Engineering & Process Handbook For Palm Oil Mill

Sterilization

TOPIC 2
Sterilization

1.0 Introduction
Sterilization is the most important process in the production line. Steam is used as the medium to
transfer the necessary heat required to raise the temperature of the oil palms Fresh Fruit Bunch
(FFB). It is used because it is cheap and readily available from the operation of the boilers and
steam turbo-alternators. Moreover, it is convenient and suitable for this purpose.

The FFB delivered and received at Palm Oil Mill must be sterilized as soon as possible to avoid
the rise in Free Fatty Acid (FFA) during prolonged storage. It is of paramount impAortance that
sterilization is carried out properly and effectively. Otherwise, it will affect the recovery of oil
and kernel.

The present method of sterilization of FFB is a batch process. With well-thought of design and
planning of sterilizer layout, a continuous operation to supply sterilized FFB into the production
line to sustain the designed Mill throughput can be easily achieved.

With poor design of layout, any interruption in the supply of sterilized FFB will result in a
disruption of downstream activities which lead to, not only reduction of throughput but also the
loss of product.

The main objectives of sterilization of FFB are:-

a.Inactivation of Oil-splitting Enzymes Lipolytic enzymes responsible for the oil- splitting action
in FFB can be destroyed by heart treatment. A minimum temperature of 550c is sufficient to
render these enzymes inactive. Enzymesnot inactivated will degrade palm oil by
promoting the rise in Free Fatty Acids (FFA).

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b. Loosening of Fruitlets From The Bunch Sterilization loosens the fruitlets in the bunch and
facilitates their removal from the bunch during the stripping/threshing process.

c. Conditioning the Mesocarp For Good Oil Recovery.

During the process of sterilization, the mesocarp is softened. During digestion and
pressing processes the mesocarp will be separated from the nut which is further polished
in the depericarper drum.

d. Nut Conditioning For Better Cracking

In order to achieve good nut cracking efficiency in the Nut Crackers or Ripple mills, the
nuts must be dried to a given temperature for a given time. Normally, sterilization at a
pressure of over 40 psig for
90 minutes or more will be sufficient to ensure good stripping of fruitlets and good nut
cracking efficiency.

The main machinery in sterilization process is Sterilizer, and it is categorized as unfired

pressure vessels. Sterilizer and its related equipments will be further described in this topic.

2.0 Types of Sterilizer

Currently there are six (6) types of sterilizer available in the palm oil industry such as follows:
a. Horizontal Sterilizer
b. Vertical Sterilizer
c. Oblique Sterilizer
d. Tilting Sterilizer
e. Ball Tipper (Spherical) Sterilizer
f. Continuous Sterilizer

The most common type of sterilizer used in the palm oil industry is Horizontal Sterilizer.

a. Horizontal Sterilizer Type 1

With the increased milling capacity in modern palm oil mills, horizontal and larger size
sterilizers are now commonly used. These are cylindrical steel tanks complete with one (1) or
two (2) doors depending on the Sterilizer Station layout configuration. Their length and
diameter depend on the cage size and mill throughput. The evolution of the cage sizes and
sterilizer diameters are shown in Figure 1 (a) & (b).

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According to their length the vessels are mounted on two or more stools. The stool nearest to the
door is fitted rigidly. The others rest on rollers in order to allow for the free expansion and
contraction to which the shell is subjected by the ever changing temperatures within. The horizontal
cylindrical steel tank shell is mounted on several supports or saddles. The number of supports
required is dependent on the total length of sterilizer tank shell.

Horizontal Sterilizers offer a wide variability in effective capacity: from two (2) FFB cages, each
holding 1.5tons of FFB (i.e 3 tons of FFB per charge), to nine (9) FFB cages, each holding 2.5tons
of FFB (i.e 22.5 tons of FFB per charge), and as high as four (4) FFB cages, each holding 16tons of
FFB (i.e 64 tons of FFB per charge). They are designed as cylindrical, electrically welded steel
pressure vessels. Their diameter is either 1700mm or 2100mm or 2900mm, depending on type of
fruit cage used (for 1.5 tons or 2.5tons or 16tons). The length of the vessel is adapted to the number
of cages it should hold.

2.5mt capacity

3.5mt capacity

12mt capacity

16mt capacity

Figure 1 (a): Evolution of FFB Cage size

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Figure 1 (b): Evolution of Horizontal Sterilizer diameter

The sterilizer door covers the full diameter of the vessel. It is perfectly balanced by swivel arm
fitted on top. Owing to this design the door can swing freely to the side of the sterilizer,
allowing free access to the inside. As a general rule sterilizers have a door at one end only;
they may, however, be fitted with doors at both ends. The doors are equipped with a safety
device, which prevents opening before decompression and safety catches to prevent the doors
from being blown-out after they have been moved to their open position.

With one (1) door system, the support nearest the door is rigidly fixed whilst the rest are on
rollers to allow for free movement caused by the expansion and contraction of the tank shell
as a result of the changing temperature. However, with the two (2) door system, the support at
the centre is fixed whereas both sides of the remaining saddles are free to move.

Figure 2: Horizontal Sterilizer capacity of 2.5mt x 9 units FFB Cages x 4 units Sterilizer
(One door system)

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Figure 3: Horizontal Sterilizer capacity of 16mt x 4 units FFB Cages x 4 units Sterilizer (Two
door system).

Figure 4: Schematic view of Sterilization Station layout using Horizontal Sterilizer with Two
Door System.

All Horizontal Sterilizers are normally provided with a pair of internal rail tracks to allow the FFB
cages to be pushed in for sterilization. These are normally fabricated from square-bar or unequal
angles.

The complete sterilizer is insulated with rock wool insulation materials to prevent heat loss and for
safety reasons. Most sterilizers in used are fitted with wear liners on the lower half of the tank shell
to protect the corrosive actions of the condensate and erosion. Special care must be taken to ensure
gas-tightness of the welds joining these wear liners to the inner side of the sterilizer tank shell.

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Figure 5: Sterilizer insulated with rock wool material.

Design Requirement General

The sterilizers and all its valves and fittings must be manufactured and tested in accordance
with practice acceptable by the Factories and Machinery Department of Malaysia under the
Ministry of Labor. They are normally designed and manufactured under the British Standard
and ASME Code of Practice.

Figure 6: General arrangement of Horizontal Sterilizer with mountings and piping.

Figure 7: Horizontal Sterilizer with steam piping and safety valve.

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Two types of door shutting devices are being applied: the bayonet type and the umbrella type. Both
types meet three important requirements:
Absolute safety in everyday use.
Perfect alignment to prevent leaking.
Simple and rapid opening and shutting by unskilled labor.

Figure 8: Pneumatically controlled valves for Horizontal Sterilizer

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Figure 10: Front view of Transfer Carriage

Figure 11: Side view of Transfer Carriage

Figure 9: Pneumatic valve program for operation of Horizontal

Sterilizer

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a-1. Transfer Carriage (with or without Cage Push Out mechanism)

Transfer carriage system is for variety of different cage sizes used in a typical palm oil mill. For
cage size from 3.5ton; 5ton to 7.5ton are typically twin cage or triple cage per transfer carriage
movement. For cage size of 10ton; 15ton to 16ton could use single cage or twin cage transfer
carriage depending on the design of layout and proper calculation of time study.

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Figure 12: Twin Cage Transfer Carriage

A few different types of design of transfer carriage for cage push out:
Tilting type transfer carriage (using two cylinders to jack up platform).
Undertow type transfer carriage (using hydraulic motor to push out).
Indexer type transfer carriage (using cylinder to push cage out).
Empty type transfer carriage (cage charging and discharging of using Indexer mounted before
each transfer carriage) Transfer Carriage c/w Rotary Lock Hydraulic System is designed to
provide a faster yet smoother cage transfer operation from one lane to another.

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Transfer carriage is positioned precisely without much adjustment as compare to latching cylinder
used in earlier design.
Rotary Lock c/w bearings and other accessories provided driven by compact Hi Performance High
Torque Low Speed.
Fully automatic locking and un-locking thus alignment of carriages.
Manual / Automatic available with Proximity sensors provided for inter-locking.
Actuators used: Carriage traveling forward & reverse.
Cage discharge: either hydraulic motor or hydraulic cylinder.
Carriage alignment & latching: Hydraulic driven Rotary Lock is preferred now to two
horizontally mounted tie-rod cylinders provide locking & latching of carriage.

Figure 13: Transfer Carriage without Cage Push Out mechanism

Figure 14: Transfer Carriage with Cage Push Out mechanism

a-2. Undertow System

Undertow system is used for FFB Cage movement in Horizontal Sterilizer. Undertow system is
designed to suit the robustness of use while maintaining cost effectiveness and to meet requirement
of continuous production. Its component provides higher uptime, increases

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system efficiency and reduces power losses due to low internal leakage.

Two types of Undertow System namely:

i. Undertow Conveyor
ii. Undertow Link Chain

Figure 15: Undertow Conveyor

Figure 16: Undertow Conveyor for Cage movement from Tipper

Hydraulic system used in this application required a hydraulic power unit (HPU) to drive the
high torque low speed hydraulic motor that is directly attached to a sprocket of undertow
conveyor chain mounted on a frame with tipping dogs to push the cage. The movement could be
forward and reverse via the directional control valve. The system could be customized to suit the
requirement:
HPU: Electric motor sized up for maximum system operating pressure at 250 bar. Built-in
over-load & over-torque protection adjustable safety relief valve incorporated within. HPU is
normally located near the actuator.

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Controls: Smooth and reliable spool movement. Excellent inching operation by precision
machined spool notches. Variable speed control. Installed on top of HPU.
Actuator: Radial piston motor fitted with planetary reducer. Hydraulic motor is of latest
generation of high-torque low speed drive, providing high starting and running torque minimizing
internal leakage.

Figure 17: Undertow Link Chain for Cage movement from Transfer Carriage

Figure 18: Undertow System for Cage movement into Sterilizer

a-3. Indexer System

Indexer System is also used for FFB Cage movement in Horizontal Sterilizer. Indexer system as
Cage material handling that eliminates the need and use of tractors, bulldozers, capstans and
winches of for Horizontal Sterilizer with Double Doors in Sterilization Station. The system is for
owner looking for a process controlled instead of human dependable in sterilization station. Typical
Cage size used varies from 10ton; 15ton; 16ton to 20ton and Sterilizer Diameter of 2700mm and
3200mm.

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Figure 19: Indexer System for Cage movement

Indexer system is a total material handling solutions in sterilizer station. The latest generation is
less maintenance, bumper-to- bumper cage movement for single cage and/or twin cage
movement.

The indexer system package provides options on various equipment for material handling of
Fresh Fruit Bunches:
Loading Ramp via FFB Conveyors to Feeding Point
FFB Cage Feeding to Dry End Transfer Carriage
Dry End Transfer Carriage to move in FFB Cages to Sterilizer
Moving out SFB Cages from Sterilizer to Wet End Transfer Carriage
Wet End Transfer Carriage to Cage Tipper, to SFB Hopper, via SFB Conveyor to Threshing
Station
Moving Empty Cage from Tipper to Feeding Point

Figure 20: Indexer System for Cage movement between Tipper and Horizontal Sterilizer

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Figure 21: Indexer System for Cage movement via Cantilever Drawbridge from/ to
Horizontal Sterilizer
sterilizer station and then to threshing and press station. This leads to significant
improvement in productivity and enhanced throughput.

Figure 23: Schematic view of Sterilization Station layout using CMC System.

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Indexer
Mechanism

Figure 22: Indexer System for Horizontal

Sterilizers door.

a-4. Compact Modular Continuous (CMC) System CMC systems as Cage material handling for
Horizontal Sterilizer with Single Door in Sterilizer Station for owner looking for an enhanced
automated material handling and steam management process controlled in a smaller foot print area.
Typical Cage size used is 10ton for a single door 20ton Sterilizer or 15ton for a 30ton Sterilizer,
with diameter of 2700mm and 3200mm, respectively. The Modular design is suitable for a 20tph to
120tph mill.

CMC systems derived the cage movement from earlier generation of Indexer system. Indexer
movement is based on twin cage. As the building footprint is small, thus this is compact, modular,
continuous run material handling system for the sterilization process to perform synchronization
and control of flow of FFB from loading ramp to

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Figure 24: CMC with Indexer System for Horizontal Sterilizer and Cantilever Drawbridge.

Figure 25: CMC with Indexer System for Horizontal Sterilizers door.

The CMC package provides with an enhanced technology on various mechanical; power
transmission and automation equipment from Loading Ramp Station to Threshing Station to the
following flow:
Loading Ramp via various FFB Conveyors to Feeding Point.
Feeding Point is utilizing FFB Hopper as storage buffer for Tipper.
Moving out SFB Cages from Sterilizer to Tipper via Indexer.
Tipper to SFB Hopper, via SFB Conveyor to Threshing Station.
FFB Hopper to fill empty Cage in Tipper.
Moving in FFB Cages from Tipper to Sterilizer via Indexer.
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Figure 26: CMC with Indexer System for Cage movement between Tipper and Horizontal
Sterilizer.

Some of important recognized benefits are:

Improvement in working conditions and safety for operators as well as reducing manual handling
of the cages.
Ease of monitoring: Monitoring of movement of indexer is via automation system. Control Panel
grouping are available via Integrated Indexing Systems or Simple Indexing Systems. Remote
Console Panel controls different equipment to perform multiple functions as well as
interlockAing.
Ease of operation: Easy to operate using a single touch control on push buttons as well as Remote
Consoles.
Control: Auto/Manual/By-Pass -- Auto mode will move the hydraulic cylinder on indexer to
forward and backward stroke until the cage moves forward by a distance of cage length. Manual
operation would require operator to

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operate via push buttons on Remote Consoles. By-pass operation is for operator to
operate via Local Panels nearby each grouping of equipment.

Figure 27: CMC Systems Control Panel via Integrated Indexing System.

a-5. Compact Hydraulic Wire Rope Winch System Wire rope winch system is design for
Horizontal Sterilizer, line pull for position in between sterilizer rail track line. Typically
used for replacement of double drum capstan driven by electric motor gear-motor as well
as for cage handling using winch design.

The main advantage of hydraulic driven winch is on the following:

It comes with wire rope and hook; manual or solenoid control valve; starter panel for
Hydraulic Power Unit (HPU), option of stainless steel (SUS) tubing or mild steel
tubing.
Hi-performance High Torque Low Speed radial piston motor specially designed for
palm oil industry with option of free-wheeling.
Option of variable winch speed if choosing solenoid directional control valve.
HPU is sized up for maximum line pull force with extra safety factor of 1.5 times.
Width of Compact Winch Drum is standardized to less than one meter for all different
sizes.
Built-in over-load & over-torque protection adjustable pressure relief valve for
preventing wire rope to snap.
Full drum reversal at maximum line speed capability. For maintaining wire rope in
winch drum when not in used.
The following Winch Drum capacity is made available for pulling a train of cages of different
capacity (3.5ton / 5ton / 7.5 ton / 10ton / 15ton). Wire rope used is of 6x36 IWRC from 16mm;
18mm; 20mm to 22mm.
3-ton line pull capacity for 40-ton
4/5-ton line pull capacity for 75 to 90 ton
7-ton line pull capacity for 120ton
10-ton line pull capacity for 150ton
12-ton line pull capacity for 180ton

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Hydraulic system used in this application required a hydraulic power unit (HPU) to drive a high
volumetric and mechanical efficiency high torque low speed hydraulic motor that is directly
attached to a mechanical winch drum. The drum outer surface machined with grooves for easy wire
rope pay-in and out. The movement could be forward and reverse via a manual control valve
installed on top of the winch structure or mounted at an elevated platform.

Both Horizontal Wire Rope Winch and Vertical Capstan with Hydraulic Drive are available.

Figure 28. Hydraulic Power Unit and its connection to Winch Drum using Stainless Steel or
Mild Steel Tubing

Figure 29. Side view of Hydraulic Driven Winch Drum

Figure 30. Front view of Hydraulic Driven Winch Drum complete with Wire Rope

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