International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:13 No:04 29

Heat Exchanger Analysis to Reduce Hexane Loss in

Palm Kernel Oil Extraction Plant
Sivaraos1,*, N. Kumar1, Aidy Ali2, Taufik1, S. Dhar Malingam3, M.S.Kassim1, M.A.Sulaiman1
1
Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, 76100, Durian Tunggal, Melaka, Malaysia
2
Department of Mechanical Engineering, Faculty of Engineering, University Pertahanan Nasional Malaysia (UPNM) Kem
Sungai Besi, 57000, Kuala Lumpur, Malaysia
3
Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, 76100, Durian Tunggal, Melaka, Malaysia
*Corresponding author:sivarao@utem.edu.my

Abstract-- The aim of this study is to reduce hexane loss
during the process of extraction oil from palm kernel that
would reduce the production cost and increase the net profit.
The study is carried out in a leading palm oil factory in
Malaysia. At present solvent extraction plant are facing
problem of high hexane loss, average 9.5 litre/metric ton
(ltr/mt). To reduce the hexane loss, critical investigations were
performed to improve the heat transfer between hexane
vapour and water condenser shell and tube. Preliminary
investigations reveal that 21% of the hexane is being loss
during plant operation. The present redesigned heat exchanger
is successfully reduced the hexane loss from 9.5% ltr/mt to
7.5ltr/mt per day of the same operating plant which saves
about RM904, 800 per annum for the industry. Ultimately, the
outcome of this study gives a great economic impact to the
industry by reducing the production cost leading into the
reduction of oil price for the nation. In addition it is found that
not only the monetary impact is benefited, but, the release of
hexane to atmospheric also reduced to ensure safe healthy life
of people surrounding the plant.
Index Term-- Palm kernel oil, hexane, solvent extraction
plant, palm oil extraction, heat exchanger design, hexane
saving
1.0 INTRODUCTION
The utilizations of hexane to extract the oil are
commonly used for oilcake, oilseeds, vegetable oils, grains
etc. Hexane is a very volatile aliphatic hydrocarbon with the
chemical formula C6H14. It is a constituent in the paraffin
fraction of crude oil and natural gas and is also used as an
industrial chemical and laboratory reagent [1]. Laboratory
and industrial solvents such as hexane and petroleum ether
contain hexane from <0.1% to as much as 33% [2]. Various
types of commercial grades of hexane are available, and the
constituents besides hexane are usually an intentional part of
the process for preparing these commercial mixtures.
Where else, intended for specialized oil extraction or
laboratory uses, the purity of the hexane products may be in
the range of 95-99% hexane; for a variety of uses where
purity is not as important, commercial hexane mixtures (in
the range of 20-80% of hexane) may contain small amounts
of chemicals such as acetone, methyl ethyl ketone,
dichloromethane, and trichloroethylene, aromatics such as
toluene, and other types of petroleum hydrocarbons [3,4]. In
commercial grades of hexane, some of the constituents are
purposefully added as denaturants, often to discourage the
abuse of the chemical to induce “highs” through sniffing or
inhalation [5]. Although this plant uses hexane as the
solvent to extract oil from palm kernel to gain a better yield
at 48.50% compared to other conventional press which only
achieve 44.50% in average [6] but recovering hexane
efficiently is becoming the main problem. Average hexane
loss at the end of the day is about 9.5 ltr/mt of palm kernel.
Basically this plant is facing high hexane losses during the
process of extracting oils from palm kernels. Reducing
production cost by reducing the hexane loss during the
process is the key point of this study. The main intention of
this research work was to reduce hexane loss during the
process of extraction oil from palm kernel, reduce the
production cost, and increase the net profit of the industry.
The scope of this project lies within the auditable distillation
sections as shown in Fig. 1.

Fig. 1. Initial Distillation Condensers

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 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:13 No:04 30

The hexane vapours from falling film economizer, the atmosphere with the maximum hexane content and the
rising film economizer, rising film evaporators 1 and 2 and absorber oil is stripped with direct stream to remove the
from stripper column will be sucked into condensers to traces of hexane and send for re-circulation to cold absorber.
condense hexane vapour into liquid form. The hexane To reduce the hexane content in vent air, two options were
vapour which is not condensed in the last condenser is proposed which is either to upgrade complete absorption
typically passed through a mineral oil absorption system. section or heat transfer analysis (which is justified by
The hexane liquid is then transferred into the special water analysis). Since the earlier would incur extremely high
separator to remove the waste water. After a maximum implementation cost, decision was made to embark on latter
recovery by condensation further hexane content in the proposal to forecast the result by redesigning the condenser
exhaust air can be further reduced only by an absorption by in the distillation plant. Table I shows the preliminary
intimate contact with chilled mineral oil in specially performance.
designed packed column. Thereafter the air is exhausted to
Table I
Actual Details of Existing Distillation Condensers
Water Hexane Vapour
Condenser
Area Water Flow Temperature Temperature
(m2) Rate (m3/hr) In Out In Out

C1 450 133.33 32 36 100 42

C2 450 133.33 32 36 90 40
C3 450 133.33 32 36 90 40
Forecast studies – To add one new 450m2 condenser

2.0 REDESIGNING CONSIDERATION - DECISION M AKING ---------------------------------

ANALYSIS Equation (2)
o o
=
Earlier, there were three condensers operating in the
plant. Decision was taken to analyse in adding one more
condenser to make total surface area from 1350 m2 to 1800 =
m2. Additional of one more condenser, the rate of water
distribution for all four individual condensers is reduces,
̇ = 185m3/hr
from initially at 133.33 m3/hr, to 100 m3/hr. To prevent
from reducing the water flow rate, it is proposed to maintain
the same flow rate without any major investment. This only Hexane mass flow rate, ̇
can be done by changing pump impeller [7]. Referring to
Euroflo Pump Performance Curve model ECS A150-460,
with existing initial pump impeller diameter is 423 mm. By
replacing the pump impeller to 443 mm diameter, the water
flow rate managed to increase to 533 m3/hr. To better Counter flow heat exchanger rates are equal, Qwater
understand the water mass flow rate is calculated as follows: = Qhexane

Water mass flow rate, =

= (1.654 kJ/kg o
̇, ---------------------------------- = 50.12°C
-- Equation (1)
Since the incoming hexane vapour to all four
3 condensers are constant,
̇ = 533m /hr
T1h,in = T2h,in = T3h,in = T4h,in = 90°C

The hexane liquid temperature out for the 4 th

condenser is,
T4h,out = 90°C - 50.12°C = 39.88°C

which is lower than 40°C and fulfil the objective to

÷ 4 (water distribute evenly to get the hexane liquid temperature out from the 4th
all 4 condenser) condenser to maintain or lower than 40°C.
=> maintain same flow to all
the condensers A further calculation carried out as per log mean
temperature difference to justify hexane liquid
Heat transfer rate for water, temperature out from 4th condenser, Th, out.

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 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:13 No:04 31

Qwater = Qhexane Cmax = 154.71 kw/0C

=
=
=
These shows Maximum heat transfer rate,

To justify Th,out for 4th condenser, Overall heat Qmax = Cmin (Th,in – Tc,in)
transfer coefficient,
Qmax = (12.36 kw/0C) × (900C - 320C)
Qmax = 716.88 kw
------------------------------
Equation (3) Number of Transfer Units (NTU) Method;
Effectiveness relations of the heat exchangers,
Where, Q , A = 450m2 -----------------------------
Equation (4)
⁄ Where, U = 57.396 w/m2, A = 450m2, Cmin = 12360
w/0C
Where,ΔT1 = Th,in – Tc,out = 90°C - 36°C = 54°C
ΔT2 = Th,out – Tc,in = 39.88°C - 32°C =
7.88°C NTU = 2.09

The effectiveness of this heat exchanger

( ) corresponding to C = 0.08 and NTU = 2.09, refer to
Fundamental of Heat Transfer and Mass Transfer.
Correction factor F is,
 Parallel flow
 One shell and two passes € = 86%

The actual rate of heat transfer becomes,

Q = €Qmax= (0.86) (716.88 kw) = 616.52 kw
Finally, the outlet temperatures of the cold fluid
streams are determined to be,
Fundamental of Heat Transfer and Mass Transfer, Q = Ch(Th,in – Th,out)
F=1 616.52 kw = ) (90°C - Th,out)
Th,out = 40.110C
This proves Th,out as per observed and design
analysis are almost at the same numeric.
Heat capacity rate,
o
3.0 IMPLEMENTATION
Ch = ṁh ,h = (7.47 ) (1.654 kJ/kg
Having analysed the above conditions, the decision
o has taken to increase heat transfer surface area from 1350
Cc = ṁc ,c=(37.03 ) (4.178 kJ/kg m2 to 1800 m2 by adding one more condenser 450 m2 which
simultaneously increases the cooling capacity from 1350 m2
to 1800 m2. The additional condenser is able to condense the
When Ch≠Cc, Cmin=Ch which is the smaller of two vapours from economizers, evaporators and stripper and
heat capacity rates. reduce the excess load in absorption section. Fig. 2 shows
the implemented of the re-designed condenser with their
Cmin = 12.36 kw/0C respective operational performance numeric.

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 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:13 No:04 32

Fig. 2. Four Condenser Design Layout After Implementation

reduction are shown in Fig. 3. Hence, the hexane loss
4.0 RESULTS AND D ISCUSSION reduced from 9.5 liter/mt to 7.5 liter/mt in average.
The improved condenser design implementation and
the plant performance results in terms of hexane loss

16,000 10.0
9.5 9.0
14,000 7.5
PK Throughput, mt

7.3 7.8 7.4 7.5 8.0

Hexane Loss ,
12,000
7.0

ltr/mt
10,000 6.0
8,000 5.0
6,000 4.0
3.0
13,652

12,723

12,557

15,086
7,943

4,000
2.0
2,000 1.0
- -
Jan-12 Feb-12 Mar-12 Apr-12 May-12

Actual - Kernel Thruput Hexane Loss (average) before improvement Hexane Loss after improvement

Fig. 3. Hexane Loss vs. PK Throughput (Experimental Validation For Five Months Period)
transfer area, the hexane loss started to reduce from 9.5lit/mt
The hexane loss is one of the critical areas where it to 7.5/mt, which about 2 lit/mt saving RM 904,800 per
needs a deep study to carry out to identify causes of high annum for the industry.
consumption of hexane. The high hexane loss results in high
production cost, high fugitive gas emission, poor quality of
crude oil and the by-product. This research has convergent a
bright methodology to overcome all the problems and issues
as mentioned earlier. After the improvement in the heat

Fig. 4. Hexane Losses reduction after improvement (Jan.–Aug. 2012)

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 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:13 No:04 33

This reduced the production cost and increased the net On the other hand, Fig. 4 shows the reduction in hexane loss
profit. Based on result shows in Fig. 3, this research after the new design was implemented.
achieved a great benefit to the respective industry by
reducing hexane loss while improving the extraction yield.
Table II
Total Savings Based On Hexane Loss After Implementation

Jan-12 Feb-12 Mar-12 Apr-12 May-12

PK throughput (mt) 7,943 13,652 12,723 12,557 15,086
Hexane Loss (litre/mt) 7.3 7.8 7.4 7.5 7.5
Hexane Price (RM/litres) 2.89 2.82 2.82 2.43 3.17
Average Hexane loss in year 2012 9.5 9.5 9.5 9.5 9.5
Monetary Saving (RM) 50,502 65,448 75,346 61,027 95,645

REFERENCES
Table II indicates the total saving of RM 34, 968 from [1] Natural Versus Organic (NVO) Hexane Report, Soy Protein And
January 2012 to May 2012 after the improvements we Chemical Solvents In Nutrition Bars And Meat Alternatives,
implemented. As for now, the output averagely maintains Cornucopia Institute, 2010.
almost the same showing steady savings with optimized [2] Creaser C, Welch J, Bishop K., N-Hexane in Petroleum Ether
Fractions. Ann Occup Hyg, 27(2), pp.229-230 (1983).
production. [3] Jorgensen NK, Chor KH, n-Hexane and its toxicologic effects: A
review. Stand J Work Environ Health, 7, pp. 157-68 (1981).
[4] Takeuchi Y., Hisanaga N., Ono Y, Modification of metabolism and
5.0 CONCLUSIONS neurotoxicity of hexane by co-exposure of toluene, International
This research has came out with the solution to Archives Occupational,65 (1), pp. 227-230 (1993).
[5] Altenkirch H, Wagner HM, Stoltenburg G, Nervous System
minimize the hexane loss from 9.5lit/MT to 6.5lit/MT. The Responses Of Rats To Subchronic Inhalation Of N-Hexane And N-
observation of hexane loss was recorded at every shift Hexane Methyl-Ethyl-Ketone Mixture. Journal of Neurol Science,
which then accumulated and averaged into months for the 57, pp. 209-219 (1982).
duration of eight months period. This research managed to [6] Hai, T.C, The Palm Oil Industry in Malaysia: From Seed to Frying
Pan, Prepared for WWF Switzerland, 2002.
reduce hexane loss from 9.5litres/MT to 6.5litres/MT which [7] Khin Cho Thin, Mya Mya Khaing, and Khin Maung Aye, Design
considered as a successful research due to huge cost saving, and Performance Analysis of Centrifugal Pump, World Academy
from January 2012 to August 2012 was RM 727,654 and the of Science, Engineering and Technology, 46, pp. 422-429 (2008).
payback period only 1.6 years. Thus rounds up the annual
saving to the industry is about RM 1.35 Million was made
by this research to the respective palm kernel oil extraction
plant.
The hexane loss is one of the critical areas where it
needs deep study to carry out to identify causes of high
consumption of hexane. The high hexane loss results in
high production cost, high fugitive gas emission, poor
quality of crude oil and the by-product. This research has
given a good lesson to overcome all the problems and issues
mentioned earlier. After the improvement in excess,
fugitive and purging losses, the hexane loss started to reduce
from 9.5lit/MT to 6.5/MT, which about 3 lit/MT saving.
This reduces the production cost and increase the net profit.
Base on the above result, this research full filled its main
aim to reduce hexane loss in improvising the process of oil
extraction from palm kernel.

ACKNOWLEDGMENTS
Special thanks to Faculty of Manufacturing
Engineering and Universiti Teknikal Malaysia Melaka
management for their support. Special thanks to Ministry of
Higher Education (MOHE) for awarding research grants
(GLuar/2012/FKP(1)/G00010) and
(PRGS/2012/TK01/FKP/02/1/T0003) which was very much
leaned in completing this research without much hurdles.
Thank you very much for the palm oil mill which gave me
the great research opportunity.

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