ChE331 Palm Oil & Oleochemical Process Assignment 1: Bleached Deodorized Palm Oil (RBDPO)

Name Student ID Lecturer Due Date Signature : Goh Wui Seng : 7E0A7458 : Florence Wong : 30th March 2012 :

Executive Summary
This report mainly discusses about the production of refined bleached deodorized palm oil (RBDPO) from fresh fruit bunch (FFB). Understanding in palm oil processing as well as fulfill the learning outcomes of this unit are expected to be achieved after this report. The production of refined bleached deodorized palm oil from fresh fruit bunches is mainly consisted of two stages, which are palm oil milling process and crude palm oil refinery process. Palm Oil mill process consists of processes like sterilization, threshing, stripping, digestion, extraction and clarification, while Crude palm oil refinery process includes degumming, bleaching and deodorizing. This report provides brief description of every process in the stages mentioned.

Contents Executive Summary ............................................................................................................ 2 1 Introduction ...................................................................................................................... 4 2 Palm Oil Milling Process ................................................................................................. 5 2.1 Plantation of Oil Palm & Harvesting of Fresh Fruit Bunch ...................................... 5 2.2 Transportation of Fresh Fruit Bunches...................................................................... 5 2.3 Reception Station ...................................................................................................... 6 2.4 Sterilization ............................................................................................................... 6 2.5 Threshing & Pressing Station.................................................................................... 7 2.6 Clarification ............................................................................................................... 7 2.7 Crude Palm Oil Storage Tank ................................................................................... 8 3 Crude Palm Oil Refinery Process (Physical Refinery) .................................................... 8 3.1Degumming Process ................................................................................................... 8 3.2 Bleaching ................................................................................................................... 9 3.3 Deodorizing ............................................................................................................... 9 4 Conclusion ..................................................................................................................... 10 5 References List............................................................................................................... 11 6 Appendixes (List of Figures) ......................................................................................... 12

1 Introduction
The oil palm is originally from Africa but Malaysia was the first country to embark on large-scale planting and processing. It has been developing its own technology and adopting innovative policies in order to boost up the production. The commercial value of this crop lies mainly in the oil that can be obtained from mesocarp of the fruit palm oil and the kernel of the nut-palm kernel oil. Currently in Malaysia, all palm oil refining plants are using physical refining method as it is proven to be more cost effective compared to chemical refining method. Generally, physical refining of palm oil consists of two stages namely pre-treatment stage and deodorization stage. Pre-treatment stage involves degumming and bleaching of palm oil. Before the refining process of palm oil, there is a palm oil milling process beforehand. This milling process mainly includes sterilization of fresh fruit bunch and threshing and pressing stages. Below is the overview features for the production of Refined Bleached Deodorized Palm Oil. Instead of Chemical Refining Process, Physical Refining is discussed in this report.
Plantation of Oil Palm & Harvesting of Fresh Fruit Bunch Deodorization Process

Transportation of Fresh Fruit Bunch

Bleaching Process

Reception Station

Degumming Process

Sterilization

Crude Palm Oil Storage Tank

Threshing and Pressing Station

Clarification Station

2 Palm Oil Milling Process

2.1 Plantation of Oil Palm & Harvesting of Fresh Fruit Bunch
Oil Palm tree (Figure 4) grows up to 20 meters in height and grow best at temperature of 24-27oC. Oil Palm tree requires a humid climate and the cultivated oil palm carry fruit from their fourth year onward and can be harvested for 40-50 years (Bockish, 1993). In Malaysia, Tenera (hybrid of Dura with Psifera) palm fruit is widely cultivated due to commercial and processing viability as harvesting becomes easier since the palm trees are relatively shorter, producing good fruit bunch and higher fruit oil content (Noor Azian, 1995). Figure 1 shows 3 genotypes of palm oil where clear differences in their fruit morphology are revealed. The dura fruit form has no shell. The hybrid between the two, the tenera fruit form has a shell of intermediate thickness and a surrounding of fiber stands in the mesocarp (Noor Azian, 1995). Mesorcarp accounts for about 60% of the total composition of palm oil fruit and crude palm oil is derived from this part. Figure 2 shows overall composition of palm oil. Seedlings are raised in the nursery for about 12 months prior to transplanting in the field. After about 24 to 30 months, the oil palm starts to yield fruit in compact bunches called Fresh Fruit Bunches (FFB) (Figure 5). Harvesting involves cutting ripe bunches manually using a chisel or sickle. Collection of harvested fruits is either done manually, sometimes with a wheelbarrow, or mechanically using a tractor-mounted grabber with trailer. The harvested FFBs are then being loaded in trucks for transporting to Palm Oil Mill.

2.2 Transportation of Fresh Fruit Bunches

Normally the harvested FFBs are being transported using 40-45 tons trucks (Figure 6). Most of the palm oil mills are generally located near the plantations area to facilitate timely transportation and effective processing of the fruit bunches.

2.3 Reception Station

The harvested FFBs are sent to the mill for further processing as soon as possible. This is because after the FFB is harvested from its maternal (i.e the Oil Palm Tree), Free Fatty Acids will increase rapidly in the FFB. FFB normally arrives at the Reception Station as bunches or loose fruit in emptied wooden boxes so that the quantity of the fruit bunches arriving at the processing site can be easily checked (FAO, 2002). The quality of FFB is graded according to Malaysia Palm Oil Board grading manual. Basically there are several grades for FFB which are Unripe Bunch, under ripe bunch, ripe bunch, Over Ripe Bunch, Empty Bunch, Old Crop and Long stalk bunch.

2.4 Sterilization
FFB are sent into sterilizer after grading and weighing processes by using conveying belts. Sterilization means the use of high-temperature wet-heat treatment of loose fruit. Pressurized Steam that generated from the boiler is used to sterilize the FFB. This process is mainly for arresting the formation of free fatty acid (FFA), loosening the oil cells, releasing nuts from bunches and preparing fruit mesocarps for the later processes (AKAM. G, 2012). There are basically 5 types of sterilizers, which are mainly Horizontal Sterilizer, Vertical Sterilizers, Tilting Sterilizer, Spherical Sterilizer, and Continuous Sterilizer (AKAM. G, 2012). (Figures 7, 8, 9) Most of the mini-scale mills do not have the capacity to generate pressurized steams, instead, the FFBs will proceed to the threshing process. After threshing process, the whole bunches are cooked in hot water. This step is essential as it will ensure to reach the same objective as the original sterilization process.

2.5 Threshing & Pressing Station

After the sterilization process, the FFB are softened and their nuts are loosely released from the brunches. These sterilized FFBs are then sent to a rotating drum thresher to carry out threshing process (Figure 10). Threshing process is mainly performed to separate all the fruit from those bunches in aid of centrifugal force. As a result, the empty fruit bunches are used as fuel for Boiler or transported to the plantation site for mulching. Oil Palm fruit that separated from bunches is next sent to the pressing station. Right after threshing process, there is actually an optional stage named Digestion. The digestion process is usually just right after threshing process and before the Pressing station. The aim of digestion is to reduce the viscosity of fruit oil and destroy the fruits exocarp. This step is optional because normally, the fruits exocarp has already been destroyed during the sterilization process. In the pressing station, the fruit oil is squeezed out by applying mechanical pressure on the fruit (i.e pressing) (Figure 11). The press cake produced after the oil is extracted out from the fruitlets will be sent for further processing into palm kernel oil.

2.6 Clarification
This is the final stage of extracting crude palm oil from the FFB. The clarification process (Figure 12) is to remove water as well as impurities such as cell debris, fibrous material, and non-oily solids from the extracted oil before it is sent to the storage tank. There are several subprocesses in this stage. They are screening, clarifying, oil recovery and purifying and moisture removal. The extracted oil firstly goes through screening process which separates the crude oil from filterable impurities like fibre and debris by passing through a vibrating screen. The filtered oil is collected using continuous settling tank.

Hot water is added to thinner the viscous sludge mixture. After the mixture is boiled for one or two hours, it is then allowed to settle down in a large tank. The crude palm oil will be on top of the mixture as it is lighter while others will stay at the bottom. A decanter is used to filter the impurities. After the oil is withdrawn, it is then sent to the purifier (Figure 13) with the clean oil that collected from the condensing tank for purification process. Vacuum dryer is used to remove and reduce the traces of water and moisture content of the oil.

2.7 Crude Palm Oil Storage Tank

Crude Palm Oil is finally obtained from the clarification and it is stored in save and clean tank (Figure 14) to maintain the purities and moisture level of the oil.

3 Crude Palm Oil Refinery Process (Physical Refinery)

3.1Degumming Process
In crude palm oil physical refining process, the unwanted gums in the crude palm oil (CPO) will be removed in the degumming process. Firstly, the CPO will be heated up to around 100oC before phosphoric acid is added (Bede. S, 2012). Phosphoric acid is used to decompose the non-water soluble phosphides and to coagulate the phosphatides. Degumming process causes the phosphatides to become insoluble in the oil so that it is easier to be removed in the next stage. This process is necessary because phosphatides will impart undesirable flavor and colour. On the other hand, it will shorten the shelf life of oil. This is because phosphatides emulsifying action is the main culprit that causes the oxidative instability of the crude palm oil.

3.2 Bleaching
After the degumming process, the degummed oil will be send to bleaching process. Bleaching earth is added to the oil before the oil is heated up to 100oC. It is then sent into the vacuum bleacher. The trace metal complexes such as iron, copper and etc, coagulated phosphides, pigments, oxidation products and also residual of phosphoric acid are removed by adsorptive effect of the bleaching earth. The bleaching process will be carried out continuously for half an hour per batch with a certain concentration and quantity of bleaching earth. After this process, the bleached oil is then filtered before proceed to the last stage (Rohani M.Z. 2006).

3.3 Deodorizing
The filtered bleached oil is then sent into the deodorizer for the deodorization and deacidification process. Under the temperature of 250oC and vacuum condition, a direct steam is injected into the deodorizer to mix with the oil. FFA in the oil is then be removed as refining waste at the upper section of deodorizer. Other than FFA, substances like primary and secondary oxidation products, as well as carotenoids pigments are also being removed. These substances contribute to off-flavors and also they will contribute to form Palm fatty acid distillate. Refined bleached deodorized palm oil (RBDPO) is then obtained at the lower section of the deodorizer. The RBDPO is then cooled before it is filtered by means of polishing filter and sent to storage tanks (Rohani M.Z. 2006).

4 Conclusion

As a conclusion, in the production of refined bleached deodorized palm oil (RBDPO) from fresh fruit bunches (FFB) mainly separate into two procesess which are milling process and refinery process. The former process consisted of processes like sterilization, threshing, pressing, extraction and clarification while the latter process included degumming, bleaching and deodorizing. Nevertheless, the purpose of this report writing has been achieved as the understanding of this process has been improved. The palm oil refining industry is today among the most important manufacturing sectors in the country. Besides contributing to the Gross Domestic Product (GDP) and increasing employment opportunities in the country. The refining sector has contributed significantly to the growth of palm oil industry in Malaysia.

5 References List
Akam. G, 2012, Lecture slides 2: Palm Oil Milling, Curtin University. Bede. S, 2012, Lecture slides 3: Palm Oil Refining Process in Refinery, Curtin University. FAO, 2002, Small Scale Palm Oil Processing in Africa, http://www.fao.org/DOCREP/005/Y4355E/y4355e00.htm#Contents (accessed on 18 March 2012) FAO, 2002, Palm Oil Processing, http://www.fao.org/DOCREP/005/Y4355E/y4355e04.htm (accessed on 18 March 2012) Rohani M.Z. 2006, Process Design in Degumming and Bleaching of Palm Oil, Centre of Lipids Engineering and Applied Research (CLEAR) University Technology of Malaysia. RSPO.org, 2012, Roundtable on Sustainable Palm Oil, http://www.rspo.org (accessed on 19 March 2012) Richard-seaman, 2012, The Exotic Adventures of Richard Seaman, http://www.richard-seaman.com/Travel/Malaysia/Peninsula/index.html(accessed on 19 March 2012) Noor Azian, M. (1995), The Physical Properties of Palm Oil Mixtures for Design of Process Equipment University of Leeds. Ph. D Thesis. TSH Biotech Sdn Bhd, 2011, Palm Oil in Malaysia, http://www.etawau.com/OilPalm/PalmOil.htm (accessed on 20 March 2012) Wong. F, 2012, Lecture slides 1: ChE331 Palm Oil and Oleo-chemical Process, Curtin University.

6 Appendixes (List of Figures)

Figure 1 Tenera Hybrid Obtained from Dura and Pisifera Parents (Noor Azian, 1995)

Figure 2 Composition of Palm Oil Fruit (Bockish, 1993)

Figure 3 Caption of a Oil Palm Plantation in Taman Negara (Richard Seaman, 2012)

Figure 4 Palm Oil Tree

Figure 5 Fresh Fruit Bunch

Figure 6 Truck used for FFB transportation (AKAM, 2012)

Figure 7 Horizontal Sterilizer (Akam, 2012)

Figure 8 Tilting Sterilizer (Akam, 2012)

Figure 9 Vertical Sterilizer (Akam, 2012)

Figure 10 Threshing Station (Akam, 2012)

Figure 11 Pressing Station (Akam, 2012)

Figure 12 Clarification Station (Akam, 2012)

Figure 13 Purifier (Akam, 2012)

Figure 14 Crude Palm Oil Storage Tank (Akam, 2012)