4.0 Palm Oil
4.0 Palm Oil
4.0 Palm Oil
industries
Content:
Oleochemical industry
Introduction :
Introduction :
Mesocarp
Fresh fruit bunch (FFB)
Palm oil
Fractionated into
palm olein and
stearin
Palm olein food
Palm stearin
nonfood /
oleochemicals
Fractionated into
palm kernel olein
and
kernel stearin
Palm kernel stearin
food
Palm kernel olein
nonfood /
oleochemicals
Palm Olein
Palm Stearin
Introduction :The oil palm industry can be divided into several main
sectors according to their activities:
a)
Plantations
- planting of the oil palm and harvesting of the
fresh fruit
bunches(FFB)
b)
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(a)
Planting and harvesting of fresh fruit bunch and
transporting it to palm oil mill
Palm oil:Harvestin
g :-Oil palm starts bearing fruits bunches 2 to 3
1.
years after field planting.
2. A good and convenient time to harvest is
when the ripeness of the bunch has reached a
stage where at least some loose fruits drop
from the bunch.
3. The usual frequency of harvesting round is 2-3
times a month.
4. Operation: 7 a.m to 12 noon in cutting of the
bunch from the tree
5. The time from harvesting until sterilizing of
Grade as follows :
fruits bunch with less than 10 loose fruitlets
unripe
fruits bunch with 10 or more loose fruitlets
ripe
bunch with excessive loose fruits detached
overripe
bunch with loose fruits completely detached
rotten
bunch with long stalk and consignment with
excessive trash are also noted.
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(b)
Palm oil mills
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Purification
- high speed centrifuge
to clean the oil from
impurities
Vacuum
drying
Sterilization
Stripping
- steam-heat
treatment at pressure
3 kg/cm2 and T=140oC
Clarification
- clarification tank
for oil separation (T
= 90oC)
Cooling at
45oC
Digestion
- fruits are heated
under steam
- The mesocarp
loosened from the
nuts
Screening
- vibrating screen of
30-40 mesh to remove
the major part of the
fibre and residue
Storage
Pressing
-
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Palm oil milling process :(1) Sterilization :Sterilization means the use of high-temperature
wet-heat treatment of loose fruit
Purposes:
i. Prevention of further rise in fresh fruit bunch
due to
enzymatic action.
ii. Facilitation of stripping of the fruits from the
spikelets
iii. Preparation of the fruit mesocarp for
subsequent
processing by coagulating the mucilaginous
material which
facilitates the breaking of the oil cells
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Palm oil milling process :(2) Bunch stripping :The containers with the sterilized bunches are
emptied into a rotary drum threshers where the
fruits are separated from the bunch stalk
The empty fruit bunch completely stored for
minimize the mass of residue
Palm oil milling process :(3) Digestion :After the bunches have been stripped, the sterilized
fruits must be reheated and the pericarp loosened
from the nuts and prepared for pressing.
Carried out in steam heated vessels provided with
stirring arms known as digesters or kettles.
Within a temperature of close to 100C :
the arms stir and rub the fruits
loosening the pericarp from the nut
breaking open as many of the oil cells as possible
The digester converts the stripped fruits into a
homogeneous mash.
The digester is kept full, as the digested fruit is drawn
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Palm oil milling process :(5) Clarification and purification :To give a clear stable product of acceptable
appearance, water and impurities removed.- carried
out in the clarification section of the mill.
Clarification systems used for palm oil are gravity
settling or direct process.
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Palm oil milling process :(7) Storage:the purified and dried oil is transferred to a
tank for storage prior to dispatch from the mill
Since the rate of oxidation of the oil increases
with the temperature of storage the oil is
normally maintained around 50C, using hot
water or low-pressure steam-heating coils, to
prevent solidification and fractionation
Press cake
Depericarper
Nut
Rotating
drum
Fibre
Nut
cracker
Boiler house
Boiler fuel
Silo dryer
Kernel oil with moisture < 7%
Kernel
(oil)
Hydrocyclone
Shell
Kernel process
1)
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Aqueous effluent
Large- and medium-scale mills
produce copious volumes of liquid
waste from the sterilizer, clarifying
centrifuges and hydrocyclones.
This effluent must be treated before
discharge to avoid serious
environmental pollution.
Refining of crude palm oil :The purpose is to produce a clean and attractive looking
oil or fat by removing impurities which cause the oil to
have an unattractive colour and taste.
2 types :a) Physical refining
- it is the common process in Msia due to its higher
efficiency,
low operating and capital cost and negligible
effluent
handling
b) Chemical refining
- it is not very popular process because of high
operating cost
and high refining losses
- the inherent problems of pollution due to the
0.1-0.2% ortho-phosphoric
acid, Temp.:85oC, 15 min.
Bleaching
Filtration
Temp: 60-70 oC
Deodorization
Refined, bleached
and deodorized
palm oil
Steam
Temp: 240 270oC, time: 30 min
a) Physical refining
Degumming
a) Physical refining
Bleaching
The functions of bleaching process:
i - to adsorb the undesirable impurities such as trace metals,
moisture,
insoluble matter and part of carotenoids and other pigments
ii - to reduce the level of oxidation products
iii - to adsorb the phospholipids precipitated by the phosphoric acid
iv - to remove any excess phosphoric acid present in the oil after
degumming
v - to obtain the lightest colour possible
vi - to remove traces of soap present from the alkaline process
which can
effect hydrogention by making it erratic, non selective and
difficult to control
vii -to remove traces of nickel from hydrogenated oil (nickel will
disturb
deodorisation process later by changing the flavor and colour of
the final product
Carried out under a steam or nitrogen blanket or under vacum20
a) Physical refining
Filtration
eral types of equipment are used :te and frame filter, vertical leaf pressure filter and horizonta
a) Physical refining
Deodorization
Degumming
Soap stock
Neutralisation
Acidulation
using H2SO4
Pretreatment
Bleaching
Acid oil
Deacidification/
Deodorisation
NaOH
Bleaching
earth
Steam
Temp: 240 270oC
b) Chemical refining
Neutralisation
The process involves the use/ addition of alkali; caustic soda
(sodium hydroxide) to neutralised the oil
The reaction:
NaOH + FFA
soap stock
b) Chemical refining
Pretreatment
Bleaching
Deacidification/
Deodorisation
Crystallization
(supercooling)
Filtration/Centrifuge
Filter
press
Oleochemical industry
Oleochemical industry
In
Oleochemicals
PRETREATMENT
FAT SPLITTING
METHANOLYSIS
Sweet water
PRE-TREATMENT
DISTILLATION
Distilled methyl
esters
HYDROGENATION
Fatty alcohol
DISTILLATION
ESTERIFICATION
HYDROGENATION
DISTILLATION
Hydrogenated
fatty acids
FRACTIONATION
Fractionated fatty alkohol
Soap
Fractionated
Fatty acid
ESTERIFICATION
Distilled esters
NEUTRALIZATION
FRACTIONATION
Distilled
hydrogenated
fatty acids
BLEACHING
DISTILLATION
USP grade
glycerine
Distilled
fractionated ester
fatty acids
methyl ester
fatty alcohols
fatty amines
glycerol.
BASIC OLEOCHEMICALS
FATTY ESTER
FATTY ALCOHOL
GLYCERINE
FATTY AMINE
FATTY ACID
Surfactants in
agrochemicals e.g. in
pesticide formulation
Surfactants in
detergent and
softener
formulation
Oleochemical
uses
Soaps
Candles
Lubricant and
grease
Pharmaceuticals
Products
Raw materials
Waste/by-Products
Solid waste
Wastewater
Greenhouse gas
In a well run palm oil mill, it is expected that each 100 tonnes of
Solid waste
Wastewater
Liquid waste treatment involves anaerobic fermentation
followed by aerobic fermentation in large ponds until the effluent
quality is suitable for discharge.
In some of the mills the treated effluent is used on the farm as
manure and source of water for irrigation.
The sludge accumulating in the fermentation ponds is
periodically removed and fed to the land.
To manage the amount of oil entrained in the effluent, while at
the same time improving the efficiency of oil recovery, the large
mills use de-watering and decanting centrifuges at various
locations in the process line.