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How can the extraction of palm oil be improved and at the same time prepare the biomass for the milling process to produce glucose and xylose.
Dr. Azis Ariffin
Do you know that palm oil milling process is actually a process to produce glucose
and its little sister xylose.
And coincidently the more glucose we produce, the more oil we recover!
And that almost all the glucose from the fresh fruit bunch (FFB) is produced
during the sterilization process.
Glucose is pleasantly sweet and quite expensive.
Its little sister xylose is more expensive.
And just to remind you that in the palm oil mill, the more glucose we produce
the more oil we recover.
Dr. Azis
Cell wall
Cytoplasm
Plasmalema
Mesocarp cells and fibers
(Hemicelluloses)
Fiber (lignified cellulose)
(oil body & water)
(alpha-cellulose)
Morphology (include cross-sections) of
mesocarp cells.
2 most important organic compounds (oil and carbohydrate) in FFB
lignocellulose fiberxylose +
glucose
xylose
+
glucos
e
oil
In the mill oil expresses least chemical changes.
In the mill hemicellulose expresses most chemical changes. The more the merrier.
Under the current circumstances all we want is just the oil.
Every palm oil mill around the world gets the oil but quantity-wise is never satisfied.
There has always been attempts of palm oil millers to improve their OER.
Numerous attempts to improve OER have been made but the OER, seventy years ago, yesterday, now, tomorrow, perhaps, in future will still remain glaringly similar.
USB~ 5% High oil
in pressed fiber
High oil in effluent
Current predicaments
Unsatisfactory OER
Ripeness of FFB
Excessive oil loss as observed in the first and second effluent ponds.
Contributor of low OER: oil in ponds
Partially treated effluent
Oil and grease 20 – 34 mg/liter
Cellulose (%) 52.2 +/- 6.5Hemicellulose (%) 28.8 +/- 1.1Lignin (%) 17.1 +/- 3.6
This effluent pond
Oil and grease >200mg/liter
Cellulose (%) > 55 Hemicellulose (%) > 30 Lignin (%) ~ 15
OER 70 years passed… and now
OER (oil extraction rate)
Thailand
Pen. Malaysia
Sabah + Sarawak Malaysia/Kalimantan Indonesia
Sumatra Indonesia
~18%
~20%
~22%
~24%
“Better” milling appliances/devises (e.g., boilers, turbine, sterilizers, thresher, pumps, automations, etc.) are being used …….
Nonetheless, OER of the respective geographical locations continues to virtually remains the same.
Better process management and automation are realized for palm mill processing.
Why?
Chemical innovations
Get the respective processing (ramp, conveyer, sterilizer, digester, press, vibrating filter, dilutions, clarifier, centrifuge, vacuum dryer, storage tank, dispatch) conditioning right will optimize degradation of identified chemicals (esp., hemicellulose, cellulose), to retain property of oil, to enhance complete separation oil molecules from the degraded hydrophilic molecules.
Made possible by the milling contraptions
Made possible by mill incorporating; chemical catalysts or/and enzymes additivesduring the milling or oil extraction process.
The current efficiency of the respective processing (ramp, conveyer, sterilizer, digester, press, vibrating filter, dilutions, clarifier, centrifuge, vacuum dryer, storage tank, dispatch) conditioning to maximize degradation of identified chemicals help separation oil molecules is low. Addition of chemical or biochemical catalyst that helps to degrade, esp., hemicellulose, cellulose to free more oil.
+
Enhancing oil recovery via
We inject steam into the vessel containing FFB and after a period of time, fruits detach from the bunch and cells free from each other.
The process produces …….. glucose (6 carbon) and ……… xylose (5 carbon)
and Dr Azis
Sterilization is purely a
chemical process…
glucose xylose
hemicellulose (long molecule)
+H2O of
palm bunchglucose xylose
hemicellulose (long molecule)
OH
xylose
OH
glucose
++
+hemicellulose (short molecule)
cellulose (short molecule)
OHOH
OH
OH
disaccharide
cellulose (short molecule)
+ ++
++
OHOH
OH OHOH
OH OH
disaccharide (sucrose)
+
+
+
++
++
120oC 10 mins. steam
glucose xylose
hemicellulose (long molecule)
+Energized
H2O of
palm bunch
Loss of this water (H2O) through evaporation leads to hydrolytic deficiency
Dr Azis
…. for 10 tons FFB
100oC ……. ~ 2 hrs for zero USB
120oC ……. ~ 1 hrs for zero USB
140oC ……. ~ 0.5hrs for zero USB
…. for 10 tons FFB
…. for 10 tons FFB
Steam peeling of potato
Steam peeling is carried out either as a batch-wise or a continuous
process. Batch-wise the raw materials (roots, tubers) are treated in a
pressure vessel and exposed to high-pressure steam (145psi or 10bars
(180°C) – 203psi or 14bars (200°C)). The high temperature causes a
rapid heating and cooking of the surface layer (within 15-30 s). The
pressure is then instantly released, which causes flashing-off of the
cooked skin. (http.www.hyfoma.com)
200psi steam
Chips, crisps
Glucose and xyloses are consistently produced at every processing step in the mill.
The amount produced depends on the sequential biomass and processing conditions (temperature, pressure and processing throughput).
a n d a t t h e s a m e t i m e p r e p a r e t h e b i o m a s s f o r t h e m i l l i n g p r o c e s s to p r o d u c e g l u co s e a n d x y l o s e .
Fresh loose fruits
Cellulose 100%Hemicellulose 100%
Glucose = 0%Xylose = 0%
Press/filter
Filtrate Residue Pressedcrude
Pressedfiber
Cellulose 100%Hemicellulose 50 - 70%Glucose = >15% Xylose = >5%
“Roborest”… 50 – 70 psi
30 – 60 mins
Press/filter
Filtrate Residue Pressedcrude
Pressedfiber
Cellulose 100%Hemicellulose 70 - 80%Glucose = 10 – 15%Xylose = 3 – 5%
Horizontal/vertical/tilting/spherical … 40 – 45 psi
1 – 1.5 hr
Press/filter
Filtrate Residue Pressedcrude
Pressedfiber
Cellulose 100%Hemicellulose 80 – 90%Glucose = 5 - 10% Xylose = 1 - 3%
Continuous sterilization (CS)… 14.5 psi (steam)
40 meter conveying
Press/filter
Filtrate Residue Pressedcrude
Pressedfiber
Percentage of oil in pressed fiber at the press station [email protected]
Milling process is the chemical breakdown of
hemicellulose and physical breakdown of a-cellulose
and oil is waste and a lot of waste.
OR
Milling process is the production of glucose, xylose, and
the waste is oil
““ Milling process is
about extraction of oil””
The perception of milling
Be changed to
Chemical catalysts
Highest sterilization steam pressure 40 to 45psi (~3 bars) for 1 to 1.5hrs.
0.5 to 0.75 % OER increment of 20% (W. Malaysia)
USB ….. Significant %
Effluent lower BOD“ COD
Sterilization
Chemical innovations Enzymes
Preparative step
Extr
acti
ve a
nd
pu
rifi
cati
on
step
s
Chemical catalysts
Highest sterilization steam pressure 50 to 70psi (~4 to 5 bars) for < 1hr.
21 to 22% OER from current 20% (W. Malaysia)
USB ….. 0%
Effluent significantly lower BOD“ “ COD
Sterilization
Chemical innovations Enzymes
Preparative step
Extr
acti
ve a
nd
pu
rifi
cati
on
step
s
Components POME PPF(palm oil mill effluent) (palm pressed fiber)
• Suspended solid 25.0 – 29
High BOD/COD effluent
Low BOD/COD effluent
100ml water = 0.5gm oil1000ml ( 1 liter = 1 kg) = 5gm oil1,000liter = 1 ton = 5000gm oil30 ton water = 150,000gm = 150kg oil.
Biochemical Oxygen Demand or Biological Oxygen Demand (BOD), is
a measurement of the amount of dissolved oxygen (DO) that is used by aerobic
microorganisms, in ppm or mg/L.
Chemical oxygen demand (COD) is a measure of the capacity of water to consume
oxygen during the decomposition of organic matter and the oxidation
of inorganic chemicals, in ppm or mg/L.
**
*
*
Re s o l v i n g t h e e f f l u e nt p r o b l e m
pH 4.0 – 5.0 ----
Cellulose 0.25 – 8.0 1.70 – 13.97
Lignin 0.90 – 7.98 24.90 – 25.60
Crude protein 11.11 – 16.66 6.00 – 6.70
Crude fiber 14.44 – 16.66 35 - 40
Moisture content 8 – 12 5 – 5.25
Ash 18.88 – 22.22 10.20 – 10.40
Nitrogen free extract 28.88 – 53.33 35.40 – 41.79
High glucose, xylose…
Thank you very much
