TYPICAL MATERIAL BALANCE FOR A

90000
KG FFB/HR PALM OIL MILL
[Assuming FFB Processed is all DXP (Tenera) oil palm]
Sterilizer Condensate
Oil
Water
Nos
Total
Loss (Oil to Nos)

%
0.89
93.32
5.79
100

Crude Oil
Oil
Water
NOS
Total

kg/hr
16963
8208
29549
36480

%
31
15
54
100

kg/hr
200.25
20997
1302.75
15000
9.76%

Fresh Fruit Bunches

90000
Composting Plant
Sterilizer Condensate
22500 kg/hr

Sterilization Process

Steam Exhaust

Empty Bunch
Oil
Water
Nos
Total

Steam Input
24300 kg/hr
Sterilized FFB
81000 kg/hr

10800 kg/hr
Threshing Process

%
3.87
64.69
31.44
100

kg/hr
696.6
11644.2
5659.2
12000

Shredder
Empty Bunches
18000 kg/hr

Steam Input
4500 kg/hr
Screened Solids
2700 kg/hr

Sterilized Fruitlets
63000 kg/hr

To Boiler As Fuel
Fibre + Kernel Loss
14850 kg/hr

Digestion Process

Diluted crude oil

57420 kg/hr

Digested Mash
70200 kg/hr

Undiluted crude oil

40950 kg/hr

Screening Process

Nut
14400 kg/hr

Pressing Process
Dilution Water
16470 kg/hr

Screened Diluted Crude Oil

54720 kg/hr

Fibre + Shell + Kernel Loss

22860 kg/hr

Depericarping Process

Cracked Mixture
14400 kg/hr
Nut Cracking Process

Light Shell & Dust + Kernel Loss

2700 kg/hr

Press Cake + Oil Loss

29250 kg/hr
Water
10800 kg/hr
Sludge
49050 kg/hr

Sand
490.5 kg/hr

Clarification Process

Dry Kernel
4770 kg/hr

Cracked Mixture
6930 kg/hr
Shell + Kernel Losses
5310 kg/hr

Hydrocyclone Separation Process

Desanding Process

Clarified Oil
18270 kg/hr

Wet Kernel
1620 kg/hr

Pre-Cleaned Sludge
48560 kg/hr

Recycled Oil Sludge (L.P)

12600 kg/hr

Kernel Drying Process

Vacuum Drying Process
Production Oil
18000 kg/hr
CPO Storage Tank

Purification Process

Centrifugal Separation
Process- DECANTER

Purified Oil
18180 kg/hr
Dirt & Water
90 kg/hr

Effluent (H.P)
32360 kg/hr

Production Kernel
4500 kg/hr
Bulk Kernel Storage

Solid Waste
3600 kg/hr

To Effluent Treatment Plant

Despatch
Recycled Oil Sludge
Oil
Water
Nos
Total

%
30.7
61.8
7.5
100

kg/hr
3868
7787
945
8400

Sludge
Oil
Water
NOS
Total
Effluent
Oil
Water
Nos
Total
Loss (Oil to Nos) : 10.16%

%
3
12
85
100

kg/hr
1472
5886
41693
32700

%
0.71
95.48
3.81
100

kg/hr
230
30897
1233
23973

Shell + Kernel Loss

8010 kg/hr

Winnowing Separation Process

To Effluent Treatment Plant

Hydrocyclone Waste
10800 kg/hr

Moisture
1890 kg/hr

Fresh fruit bunches

Empty Bunches
Liquid from EFB Press
Potash (Bunch Ash)
Fruitlets on bunch
Fruitlets in Empty Bunch loss
Digested Mesh (MPD)
Press Cake
Extraction CPO and Palm Kernel
Wet Fibre & Nuts to depericarper
Wet Fibre to Boiler
Wet Nut Ex-Winnowing
Cracked Mixture
Kernel
Shell
Water for Hydrocyclone
Clay for Claybath System
Crude Oil diluted with water
Clarified Crude Oil to Purifier
Sludge to Decanter/ Separator

%/FFB
Oil
100
25
25
0.75
8.3
0.25
0.5
66
24.25
2
0.735
64
23.52
26
1.56
38
21.96
25.75
1.55
12
1.08
13.75
0.47
12.5
5.5
7
80
5

F3 Water for Hydrocyclone 80 80kg 0 80 240 400 800 1,600 2,400 3,600 4,800 7,200 9,600
F4 Clay for Claybath system 5 5kg 5 15 25 50 100 150 225 300 450 600
G Crude oil diluated with water 53.2 21.96 30.4 0.84 0 532 1,596 2,660 5,320 10,640 15,960 23,940 31,920 47,880 6
G1 Clarified crude oil to Purifier 25.00 21.96 2.20 0.84 0 250 750 1,250 2,500 5,000 7,500 11,250 15,000 22,500 30,
G2 Sludge to Separator 42.31 21.74 19.81 0.8 0 423 1,269 2,115 4,230 8,460 12,690 19,035 25,380 38,070 50,760
H Clean oil to Oil dryer 23.91 21.74 2.17 0 239 717 1,195 2,390 4,780 7,170 10,755 14,340 21,510 28,680

H1 Clean & dry CPO to stoarge tank 21.52 21.50 0.01 0.009 0 215 645 1,075 2,150 4,300 6,450 9,675 12,900 19,35
J Raw water 1000 1000kg kg 1,000 3,000 5,000 10,000 20,000 30,000 45,000 60,000 90,000 120,000
J1 Boiler feed water 700 700 kg kg 700 2,100 3,500 7,000 14,000 21,000 31,500 42,000 63,000 84,000
J2 Precess water 120 120kg kg 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400
J3 Domestic water 180 180kg kg 180 540 900 1,800 3,600 5,400 8,100 10,800 16,200 21,600
K Solid waste fuel to boiler ( 30% moist.) 43 0.01 12.9 30.09 430 1,290 2,150 4,300 8,600 12,900 19,350 25,800 38,
K1 Fibre 12 0.016 3.6 8.384 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400
K2 Shell 8 0.008 1.2 6.792 80 240 400 800 1,600 2,400 3,600 4,800 7,200 9,600
K3 Light particals 0.5 0.0005 0.025 0.4745 5 15 25 50 100 150 225 300 450 600
K4 De-oiled empty bunches 22.5 0.008 6.75 15.742 225 675 1,125 2,250 4,500 6,750 10,125 13,500 20,250 27,000
L Boiler steam generation ( kg / ton FFB ) 660 660kg 660 1,980 3,300 6,600 13,200 19,800 29,700 39,600 59,400 79

L1 Turbine steam requirement 600 600kg 600 1,800 3,000 6,000 12,000 18,000 27,000 36,000 54,000 72,000
L2 Sterilisation steam requirement 540 540 kg 540 1,620 2,700 5,400 10,800 16,200 24,300 32,400 48,600 64,800
L3 Process heating steam requirement 120 120 kg 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400
M Wast water Effluent ( kg / ton FFB ) 1000 1000kg kg 1,000 3,000 5,000 10,000 20,000 30,000 45,000 60,000 90,0
M1 From Clarification 550 kg 550 1,650 2,750 5,500 11,000 16,500 24,750 33,000 49,500 66,000
M2 From Steriliser condensate 150 kg 150 450 750 1,500 3,000 4,500 6,750 9,000 13,500 18,000
M3 From PK recovery plant 80 kg 80 240 400 800 1,600 2,400 3,600 4,800 7,200 9,600
M4 Boiler blow down 120 120 360 600 1,200 2,400 3,600 5,400 7,200 10,800 14,400
M5 From OTHERS & cleaning 100 kg 100 300 500 1,000 2,000 3,000 4,500 6,000 9,000 12,000
N Power generation ( kw / ton FFB / hr ) 25 KW 25 75 125 250 500 750 1,125 1,500 2,250 3,000
N1 Process 20 KW 20 60 100 200 400 600 900 1,200 1,800 2,400
N2 Mill lighting & grounds 2 KW 2 6 10 20 40 60 90 120 180 240
N3 Domestic 3 KW 3 9 15 30 60 90 135 180 270 360
Perunding AME / POMProMatrix / 16th November 1998 /nw. 5/10/00
PROCESS MASS FLOW AND LOSSES DURING PRODUCTION
Based on

Water

Solid
48.5
18
7.4

6.25
0.664

37
1.121
35.88
10.9
15.2
10.82
3.6
0.76

7
0.212
6.79
14
0.84
13.29
6.48
12.53

Other

0
0.5
0
0
0
0
0
0
0
0
0
0
0

80

15,960 23,940 31,920 47,880 63,840

,500 11,250 15,000 22,500 30,000
19,035 25,380 38,070 50,760
4,340 21,510 28,680

,300 6,450 9,675 12,900 19,350 25,800

90,000 120,000
00 63,000 84,000

600 12,900 19,350 25,800 38,700 51,600

10,125 13,500 20,250 27,000

9,800 29,700 39,600 59,400 79,200

00 36,000 54,000 72,000

24,300 32,400 48,600 64,800
400 7,200 10,800 14,400
000 30,000 45,000 60,000 90,000 120,000
,500 66,000
3,500 18,000