MILL SUPPORT AND QUALITY CONTROL DIREKTORAT ENGINEERING PERBANDINGAN TYPE STERILIZER PMKS M. Ichsan Grand Sahid Jaya Hotel, jakarta, 18 Oktober 2017
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MILL SUPPORT AND QUALITY CONTROL DIREKTORAT ENGINEERING
PERBANDINGAN TYPE STERILIZER PMKS
M. Ichsan Grand Sahid Jaya Hotel, jakarta, 18 Oktober 2017
SEKILAS TENTANG MUHAMMAD ICHSAN Pekerjaan &Jabatan : Mill Support and Quality Control Division Head
Institusi dan alamat : PT. ASTRA AGRO LESTARI TBK
Jl. Pulo Ayang Raya Blok OR-1 Kawasan Industri – Pulogadung
Jakarta Timur - 13930
Telp 021 – 4616555 (ext. 5206) Fax : 021 – 461668
Kewarganegaraan : Indonesia.
Kualifikasi akademik : S1 – Teknik Mesin – ITS
Pengalaman Kerja : PT. Astra Agro Lestari 1994 s/d sekarang,
Dosen POLMAN ASTRA – JURUSAN TPHP, 2008-2012.
PEMBICARA UTAMA WORKSHOP NASIONAL – Up-Dating
Teknologi Pengolahan Kelapa Sawit, HOTEL BIDAKARA, 26 –
27 MEI 2010.
PEMBICARA – PALM OIL SEMINAR ; Improving the Efficiency
of Palm Oil Process and Need of Right Palms and Valves for
Various Application. Hotel ARYA DUTA – Jakarta, 28 April 2011.
HP : 0811-99-34-10
TYPE OF STERILIZER
STERILISASI : Adalah tahap pertama kali minyak dan kernel dikutip, bila proses ini gagal maka proses
selanjutnya akan bermasalah/gagal.
TUJUAN STERILISASI :
• KIMIAWI : Menon-aktifkan enzym Lipase yg menaikkan FFA
• FISIKA : Dehydrasi buah
• Memudahkan pelepasan brondolan di Thresher.
• Melunakkan daging buah (mesocarp) sehigga mudah dilumatkan di digester.
• Memudahkan pengutipan minyak.
• Mengkondisikan nut mudah dipecahkan.
BASIC CONCEPT STERILISASI
OUTER FRUIT
MIDLE FRUIT
INNER FRUIT
RACHIS SYARAT LEPASNYA BRONDOLAN DARI SPIKELET ADALAH DENGAN
MENGGUNAKAN STEAM PADA TEKANAN ATMOSPHERE, TEMPERATUR 100 C
SELAMA 20 – 40 MENIT
Mongana Report – hal – 35 – (figure 55)
SYARAT MATINYA ENZYM LIPASE YANG MENAIKKAN FFA ADALAH TEMPERATUR
55 oC
STORK PALM OIL REVIEW – hal – 3
KONDUKSI SILINDER BERLAPIS pada FRUIT
C
B
r4
r3
r2 r1
T1
T2
T3
T4
q
Lapisan udara film
Lapisan mesocarp
Lapisan shell
Lapisan kernel
Lapisan steam
T0
A
D
q = ΔT
= Σ Rth
ΔT
RD + RC + RB + RA
q = ( T4 - T0 )
2πkDLD
ln (r4/r3)
2πkCLC
ln (r3/r2)
2πkBLB
ln (r2/r1)
2πkALA
ln (r1) + + +
132oC to 85o C
DAYA SERAP PANAS
PRESSURE STERILISATION (PS)
VS
ATMOSPHERIC STERILISATION (AS) :
PS/AS = 166/90 = 1.84
PS = 1.84 X AS
“Pressure sterilisation daya serap panas dari steam lebih effektif 1.84 kali dibandingkan dengan Atmospheric Sterilisation”
Inilah mengapa di Atmospheric Sterilisation untuk mematangkan lagi fruits disterilisasi di POST HEATING COOKER, sebelum masuk ke DIGESTER dan PRESSING.
Instantaneous throughput of steam during a triple peak sterillization of one
tonne of bunches ( consumption limited to 1000 kg/hour )
Mongana Report hal 83 (figure 22)
Kg/C
m2
Total Consumption : about 260 kg
Zona of variable troughput
0 to 200 kg/hour
100Kg of steam
Kg o
f ste
am/h
our p
er to
nne
of
bunc
hes
1
2
3
0
200
400
600
800
1000
10 20 40 50 60 30 Time (Minute) 10 50 40 20 30 80 70 60
32
8
2
ltr Air/K
g S
tea
m
D
B
No
rma
l
Blo
wd
ow
n
No
rma
l
Blo
wd
o
wn
Sw
e
ep
in
g
Blo
wd
ow
n t
rou
gh
t a
irve
nt
Sw
ee
pin
g
Blo
wd
ow
n
Blo
wd
ow
n
tro
ug
ht
airve
nt
Continuous blow off
A C E
KEBUTUHAN STEAM VS PEMBUANGAN UDARA
EVAPORATION in STERILISATION R
ela
tive P
resu
re (
Kg
/cm
2)
Time (in minutes) 15 45 30 60 75 90
Tem
p in
th
e r
ach
is o
C
30ºC
40ºC
50ºC
60ºC
70ºC
80ºC
90ºC
100ºC
110ºC
120ºC
130ºC
1.8
2.2
2.8
1
2
3
Hasil perebusan yang
optimal untuk
mendapatkan
pengutipan minyak
dimana kandungan
moisture di pericarp
10 % - 14 %.
STORK – PALM OIL
REVIEW hal 15
OPERATIONAL IMPROVEMENT MENAIKKAN THROUGHPUT DARI 30 KE 50 TPH
Cycle Time
Interval waktu
Interval waktu
Stz #1
Stz #2
Stz #3
~
FEED WATER PUMP
BACK PRESSURE VESSEL
BOILER TURBIN
TO STERILISER
TO PROCESS
MAKE UP STEAM
STEAM FLOW CHART – POM
SATURATED BOILER
P = 1 bar abs T = 80 OC
P = 21 bar abs T = 80 OC
P = 21 bar abs T = 100 OCc
P = 21 bar abs T = 215 OC
P = 19 bar abs T = 209 OC
P = 4 bar abs T = 143.6 OC
1
2
3a
3b
STEAM SEPARATOR
5
P = 4 bar abs Camp 90%
6 9
STEAM TRAP
4
5 6
~
FEED WATER PUMP
MAKE-UP
WATER
PUMP
BACK PRESSURE VESSEL
BOILER
SU
PE
R H
EA
TE
R TURBIN
TO STERILISER
TO PROCESS
MAKE UP STEAM
STEAM FLOW CHART – POM
SUPERHEATED BOILER
P = 1 bar abs T = 80 OC
P = 21 bar abs T = 80 OC
P = 21 bar abs T = 100 OCc
P = 21 bar abs T = 215 OC
P = 21 bar abs T = 260 OC
P = 19 bar abs T = 250 OC
P = 1 bar abs T = 80 OCc
P = 4 bar abs T = 80 OC
P = 4 bar abs T = 143.6 OC
1
2
3a
3b 4
4
P = 21 bar abs T = 260 OC
STEAM SEPARATOR
5
P = 4 bar abs T = 150 OC
6
7
8
9
STEAM FLOW CHART SATURATED & SUPERHEAT BOILER
1a
2 3a
6,9
3b
s = konstan
hcs hs
PROPERTIES SATURATED BOILER FOR PROCESSING
Atmospheric Pressure CS
BPV 4 Bara
BPV 3 Bara (CS)
hhz
1a
2 3a
6
4 3b
5
7
8
9
Sensible heat
= m cp Δt Latent
heat Sensible heat =
m cp Δt
hf hhz hsh
s = konstan
Mass balance 4 Bara
mf + msh = mg
mg > msh…...................... (1)
Energi balance 4 Bara
mf.hf + msh.hsh = mg.hg
mg.hg > msh.hsh….............(2)
hsh > hg…..........................(3)
PROPERTIES SUPERHEATED BOILER FOR PROCESSING
BPV 4 Bara
BPV 3 Bara (CS)
Atmospheric Pressure CS
hcs
OPERATIONAL COMPARATION NO ITEM EVALUASI CONTINUOUS HORISONTAL HORIZONTAL INDEXER VERTICAL/OBLIQUE Keterangan
Cost Of Investment 1,125 1,010 1,019 1 (investment index)
Preelemeneries, Mechanichal, Earth work and civil,
Building, Elektrical, Workshop equipment, Anciliary
Building, Piping work, Fire fighthing equipment,
Material for commisioning, Lab Equip
Investasi rumah RUMAH : lebih sedikit OVS RUMAH: banyak/16 RUMAH: sedikit/8 RUMAH: sedikit/6 Jumlah mesin atau bangunan.
Luas areal 8 Ha 10 Ha 10 Ha 10 Ha
2 Man power process 4 14 (1 line) 8 (1 line) 6 1 Shift & 1 Line dari L. Ramp ke Tresher
3 Cost Operasional 1.24 1.54 (45 Tph) / 1.56 (60 Tph) 1.41 (60 Tph) 1 (cost index) Utilitas 80%, Cost index = 129.74
4 Operation simple/automatic ribet/manual simple/automatic simple/automatic
5 Maintenance Maintenance Chain + hidroulic Maintenance lorry + hidraulic Maintenance lorry + hidraulic Maintenance hidraulic Sistem TPM
Process Control
Dobi 2,94 2,62 2,72 2,65 Kualitas Buah Average TBS inti
Oil Sebelum Bunch Press 2,04 2,83 2,60 5,11 % OWB on sample
Oil Sesudah Bunch Press 0,65 0,92 0,71 1,05 % OWB on sample
Oil in Liquor 3,92 7,69 3,70 5,34 % OWB on sample
Volume Liquor 8,63 5,02 8,33 6,18 % on TBS Olah
Oil Condensate 10,81 1,26 1,40 13,10 % OWB on sample
Volume Condensate 13,15 18,61 19.15 16,23 % on TBS Olah
Volume Limbah ± 63% ± 50% ± 50% ± 48% % on TBS Olah
7 Steam consumption (Kg/Ton TBS) 600/350 550/330 520/300 500/280 Steam for Processing/Steam for Sterilizer
8 Power consumption 18 KW/ton TBS 20 KW/ton TBS 20 KW/ton TBS 18 KW/ton TBS Hanya St. sterilizer
9 Kemampuan sebagai storage Loading ramp saja Loading ramp + lorry Loading Ramp saja Loading ramp saja Dihitung buffer untuk terima TBS
Safety Health and Environment
Emisi sedang sedang sedang sedang
Safety safety Unsafe relatif safe relatif safe Unsafe karena banyaknya handling
Operator Maintenance 1. HPU Hydroulic 1. Feeding & Discharge Area 1. Feeding & Discharge Area 1. Feeding & Discharge Area
2. Railtrack 2. Railtrack & Tipper 2. HPU Hydroulic
3. HPU Hydroulic 3. HPU Hydroulic Automation
Noise (Kebisingan) Tidak Ada standard standart standard
1
10
6
TERIMA KASIH
TOP DOOR OF STERILISER
USED TO FILL FFB
IMPROVEMENT : auger digantikan dgn STEAM FLUSHING
Y
X
FROM FFB FEEDING CONVEYOR
BUNCH CONDITIONER
INLET FLAP VALVE
OULET FLAP VALVE
LIVE STEAM INJECTION
TWO DECK CONVEYOR
TO THRESHER STERILISED
BUNCHES
OUTER
FRUIT
MIDLE
FRUIT
INNER
FRUIT
RACHIS
SYARAT LEPASNYA BRONDOLAN DARI SPIKELET
ADALAH DENGAN MENGGUNAKAN STEAM PADA
TEKANAN ATMOSPHERE, TEMPERATUR 100 C
SELAMA 20 – 40 MENIT
SYARAT MATINYA ENZYM LIPASE YANG
MENAIKKAN FFA ADALAH TEMPERATUR 55 oC
Mongana Report – hal – 35 – (figure 55)
STORK PALM OIL REVIEW – hal – 3
OUTER
FRUIT
MIDDLE
FRUIT
INNER
FRUIT
RACHIS
TR
TS
Penampang TBS dan Dimensinya
qCOND = k A R
TS – TR =
R
140 - 30 k A
(Panas yang diterima oleh buah) (Panas diberikan steam)
Panas Latent = hfg
PRESSURIZE SYSTEM
OUTER
FRUIT
MIDDLE
FRUIT
INNER
FRUIT
RACHIS
TR
TS
Penampang TBS dan Dimensinya
qCOND = k A R
TS – TR =
105 - 30 k 2A
(Panas yang diterima oleh buah) (Panas diberikan steam)
Panas Latent = hfg
ATMOSPHERIC SYSTEM
¼ R
PIECES OF
CRUSHED FRUIT
udara
BODY STZ
HEAT LOSS
STEAM
CONDENSATE
CAGES
HEAT TRANSFER
isolator
Horizontal Steriliser
kudara = 0,0285
W/(kg.K), at T = 60 oC
kf = 0,687 W/(kg.K),
at p = 3 barg
kg = 0,029 W/(kg.K),
at p = 3 barg
Instantaneous throughput of steam during a triple peak sterillization of one
tonne of bunches ( consumption limited to 1000 kg/hour )
Mongana Report hal 83 (figure 22)
Kg
/Cm
2
Total Consumption : about 260 kg
Zona of variable troughput
0 to 200 kg/hour
100Kg of steam
Kg
of ste
am
/ho
ur
pe
r to
nn
e o
f
bu
nch
es
1
2
3
0
200
400
600
800
1000
10 20 40 50 60 30
Time (Minute)
udara
HEAT LOSS
STEAM
CONDENSATE
HEAT TRANSFER
isolator
Vertical Steriliser
BODY STZ
udara
HEAT LOSS
STEAM
CONDENSATE
HEAT TRANSFER
isolator
Continuous Steriliser
BODY STZ
STORK PALM OIL REVIEW – hal 23
Cp, TBS = 0.6 kcal/kg oC
Cp, TBS = 2.52 kj/kg oC
Cp,f = 4,217 kj/kg oC
~
FEED WATER PUMP
BACK PRESSURE VESSEL
BOILER
SU
PE
R H
EA
TE
R TURBIN
TO STERILISER
TO PROCESS
MAKE UP STEAM
CONTINUOUS STERILISATION
SUPERHEATED BOILER
P = 1 bar abs
T = 80 OC
P = 21 bar abs
T = 80 OC
P = 21 bar abs
T = 100 OCc
P = 21 bar abs
T = 215 OC
P = 21 bar abs
T = 260 OC
P = 19 bar abs
T = 250 OC
P = 1 bar abs
T = 105 OC
1
2
3a
3b 4
4
P = 21 bar abs
T = 260 OC
STEAM
SEPARATOR
5
P = 4 bar abs
T = 150 OC 6
9
1a
2 3a
6
4 3b
5
7 9
Sensible heat
= m cp Δt Latent
heat Sensible heat =
m cp Δt
LATENT HEAT FOR
STERILISATION
CS - SUPERHEATED STEAM
Pressure
drop
~
FEED WATER PUMP
BACK PRESSURE VESSEL
BOILER TURBIN
TO STERILISER
TO PROCESS
MAKE UP STEAM
CONTINUOUS STERILISATION
SATURATED BOILER
P = 1 bar abs
T = 80 OC
P = 21 bar abs
T = 80 OC
P = 21 bar abs
T = 100 OCc
P = 21 bar abs
T = 215 OC
P = 19 bar abs
T = 209 OC
P = 1 bar abs
T = 100 OC
1
2
3a
3b
STEAM
SEPARATOR
5
P = 4 bar abs
Camp 90% 6 9
STEAM TRAP
1a
2 3a
6
3b
9
s = konstan
CS - SATURATED STEAM
LATENT HEAT FOR
STERILISATION
Pressure
drop
JENIS-JENIS PROSES HEAT TRANSFER
T2 T1
T1 > T2
q”
FLUIDA BERGERAK,
T∞
Ts > T∞
Ts
q1”
q2”
Surface, T1
Surface, T2
KONDUKSI KONVEKSI RADIASI THERMAL
KONDUKSI MELALUI
BENDA PADAT ATAU
FLUIDA YANG DIAM
KONVEKSI DARI SUATU
PERMUKAAN KE FLUIDA
YG BERGERAK
RADIASI NETTO
PERTUKARAN PANAS
ANTARA DUA PERMUKAAN
EVAPORATION in STERILISATION R
ela
tive P
resu
re (
Kg
/cm
2)
Time (in minutes) 15 45 30 60 75 90
Tem
p in
th
e r
ach
is o
C
30ºC
40ºC
50ºC
60ºC
70ºC
80ºC
90ºC
100ºC
110ºC
120ºC
130ºC
1.8
2.2
2.8
1
2
3
Pressure Sterilisation
TBS in =
30 C
TBS out =
85 C
Evaporation 10 %
Small vertical stz cap 1 ton
FFB. Max temp of steam
130 C.
Sensible heat diterima buah
Cp = 0.6 kcal/kg oC
Cp = 2.52 kj/kg oC
Latent heat diserap buah
MOLLIER CHART
P = 1 bar
P = 2.7 bar
T =
30 C
T =
85 C
T =
130 C
hg,130 hf,130
h85
hf,85
Sensible
heat diserap
TBS
Latent heat
diserap TBS
Laten heat
diberi
steam
∆T
Pressure Sterilisation
TBS in =
30 C
TBS out =
85 C
Evaporation 10 %
Small vertical stz cap 1 ton
FFB. Max temp of steam
130 C.
Sensible heat diterima buah
Latent heat diserap buah
QS = 900 kg x 2.52 kJ/kg oC x (85 – 30) C
QS = 124,740 kJ
QL = 100 kg x (hg,130 – hf,85) kJ/kg
QL = 100 x (2718.9 – 355.75)
QL = 236,315 kJ
Latent heat steam T = 130 C
Qfg = (hg,130 – hf,130) kJ/kg
Qfg = (2718.9 - 546.11) kJ/kg
Qfg = 2173 kJ/kg
Panas Total yang diterima oleh 1000 kg FFB :
Sensible heat diterima buah Latent heat diserap buah
Latent heat steam T = 130 C
+ =
QS = 124,740 kj QL = 236,315 kj
= 361,055 kj
Steam Consumption (kgs steam/ton FFB) :
Sensible heat diterima buah Latent heat diserap buah +
=
= 361,055 kj / 2173 kj/kg = 166 kgs steam/ton FFB
Pressure Sterilisation
Atmospheric Sterilisation
TBS in
30 C
TBS out
85 C
Evaporation 3 %
MOLLIER CHART
P = 1 bar P = 1 bar
T =
30 C
T =
85 C
T =
100 C
hg,130
hf,130 h85
hf,85
Sensible
heat
diserap
TBS
Latent heat
diserap TBS
Laten heat
diberi
steam
∆T
Atmospheric Sterilisation
TBS in =
30 C
TBS out =
85 C
Evaporation 3 %
Actual continues stz. Max
temp of steam 100 C, in 1
ton FFB
Sensible heat diterima buah
Latent heat diserap buah
QS = 970 kg x 2.52 kJ/kg oC x (85 – 30) C
QS = 134,442 kJ
QL = 30 kg x (hg,100 – hf,85) kJ/kg
QL = 30 x (2674.9 – 355.75)
QL = 69,575 kJ
Latent heat steam T = 130 C
Qfg = (hg,100 – hf,100) kJ/kg
Qfg = (2674.9 - 418.87) kJ/kg
Qfg = 2256 kJ/kg
Panas Total yang diterima oleh 1000 kg FFB :
Sensible heat diterima buah Latent heat diserap buah
Latent heat steam T = 100 C
+ =
= 204,017 kj
Steam Consumption (kgs steam/ton FFB) :
Sensible heat diterima buah Latent heat diserap buah +
=
= 204,017 kj / 2256 kj/kg = 90 kgs steam/ton FFB
QS = 134,442 kJ QL = 69,575 kJ
DAYA SERAP PANAS
PRESSURE STERILISATION (PS)
VS
ATMOSPHERIC STERILISATION (AS) :
PS/AS = 166/90 = 1.84
PS = 1.84 X AS
“Pressure sterilisation daya serap panas dari steam lebih effektif 1.84 kali dibandingkan dengan Atmospheric Sterilisation”
Inilah mengapa di Atmospheric Sterilisation untuk mematangkan lagi fruits disterilisasi di POST HEATING COOKER, sebelum masuk ke DIGESTER dan PRESSING.
Menaikkan Throughput Steriliser
CC = Kapasitas Cage/lorry, (Ton)
nC = Jumlah Cage/lorry dalam satu steriliser
ns = Jumlah steriliser
Cycle time = Waktu dari tutup pintu ke tutup pintu stz, (menit)
60 = konstanta, 1 jam = 60 menit.
timecycle
60 x n x n x C STZ THROUGHPUT SCC
Menaikkan Throughput Steriliser
CC = Menaikkan Kapasitas Cage/lorry, (Ton)
nC = Jumlah Cage/lorry dalam satu steriliser
Cycle time = CT = Waktu dari tutup pintu ke tutup pintu stz, (menit)
timecycle
60 x n x n x C STZ THROUGHPUT SCC
= Pengisian lorry yg maksimal, kapasitas lorry diperbesar.
= steriliser diperpanjang
nS = Jumlah steriliser
= unit steriliser ditambah.
= cycle time dikurangi dengan cara menambah supply
steam dan by pass steriliser.
TBS TON
STEAM TON 30.025.0 Ratio
NOTE : Steam dianggap memenuhi proses bila tekanan di
BPV selalu konstan 3 barg pada throughput berapa pun.
BY PASS STERILIZER
(exhaust peak 3 stz #1 to start up steam inlet peak 1 stz #1)
By Pass steriliser
Tahap-tahap Menaikkan Throughput Steriliser
Stz Throughput
60 x n x n x C CT Time Cycle SCC
1. Tentukan Throughput Steriliser
2. Tentukan Cycle Time
3. Tentukan Interval waktu antara steriliser
sn
CT waktu Interval
Cycle Time
Holding Time
Deaeration Penetration
Open - close
Blow off
Cycle Time
Interval
waktu
Interval
waktu
Stz #1
Stz #2
Stz #3
GRAFIK BPV SLS2 3.2 BARG KONSTAN
(THROUGHPUT 50 TPH)
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