ISSUE NO. 118 (Jan. - Mar.

2016)

LEMBAGA MINYAK SAWIT MALAYSIA

MALAYSIAN PALMPALM
OIL O
BOARD
IL ENGINEERING BULLETIN NO. 118 1
KEMENTERIAN PERUSAHAAN PERLADANGAN DAN KOMODITI MALAYSIA
MINISTRY OF PLANTATION INDUSTRIES AND COMMODITIES, MALAYSIA
www.mpob.gov.my
 2
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PALM OIL ENGINEERING BULLETIN NO. 118

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 Editorial
CONTENTS

T
Editorial
1

TRAINING AND SEMINARS

MPOB Training Programme 2016 7
he oil palm industry in
MPOB Conferences and Seminars 2016 8 Malaysia has developed
into a major economic sector
FEATURE ARTICLES contributing over RM 60 billion in export
Heat Pipe Technology for Economiser and last year. While it has been generating
Air Preheater 11 good returns to most players in the whole
production chain, there are still many
Technology Improvement in Sterilisation 21 challenges facing the industry. In recent
times, sustainability including issues
TITBITS
Is Ripple Mill Suitable for Cracking Nuts? on the carbon footprints have gained
45
prominence with increasing number of
DATASHEET customers insisting on sustainable palm
Guidelines for Crude Palm Oil Quality 48 oil. To address these challenges, the
Malaysian Sustainable Palm Oil (MSPO)
certification scheme was implemented in
January 2015, and the regulations set by
the Department of Environment regarding
the biological oxygen demand level of
EDITORIAL BOARD POME, black smoke particulate emission
Chairperson
level and odour intensity are becoming
Datuk Dr Choo Yuen May more stringent. Palm oil mills need
technology improvement to comply with
Members all the requirements, and this demands
Dr Ahmad Kushairi Din
Dr Lim Weng Soon
intensive research and development
Ab Aziz Md Yusof efforts. The market has offered many
solutions such as zero discharge systems,
Secretary methane capture systems, methane
Ir N Ravi Menon
avoidance approaches and proposals to
Malaysian Palm Oil Board solve various issues in the palm oil mills.
Ministry of Plantation Industries and Commodities,
Malaysia Technology advancement should
6, Persiaran Institusi, Bandar Baru Bangi,
43000 Kajang, Selangor, Malaysia.
not be focused just on sustainability.
Tel: 603-8769 4400 Innovations must be adopted to increase
Fax: 603-8925 9446 efficiency of processing, improve oil
Website: www.mpob.gov.my extraction rate, reduce oil losses, reduce
© Malaysian Palm Oil Board, 2016
labour and optimise energy use. Two
All rights reserved. technologies are featured in this issue.
No part of this publication may be reproduced, stored in a
retrieval system, in any form or by any means, electronic, Development on heat exchangers for
mechanical, photocopying, recording, or otherwise,
without the prior written permission of the publisher.
heat pipes enable waste heat recovery
thus reducing fuel consumption. This will
Products and services advertised in this give a positive impact to the environment.
Palm Oil Engineering Bulletin do not
connote endorsement by MPOB.
The Tilting Steriliser aims to reduce
maintenance cost, improve the working
environment and enhance safety via
automation.

PALM OIL ENGINEERING BULLETIN NO. 118 1

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2 PALM OIL ENGINEERING BULLETIN NO. 118
www.sumitomodrive.com
Taner Industrial Technology Sdn. Bhd. - inside the bulletin – colored

PALM OIL ENGINEERING BULLETIN NO. 118 3

 Okutech Sdn. Bhd. - inside the bulletin – colored.

4 PALM OIL ENGINEERING BULLETIN NO. 118

 EFFICIENT SOLUTIONS FOR
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FROM AUTONICS

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Proximity Sensors Photoelecric Sensors Photoelectric Sensors

Recoders Converters Indicators

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5
Unit No. 613 & 614, Block A, Fax 03-7805
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OIL ENGINEERING BULLETIN NO. 118
Kelana Business Centre, Technical Toll 1800-88-8381
Jalan SS7/2, Kelana Jaya, 47301 P.J, Selangor. Email malaysia@autonics.com
 Xylem Water Solutions M’sia Sdn Bhd - inside the bulletin – colored.

6 PALM OIL ENGINEERING BULLETIN NO. 118

Training & Seminars

MPOB TRAINING PROGRAMME 2016

Code Title Date Venue

No.
A COURSES
OIL PALM
A1.1 Kursus Kemahiran Menggred Buah
Sawit
26-28 Jul Ritz Garden Hotel, Perak
Wilayah Utara
20-22 Sep Putri Resort, Air Keroh,
Wilayah Tengah
Melaka
9-11 Ogos PLASMA
Wilayah Sabah Lahad Datu,
Sabah
23-25 Ogos GreenPark Hotel, Temerloh,
Wilayah Timur
Pahang
6-8 Sep Dorset Boutique Hotel,
Wilayah Sarawak
Kuching, Sarawak
Wilayah Selatan 11-13 Okt Katerina Hotel, Batu Pahat,
Johor
A1.2 Intensive Diploma in Oil Palm
Management & Technology (IDOPMT)
Semester I 19 Sep-7 Oct

Semester II 20 Oct-18 Nov MPOB, Head Office

Estate Attachment 21-25 Nov
Semester III 28 Nov-9 Dec
A1.3
Kursus Operator Mekanisasi Ladang
(KOML)

Tahap 2 April (5 month)

PLASMA Keratong, Pahang
October
Tahap 3
(5 month)
Kursus Pengurusan dan Penyeleng-
A1.4
garaan Tapak Nurseri Sawit
Dorset Boutique Hotel,
Wilayah Sarawak 29-30 Mar
Kuching, Sarawak

Wilayah Sabah Promenade Hotel, Tawau,

19-20 Apr
Sabah
Wilayah Timur/Selatan 24-25 Mei Classic Hotel, Muar, Johor
Wilayah Utara Grand Court Hotel, Teluk
23-24 Ogos
Intan, Perak
Wilayah Tengah 25-26 Okt *

PALM OIL ENGINEERING BULLETIN NO. 118 7

 Training & Seminars

2 PALM OIL
A2.1
Diploma in Palm Oil Milling
Technology & Management (DIPOM)

Semester I 7 -16 Mar

MPOB Sabah Region
Semester II 9 -18 May
Semester III 25 Jul-3 Aug
Examination 5-6 Sep
th
A2.2 30 MPOB Oil Palm Products Surveying 15-19 Aug *
Course
th
A2.3 29 MPOB Oil Palm Products 18-20 Oct *
Surverying Examination

A2.4 Kursus Penyelia Kilang Sawit 26-30 Sep MPOB, Head Office

Peperiksaan Kursus Penyelia Kilang Sawit 3 Oct

A2.5 Kursus Pengendali Makmal Kilang Sawit 19-27 Sep MPOB, Head Office

A2.6 Kursus Asas Rawatan Efluen Sawit 18-20 Oct *

A2.7 Margarine Course 15-18 Aug MPOB, Head Office
A2.8 Kursus Penyelia Bengkel Kilang Sawit 14-20 Nov PLASMA Lahad Datu,
Sabah
A2.9 Cosmetic Course 8-12 Aug MPOB, Head Office
B MPOB CONFERENCES AND SEMINARS
1 Palm & Lauric Oils Price Outlook Conference 7-9 Mar Shangri-la Hotel,
& Exhibition (POC 2016) Kuala Lumpur
2 Forum on Ganoderma and other Diseases 8 Apr MPOB, Head Office
3 PAC Seminar 14 Apr MPOB, Head Office
4 Seminar Guna Tenaga di Sektor Perladan- 26 Apr Hotel Sabah,
gan Sawit Sandakan, Sabah
5 TOT Seminar 2 Jun MPOB, Head Office
6 GSAS Seminar 3 Jun MPOB, Head Office
7 Palm Oil Industry Labour: Issue Performance 19-21 Sep Sandakan, Sabah
Sustainability (PILIPS) Seminar & Palmmech
8 IOPRI-MPOB International Seminar on Pests 27-29 Sep Medan, Indonesia
and Disease
9 Persidangan Kebangsaan Pekebun Kecil 11-12 Oct Hotel Kinta Riverfront,
Sawit 2016 Ipoh, Perak
10 National Seminar on Palm Oil Milling, 29-30 Nov The Royal Chulan Hotel,
Refining Environment and Quality (POMREQ) Kuala Lumpur
Note: *To be confirmed.

For enquiry or further information, please contact:

HRD & Conference Management Unit

Tel. No. : 03-8769 4400 ext. 4865, 4860, 4867
Fax No. : 03-8925 7549
E-mail : rubaah@mpob.gov.my
MPOB’s website : www.mpob.gov.my

All information are correct as at press time.

8 PALM OIL ENGINEERING BULLETIN NO. 118

First Announcement

2016
NATIONAL SEMINAR ON
PALM OIL MILLING, REFINING,
ENVIRONMENT AND QUALITY

POMREQ
29-30 November 2016
The Royale Chulan Hotel
Kuala Lumpur

POMREQ

To be Officiated by
MINISTER OF PLANTATION INDUSTRIES AND COMMODITIES, MALAYSIA

Organised by
MALAYSIAN PALM OIL BOARD
MINISTRY OF PLANTATION INDUSTRIES AND COMMODITIES, MALAYSIA
PALM OIL ENGINEERING BULLETIN NO. 118 9
www.mpob.gov.my
 E-Cool Technology (S) Pte Ltd was established on year 2000. We are specializes in the
provision of services in environment engineering and waste heat recovery solu�ons for the
improvement of energy efficiency of industrial systems and plants. One of the industries
that we are focusing on is the palm oil industry and using the Heat Pipe Heat Exchanger
to recovery the waste heat from the boilers.

E-Cool Technology (S) Pte Ltd - inside the bulletin – colored pls place next
to their feature
article on “Heat Pipe….

Stage 1

Stage 2

7030 Ang Mo Kio Ave 5 #08-17, Northstar @ AMK. Singapore 569880

10 Mr. Tan Aik
PALMSeoh (MD) HP:BULLETIN
OIL ENGINEERING +65 9692 4139 Mr. Harry Chua HP: +65 9117 5757
NO. 118
Email: www.boilereconomizer.com.sg
Feature Article
Heat Pipe Technology for Economiser and Air
Preheater**
Harry Chua*
H
INTRODUCTION
eat recovery can take many dif-
ferent forms. In general terms,
it can be classified as direct re-
covery, indirect recovery and secondary re-
covery. Direct recovery refers to the use of
flue gas, which is a combination of carbon
dioxide, nitrogen and oxygen generated by
the combustion process in an incinerator or
boiler, to preheat or dry products directly.
Indirect recovery takes place when flue gas
is used to preheat combustion air or fuel.
Secondary recovery utilises the waste heat
to preheat an external medium or to gener-
ate power.
Fuel savings is the most obvious benefit
of waste heat recovery and this is the key
motivating factor for the companies to in-
vest in equipment to tap their waste energy.
Other than that, a reduction in fuel usage
also results in less emission of pollutants,
which include carbon monoxide, hydrogen
sulfide and sulfur dioxide, to the environ-
ment. Moreover, emission of carbon diox-
ide, which is a greenhouse gas, will also be
reduced.
* E-Cool Technology (S) Pte. Ltd., 7030 Ang Mo Kio Ave
5 #08-17, Northstar @ AMK, Singapore 569880.
E-mail: ecool@singnet.com.sg
** Adapted from published paper entitled
‘Heat Pipe Technology in Water and Air Preheater’.
PALM OIL ENGINEERING BULLETIN NO. 118
WASTE HEAT RECOVERY IN BOILER
SYSTEMS
This simple concept of waste heat recovery
could be illustrated by looking at boiler
systems (Figure 1). Feed water enters the
boiler to produce process steam. The energy
for the steam production normally comes
from the combustion of biomass, diesel or
fuel oil, which produces an exhaust with a
temperature of about 220°C to 270°C. For
very old boilers, the temperature of the
exhaust gas could even be higher. The
exhaust flue gas, which still contains a
substantial amount of waste heat, is
discharged directly to the atmosphere
through the chimney systems and as a
result, precious energy is wasted.
The energy from the exhaust flue gas
could be tapped through the use of heat ex-
changers, as shown in Figure 2 below.
In this case, the exhaust flue gas is used
to preheat the feed water and the combus-
tion air. Consequently, much less fuel is
required to produce the same amount of
steam. For example, an 8 t hr-1 boiler in
11
 Feature Article

Figure 1. Schematic diagram of a typical boiler without heat

recovery system.

Figure 2. Schematic diagram of a typical boiler

with waste heat recovery system.

which the flue gas flow rate is 9700 Nm3 hr-1
would result in approximately 22 000 litre
savings per year in fuel oil or diesel con-
sumption for every 10°C recovery of the
exhaust gas temperature. This would be
translated to more than USD 5000 in actual
dollar savings annually.
The dew point of the flue gas is normally
in the range 110°C to 140ºC, depending on
the sulfur content in the fuel used. There-
fore, for most applications, the temperature
of the exhaust fumes could theoretically be
reduced by at least 70ºC before low tem-
perature corrosion occurs. This results in
potential savings of more than USD 35 000
a year.
PROBLEMS WITH CONVENTIONAL
HEAT EXCHANGERS IN WASTE HEAT
RECOVERY
However, most industrial boilers that
are smaller than 10 t hr-1 are normally not
equipped with heat exchangers to recover
the waste heat. This is because there are
many maintenance problems associated
with low temperature corrosion if conven-
tional heat exchangers are used for such ap-
plications.
Low temperature corrosion refers to the
corrosion at the tube walls of the heat ex-
changers as the gas film temperature at the

1
Assuming that the calorific value, density and price of the fuel is 43.6 MJ kg-1, 970 kg m-3 and USD 0.24
litre-1 respectively.

12 PALM OIL ENGINEERING BULLETIN NO. 118


Figure 3. Corrosion seen within three years in a
conventional heat exchanger.
wall is below the dew point of the flue gas.
This is because the gas side heat transfer
coefficient is relatively low. This results in
a huge temperature gradient between the
tube wall and the flue gas. As a result, the
flue gas temperature must always be main-
tained at around 200ºC if conventional heat
exchangers are used. Due to the above, it
is not economically viable to install waste
heat recovery systems for smaller boilers in
the past. For larger boilers that use conven-
tional heat exchangers for heat recovery, the
amount of waste heat released to the envi-
ronment is still significant (Figure 3).
HEAT PIPE HEAT EXCHANGERS
The corrosion and maintenance problems
faced by conventional heat exchangers in
Figure 4. Heat pipe heat exchanger.
PALM OIL ENGINEERING BULLETIN NO. 118
Feature Article
heat recovery systems could be addressed
using the heat pipe heat transfer techno-
logy. In terms of industrial applications,
this is still a relatively novel technology.
Early efforts were directed toward space
applications; however, due to the high cost
and the rapid rise in demand in energy, the
commercialisation and application of heat
pipe heat exchangers (Figure 4) in other
industries have become more widespread
in recent years. Figure 4 shows a schema-
tic diagram of a heat pipe heat exchanger.
Heat pipes are simply pipes that contain
a working fluid. They are sealed at both
ends after a vacuum is created above the
working fluid.
The heat exchanger is divided into two
ends: evaporating and condensing ends.
The hot medium flows through the evapo-
rating end and evaporates the working flu-
id. The vapor rises up the heat pipes, and
condenses at the condensing end such that
energy is transferred to the cool medium.
As such, heat pipes operate at almost con-
stant temperature.
The phase change heat transfer in heat
pipes gives them very high thermal con-
ductance. In fact, the conductivity of heat
pipes is about 100 times higher than copper.
13
 Feature Article

Moreover, the ratio of the heat transfer HEAT PIPE HEAT EXCHANGER
area between the evaporating and conden- PROJECT IN MALAYSIA
sing ends of the heat exchanger could be PALM OIL MILL
easily manipulated by adjusting the height
of, and adding fins to, the evaporating and Palm Oil Mill No. 1
condensing ends.
Project 1
ADVANTAGES OF HEAT PIPE HEAT
EXCHANGERS Date of installation: April 2011

Owing to the high thermal conductivity of
heat pipes, their simple construction with
no mechanical moving parts and the ease
of manipulating the heat transfer area, heat
pipe heat exchangers offer many advantag-
es compared to conventional heat exchang-
ers.
• Heat transfer up to 97%.
• Fuel saving. Fuel consumption : 8430 kg hr-1
• CO2 reduction for climate change.
• Low flue gas temperature discharge to
chimney.
• Boiler efficiency increase by 3%-15%.
• Small volume and light weight.
• Simple structure.
• Small pressure drops on gas side.
• More resistant to low temperature cor-
rosion.
• Carry on running even when some of
the pipes corrode over time.
• Simple installation.
• Maintenance free, except using MFO
and Biomass as fuel.
• High investment return due to high
energy recovery.
• Life spends between 4-10 years, de-
pend on individual condition.
One key advantage is that the tempera-
ture gradient between the wall of a heat
pipe and the flue gas is not drastic. There-
fore, the heat exchanger is extremely tole-
rant to low temperature corrosion and the
effluent flue gas temperature could be as
low as 140ºC. This makes this kind of heat
exchangers extremely economically viable
for waste heat recovery applications.
Stage 1: Heat Pipe Heat Exchanger
Economiser
1. Operating parameters (as provided
by client)
Capacity of boiler : 45 t hr-1
Operating mode : 24 hr day-1, 330
-1
day yr
Type of fuel : Fibre/EFB
Fuel price : Fibre RM 20 t-1,
Shell RM 120 t-1
Flue gas inlet : 330°C
temperature
Feed water inlet : 30°C
temperature
Feed water flow : 39 000 kg hr-1
rate
2. Design specification (non-pressure
vessel)
Flue gas inlet : 300°C
temperature
Flue gas outlet : 210°C
temperature
Feed water inlet : 30°C
temperature
Feed water outlet : 70°C
temperature
Feed water flow : 39 000 kg hr-1
rate
Heat exchanger : 2170 kW
duty

14 PALM OIL ENGINEERING BULLETIN NO. 118

 Feature Article

Figure 5. Mill 1, Project 1, Stage 1: HPHE for Economiser.

Mill 1, Project 2 Feed water flow : 73 800 kg hr-1

rate
Date of Installation: May 2014 Heat exchanger
duty : 3926 kW
Heat Pipe Heat Exchanger Stage 1 -
Economiser (Figure 5)
(a)
1. Operating parameters (as provided by
client)
Capacity of boiler : 70 t hr-1
Operating bode : 24 hr day-1, (b)
330 day yr-1
Type of fuel : 50% Fibre,
50% EFB
-1
Fuel consumption : 25 920 kg hr
Fuel price : RM 160 t-1
Flue gas inlet : 340°C
temperature
Feed water inlet : 25°C
temperature
Feed water flow : 73 800 kg hr-1
(c)
rate

2. Design specification (non-pressure

vessel)
Flue gas inlet : 340°C
temperature
Flue gas outlet : 266°C
temperature
Feed water inlet : 25°C
temperature
Feed water outlet : 70°C Figure 6a-c. Mill 1, Project 2, Stage 2: HPHE Air
temperature preheater installed and in operation.

PALM OIL ENGINEERING BULLETIN NO. 118 15

 Feature Article

Heat Pipe Heat Exchanger Stage 2 - Air Flue gas outlet : 263°C
Pre-Heater temperature

The photographs of layout diagram, Air 2. Design specification (non-pressure

Inlet and Heat pipe details are shown in vessel)
Figures 7-10. Combustion air : 28°C
inlet temperature
1. Operating parameters (as provided by Combustion air : 150°C
client) outlet temperature
Capacity of boiler : 70 t hr-1 Combustion air : 63 326 Nm3 hr-1
Operating mode : 24 hr day-1, flow rate
330 day yr-1 Heat exchanger : 2851 kW
Type of fuel : 50% Fibre, duty
50% EFB
Heat Pipe Heat Exchanger Stage 2 -
-1
Fuel consumption : 25 920 kg hr
Economiser
-1
Fuel price : RM 160 t
Flue gas inlet : 266°C
temperature 1. Operating parameters (as provided by
Flue gas outlet : 199°C client)
-1
temperature Capacity of boiler : 60 t hr
Flue gas flow rate : 154 440 kg hr-1 Operating mode : 24 hr day-1,
330 day yr-1
2. Design specification (non-pressure Type of fuel : Fibre/EFB
vessel) Fuel consumption : 16 000 kg hr-1
Combustion air : 30°C Fuel price : Fibre RM 20 t-1,
inlet temperature Shell RM 120 t-1
Combustion air : 150°C Flue gas inlet : 263°C
outlet temperature temperature
Combustion air Feed water inlet : 30°C
flow rate : 75 730 Nm3 hr-1 temperature
Heat exchanger : 3364 kW Feed water flow : 54 000 kg hr-1
duty rate

Palm Oil Mill No. 2 2. Design specification (non-pressure

vessel)
Date of Installation: November 2013 Flue gas inlet : 263°C
temperature
Heat Pipe Heat Exchanger Stage 1 - Air Flue gas outlet : 165°C
Pre-Heater (Figures 7-10) temperature
Feed water inlet : 30°C
1. Operating parameters (as provided by temperature
client) Feed water outlet : 75°C
Capacity of boiler : 60 t hr-1 temperature
-1
Operating mode : 24 hr day , Feed water flow : 54 000 kg hr-1
330 day yr-1 rate
Type of fuel : Fibre/EFB Heat exchanger : 3018 kW
Fuel consumption : 16 000 kg hr-1 duty
Fuel price : Fibre RM 20 t-1,
-1
Shell RM 120 t
Flue gas inlet : 350°C
temperature

16 PALM OIL ENGINEERING BULLETIN NO. 118

 Feature Article

Palm Oil Mill No. 3

Date of Installation: May 2014

Heat Pipe Heat Exchanger Stage 1 -

Economiser

1. Operating parameters (as provided by

client)
Capacity of boiler : 70 t hr-1
Operating mode : 24 hr day-1,
Figure 7. Mill No. 2 HPHE Air Pre-Heater under
installation. 330 day yr-1

Figure 8. Layout plan of HPHE.

Type of fuel : 100% Fibre

Fuel consumption : 23 400 kg hr-1
Fuel price : RM 160 t-1
Flue gas inlet : 340°C
temperature
Feed water inlet : 25°C
temperature
Feed water flow : 73 800 kg hr-1
rate
Figure 9. Air Inlet HPHE.
2. Design specification (non-pressure
vessel)

Flue gas inlet : 340°C

temperature
Flue gas outlet : 261°C
temperature
Feed water inlet : 25°C
temperature
Feed water outlet : 69°C
Figure 10. Heat Pipe Inside HPHE. temperature

PALM OIL ENGINEERING BULLETIN NO. 118 17

 Feature Article

Feed water flow : 73 800 kg hr-1

rate
Heat exchanger : 3826 kW
duty

Figure 11. Mill No. 3: HPHE in Economiser.

Figure 12. Mill No. 3: Economiser and Air Pre-Heater.

Heat Pipe Heat Exchanger Stage 2 - Air 2. Design specification (non-pressure

Pre-Heater (Figures 11 and 12). vessel)
Combustion air : 30°C
1. Operating parameters (as provided by inlet temperature
client) Combustion air : 150°C
-1
Capacity of boiler : 70 t hr outlet temperature
Operating mode : 24 hr day-1, Combustion air : 70 162 Nm3 hr-1
330 day yr-1 flow rate
Type of fuel : 100% Fibre Heat exchanger : 2851 kW
Fuel consumption : 23 400 kg hr-1 duty
Fuel price : RM 160 t-1
Flue gas inlet : 261°C The tubes exposed to flue gases as also
temperature subjected to ultrasonic soot removal sys-
Flue gas outlet : 193°C tems in order to maintain maximum heat
temperature transfer. The system is shown in Figures
Flue gas flow rate : 141 840 kg hr-1 13a-d.

18 PALM OIL ENGINEERING BULLETIN NO. 118

 Feature Article

Figure 13a. HPHE door and ultrasonic scoot cleaning system.

Figure 13b. HPHE after Figure 13c. HPHE while in Figure 13d. No black
cleaning. operation. smoke emission.

CONCLUSION temperature levels are unique features of

The heat pipe heat exchanger offers many
advantages compared to a conventional
heat exchanger. It allows for large quan-
tities of heat to be transported through a
small cross-sectional area over a consider-
able distance with no additional power in-
put to the system. Furthermore, design and
manufacturing simplicity, small end-to-end
temperature drops, and the ability to con-
trol and transport high heat rates at various
heat pipes. These features make it extreme-
ly appropriate for waste heat recovery ap-
plications.
Waste heat recovery not only helps to
protect the environment, but will also result
in substantial cost savings for the company.
Results from case studies have shown that
the payback period for such investments
using the heat pipe heat transfer technology
is within two years.

PALM OIL ENGINEERING BULLETIN NO. 118 19

 Besteel Bhd - inside the bulletin – colored – pls place next to their
feature article on “Technology Improvement..

20 PALM OIL ENGINEERING BULLETIN NO. 118

Feature Article
Technology Improvement in
Sterilisation
Quah Ban Lee*
M
INTRODUCTION
ill processing concepts to im-
prove the oil yield as well as its
quality have always been the
prime objective of the millers as most of the
changes focused on an increase in profit.
The present focus seems to be shifting away
from the profit oriented culture to one of
environment protection.
The processing activities in a palm oil mill
revolves around maximum oil recovery by
reducing oil losses without sacrificing oil
quality. There are limitations in the mechan-
ical extraction systems as compared to soya
bean which uses solver extraction methods
which can give very efficient oil recovery.
The newly harvested fresh fruit bunches
*Besteel Berhad, Lot 9683 Kawasan Perindustrian Desa
Aman, Batu 11, Desa Aman, 47000 Sungai Buloh,
Selangor, Malaysia.
E-mail: quahbl@besteelberhad.com
PALM OIL ENGINEERING BULLETIN NO. 118
(FFB) after weighing- in at the weighing
bridge undergoes a series of operations in
the mill by mechanical extraction process.
FFB after weighing is delivered into
the FFB hoppers from where it is fed into
a number of FFB cages that can either be
loaded into individual cages or loaded at a
single diacharge point that will reduce spill-
age of loose fruits in the marshalling yard
where the raiway lines are installed for
marshalling the FFB cages. The filled cages
are transferred to the sterilisers using cap-
stans or towed by skid steer loaders. The
mill processing operations comprises steri-
lisation, stripping, digestion, pressing, clari-
fication, purification, drying and storage of
production oil. The system described until
now is the conventional method of filling
steriliser cages. The sterilisation process
have undergone more improvements than
any other processing stations in the palm
oil mills. This article intends to examine an
effective sterilisation system that appears to
perform well.
21
 Feature Article
PURPOSE OF STERILISATION
Sterilisation Process is the first step in the
processing operation. The word sterilisation
does not convey its major role in the palm
oil mills. Apart from the role of sterilisa-
tion that can inactivate lipases at relatively
low temperatures to prevent the rapid rise
of FFA in the fruit, it has another useful
purpose of pressure cooking the bunches
at an elevated temperature of 130°C. This
pressure cooking contributes towards the
following:
• Softens the wax that binds the fruit to its
socket so that the fruits can easily detach
from the bunches.
• Softens and conditions the mesocarp so
that the fruits can be easily digested and
pressed.
• Partially dries the kernel residing within
the shell imparting uniform heating to
it.
• Improved ability of oil to settle.
• Improved oil extraction efficiency from
digested mash.
• Reduce nut breakage.
• Improve nut cracking efficiency.
• Improve oil bleachability.
TECHNOLOGY DEVELOPMENT
The FFB sterilisation systems currently
practices in palm oil mills are far from per-
fect not only in terms of effectiveness in
its performance but also from the point of
view of applied thermodynamics on heat
transfer and efficient utilisation of steam.
Some of the new sterilisation systems flood-
ing the market seem to be alienated from
well-established fundamental thermody-
namic principles. Most of the existing sys-
tems fail to extract even 50% of the energy
contained in the steam. Most of the steam
is discharged in vapour form carrying with
it the entire enthalpy of evaporation. This
is the basis of designing our system that
faithfully follows the efficient utilisation of
steam.
22 PALM OIL ENGINEERING BULLETIN NO. 118
The palm oil industry started off with
small vertical sterilisers with low capaci-
-1
ties between 1 to 2 t hr that was quite suffi-
cient to process the crop available from the
African small holders. When the volume of
crop delivered to the mill started to increase
from 20 t to a few hundred tonnes per day
the small capacity verical steriliser could no
longer be used for handling the sterilisation
of the crop. This gave rise to the develop-
ment of horizontal units which are still the
most popular sterilisers in palm oil mills.
The different types that made their appear-
ance is listed below:
• small capacity vertical sterilisers
• small and inclined sterilisers
• large horizontal sterilisers
• continuous sterilisers
• huge vertical water filled sterilisers
• huge vertical dry type sterilisers
• hydraulically operated tilting sterilis-
ers
• spherical pivoted sterilisers
Tilting Steriliser (TS) was invented after
going through years of research and deve-
lopment to alienate all the negative features
on the existing systems.
Tilting Steriliser was invented by taking
into consideration the benefits of all the
earlier sterilisation method and disposing
the areas of sterilisation which gives
negative effect.
Maintained and Improved Best Method of
Sterilisation
Tilting Sterilisers have maintained the
’Horizontal Sterilisation‘ method whereby
sterilisation is done when it is brought to
horizontal position which ensures an even
distribution of steam and good timing
together with easier condensate discharge.
Minimising Empty Space (dead space)
Tilting advance the area of sterilisation
by shortening the time of sterilisation due

to more compact and ’No Dead Space‘ in
the vessel. The tilting feature of the steri-
liser gives great advantage in preventing
the bunches from getting compacted by the
sliding motion of the bunches within the
steriliser during feeding.
Effective Process Steam Integration
The 1-3 Peak process is an integrated
process requirement of steam based on pro-
viding pre-heating, de-aeration and con-
densation. The de-aeration process allows
evacuation of the air from the sterilisers.
The Tilting Sterilisers share some of its fea-
tures with the proven horizontal sterilisers
with added features like:
• The abity to fill it up to the brim of the
sterilisers with the FFB causing sig-
nificant reduction in air space that can
make vast difference in the effective
steam pressure which can be main-
tained at a much higher level
• Better sterilisation due higher partial
pressure of steam
• Better strippability resuting from high-
er partial pressure of steam
• Easier loading of the sterilisers
• Shorter sterilisation time
• Lower steam consumption in Tilting
Sterilisation Method due to minimal
dead space the requirement is only
maximum two peaks as this allowed
shorter process time and steam re-
quirement (Horizontal about 300-320
-1
kg t FFB while tilting about 200-220
-1
kg t FFB).
Minimise Mechanical Activity
Tilting has adopted the tipper method of
feeding and discharging of FFB. The pro-
cess is engineered to use the force of grav-
ity to feed the FFB in to the vessels avoiding
cages, rail tracks, winches, crane and shov-
els. Further on discharging, the gravity pull
would easily discharge the sterilised fruits
from the vessel into a hopper for transpor-
tation by conveyors to the thresher for strip-
ping effect.
PALM OIL ENGINEERING BULLETIN NO. 118
Feature Article
Lower Maintenance Cost
Contrary to expectations the maintenance
cost of tilting sterilisers is low despite the
heavy duty tilting mechanism used for
tilting the sterilisers. The maintenance in-
volves only on the door seal of steriliser,
hydraulics seal, hydraulics oil and chains
for the conveyors. On general average the
maintenance cost per ton of horizontal steri-
liser system of 60 t hr-1 mill from an average
-1
of RM 4.00 t FFB can be reduced to lower
than RM 1.00 t-1 FFB on yearly basis.
A simple effective manner is to reduce
cost and increase revenue.
FOOTPRINT -
CONTINUATION MILL PROCESS
Tilting station is able to adapt to the space
of existing mill processing space with steri-
liser station assembly and inter connectied
conveyors with minimal disruption in mill
processing. This allows mill production ex-
pansion with minimal downtime yet with a
better and effective system.
Automation and Safety
This Tilting Steriliser permits easier op-
eration through automation controls with
adequate safety features as no human inter-
vention is called for opening or closing the
door of the sterilisers.
CONCLUSION
The Tilting Steriliser design and opera-
tion are based on the proven horizontal
sterilisers. It has all the good features of the
horizontal sterilisers combined with the
elimination of its weakness in the form of
trapped air that could not be satisfactorily
evacuated because of the large empty space
the horizontal sterilisers had to live with.
The almost complete elimination of the air
is the greatest feature of this steriliser.
23
 Feature Article

The biggest weakness of the horizontal
sterilisers is the large volume of air space
inside after the steam has been injected into
the steriliser which is estimated to occupy
one-third space of the steriliser the remain-
der being air. This results in a drop of the
temperature of the mixture of steam and
air by 13°C (in practice 8°C) based on Dal-
ton Law of partial pressures. This problem
has been present and still continues in the
palm oil mills. The tilting feature of the
Steriliser has effectively solved this prob-
lem that had been plaguing the industry for
a long time.
Tilting have addressed the issues above
by lesser working parts hence reduction of
cost of maintenance, clean environment by
eliminating cages, rail tracks and simplify
the feeding of FFB and discharging steri-
lised fruit bunches (SFB).
Optimal design of 58 m3 of vessel capaci-
ty and the inclined feeding allows minimal
air space and hence reduction of steam re-
quirement. With the integrated automation
of the system combined with safety features
and reduction of manual operation the is-
sue of safety is minimised.

The negative points raised by users are Improvement and advancement of the
appended below. era of automation and technology has given
• higher maintenance cost; birth to Tilting Sterilisation.
• environment hazard;
• inefficient use of steam; REFERENCE
• high concern over safety; and
• not-user friendly. LOH, T T (2010). Tilting Steriliser. Palm Oil
Engineering Bulletin, No. 94: 29-42.

CALL FOR ARTICLES

The millers 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
maintenance.

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.

24 PALM OIL ENGINEERING BULLETIN NO. 118

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PALM OIL ENGINEERING BULLETIN NO. 118 27

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44 PALM OIL ENGINEERING BULLETIN NO. 118

Titbits
Is Ripple Mill Suitable for Cracking Nuts?
T
Figure 1. A common type of smock mill.
his ripple mill story was main-
ly extracted from Wikipedia.
When ripple mill made its de-
but in Malaysia it was well received by the
mills its main attraction being the mills can
do away with the nut drying silos and also
it’s relatively easier maintenance require-
ments compared to the centrifugal nut
crackers which ripple mills replaced. These
two advantages gave a big boost to the rip-
ple mills leading to the virtual disappear-
ance of the old faithful centrifugal crackers.
It will be of historical interest to note that
ripple mills were not specifically designed
to crack oil palm nuts. It was initially de-
signed to grind corn using smock mills. It
will be interesting to trace back how the
ripple mills originated. As electrical motors
were non existant in the earlier days, the
Source: Wikipedia and Ravi Menon (2016).
PALM OIL ENGINEERING BULLETIN NO. 118
shaft power was provided by smock mills
that used timber framed sails using wind
power. Figure 1 shows a common type of
smock mill used for operating the ripple
mills used widely for grinding corn.
The smock mills were either hexagonal
or octagonal in shape the latter being most
common. The number of sails could either
be four or five. The Chimney Mill in Spital
Tongues, Newcastle Upon Tyne smock mill
a five sailed mill designed by John Smeaton,
a civil engineer was built in 1782 which is
still surviving but without the cap and the
sails. The oldest smock mill which is a hex-
agonal one built in 1650 that is still surviv-
ing after restoration by Chiltern Society is
the one at Lacey Green in Buckinghamshire.
45
 Titbits
Our mill engineers are kindly requested to
visit these places when they go to United
Kingdom for holidays. Some of the smock
mills still survive in Kent but most others
had given way to steam engine driven mills
or electric power driven ripple mills which
also have undergone significant improve-
ments.
Let us now examine the development of
smock mills in USA mainly centred around
Massachusetts, one of which built in 1746
by Nathan Wilbur, a sailor is still opera-
tional! This mill known as ‘the Old Mill’ is
located in Nantucket Island, Massachusetts.
Out of the five smock mills that graced the
windy hills in Nantucket town ‘the old mill’
still survives although it’s condition is far
from satisfactory. After about 100 years
of service the old mill was written off and
sold as scrap to a carpenter Jared Gardner
for USD 20. Gardner restored the mill and
started back operation for grinding corn. In
1866, he sold it off to Francis Sylvia a Por-
tuguese miller who continued its operation
until 1892 when it was shut down for good.
In 1897 Miss Caroline French purchased it
for USD 850 and donated it to Nantucket
Historical Association (NHA), which after
the restoration work in 1937 continues to
operate for demonstration to tourists.
TABLE 1. WITH THE NUT SILO HEATER - CENTRIFUGAL NUT CRACKER
FFB Sterilised fruit Digester
25% 25%-21% 21%-18%
Note: *Assumed variations in the moisture levels of kernel during its passage from FFB to
production kernel (%).
46 PALM OIL ENGINEERING BULLETIN NO. 118
This story confirms that the ripple mills
had been around for more than 300 years
and all along its use was confined to grind-
ing corns. There is no mention of it being
used for cracking any kind of nuts. Let us
now analyse whether equipment specifi-
cally designed for grinding materials like
grain can satisfactorily crack nuts. It may or
may not be suitable. I have carried out some
trials in one mill to find out the impact of
nut pulverisation in a ripple mill. I collected
a wheel barrow of pulverised kernel within
5 min when the cracked mixture was sieved
for 5 min. This may be one off incident. We
need more trials preferably by few mills to
confirm.
There in however one weakness in the
ripple mill associated processing configura-
tion. One kernel heating stage through the
nut heating silo has been omitted and this
heating within an enclosed shell does seem
to dry the kernel more evenly without per-
mitting the kernel oil to ooze out of its skin
in the kernel silo as is seen in almost all mills
where ripple mills are in operation. It is a
common sight in mills to witness a drum
placed underneath the kernel drying silo
for collecting kernel oil. The reason could
be the high temperature gradient. Kernel
drying starts from sterilisation onwards.
Nut silo Kernel silo Production
kernel
18%-12% 12%- 6% 6%

Let us assume the following moisture levels
for the kernels at different points during its
flow from FFB until the final stage as pro-
duction kernel. The moisture levels shown
are not based on actual analysis.
In Table 2 the kernel silo is required to
dry the kernel moisture from 21% to 6%
that probably results in the kernel oil to
ooze out from the kernel. The nut silo heat-
ers serve a very specific purpose of prepar-
ing the kernel within the nut to shrink and
break loose from the shell so that when the
nuts are hurled against the liner of the cen-
trifugal nut crackers the shell breaks loose
to allow the kernel to free itself. That is why
the bottom air ducting in a nut silo cold air
is blown. The hot nuts descending down
to the shaking grate should be cooled as
otherwise the hot shell that remains elastic
will cause difficulty in proper cracking.
TABLE 2. WITHOUT THE NUT SILO HEATER - RIPPLE MILL
FFB Sterilised fruit Digester
25% 25%-21% 21%-18%
Note: *Assumed variations in the moisture levels of kernel during its passage from FFB to
production kernel (%).
PALM OIL ENGINEERING BULLETIN NO. 118
Titbits
This arrangement ensures low broken
kernels that seldom exceed 5% as compared
to no less than 15% when using ripple mill.
It has to be emphasised that the centrifugal
nut cracker was designed specifically for
cracking oil palm nuts and it has served
that purpose very well whereas ripple mills
were not designed for cracking oil palm
not as such it will have to undergo some
changes to satisfy the characteristics of the
nuts that we want to crack without produc-
ing very high percentage of broken kernel
coupled with the undetected pulverised
kernel that is escaping as fuel for boilers.
The millers are urged to verify the accuracy
of this hypothesis and act accordingly to
reduce product loss as well as improve kernel
quality.
Nut silo Kernel silo Production
kernel
No heating 21%- 6% 6%
Excessive heating
47
 Datasheet

Guidelines for Crude Palm Oil Quality*

Parameter Codex H&C H&C Loncin Johansson Young PORIM
Alimentarius Stan- Lotox (1971) and (1981) 1997/98
dard Rehrelegard Survey
(1977) (Mean
results)
Moisture 0.2 0.18 0.18 < 0.1 0.2 max 0.2 max 0.18
(%)
Dirt (%) 0.05 0.02 0.02 <0.02 0.02 max 0.05 max 0.03
FFA (%) Acid value 3.5 2.5 1.0 – 2.5 2.5 max 4.0 max 3.2
10 max
IV 50 – 55 53 – 55 53 – 55 51.5 – - 52 - 55 52
54.5
PV (meq 10 max 5 3 max 5 – 20 3.0 max 10 max 0.7
-1
kg )
AV - - 4.0 max 5 – 10 3.0 max 5 max 4.7
Fe (ppm) 5 max 5 3 max <5 3.0 max 4 max 4.8
Cu (ppm) 0.4 max 0.2 0.2 max < 0.1 0.04 max 0.2 max 0.1
Carotene 500 min, 2000 - 650 Ca. 500 - 500 min 582
max typical
E269 - - ≥ 0.3 - - 0.6 max 0.3

Note: *Extracted from the nation-wide survey of crude palm oil quality and identify
characteristics by analysis 1300 samples from 105 palm oil mills and 32 refineries.

Source: TAN, Y A et.al, (1999). Proceedings of the 1999 PORIM International Palm Oil Congress.
PORIM, Kuala Lumpur.

48 PALM OIL ENGINEERING BULLETIN NO. 118

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MPOB PALM OIL ENGINEERING BULLETIN - FULL PAGE

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 follow-
ing 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: milleng@mpob.gov.my

Advertising Schedule for MPOB Palm Oil Engineering Bulletin

Issue Quarter Deadline for Deadline for

Registration Submission of Artwork
119 Apr - Jun 2016 30 Apr 2016 31 May 2016
120 Jul - Sep 2016 30 Jul 2016 30 Aug 2016
121 Oct - Dec 2016 31 Oct 2016 29 Nov 2016
122 Jan - Mar 2017 30 Jan 2017 27 Feb 2017

REPLY-SLIP

Dr. Lim Weng Soon/Ir. N. Ravi Menon

Engineering and Processing Division
Palm Oil Engineering Bulletin
MPOB
6, Persiaran Institusi
Bandar Baru Bangi
43000 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)

#

* Made payable to ‘MALAYSIAN PALM OIL BOARD’.

PALM OIL ENGINEERING BULLETIN NO. 118 49
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.
 ADVERTISEMENT

F
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
MPOB PALM OIL ENGINEERING BULLETIN - VENDOR’S LIST

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: nravi@mpob.gov.my

Ms. Lim Soo Chin ext. 4676 or e-mail: milleng@mpob.gov.my

REPLY SLIP
Dr. Lim Weng Soon/Ir. N. Ravi Menon
Engineering and Processing Division
Palm Oil Engineering Bulletin Advertisement
MPOB, 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/dryers Fans Pumps/services

Air separators Filter press/materials Purifiers
Bearings/belts/bushes Fluid control system/couplings Renewable energy
Bio-compost/biomass/bioproducts Gaskets/packing materials/seals Screw press/parts
Boiler spares/control/others Gear boxes Scrubbers/biogas
Boiler suppliers Hardware Sludge separators/decanters
Bunch crushers Hydraulic systems/services/spares Steam turbines/generators/spares
Castings Laboratory analysis Sterilizer/parts
Civil engineering Laboratory equipment Storage silos
Cleaning - general Laboratory fittings and furnitures Vacuum pumps
Condition monitoring/services Lubricants Valves/seats
Consultancy services/certification Mill machinery/spares Water treatment
Control/automation/spares Miscellaneous Waste water treatment
Conveyors/chains/elevators/belts Nut crackers Weighing machines
Dust collectors Oil recovery systems Welding equipments/spares
Diesel engines/services/spares Palm kernel oil crushing plant Wheel loaders/spares
Dynamic balancing Plate heat exchanger
Edible oil processing system Pollution control/safety systems
Electric motors/electrical systems Power plant
Expansion joints Pressure vessels
Fabrication works Processing system

Signature:

Name:

Date: Company stamp

50
#

PALM OILReply
Advertisement ENGINEERING BULLETIN
Form received NApril
on/after 1 O. 118
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)

PALM OIL ENGINEERING BULLETIN NO. 118 51

#
 STAMP

Chairman
The Editorial Board
Palm Oil Engineering Bulletin
Malaysian Palm Oil Board
P. O. Box 10620
50720 Kuala Lumpur
Malaysia

52 PALM OIL ENGINEERING BULLETIN NO. 118

Eita Electric Sdn Bhd - Inside
Back-Cover page.

PALM OIL ENGINEERING BULLETIN NO. 118 53

 Total Refining & Full Integrated
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OILTEK is a leading and the first processed

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Bhd. - Back Cover page.
professional, cost effective, durable and efficient Renewable Energy
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Tel: + 603 – 5542 8288 Fax: + 603 – 5541 8288
Email: enquiry@oiltek.com.my
54 PALM OIL ENGINEERING
Chamber Representatives: Sales Managers:BULLETIN NO. 118
Mr. Yong Khai Weng - Director Daniel Wong Lester Lim
Mr. Tai Cheng Huat - Operations SL Song Cia Cia Cheng
Mr. P.S Yap - General Manager VK Lee