Sterilizer stations development over the past 30 years
First generation palm oil mill
Early 70s |
Capacity: 30-60 tons / hr
Machineries :
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Second generation palm oil mill
Early 80’s to 90’s |
Capacity: 30 -60 tons / hr
Machineries :
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Third generation palm oil mill
Early 90’s & beyond |
Capacity: 90-120 tons/ hr
Machineries :
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MILESTONE OF VERTICAL STERILIZER
- FFB dropping from height causes mechanical damages on to the internal parts
- FFB knocking and bruising cause high oil loss and increases FFA
- Arching problem affects discharging of SFB
- Uneven steam distribution affects sterilization
- Prolonged sterilization cycle time
- Higher steam consumption
- 10 ton FFB per charge
THE GREAT ARCH
- Vertical Sterilizer (latest version) is designed to create arching effect during sterilization (under pressure)
- This will lessen the compactness of the sterilized fruit inside the VS
- Once the discharge door is opened, the SFB bridging (arching) will collapse naturally
- No more downtime due to bridging during SFB (sterilized fruit bunch) discharge
Horizontal Sterilizer and Cages System
- FFB are loaded into cages and charged into the sterilizer for cooking
- Area taken up by horizontal sterilizer is dependent on the size of cages
- Uses a lot of cages –ranges from 40 units @ USD2800 per cage
- Uses 5 railway tracks for a 45tones/hr mill
- Modern Mill uses tippler incl. conveyor, transfer carriage, winch, indexer, etc
- Sterilization Station is very long to accommodate length of sterilizers and large marshalling yard is required
- Oil losses resulting from spilled fruitlesduring loading to cage, transfer to sterilizer and out to thresher, oil dripping from cage and sterilizer condensate.
- Triple or double sterilizing cycle is required for proper cooking.-Condensate oil cannot be recovered due to iron pick-up.-Reduced cages lifespan
- Savings of labor as less manpower is required to operate the mill
- High maintenance cost for railway, tracks, boogie wheels for cages, overhead crane/ tippler, winch / capstan, prime movers, marshalling yards upkeep.
- Pit design is required
- FFB are loaded directly into the sterilizer, NO cages are used
- Area taken up by vertical sterilizer is significantly smaller
- FFB feeding by conveyor
- Conveyor arrangement is used
- Simple FFB handling
- Smaller sterilization station with slightly higher building
- Direct filling of FFB and discharge to stripper. No spillage & oil drip. Sterilizer condensate oil is recovered to system.
- FFB cooking time is much shorter achieved due to better steam penetration
- Less workers are needed because automation features through PLC / SCADA
- Minimal maintenance cost
- Mass concrete in single level
SYSTEM COMPARISONS:VERTICAL STERILIZER –HORIZONTAL STERILIZER
ITEMS | VERTICAL STERILIZER SYSTEM | CAGE SYSTEM |
Mill layout at sterilizer station | Compact design, pit-less | Bigger area (4 times) with pits |
Labor requirement/shift(Reception-thresher) | 3 workers | 6 to 12 workers |
Steam consumption | 130-160kgs/ton FFB | 270 -350kgs/ton FFB |
Oil recovery potential | HighCondensate oil fully recoverable with minimum loss | LowCondensate oil not encouraged to be recovered (poor quality) |
Downtime and maintenance | Relatively low maintenance and breakdown (lesser machinery) | HigherMaintenance on cages,rail track, tipper/crane,cantilever, transfer car, winch/capstan,pit,sterilizer liner……. |
House-keeping | Better housekeeping.(closed system with minimum spillages, smaller floor area) | Difficult housekeeping-Oily and slippery, larger floor area, more machinery & pits |
Work hazard | SafeLess moving machines | HigherMore moving machines & pits |
Operation | Simple and safe operation (semi automatic system) | Multiple machinery & complicated operations. Mainly manual works |
CONCLUSION
- Based on the results of the mill operating on VS, the cost of operation and extraction efficiency have improved significantly
- VS system is a one-way traffic arrangement that uses cage-less & pit-less design
- VS system is more energy efficient (Steam and electrical power savings)
- VS system relatively improves food safety compares to conventional system (horizontal sterilizer)
- VS system improves operational safety and environment
Sumber : CHD Marketing Presentation
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