

esig

n e

xper

tise

•So

luti

on-d

rive

n p

rodu

ct

•V

ast

ran

ge

For

mor

e in

form

atio

n o

n h

ow

Ren

old

can

en

han

ce y

our

prod

uct

ivit

yca

ll to

day

on +

603-

5122

788

0

3805

1 M

AL c

onve

yor a

d_19

6x12

7mm

19/

03/2

012

14:

41 P

age

1

Ad (Inside Back Cover)

Renold (Malaysia) Sdn Bhd


Ad (Backpage Cover)Oiltek Sdn Bhd

Documents

Engineering Bulletin #102 front cover - Malaysian Palm Oil ...palmoilis.mpob.gov.my/publications/POEB/poeb115.pdf · MALAYSIAN PALM OIL BOARD KEMENTERIAN PERUSAHAAN PERLADANGAN DAN