perbandingan type sterilizer pmks m. ichsan · rachis syarat lepasnya brondolan dari spikelet...

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.

[email protected]

HP : 0811-99-34-10

mailto:[email protected]



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 = 100 OCc



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


BOILER

SU

PE

R H

EA

TE

R TURBIN

TO STERILISER

TO PROCESS

MAKE UP STEAM

STEAM FLOW CHART – POM

SUPERHEATED BOILER









P = 4 bar abs T = 143.6 OC

1

2

3a

3b 4

4


STEAM SEPARATOR

5


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

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


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


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


TBS in =

30 C

TBS out =

85 C

Evaporation 10 %

Small vertical stz cap 1 ton

FFB. Max temp of steam

130 C.



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


+ =

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


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



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


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


+ =

= 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)

perbandingan type sterilizer pmks m. ichsan · rachis syarat lepasnya brondolan dari spikelet...

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