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RAW MATERIALS ( PALM OIL )

An edible plant oil that derived from the mesocarpof the fruit of the oil palm (Elaeis Guineensis).

While, palm kernel oil derived from the kernel ofthe same fruit or coconut oil derived from the

kernel of coconut palm (Cocos Nucifera).They differ in colour and in saturated fat content.

Palm mesocarp oil is 41% saturated while palmkernel oil and coconut oil are 81% and 86%saturated respectively.

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Reddish in colour.

Semi-solid in room temperature.

Contains several saturated andunsaturated fats in the forms of glycerol

laurate(0.1% saturated), myristate (1%saturated), palmitate(44% saturated),stearate(5% saturated), oleate(39%monounsaturated), linoleate(10%

polyunsaturated), and alpha-linolerate(0.3% polyunsaturated).

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THEAPPROXIMATECONCENTRATIONOFFATTYACIDSINPALMOIL

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Palm oil products are made using milling andrefining processes: first using fractionation, withcrystallization and separation processes to obtain

solid (stearin), and liquid (olein) fractions. Thenmelting and degumming removes impurities. Thenthe oil is filtered and bleached. Next, physicalrefining removes smells and coloration, to produce

"refined bleached deodorized palm oil", orRBDPO, and free sheer fatty acids, which areused as an important raw material in themanufacture of soaps, washing powder and otherhygiene and personal care products. RBDPO isthe basic oil product sold on the world's commoditymarkets, although many companies fractionate it

further into palm olein, for cooking oil or otherroducts.

http://en.wikipedia.org/wiki/Mill_(grinding)http://en.wikipedia.org/wiki/Refineryhttp://en.wikipedia.org/wiki/Fractionationhttp://en.wikipedia.org/wiki/Stearinhttp://en.wikipedia.org/w/index.php?title=Olein&action=edit&redlink=1http://en.wikipedia.org/wiki/Soaphttp://en.wikipedia.org/wiki/Washing_powderhttp://en.wikipedia.org/w/index.php?title=Palm_olein&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Palm_olein&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Palm_olein&action=edit&redlink=1http://en.wikipedia.org/wiki/Washing_powderhttp://en.wikipedia.org/wiki/Soaphttp://en.wikipedia.org/w/index.php?title=Olein&action=edit&redlink=1http://en.wikipedia.org/wiki/Stearinhttp://en.wikipedia.org/wiki/Fractionationhttp://en.wikipedia.org/wiki/Refineryhttp://en.wikipedia.org/wiki/Mill_(grinding)

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PALM OIL REFINING PROCESS

To remove free fatty acids, phosphatides,odouriferous matter, water as well asimpurities such as dirt and traces of metals

from the crude palm oil (CPO).

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PHYSICALREFININGVS CHEMICALREFINING

Physical refining is also known as deacidification

(deodorisation) by steam distillation in which freefatty acids and other volatile components aredistilled off from the oil using effective strippingagent which is usually steam under suitable

processing conditions.Chemical refining or also known as alkali refining is

a conventional method used to refine the CPO.

3 stages of refining processes:

Gum Conditioning and Neutralization

Bleaching and Filtration

Deodorisation

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CHEMICAL REFINING

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CHEMICAL REFINING PLANT

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CHEMICALREFINING

Alkali-neutralization-the crude oil is heated to atemperature of 8090C. Phosphoric acid of 80

85% concentration is then dosed in at a rate of0.050.2% (of the feed oil). This serves toprecipitate the phospholipids.

The degummed oil is further treated with a causticsoda (sodium hydroxide) solution. The reactionresults in the formation of sodium soap

The neutralized palm oil (NPO) is then washed

with 10

20% hot water to remove traces of soapstill present. After another stage of centrifugalseparation, the washed oil is then dried undervacuum to a moisture level below 0.05%.

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Earth bleaching-to remove colourpigments and metal ions

The neutralized palm oil is treated withbleaching earth in a similar manner as thatdescribed in physical refining. However, in

this case, the earth also removes traces ofsoap that are present.

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Deodorization-the neutralized andbleached oil is then channelled to the

deodorizer in a similar manner to that in thephysical refinery. The oil is subjected todistillation at a temperature of 240260Cand a vacuum of 25 mm Hg with directsteam injection.

The final product, called neutralized,bleached, and deodorized (NBD) palm oil is

then cooled down to 60C and passedthrough polishing filter bags before pumpingto the storage tanks.

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ADVANTAGESOF CHEMICAL REFINING

It is likely that when chemical refining wereinvented, environmental pollution and chemicalusage in food processing industry were notbecome such main issues and thus, the chemicalrefining steps involved seem to have been fully

acceptable.However, as consumers become more concern in

health implications when consuming chemicallyrefined oil and the legislation authorities

becoming more stringent on environmentalpollution, physical refining seems to be a betteralternative for food processing.

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ENVIRONMENTAL & SAFETY

Palm oil production has been documented as a

cause of substantial and often irreversible damageto the natural environment.

Its impacts include:

Deforestation

Habitat loss of critically endangered species suchas the Orang Utanand Sumatran Tiger

Significant increase in greenhouse gas emissions

Soil erosion

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Disposal problems are associated withthe processing of soapstock and mucilage.The soap is first boiled and separated with

sulphuric acid (break up the emulsion). Fattyacids produced can be separated from the acidsolution in settling tanks. The acid solution is thenneutralised and cooled with slaked lime.

Organic substances and the remainingwastewater must comply with the followingconditions for drainage (standard German values

as a guide):maximum temperature 35C

max. sulphate content due to addition of

sulphuric acid 600 mg/l.

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The quantity of wastewater from chemical wetneutralisation and the subsequent soapstockfractionation is around 0.5 m3/t of initial productunder modern production conditions. This is onlyequivalent to about 5% of the total wastewaterfrom a refinery, but because of the high organic

content and consequently the much higherChemical Oxygen Demand (COD), this aloneamounts to 50 - 60 % of the admissible total CODload of a refinery in Germany. The discharge of

wastewater must therefore be inspected toensure compliance with the relevant limit values.

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WASTEWATER In crude oil refining, a wastewater quantity of 10-25

m3/t initial product must be assumed.

Constituents of the wastewater: sodium sulphate or sodium chloride calcium phosphate fatty acids (in part as calcium soap)

mono-, di- and triglycerides Glycerin Protein Lecithin

Aldehyde Ketones Lactones Sterines

A fi ' b d d

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A refinery's wastewater output can be reducedby up to 90% if the vapour cooling water ismanaged in a circuit. A system however, which

results in higher COD concentrations in thecircuit water. The minimum requirements for thefinal discharge of refinery wastewater must takeaccount of this circumstance. However, despite the

higher COD concentration where the cooling wateris managed in a circuit, there is an overall generalreduction in pollutant load. Biologicalwastewater treatment cannot yet be described as

the most modern state-of-the-art process in view ofthe land required, the higher energy consumptionand the problem of sludge disposal.

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TABLE1:LIMIT VALUESFORTHE DISCHARGEOF

ACID SOLUTIONSFROM SOAP FRACTIONATION

Quantity 0.3 m3/t oil

Maximum temperature 3C

pH value 6.0-9.0

Settleable solids which can precipitate in 30 mins 10mg/l

Fat 250mg/l

SO4 600mg/l

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MASS BALANCE OF PALM OIL MILL