Palm Kernel Oil Extraction Various Process...
Transcript of Palm Kernel Oil Extraction Various Process...
Palm Kernel Oil Extraction
Various Process alternatives
16th Latin American Congress on Fats & Oil ASAGA
Rosario – ARGENTINA / Oct 31 - Nov 4 (2015)
Desmet Ballestra Group, Zaventem, Belgium Represented by David de Schaetzen
Palm Kernel
Palm Kernel
Hard Shell
Fruit of the Oil Palm
Palm Kernel Oil Extraction: Process alternatives
Starting after : - Shell and Kernel separation (+ Drying & Cleaning ) …
oil palm kernel oil palm shell
Palm Kernel Oil Extraction: Process alternatives
Starting with : Palm Kernel composition :
oil palm kernel
- Oil : ~ 50% - Moisture : < 7% - Protein : ~ 9,5% - Fiber : ~ 8% - husks & impurities : < 1% - free of stones
To get : Palm Kernel oil & Palm Kernel Meal - Lauric Acid (C12H24O2) : 50%
- Oleic Acid (C18H34O2) : 16% Oleo chemicals (soap)
- Low protein : ~19% - Fiber : ~16% Ruminants or “Fuel”
Palm Kernel Oil Extraction: Process alternatives
Case 1 = Full Press (single step pressing) Case 2 = Full Press (double step pressing) Case 3 = Pre-Press + Solvent Extraction Case 4 = Direct Solvent Extraction
… For 350 TPD PK Seed ...
Palm Kernel Oil Extraction: Process alternatives
Case 1 = Full Press (single step pressing) Case 2 = Full Press (double step pressing) Case 3 = Pre-Press + Solvent Extraction Case 4 = Direct Solvent Extraction
Case 1 : Full Press
(Single step)
Case 2 : Full Press
(Double step)
Case 3 : Pre-Press
Solvent Extraction
Case 4 : Direct
Solvent Extraction
PK Inlet Seed (50% Oil) Seed (50% Oil) Seed (50% Oil) Seed (50% Oil)
Hammer Mill
Cracking
Flaking (double)
Cooking
Press (1st step)
Press (2nd step)
Oil Screening
Cake cooler
Solvent Extraction
PK Outlet Cake (10% oil) Cake (8% Oil) Meal (0,7% Oil) Meal (0,8% Oil)
Palm Kernel Oil Extraction
PREPARATION
Palm Kernel Oil Extraction: Hammer Mills
For 350 TPD PK - 2 x STOLZ model RME 17
with 90 kW + Fan 11 kW = 202 kW
For all Cases (1, 2, 3 & 4) - to pre-break the kernel before cracking
mills - & minimize the maintenance
requirements of the cracking rolls.
- Frequent replacement of Hammers and Screens - ~0,2 USD/T.
Palm Kernel Oil Extraction: Cracking
For all Cases (1, 2, 3 & 4)
For 350 TPD …. - 2 x BUHLER model OLCB 4-316
with 2 x 30 kW = 120 kW
- Frequent re-corrugation & reduced life time of rolls : ~0,4 USD/T.
- to reduce size of PK and get consistent particle size.
Palm Kernel Oil Extraction: Flaking
- to shorten path to and from oil containing cells & facilitate solvent penetration and oil extraction
For Cases (3 & 4) only : before Solvent Extraction
- PK : Double flaking to lower hexane residual in meal
Area / Volume 50:1
Area / Volume 200:1
Palm Kernel Oil Extraction: Flaking
For 350 TPD …. - 2 x 2 BUHLER model OLCB 4-316 with
90 kW = 360 kW
- Frequent re-grinding of rolls & reduced life time of rolls : ~0,60 USD/T.
For Cases (3 & 4) only : before Solvent Extraction
Palm Kernel Oil Extraction: Cooking
- Cooking to get optimum mechanical pressing.
For Cases (1, 2 & 3) : before Press
For 350 TPD Case 1 :
Full Press (Single step)
Case 2 : Full Press (Double
step)
Case 3 : Pre-Press Solvent
Extraction
Drying to 3% 4% 4%
Sizing 9 x stages Dia 4,5 m
8 x stages Dia 4,5 m
6 x stages Dia 4,5 m
Installed power 132 kW 110 kW 90 kW
Steam 150 kg/T 135 kg/T 120 kg/T
Palm Kernel Oil Extraction: Presses
- Mechanical extraction through screw press
For Cases (1, 2 & 3) : with Press
Worm Assembly
Palm Kernel Oil Extraction: Presses
- Liquid being ‘expelled’ through
For Cases (1, 2 & 3) : with Press
Lining bar and Drainage cage
Palm Kernel Oil Extraction: Presses
For Cases (1, 2 & 3) : with Press
PK Cake : High Fiber content High friction and very abrasive !!! kWh !! & Maintenance !! (Worm assembly, lining bar, …)
Oil & Cake Production
Palm Kernel Oil Extraction: Presses
For Cases (1, 2 & 3) : with Press
For 350TPD PK Seed
Case 1 : Full Press
(Single step)
Case 2 : Full Press
(Double step)
Case 3 : Pre-Press
Solvent Extraction
Oil in cake 10% 8% 20%
Presses 6 x ST600’s 2 x ST600’s 6 x ST600’s 1 x ST600’s
Installed power 6 x 200 kW 2 x 200 kW 6 x 200 kW 1 x 550 kW
Absorbed power 60 kWh/T ! 25 kWh/T !! 60 kWh /T !! 30 kWh/T
Maintenance 4 USD/T 4 USD/T 0,5 USD/T
- Rosedowns Press Sterling ST600
Palm Kernel Oil Extraction: Oil clarification &
For Cases (1, 2 & 3) : after Press
- Oil decanter …
Cake cooling
For 350 TPD PK
… Total Installed power ~55 kW
- Cake cooler …
Model WESTFALIA RCD 305-00 15 kW
Palm Kernel Oil Extraction
SOLVENT EXTRACTION
9TH TRAY
6TH TRAY
5TH TRAY
4TH TRAY
2N D TRAY
1ST TRAY
7TH TRAY
8TH TRAY
3R D TRAY
SEED = Oil + Meal
Hexane
Water
MEAL OIL
Air
Extractor Toaster Distillation Condenser Absorption
Oil + HexaneOil +
HexaneMeal +
HexaneMeal +
Hexane
Hexane
HexaneAir +
Atmospheric
Vacuum
Atmospheric Vacuum
Palm Kernel Oil Extraction: Solvent Extraction
For Cases (3) after Pre-press
PK Cake with < 20% Oil :
- 175 TPD PK Meal - 40 TPD PK Oil
For Cases (4) Direct Solvent Extraction
PK Flake with 50% Oil :
- 175 TPD PK Meal - 175 TPD PK Oil
@ Ambient temperature
@ 55-60 °C temperature
Palm Kernel Oil Extraction: Solvent Extraction
For Cases (3 & 4) after Pre-press & Direct Extraction
9TH TRAY
6TH TRAY
5TH TRAY
4TH TRAY
2N D TRAY
1ST TRAY
7TH TRAY
8TH TRAY
3R D TRAY
SEED = Oil + Meal
Hexane
Water
MEAL OIL
Air
Extractor Toaster Distillation Condenser Absorption
Oil + HexaneOil +
HexaneMeal +
HexaneMeal +
Hexane
Hexane
HexaneAir +
Atmospheric
Vacuum
Atmospheric Vacuum
Leaks
Hexane Losses
Palm Kernel Oil Extraction: Extractor
For Cases (3) after Pre-press
Hexane losses 2,25 kg / T
For Cases (4) Direct Extraction
Hexane losses 2,5 kg / T
Quantifiable losses conc. lt/MT
Meal 0.75 kg/kg 500 ppm 0.594 92.9%
Oil 0.20 kg/kg 50 ppm 0.015 2.3%
Water 50 lt/MT 20 ppm 0.001 0.2%
Vent gas 2 m3/MT 10 g/m³ 0.029 4.6%
Total quantifiable 0.435
Fugitive losses
Number of leak points does not increase proportionally to capacity.
5000 TPD plant: 0.15 – 0.3 lt/T 500 TPD plant: 0.4 – 0.8 lt/T
Palm Kernel Oil Extraction: Extractor
For Cases (3) after Pre-press
Extractor : 41 m³ Motor : 0,75 kW 7 pumps – 5,5 kW
For Cases (4) Direct Extraction
P2B
P15 P3/1 P3/2 P3/3 P3/4 P3/5 P3/6 P2A
P1HP
Fresh Solvent
from 20A
Full Miscella to 17
49/P1
Steam
To 46B
8A
2
3
4
8B/2
5
Spent Flakes to 70
58/P1
Safety Vent to Outside of building
Purge to outside of Building
Drain to Floor
36P
Vent to 20C
Vent to 20C
Client Supply
8A/CFLAKES fromPREPARATION
1A
1B
Extractor : 91 m³ Motor : 2,2 kW 7 pumps – 11 kW Percolation ! – Flake moisture < 7%
For 350 TPD PK Seed
Meal with Oil
Meal with Hexane
Hexane
Oil with Hexane
Palm Kernel Oil Extraction: Desolventizer
For Cases (3) after Pre-press
Hexane in meal : 44% Steam : 220 kg/T Desolventizer - Dia 3,0 m Installed power : 160 + 55 kW (DT + Fan)
For Cases (4) Direct Extraction
For 350 TPD PK Seed
Predesolventizing
Desolventizing
Toasting & Stripping > 100°C
11TH TRAY
7TH TRAY
6TH TRAY
5TH TRAY
4TH TRAY
8TH TRAY
1ST TRAY
3R D TRAY
9TH TRAY
10TH TRAY
2ND TRAY
Steam
Dryer (Hot air)
Cooler (Cold air)
Hexane in meal : 37,5% Steam : 145 kg/T Desolventizer - Dia 2,5 m Installed power : 110 + 30 kW
(DT) + (Fan)
Palm Kernel Oil Extraction: Distillation
For Cases (3) after Pre-press
For Cases (4) Direct Extraction
For 350 TPD PK Seed
2nd Stage Evaporator Separator
Sieve Tray Oil Stripper
Steam
175TPD PK Oil (50%) Meal Inlet @ Amb Temperature Steam : 155 kg/T Inst. power : 55 kW + 130 kW (Distillation) + (Cooling water)
40TPD PK Oil (20%) Meal Inlet @ 55-60°C Steam : 50 kg/T Inst. power : 20 kW + 75 kW
(Distillation) + (Cooling water)
Palm Kernel Oil Extraction
SUMMARY Table
What is the most economical process ?
Palm Kernel Oil Extraction: Summary - Electricity Case 1 :
Full Press (Single step)
Case 2 : Full Press
(Double step)
Case 3 : Pre-Press
Solvent Extraction
Case 4 : Direct
Solvent Extraction Hammer Mill 2 x (90 + 11) kW 2 x (90 + 11) kW 2 x (90 + 11) kW 2 x (90 + 11) kW
Cracking 4 x 30 kW 4 x 30 kW 4 x 30 kW 4 x 30 kW
Flaking (double) 4 x 90 kW 4 x 90 kW
Conveyor - Others 30 kW 30 kW 30 kW 30 kW
Cooking 132 kW 110 kW 90 kW -
Presses 6 x 200 kW 8 x 200 kW 1 x 550 kW -
Oil Screening + Cake cooler 55 kW 55 kW 55 kW -
Conveyor - Others 50 kW 50 kW 50 kW -
TOTAL Preparation 1789 kW 2167 kW 1482 kW 737 kW Extractor - - 56 kW 95 kW
Desolventiser - - 110 + 30 kW 160 + 55 kW
Distillation & cooling water - - 20 + 75 55 + 130
TOTAL Extraction - - 290 kW 495 kW
TOTAL kW Installed 1789 kW 2167 kW 1773 kW 1232 kW
TOTAL Abs Power 98 kWh/T 119 kWh/T 95 kWh/T 64 kWh/T
Palm Kernel Oil Extraction: Summary
Case 1 : Full Press
(Single step)
Case 2 : Full Press
(Double step)
Case 3 : Pre-Press
Solvent Extraction
Case 4 : Direct
Solvent Extraction Hammer Mill 0,20 USD/T 0,20 USD/T 0,20 USD/T 0,20 USD/T
Cracking 0,40 USD/T 0,40 USD/T 0,40 USD/T 0,40 USD/T
Flaking (double) 0,60 USD/T 0,60 USD/T 0,60 USD/T 0,60 USD/T
Conveyor - Others 0,10 USD/T 0,10 USD/T 0,10 USD/T 0,10 USD/T
Cooking 0,05 USD/T 0,05 USD/T 0,05 USD/T -
Presses 4,00 USD/T 4,00 USD/T 0,50 USD/T -
Oil Screening + Cake cooler 0,10 USD/T 0,10 USD/T 0,10 USD/T
Conveyor - Others 0,10 USD/T 0,10 USD/T 0,10 USD/T -
Extraction - - 0,15 USD/T 0,15 USD/T
TOTAL 4,95 USD/T 4,95 USD/T 2,05 USD/T 1,25 USD/T
Maintenance cost
Palm Kernel Oil Extraction: Summary
Case 1 : Full Press
(Single step)
Case 2 : Full Press
(Double step)
Case 3 : Pre-Press
Solvent Extraction
Case 4 : Direct
Solvent Extraction Preparation (Cooking) 150 kg/T 135 kg/T 120 kg/T -
Extraction
Desolventizer - - 145 kg/T 220 kg/T
Distillation - - 55 kg/T 155 kg/T
TOTAL 150 kg/T 135 kg/T 320 kg/T 375 kg/T
Seam consumption
Case 1 : Full Press
(Single step)
Case 2 : Full Press
(Double step)
Case 3 : Pre-Press
Solvent Extraction
Case 4 : Direct
Solvent Extraction
TOTAL - - 2,25 kg/T 2,5 kg/T
Hexane consumption
Palm Kernel Oil Extraction: Summary - Final Plant Palm Kernel Capacity 350 TPD Oil content : 50 % Cake/Meal : 175 TPD Oil : 175 TPD
PK oil : 900 USD/Ton PK Cake / Meal : 50 USD/Ton Steam cost : 15 USD/Ton Elec cost 0,07 USD/kWh Hexane cost : 1 USD/kg Day of production / year 330 days/Years
Case 1 : Full Press
(Single step)
Case 2 : Full Press
(Double step)
Case 3 : Pre-Press
Solvent Extraction
Case 4 : Direct
Solvent Extraction
USD/Year USD/Year USD/Year USD/Year Oil left in Cake/Meal 10 % 5.454.167 8 % 4.363.333 0,7 % 381.792 0,8 % 426.848 Electrical consumption 98 kWh/T 793.457 119 kWh/T 961.108 96 kWh/T 776.160 64 kWh/T 517.440 Steam consumption 150 kg/T 259.875 135 kg/T 233.888 320 kg/T 554.400 375 kg/T 649.688 Maintenance cost 5,0 USD/T 571.725 5,0 USD/T 571.725 2,1 USD/T 236.775 1,3 USD/T 144.375 Hexane consumption - kg/T - - kg/T - 2,25 kg/T 259.875 2,5 kg/T 288.750 Total : 7.079.224 6.130.054 2.209.002 2.027.100
USD/Year USD/Year USD/Year USD/Year
Oil left in Cake/Meal 10 % 5.455.000 8 % 4.365.000 0,7 % 380.000 0,8 % 425.000
Electrical consumption 98 kWh/T 795.000 119 kWh/T 960.000 96 kWh/T 775.000 64 kWh/T 515.000
Steam consumption 150 kg/T 260.000 135 kg/T 235.000 320 kg/T 555.000 375 kg/T 650.000
Maintenance cost 5,0 USD/T 570.000 5,0 USD/T 570.000 2,1 USD/T 235.000 1,3 USD/T 145.000
Hexane consumption - kg/T - - kg/T - 2,25 kg/T 260.000 2,5 kg/T 290.000
Total : 7.080.000 6.130.000 2.205.000 2.025.000
Desmet Ballestra …