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MALAYSIAN
OIL SCIENCE
AND
TECHNOLOGY
Vol. 27 No. 2 (2018)
Hybrid OxG Palms: GM Soy: High-Yield, GM-Canola for LC
High Oleic Oils High Oleic Oils ω3 Oils
Coconut Revival: New Products
New Technologies
in PO Milling
Innovations: Food
Quality & Safety
Disruptive IR 4.0
Transforming the
PO Industry
USD 12.00/RM 30.00 • FREE FOR MEMBERS
THE PUBLICATION OF THE MALAYSIAN OILand
Malaysian Oil Science SCIENTISTS’
Technology 2018AND
Vol. 27TECHNOLOGISTS’
No. 2 ASSOCIATION
a
MALAYSIAN OIL SCIENTISTS’ AND TECHNOLOGISTS’ ASSOCIATION
(PERSATUAN AHLI SAINS AND TECHNOLOGI MINYAK MALAYSIA)
29th ANNUAL GENERAL MEETING
27th April 2019 at 9am
Hall 2, Level 4 Crystal Crown Hotel
Petaling Jaya, Selangor
The Future of Palm Oil Industry
Through IR 4.0
1-Day Best Practices Workshop by
MOSTA & FUSIONEX
Thursday, 25 April 2019
Fusionex office, Level 12, Tower A, Plaza 33,
No. 1 Jalan Kemajuan, Section 13, 46200 Petaling Jaya
Limited Places
200 max (contact MOSTA)
Malaysian Oil Science and Technology (MOST)
INTERNATIONAL ADVISORY COMMITTEE: COVER STORY
James Fry (LMC,UK) While there are much geopolitical turmoil and
Dennis J. Murphy (Murphy Biotechnology
demographic problems in many parts of the world,
Consultancy, United Kingdom)
great strides have been made in agricultural oil and
Paul Hovelmann (Cognis, Holland/Germany)
Thomas Mielke (ISTA Mielke, Germany) food crops. Record yields of soybean are coming from
Yusof Basiron (Malaysia) highly mechanised US farms (Barton) and higher-
Marc Kellens (Desmet Ballestra Group, Belgium) yielding, high-oleic GM soybeans are benefiting the
farmers. Hybrid OxG oil palms (Teo & Wong) have been
EDITORIAL BOARD developed for higher oleic oils, higher tocotrienols and
Chairman many other useful traits. Except for the coconut (Dayrit
S.H. Goh +6012-363 1948 & Salum) there has generally been an oversupply of
+603-7958 1391 edible oils and this has led to much trade frictions
+614-3194 0825 giving rise to intense negative campaigns against
chmgsh@yahoo.com tropical oils with perceived sustainability issues (Park).
chmgsh@gmail.com Additionally low uptake from the biodiesel sector
Members: coupled with volatile petroleum crude have led to
Tang Thin Sue depressed prices (Park; Benny Lee) of most edible oils.
S.F. Cheng
Chuah Cheng Hock High quality palm oils are available from present
M.R. Chandran plantations with the adoption of best practices (Lee)
S. Krishnan and recommendations for new quality guidelines of
Teh Soek Sin CPO (3.5% FFA & DOBI > 2.5) for food uses have been
Mah Siau Hui made (Kellens et al). For new food safety demands on
levels of process contaminants from the EU, refining
MOSTA Council Members 2017/2018 options and affordable modifications to present
Academician Emeritus Prof Tan Sri Datuk Dr Augustine S H Ong physical refining operations have been detailed
Mr S. Krishnan (Kellens et al; Lee).
Prof Dr Chuah Cheng Hock
Ms Christine Ong May Ee Meanwhile, GM canola has been able to produce
Dr Goh Swee Hock long chain omega-3 oils (Abeywardena) which will
Datuk Dr Choo Yuen May provide the much needed nutrient as natural marine
Mr MR Chandran fish resources are being exhausted. Soy and oil palms
Mr Lee Keong Hoe can soon provide high oleic oils much demanded by
Ms Khor Yu Leng consumers while MCT oils from the coconut and palm
Tunku Alina Alias kernels are beginning to be appreciated as replantings
Printing:
of coconut will hopefully fulfill new demands (Dayrit &
Percetakan Soon Lee Heng Sdn Bhd Salum). The oil palm (Teo & Wong) has specialty Elaeis
15, Jalan Besar, Selayang Baru cultivars to provide high tocotrienols and omega-7
68100 Batu Caves, Selangor oils, as well as other traits.
Layout:
Public Media Agency Sdn Bhd
717, Menara Mutiara Majestic, Jalan Othman Acknowledgements: Pictures & Chart from CK Wong, USDA,
46000 Petaling Jaya, Selangor Dayrit & Salum, SH Goh and Benny Lee
www.publicmediaagency.org
publicmedia.agency@gmail.com
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 i
Malaysian Oil Science and Technology (MOST)
EDITORIAL POLICY INFORMATION
MOST is a regular bulletin devoted to furthering ARTICLES: Contributions are invited for feature
the objectives of Malaysian Oil Scientists’ and articles, news items, newsletters, letter to the
Technologists’ Association. This is to promote interest editor, general articles, research papers, review to
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dates of each volume. Website: http://www.mosta.org.my
ii Malaysian Oil Science and Technology 2018 Vol. 27 No. 2
CONTENTS
i Cover Story
ii Editorial Policy
iii Contents
iv Editorial
69 REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT
TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
Mark Kellens, Wim De Greyt and Antonios Papastergiadis
83 DEVELOPING INNOVATIVE TECHNOLOGIES FOR PALM OIL MILLING:
CHALLENGING - ENRICHING - PROFITABLE JOURNEYS
K.H. Lee
94 ADVANCES ON BREEDING FOR HYBRID OxG OILS
C.J. Teo and C.K. Wong
104 PRICE OUTLOOK: PALM OIL USE IN FOOD, OLEO AND BIOFUELS
(EU, US, CHINA, JAPAN AND INDONESIA)
Meezy Park
109 IT/AI SOLUTIONS FOR THE PALM OIL INDUSTRY
Ivan Teh
113 RISING GLOBAL DEMAND FOR LONG-CHAIN OMEGA3 PUFAS:
EMERGING SOLUTIONS FOR A SUSTAINABLE SUPPLY
Mahinda Abeywardena
118 WORLD SCENARIO OF SOYBEAN OIL & PROTEIN: CURRENT STATUS
(PRODUCTION, APPLICATIONS, MARKET TRENDS), ISSUES, CHALLENGES
AND FUTURE PROSPECTS
Rich Barton
127 GLOBAL SCENARIO OF COCONUT OIL
Fabian M. Dayrit and Uron N. Salum
146 ANTICIPATING 2019 MARKET DIRECTION AMIDST CHALLENGES
Benny Lee
vii News
ix Talking Points
xi On A Lighter Note
xiii Index
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 iii
Editorial
Volatile and Sinking Markets The background noise may be the tit-for-tat tariff trade
war, but it is for the all-important domination of the
Crude oil staged a brave comeback hitting $76 in the advanced digital technology and global cyberspace.
climb towards the $100 mark (in anticipation of a total
Iranian oil ban) but only to fall back dramatically to $50
(when waivers to China and other countries were given More Than A Palmful of Problems
for importing Iranian oil), an obvious consequence
The anti-palm oil campaign from EU is one case where
of too much political interventions. A low oil price is
the glut of palm oil has been considered a threat to
welcome for energy consumers (cheaper transport
competing oil crops, especially in EU. The rapid growth
and manufacturing) as GDPs can be raised 0.5-0.7%
of production of palm oil, which cannot be halted once
per $10 drop in price for importing countries. Over the
the trees are planted, has come about with producers
longer term, oil is predicted to keep rising as supplies
not taking this (marketing) into consideration. And on
can be bolstered by hydraulic fracking technology
hindsight the total takeovers of British and French oil
when prices are above $50, and probably peak oil
palm companies may not have been wise by reducing
could occur around 2050. Low petroleum crude prices
such European stakeholders.
depress CPO prices in view of the Fry’s price band
relationship due to biodiesel (Park). Previously the US which hardly imports any palm oil
(< 1%) for consumption, had launched a preemptive
Geopolitics and the US-China trade war affect other
health campaign against palm to slow its growth but
commodities such as soybeans apart from edible oils
this has now been agreed by all parties to be baseless,
(Barton; Park) while unnecessary waste of resources
unfair and unjustified. Palm oil, kernel oil and the
and increase in carbon footprint are seen as China
coconut (Dayrit & Salum) are now much appreciated
buys soybeans from S America which had been
by consumers and manufacturers for nutritional
diverted from US. The slide in prices for soybeans and
goodness and functional versatility. Furthermore, for
soyoil will cap and depress palm oil prices. Even after
many competing polyunsaturated oils, a ban has now
the temporary tariff truce, economic uncertainties
been made on trans fats from partial hydrogenation
remain and negative effects on global trade will
of such oils, on top of the warning against excessive
cause persistent volatility. Inability to be competitive
intake of omega-6 oils.
in free trade on many areas has been distorted in the
guise of sustainability, labour exploitation, or even It is clear that wealthy first world nations are not
national security issues whether they be edible oils enthusiastic of palm oil as nature’s gift to the world:
and soybeans (Barton; Park; Dayrit & Salum) or high where sight is given to those potentially going blind
technology products/services. It is clear that most rich for lack of vitamin A (abundant in CPO); potential
nations including the present superpower will do their prevention of strokes and Alzheimer’s disease from
utmost to maintain their present leadership advantage. palm tocotrienols and MCTs from kernel oil; nutritional
iv Malaysian Oil Science and Technology 2018 Vol. 27 No. 2
EDITORIAL
heart-healthy palm olein is provided with high sn-2 of global debt, with the two biggest economies also
unsaturation and for use as one of the best frying competing in the race to the bottom. The toppish
oils; palm kernel oil is provided with medium chain global markets combined with trade conflicts could be
triglycerides having special nutritional values; and the early signs that a correction of global financial excesses
availability of new potential health-giving omega-7 is about to begin or has begun.
oils. On sustainability there is no other more productive
oil crop than the oil palm: averaging 4-8 times more
yield than other major competing oil crops; ability to
Biofuels
supply about 30% of oils to the world while using only Weak crude oil prices mean weak edible oil prices due
6.6% of the land used for other oil crops; sparing use of to the relationship with biodiesel, which the present
only 1/7 of fertilizers as compared to other oil crops; a excess production has been targeted for use in the
palm tree which is a net sequester of CO2 and provider mitigation of climate change. However nations may
of green tree cover; sustainable (RSPO & MPSO) palm have found that it is economically more profitable to
oils will be produced more than market uptake as all be in the climate denial camp in an era of cheap fossil
oil palms will be MSPO-certified in Malaysia by 2019. fuels, apart from the fading enthusiasm in the use of
biofuels against climate change. Further, an adaptive
Meanwhile refined palm oils, having relatively more
strategy to negative effects seems to be gaining
diacylglycerols, face a new problem of trace process
optimistic acceptance. Excess palm oil from increasing
contaminants (GE and 3-MCPDE), but these are also
supplies from Indonesia due to maturing palms has
found in other oils that are physically refined. Mitigation
been unable to find the anticipated biodiesel market
procedures have been recommended (Kellens et al;
in developed countries which had to support their
Lee). In view of the stringent requirements demanded
domestic crops rather than the cheaper palm oil.
by EU, added costs are inevitable for physical refining
Thus, it has been disastrous for palm oil prices even
while recommendations have been made to produce
as biodiesel finds aggressive use in the home markets
better quality CPOs with less FFA (Kellens et al; Lee).
(B20 in Indonesia; B10 in Malaysia by Dec 2018).
The problems of the world trade and economy are Indonesia’s tax structure for B20 biodiesel mandate
complex, even if it is free and fair trade being targeted is commendable but implementation over the vast
to find solutions. Population pressures (Barton) and the number of the nation’s islands may be challenging.
quest for dominance of technology are difficult issues, Meanwhile the continuing increase in production from
whereby competition in agricultural produce now Indonesia for 2019 will affect prices negatively (Park),
pales in significance. It is political agenda but nothing even as price discovery and forecast is becoming
associated with sustainability of supply of food more of a Nostradamus art in the present politically
calories, the abundance of which have come about uncertain and volatile era (technical chart by Benny
from advances in science in general and genomics Lee in cover page).
in particular. This fact should be enforced unto the
With so many economic problems on the plate, climate
mindsets of environmentalists, conservationists and
deniers seem to have gained the upper hand and a
climate specialists who are pushing all the blame on
new political trend seems to be for an adaptation to
poor palm farmers; in Malaysia there has always been
global temperature rise. EU’s enthusiasm for biofuels
much available agricultural jobs for people of poorer
to mitigate climate change has waned with uncertain
neighbouring countries. Negative campaigns should
mandates and they are pushing hard for the phasing
target for less consumption (by the wealthy) of pasture
out of palm biodiesel by 2030. Perhaps, the previous
animal meats which have caused the highest carbon
drive for aviation biofuels could be rekindled as no
footprints (Barton).
other energy source can reduce this source of GHG
There are bigger world economic issues than concerns emissions. The technology is ripe to collaboratively
of food, excess or lack of it, and it could be population produce aviation jet fuel at reduced costs on
growth (Barton) within a planet of finite resources. But economies of scale.
lurking in the background is the unsolvable problem
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 v
PAGE INTENTIONALLY LEFT BLANK vi Malaysian Oil Science and Technology 2018 Vol. 27 No. 2
Refining Crude Palm Oil:
Current Status and Latest
Development to ensure High
Food Oil Quality and Safety
Mark Kellens, Wim De Greyt and Antonios Papastergiadis
Desmet Ballestra Group, Belgium
[Lecture presented at OFIC2018 Conference, 17th Oct 2018, Kuala Lumpur]
Introduction Why is palm oil under fire?
The growth of production of palm oil has been Some perceived reasons may be the following:
immense and it has become the dominant edible in the • Deforestation & destruction of wildlife habitat
world (Fig. 1). In the years 1999 to 2018 Malaysian CPO • Disregard of local community rights
production has been increasing (except in few years) • Impact on global warming
at about 0.5 MMT/yr while higher growth was from
• Ethical issue of food oil used for fuel
Indonesia at ~ 1.75 MMT/yr. Most of the oil has been
used in food with minor uses in surfactants, biodiesel,
oleochemicals, etc (Fig. 1). Palm oil is the number 1 What may be the other reason for anti-palm oil campaign?
food oil (>30%) and will continue to strengthen its • Too efficient, too versatile & too cheap?
position in the coming decades.
• Has it become a political matter, as other oils are
being threatened?
Figure 1. Production of palm oil and its widespread uses
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 69
REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
OIL QUALITY
REFINING
PROCESS
PLANT EFFICIENCY PROCESS SUSTAINABILITY
Figure 2. Efficient and sustainable refining processes for quality oils
• Is it healthy (more saturated fats) and safe (can have Cost-Efficient Sustainable Production of High
more 3-MCPDE/GE) to use? Quality Palm Oil
• Is the consumer made aware of the real facts?
Oil processors and technology providers are
continuously looking for solutions to solve current
What is the alternative? problems and prepare for new challenges to come.
Oil can be refined to the desired quality and safety
There is no alternative as no other crop is as efficient standards of consumer needs while balanced by cost
as the oil palm and no other oil is as versatile as palm and sustainability (Fig. 2)
and palm kernel oils. “Half of the world’s population
uses palm oil in food, and if we ban or boycott it,
other, more land-hungry oils will likely take place”.- Oil Refining
Inger Anderson, IUCN Director General. There will be
Oil refining means the removal of unwanted
environmental disasters and total climate change as
minor components while avoiding production of
it will need as much as five to ten times more land
contaminants as illustrated in Fig. 3. Refining removes
need to be found to cultivate other oil crops to replace
unwanted foreign as well as oil-related impurities and
palm oil.
at the same time limit or eliminate process-related
The answer is to make all production follow the contaminants. With improved analytical detection
sustainable production methods as well as oil methods, more trace process contaminants (3-MCPDE
processing techniques to be food-safe. The palm oil and GE) have been detected in oils and technologies
industry is taking measures to ensure sustainable have to be modified to reduce or eliminate them.
production of high quality crude palm oil for food GE and 3-MCPDE are new trace contaminants found
uses but these need time for implementation of in all edible oils and are compared to other trace
new policies. contaminants as well as the much larger levels of trans
fat components (Fig. 4).
Crude Oil REFINING Refined Oil
FOREIGN OIL-RELATED PROCESS-RELATED
Pesticides Gums TFA
PAHs FFA Polymers
PCB Color bodies Acrolein
Dioxins Oxidation products Dialkylketones
Aflatoxins Metals 3-MCPDE/GE
... ... ...
Figure 3. Refining to remove unwanted components and limit process -related contaminants
70 Malaysian Oil Science and Technology 2018 Vol. 27 No. 2REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
1Polycyclic aromatic hydrocarbons; 2Mostly Aflatoxins in peanut oil; 3Mainly in Marine oils;
Risk
Figure 4. Comparison of some contaminants of concern
Highest levels of 3-MCPDE
and GE are found in
physically refined Palm oil
3-MCPD esters ≠ Glycidyl Esters
Main precursors Main precursors
3-MCPDE Chloride GE “DAG”
(“organic”/ acid) (FFA/alkaline)
Figure 5. Nature and formation of 3-MCPDE and GE in oils and fats
Process Contaminants in Food Oils: the Ongoing the presence of chloride impurity. They are formed
Challenge for Palm Oil differently and have different properties and require
different and specific mitigation solutions.
Glycidyl esters (GE) and mono-chloropropandiol
esters (MCPDE) are newly detected trace processed
components found in edible oils and fats and the Targets Limits for GE
highest levels are found in physically refined palm Maximum levels for GE are described in the annex
oils. The chemical structures and their formation are to regulation (EC) No 1881/2006, section 1 in the
summarized in Fig. 5. The common precursors are the COMMISSION REGULATION (EU) 2018/290 of 26
high levels of diacyglycerol (DAG) in crude palm oil and February 2018 as given below:
208 Glycidyl fatty acid esters expressed as glycidol Maximum level (μg/kg)
ppm
4.2.1. Vegetable oils and fats placed on the market for the (1000)
final consumer or for use as an ingredient in food with 1
the exception of the foods referred to in 4.2.2
4.2.2. Vegetable oils and fats destined for the production of baby food (500)
and processed cereal-based food for infants and young children 0.5
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 71REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
As GE get enriched in Palm olein, industry may need to Target Levels for 3-MCPDE
set lower limits for RBDPO (?), such as
New suggested maximum 3-MCPDE levels according
< 0.7 ppm GE for category 4.2.1 (?) to regulation (EC) No 1881/2006, section 1 (Draft
< 0.3 ppm GE for category 4.2.2 (?) released on 4 October 2018):
As 3-MCPDE get enriched in palm olein, industry may Conventional Route of Physical Refining of Palm Oil
need to set lower limits for RBDPO (?)
< 1.5 ppm 3-MCPDE for category 4.3.1 (?) Physical refining may be summarized below to provide
< 0.5 ppm 3-MCPDE for category 4.3.2 (?) the desired refined oil of the desired specifications:
CPO Dry acid pretreatment Bleaching with ABE Stripping-deodorization
Hydrating gums, reaction Absorbing impurities, breaking Removing FFA, heat bleaching,
with metals… down pigments… eliminating taste and odour,
improving stability…
RBDPO: PORAM spec Industry
FFA (%palmitic acid): 0.1% max 0.03-0.05% max
M&I: 0.1% max 0.01-0.05% max
Colour (5.25” Lovibond cell): 3 red max 1.5-2.5 red max
M.Pt (AOCS Cc 3-25): 33-39°C (ns)
IV (Wijs): 50-55 (50.5-52.5)
PV: (ns) nil
Taste: (ns) bland
P: (ns) 1-3 ppm max
72 Malaysian Oil Science and Technology 2018 Vol. 27 No. 2REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
Conventional Physical Refining of CPO is then followed by a single temperature and pressure
stripping-deodorization (Fig. 7).
Conventional CPO refinery uses dry acid pretreatment
plus bleaching but not wet pretreatment (Fig. 6). This
Figure 6. Conventional physical refining: dry acid pretreatment and bleaching
Figure 7. Conventional physical refining: single temperature & pressure stripping deodorization
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 73REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
Mitigation of the formation of GE and 3-MCPDE has Processors may not like it as there are higher utility
been examined from various technological aspects costs in NaOH and H2SO4, higher oil losses (acid oils
(Fig. 8). CPO quality remains an important parameter vs deodorizer distillate), and troublesome soapstock
to be able to achieve low levels of 3-MCPDE. Fig. 9 splitting forming more waste water. With 70 MMT/
provides data from reasonably good quality CPO from yr of CPO produced chemical refining may not be
physical refining but better values come from chemical the solution.
refining. Chemical refining is effective process solution
for CPO as for other edible oils for low 3-MCPDE.
fresh oil with high DOBI
Crude Palm Oil QUALITY -Low FFA / low DAG (GE) CPO washing
-low Chloride (3-MCPDE)
Mitigation options Solutions
low Chloride (3-MCPDE)
Crude Palm Oil QUALITY fresh oil with high DOBI CPO washing
Low FFA / low DAG (GE)
DRY DEGUMMING Wet degumming (enzyme?) Acid washing
0.05-0.15% H3PO4(85%) Other degumming acid
70-90°C, 1-15 min - No acid at all > caustic neutralising
3-MCPDE
BLEACHING 0.6-1.2% Natural bleaching earth
Activated Bleaching Silicas/silicates /zeolites Modified bleaching
Earth, 90-110°C, 20-40 Combination of adsorbents, (NBE)
min, 30-100 mbar acid & alkaline conditions
DEODORIZATION 250- Lower temp / longer time Dual temp stripping /
265°C, 45-90 min Dual temp stripping/deodo deodorising
2-4 mbar, 0.6-1.2% Low P (1-2 mbar)
stripping steam
GE
Post-bleaching/deodorising Mild refining
Refined Palm Oil Post-stripping Low P
Figure 8. Useful conditions in physical refining to mitigate 3-MCPDE
1. Chemical Refining is the Best Solution for Low 3-MCPDE (& GE)?
Data from experiments on chemical refining are given in Fig. 9, where low guideline levels can be achieved.
Industrial + lab refined samples
3-MCPDE (ppm)
1
3-MCPD Esters in
Chemical Refined Palm Oil
0.5
CPO quality remains the key factor
Figure 9. Chemical refining can achieve the lowest levels of 3-MCPDE
74 Malaysian Oil Science and Technology 2018 Vol. 27 No. 2REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
3-MCPDE in refined palm oil (ppm)
Optimized Physical Refining
3.01
25% 2.64
2.54
40%
2.29
C/R
1.86
Washing with ¢ No ¢ Caustic ¢ Water ¢ Acid
Figure 10. Effect of CPO washing on 3-MCPDE formation
2. CPO Washing: Effect on 3-MCPDE Formation Effect of CPO Washing on 3-MCPDE Formation in Good &
Premium Quality CPO
Physical refining results for different washings are
given in Fig. 10 where water washings are given in Processing conditions. Washing with 5% water without
more detail. Chemical refining still provides the lowest acid or caustic; bleaching with 10 kg natural bleaching
level of MCPDE. Effectiveness of CPO washing depends earth/tonne oil; dual T stripping/deodorization at
on crude oil quality & when it is applied. Most effect 240°C/220°C (120 min), 8 and 12 kg/T steam, 3 mbar.
is from ‘caustic washing’, but this is less than chemical The results are given in Table 1.
refining. Oil losses of 0.05 – 0.1% occur if 5% wash water
• Washing has a determining impact on 3-MCPDE
is used and 1-2% oil/FM in wash water. Combined
mitigation
acid degumming/washing further reduce P and
other elements. • Dual temperature deodorization gives low GE at
0.24- 0.42 ppm
Table 1. 3-MCPDE formation mitigation in washing good and premium quality CPO
Feedstock Good quality CPO Good quality CPO Premium quality
not washed CPO washed Not washed
FFA% (16:0) 3.7 3.5 1.3
DOBI 2.6 / 3.4
Refining Physical refining Physical refining Physical refining Chemical refining
FFA% (16:0) 0.04 0.04 0.03 0.02
Colour Lovibond (51/4) 2.0R/51Y 2.2R/57Y 1.2R/28Y 0.7R/16Y
3-MCPDE (ppm) 1.21 0.37 0.46 0.08
2-MCPDE (ppm) 0.66 0.21 0.25 0.05
GE (ppm) 0.40 0.42 0.27 0.24
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 75REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
Nano-Washing
Nano-washing technology is shown in Fig. 11; this is efficient, flexible and provides low effluent.
Figure 11. Nano washing technology
3. Bleaching: Effect of Amount and Type of BE
Experiments conducted on the use of bleaching earths
have provided results as shown in Fig. 12.
Bleaching conditions: 105°C, 50 mbar, 30 min. Büchner
filtration over Whatman No1
Deodorization conditions: Dual T stripping/
deodorization, 240°C /220°C (120 min). Total sparge
steam : 1.6 % - pressure: 2 mbar
Lowest levels of 3-MCPDE formation can be achieved
by (a) use of natural BE iso acid activated BE is No HCl – treated BE used
recommended, (b) higher BE dosing (more pronounced
effect with natural BE). Natural BE Acid BE
pH 7.8 3.7
Cl- (mg/L) 7.1 28.4
Formation of 3-MCPDE and GE During Bleaching
Figure 12. Effect of bleaching earths
Experiments carried out on high dosage of activated on MCPDE formation
bleaching earth showed MCPDE and GE can be formed
with higher dosages of bleaching earth and further
formation of MCPDE in deodorization (Table 2). There
is no formation of GE. During deodorization there
is further formation of 3-MCPDE. Isomerisation of
3-MCPDE to 2-MCPDE occurred.
76 Malaysian Oil Science and Technology 2018 Vol. 27 No. 2REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
Table 2. Formation of MCPDE and GE during bleaching and deodorization
BE type Natural BE Acid activated BE
BE dosage (kg/T) 10 15 20 10 15 20
Bleaching T (°C) 105 105 85 105 105 105 105
FFA % (16:0) 0.05 0.06 0.05 0.05 0.05 0.05 0.05
Color Lovibond 51/4 6.1R/70Y 5.0R/70Y 6.4R/70Y 5.2R/70Y 5.5R/70Y 4.4R/70Y 4.0R/70Y
Bleached palm oil
3-MCPDE (ppm) 0.34 1.20
2-MCPDE (ppm)REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
260°C 3 mbar 60 min, 1% SS
Glycidyl esters (ppm)
1% SS 3
The lower
the P, the
higher
2 mbar
the NO
losses
240°C (MAG,
230°C DAG,
220°C 1
Toco)
0 1 2 3 4 5
Time (hr)
Figure 14. Effect of temperature on GE formation Figure 15. Balance of stripping and formation of GE
Can GE be Stripped During Deodorisation? Effect of Packed Column on Stripping GE
GE can be stripped from the oil, but…. The designed column (Fig. 16) provides short resident
times at high(er) temperatures and gives (a) almost no
• Under normal deodorizing conditions - formation
formation of GE, even at T > 240°C and (b) very efficient
of GE > stripping (Fig. 15)
FFA stipping but only limited heat bleaching.
• Stripping can only be significant at higher
Essentially, dual temperature high-temp fast stripping/
temperature and lower pressure
low-temp mild deodorization achieved.
• Best strategy therefore to limit formation (temp. <
240°C)
• Best compromise: FFA strip at high temperature,
Final Treatment of RBPO
deodorise at low temperature A dual temperature – dual pressure system allows
optional low pressure prestripping and post-stripping
(Fig. 17).
10 min, 0.5% SS
≠ GE ≠ FFA
0.1 ppm 0.08%
Figure 16. Effect of packed column: fast GE stripping and mild deodorization
78 Malaysian Oil Science and Technology 2018 Vol. 27 No. 2REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
Intermediate
cooling
+
Qualistock dual temp deodorising
Figure 17. Dual temperature-dual pressure GE stripping and deodorisation
5. Optimised Physical Refining: CPO Washing, Bleaching Optimized physical refining: 15 min/245°C followed by
with NBE and Dual Temp Deodorisation 45 min/230°C
Experiments conducted according to the given 3-MCPDE: standard PR with ABE > standard PR with
conditions provide data presented in Table 3. NBE = optimized PR > chemical refining
Standard physical refining : 60 min/260°C/3mbar. GE: standard PR with ABE = standard PR with NBE >
Chemical refining: 120 min/225°C/3 mbar optimized PR = Chemical refining
Table 3. Comparison of refining methods and optimisations
Crude Standard PHYSICAL Standard PHYSICAL CHEMICAL Optimized
Parameter Palm refining refining refining PHYSICAL refining
Oil Activated BE Natural BE Natural BE Natural BE
1% 1% 1% 1%
FFA (% C16:0) 5.83 0.02 0.017 0.013 0.02
Color (Lovibond 5 ¼ “) N.A. 1.8R/23Y 2.0R/24Y 2.3R/19Y 2.5R/32Y
Total chlorine (ppm) 5.0 N.A. N.A. N.A. N.A.
3-MCPDE (ppm) - 4.21 → 1.25 → 0.48 → 1.18
Glycidyl esters (ppm) 3.12 → 2.94 → 0.48 → 0.55
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 79REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
6. Post Bleaching: A Solution to GE Reduction and reliable at low pressures. Final treatment of RBPO
is becoming a key standard feature for new refineries.
Post-bleaching : Non HCl Activated BE, 105°C, 50 mbar.
No post-deodorisation. Results are given in Fig. 18.
0.5% ABE gives very fast and almost complete GE Post-Stripping of GE from RB palm oil
degradation: GE < 0.1 ppm within 10 min
Top pressure packed column at 1.5 mbar using Dry
0.2% ABE gives slower but still good GE degradation: condensing Sublimax 2G
GE < 0.2 ppm within 30 min
The results of GE stripping at different temperatures
are charted in Fig. 20
7. Mild Post Refining of RBPO GE Post-stripping will not only reduce GE, but may also
create additional losses as other components will
Post-bleaching conditions: 0.5% Activated BE, 110°C,
also be stripped (Tocotrienols, MAG, …)
30 min. Post-deodorization: 0.5% stripping steam, 3
mbar, 60 min. RBD PO
GE can be eliminated by post-refining, but mild 4.3
conditions are to be used as GE can be formed (Fig. 18). 2.8
3-MCPDE + GE (ppm)
Redeodorized
at 260°C
GE may again be formed during post-deodorization
so that low deodorization temperature is required. 0.3
Redeodorized
MCPDE are more difficult to remove during 0.1
at 230°C
Post-bleached
post-refining.
Equipment for the final processing of RBPO is illustrated Sample number
in Fig. 19 operating a 1 mbar. This is considered safe Figure 18. Removal of GE by post-refining
Figure 19. Equipment for RBPO final treatment
80 Malaysian Oil Science and Technology 2018 Vol. 27 No. 2REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
Chemical refining and good quality CPO can provide
low levels of 3-MCPDE and GE (< 0.5 ppm). There is
Glycidol (ppm)
200°C
a need to account for the enrichment of these trace
230°C 210°C contaminants in the oleins on fractionation.
260°C
Sparge steam (kg/ton) CPO Quality: Key Determining Factor in Mitigation of
3-MCPDE & GE
Figure 20. Removal of GE optimized
Industry has to adopt new best practices to ensure
highest CPO quality for food safety. There is a clear
Palm Oil Physical Refining: Steps to Mitigate 3-MCPDE need for segregation of good & excellent quality for
& GE food versus the rest for non-food uses (Fig. 21). The
A summary is given diagrammatically and tabulated palm oil industry can provide excellent quality food oil
below. (70%) with FFA < 3.5% and DOBI > 2.5 which is sufficient
for the PO used in foods, so where is the problem?
Dual bleaching with Dual temp Stripping-
CPO wet pretreatment
NBE/ABE deodorization
Q Mitigate 3-MCPDE Mitigate 3-MCPDE Mitigate GE
RBDPO: PORAM spec Industry
FFA (%palmitic acid): 0.1% max 0.03-0.05% max
M&I: 0.1% max 0.01-0.05% max
Colour (5.25” Lovibond cell): 3 red max 1.5-2.5 red max
M.Pt (AOCS Cc 3-25): 33-39°C (ns)
IV (Wijs): 50-55 (50.5-52.5)
PV: (ns) nil
Taste: (ns) bland
P: (ns) 1-3 ppm max
3-MCPDE 2.5 ppm max*
GE 1 ppm max*
personal care
oleochemicals food
Objective parameters
DOBI > 2.5?
FFA < 3.5?
biodiesel Chloride < 2 ppm ? infant food
Palm Oil
Figure 21. Palm oil quality for food and non-food uses
Feedstock Good quality CPO Good quality Poor quality CPO Premium quality
not washed CPO washed Not washed CPO, Not washed
FFA % (16:0) 3.4 6.7 1.3
DOBI 2.6 1.7 3.4
Refining Physical Physical Physical Physical Physical Physical
refining refining refining refining refining refining
FFA % 0.04 0.04 0.06 0.02 0.03 0.02
Colour lovibond (51/4) 2.0R/51Y 2.2R/57Y 6.0R/70Y 2.4R/16Y 1.2R/28Y 0.7R/16Y
3-MCPDE ppm 1.21 0.34 2.78 1.76 0.46 0.08
2-MCPDE ppm 0.66 0.21 1.31 0.05 0.25 0.05
GE ppm 0.40 0.42 0.59 0.24 0.27 0.24
Figure 22. CPO quality: refining for food quality and safety
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 81REFINING CRUDE PALM OIL: CURRENT STATUS AND LATEST DEVELOPMENT TO ENSURE HIGH FOOD OIL QUALITY AND SAFETY
Quality and Origin of CPO (3) Technology development, finding the right
balance between efficiency, quality & sustainability
For a long time it is known that quality does matter
as regards to the CPO and the levels of trace process Various mitigation solutions (preventive and
contaminants. The tabulated results below confirms curative) have been developed, some already
this point again. Good quality CPO is the key for low applied, others still under investigation, taking
3-MCPDE formation. GE can be managed during into account COST factor (CAPEX & OPEX), as the
refining by prevention or correction. final refined food oil must remain affordable.
Abbreviations. ABE = activated BE; BE = bleaching earth; CSR =
CPO Quality: New Commercial Standard For Food Oil corporate social responsibility; CSPO = Certified Sustainable Palm
Oil; CSV = creating shared value; DAG = DG or diacylglycerol; DHA
= docosohexaenoic acid; EFSA = European Food Safety Authority;
In view of the new demands for edible oils quality ENGO = environmental NGO; EPA = eicosopentaenoic acid; EU
with respect to trace process contaminants, standards = European Union; FA = fatty acid; FEDIOL = Federation of the
for palm oil quality may need to be reviewed. Figs. European Vegetable Oil and Proteinmeal Industry; FELDA = Federal
Land Development Authority of Malaysia; FFA = free fatty acid;
22 & 23 illustrate the main parameters that may be FFB = fresh fruit bunches; Fob = free on board (responsibility for
useful to set guidelines for CPO quality for food. goods until leaving a specified point); GE = glycidyl ester; GM =
genetically modified; GMO = genetically modified organism; Ha =
High quality CPO for food can be selected from the hectare; IARC = International Agency for Research on Cancer; LOD
palm oil mill. As good practices, low quality oils (e.g. = limit of detection; MAG = monoacylglycerol or monoglyceride;
MCPD = monochloropropandiol; MCPDE = MCPD esters; Mln, mln =
sludge, condensate and FFB oils) in milling must not be million; MPOA = Malaysian Palm Oil Association; MPOB =Malaysian
recycled to the food quality CPO. Reserve low quality Palm Oil Board; MPOC = Malaysian Palm Oil Council; MUFA =
monounsaturated fatty acid; NBE = natural bleaching earth; NGO =
CPO for oleochemicals and other non-food uses or non-government organization; NO = non- odoriferous; OFIC = Oils
process bad quality CPO into biodiesel (Fig. 21). and Fats International Congress organized regularly every two years
by MOSTA; P = phosphorus or pressure; PAHs = polycyclic aromatic
hydrocarbons; PCBs = polychlorinated biphenyls; PFAD = palm fatty
distillate; PO = palm oil; POPs = persistent organic pollutants; ppb =
Conclusion parts per billion; ppm = parts per million; ppt = parts per trillion; PR =
physical refining; PUFA = polyunsaturated fatty acid; R = red; RBDPO
There is no “one size fit all” in 3-MCPDE & GE mitigation = refined, bleached and deodorized PO; RSO = rapeseed oil; RSPO =
Round Table on Sustainable Palm Oil; SAFA = saturated fatty acid; SBO
solutions. Best solution depends on: = soybean oil; T = tonne, also temperature; TFA = trans fatty acid; Y =
(1) Plant configuration: chemical or physical, new or yellow; Yr = year
existing plant
(2) Required specs: special vs commodity; individual
or formulated fat
Max
5%
FFA
Max
3.5%
M&I DOBI
(moisture & CPO Quality (Deterioration of
Impurities) Bleachability Index)
Max 0.25% Min
2.3%
Max 5%
Chloride
(after washing)
Min
2.5%
Max 2 ppm
Figure 23. Guidelines for food-quality palm oil
82 Malaysian Oil Science and Technology 2018 Vol. 27 No. 2Developing Innovative
Technologies for Palm Oil
Milling: Challenging -
Enriching - Profitable Journeys
KH Lee
IHMS & MOSTA
[Presented at the Palm Oil Milling Workshop, 14th Aug 2018, Johor Bahru, Malaysia]
Introduction
Oil palm plantations have been around for 101 years
and extraction of fruit oil has been following closely
the increasing fruit harvest for the last century. The oil
palm fruit is unique in having heavy bunches which
need to be sterilized to stop enzymatic action, cooked
to release the fruits from the bunches, have the fruits
separated and screw-pressed for the mesocarp oil and
kernels and the pressed oil separated, pumped dried
and stored. While conceptually simple, the engineering
and technologies have to be designed and adapted
for this unique oil and the successful development Figure 1. Tan Sri Ong of MOSTA and Calvin Ho of Ladang
TaiTak agreed to collaborate to hold a milling workshop
to commercial plants spanned over half a century. for the Malaysian palm oil industry
While many would have thought that milling has not
made much of advances for decades, it is surprising from indigenous technologies to be adapted uniquely
that many incremental improvements have been for the oil palm crop. Further downstream processing
happening among the mills of the major corporate technologies provide a versatile range of fats and
oil plantation companies. The present revelation oils ranging from nutritious liquid oils, semi-solid fats
comes from the MOSTA workshop on milling held and solid fats demanded by the needs of the variety
in August 2018 in collaboration with Ladang TaiTak of foods and cuisines around the world. Processing
(Fig. 1), which is a follow-up from the MOSTA workshop for specialty fats, infant formulas, functional foods,
on Agronomics held a year earlier in Ipoh. fat-soluble vitamins and medicinal supplements have
The farm-to-fork quality of vegoils from the oil palm been made available.
that are supplied to world consumers is remarkable
in that the technologies in the multiple steps of the The Start of the Innovation Journey for the Palm Oil Mill
supply chain has been developed in the third world
The earlier developments by MARDI and PORIM have
countries of SE Asia. Best practices begin with the
provided the basic framework for commercial palm oil
plantations producing 4 to 6 tonnes of palm fruit oil per
mills with engineering technologies for sterilization of
hectare sustainably with MSPO and RSPO standards;
fruit bunches, separation of fruits from empty bunches,
such yields far exceed all the other oil crops. The
pressing out of mesocarp oil, recovery of kernels and
extractions of palm oil and kernel oils have evolved
separation of oil from effluent water. For decades the
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 83DEVELOPING INNOVATIVE TECHNOLOGIES FOR PALM OIL MILLING: CHALLENGING - ENRICHING - PROFITABLE JOURNEYS
Figure 2. Pioneering engineers and supporting staff at Riverside Palm Oil Mill (1971)
basic milling technology remained without advances or she probably just stands aside and comments
although there were attempts to introduce more from afar.
automation. In 1971 young engineers shown in Fig. 2
and elsewhere embarked on a journey of innovation Mill Engineers Stand
to create more efficient milling using technologies as
they become available. • Mills must not piggy back claim on any pride in
any achieved higher palm product extractions on
The vision to develop innovative technologies is FFB arising from better planting material or field
important and led by many and this paper has practices.
highlighted the wide expertise of the Executive
Director of IHMS Sdn Bhd. • They can only be proud in their use of GOOD Milling
Practices & Technology in achieving lowest possible
milling loss, irrespective of any outcome values in
Innovative Developing Technologies
extractions on FFB. After all, milling does not add in
It is recognized that many of these are already any extra quantity of palm products and can only
around and available in the market place; but what is optimize recoveries (lower Milling Loss).
still lacking:
• In any instances, whenever perceptions of poor
• Successful uses in milling are few possibly due to milling arise, do bring in competent, independent
lack of the following: and professional Milling Auditors who can provide
not only the Whys and the Whats but also the Hows.
i. Inability to synergize with the current milling
Avoid any ‘YES Sirs’ auditors boosting their own egos
operation and know-how
and/or with business wise focus supporting pre-biased
ii. No clarity to define performance expectations to top management perceptions.
mill owners except financial gain promises and
guarantee of $$$ returns
Successful Technology Selection and Use
iii. In-Correct and In-Efficient ideas may
unexpectedly lead to incorrect and inefficient • Technology has to be verifiable based on science &
uses engineering
iv. Most mill managers and engineers have • Developing New Technology – In Stages • proof of
their hands full from ever administrative and concept g pilot trials g comparative runs g use
environmental regulations, demands and • Use of Proven Developing Technology: • Non-sense
compliances added on to their high workload to conduct further re-evaluation tests WITHOUT
for optimize milling cost, higher food quality sizeable comparative tests and proper certified
demands and lower milling palm product loss, & qualified team participation; • Need to identify
They are understandingly unable to participate shortfalls for corrections as no two Mills are built to
and contribute productively; at best or worse he the same design flow system and capacity.
84 Malaysian Oil Science and Technology 2018 Vol. 27 No. 2DEVELOPING INNOVATIVE TECHNOLOGIES FOR PALM OIL MILLING: CHALLENGING - ENRICHING - PROFITABLE JOURNEYS
Resource Support Brief on Tai Tak Palm Oil Mill
• Hands-on Participation inputs WILL assure any • It is a very OLD Mill, 50 Loving Milling Years; built in
Technology Input success Y1968
• Patience & Confidence needed from Mill Owners - • Free flow of finger food and drinks at reception
clear understanding of any needed extended times to
• Productive & smart blending of YOUNGIES & OLDIES
SUCCEED
• Mill IMAP Advisors (5 persons) totaling 240 MILLING
• Team players (Providers – Participators – Users)
YEARS milling experience
having win-win-win interests (monetary, right of
use, recognition, satisfaction), WILL bring out effective • WILLING to share Milling Practices & Technology
values to enhance and make good any shortcoming in
• Proud but not prideful or boastful
the use of technology.
Tai Tak Palm Oil Mill Open Day on 14th August 2018 further
Technology Development Project Management
reinforced both Tai Tak and IHMS’s intention and commitment
Manage and Motivate to place their developed and developing Innovative Technology
in the PUBLIC DOMAIN as Open Source.
• Manage the team and activities in communicating,
supporting, and helping with decisions. The Visit focused on the following:
• Inexperienced members of the team prefer clear 1. Mechanized Sterilization Indexer System – Y2003
instructions, but these on the contrary can de- 2. Oil Room Discharge / Mill Waste Separation – Y2018
motivate experienced and creative people 3. Auto Sterilization / Safe Use – Y2003
• Manage these people by the results they get 4. Saturated Steam for Sterilizing – Y2018
5. Megasonic (Ultrasound) – Oil Capture – Y2010
• Share plaudits with your team, but never, never
accept plaudits yourself 6. Non-Oil Screen Waste Removal (Puree) – Y2015
7. Sterilized Detached Fruits Storage (SDF) – Y2010
• Never ‘dump’ blames on anyone in your team. As
project manager any problem is always ultimately 8. Pre- Recovery of Pressed Oil (PRS) – Y2013
down to you anyway. 9. Quality & Loss Control Lab (NIR) – Y2011
10. Boiler Flue Gas Pre-Scrubber (BGSS) – Y2017 / ESP
Check, Measure, Monitor, Review Project Progress Scrubber Use by Y2019
11. Condensing Turbine for Low Use of Power Steam –
• Check the progress of activities against the plan.
Y2014
• Review performance regularly and at the stipulated 12. H.P. to L.P. Steam – Process Steam – Y2014 - Y2018
review points, and confirm the validity and relevance
13. 13 Boiler (Biomass) Fuel Feed System – Y2016
of the remainder of the plan.
14. Separate Oil Traps – Oil Station/Milling Waste –
• Adjust the plan if necessary, in light of performance, Y2018
changing circumstances, and new information, 15. Biogas Extraction (CUBRA). For Heat Energy Plant –
but remain on track and within the original terms Y2017
of reference.
16. Low Collectable Oil ETP/Enzyme Assisted – Y2013
• Identify, agree and delegate appropriate new 17. Launching IMAP Center (240 Milling Years’
actions. Experience) – (Advisors in place Since Y2003)
18. INTER-ACT Center (Milling Participators)
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 85DEVELOPING INNOVATIVE TECHNOLOGIES FOR PALM OIL MILLING: CHALLENGING - ENRICHING - PROFITABLE JOURNEYS
Figure 3. Workshop sharing interactions: challenges in the use of innovative developing technologies
Sterilization and Cooking of Fruits stage provide an efficient way to remove chloride
impurity which will be the cause of trace processed
Palm fruit bunches harvested from plantations arrive contaminants (MCPDE). While high temperatures
at the oil extraction mill and they need to be sterilized are useful, saturated steam temperature ofDEVELOPING INNOVATIVE TECHNOLOGIES FOR PALM OIL MILLING: CHALLENGING - ENRICHING - PROFITABLE JOURNEYS
• A DEFINITE VALUABLE SYSTEM TOOL minimizing
Sterilizer Condensate Oil Loss
The installation of the Sterilizer Indexer System was fully
participated by the owner (Fig. 4). As this system is the
first of its kind in the world, the technology team (needed
be “fearless and righteous”) was blessed. The steadfast
step by step approach to successful use re-established
confidence from “God help you” doubters.
Figure 6. Manual loading of fruits into old B4 sterilizer
cages
The old B4 sterilizer cages involved a lot of manual
labour in charging and moving the cages with much
leakages and fruit losses causing greasiness and litter
(Figs. 5 and 6).
Tai Tak Palm Oil Mill: Megasonic Journey
Ultrasonics have been used in science and industry
Figure 4. Installation of the semi-automatic Sterilizer
for heating, cleaning, cellular disruption, cavitation
Indexer System catalysis and recently investigated by CSIRO for milk
fat emulsification or agglomerating milk fat particles.
It was a challenge to the palm oil industry which faces
separation problems of oil micro-emulsions during
milling and this technology was made known to
MPOB in 2010 (Fig. 7). Tai Tak Palm Oil Mill took up the
development of this Technology Intense discussions
were carried out at Tai Tak Mill (Fig. 8) in Sept 2010 and
by Oct decision based on the proof of concept was
A GO (Fig. 9), followed by planning and intense work
(Figs. 10 & 11).
Figure 5. Milling in the old system of sterilizer cages
with fruits shunting continue without Mill Shutdown
Figure 7. PAC meeting of MPOB in April 2010 (Dr YM Choo of MPOB, front row, 8th from right; Tan Sri SH Ong, front row,
7th from right; CSIRO’s Mary Ann Augustin, 3rd row, 3rd from left; Ir KH Lee of IHMS, last row, 2nd from left; Dr PT Gee, 3rd
row, 3rd from right)
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 87DEVELOPING INNOVATIVE TECHNOLOGIES FOR PALM OIL MILLING: CHALLENGING - ENRICHING - PROFITABLE JOURNEYS Figure 8. Intense discussions on engineering aspects of the project Figure 9. Decision to go ahead at the mill for proof of concept in Oct 2010 Figure 10. Planning and aspects of work in progress Figure 11. By 18th Sept 2012 it was demo day and celebration 88 Malaysian Oil Science and Technology 2018 Vol. 27 No. 2
DEVELOPING INNOVATIVE TECHNOLOGIES FOR PALM OIL MILLING: CHALLENGING - ENRICHING - PROFITABLE JOURNEYS
Figure 12. AOCS Corporate Achievement Award in 2013
Achievements with Megasonic samples, analyses and measurements since Nov 2013
to confidently claim:
Megasonic reduces oil loss consistently to 2.5 kg/T FFB
and there is zero run-away oil loss. Rapid oil separation i. The low oil loss in sludge centrifuge discharges
provides better oil quality. POME discharge is lower. achieved at 2.3-2.99 kg/T FFB
The most rewarding moment comes from the AOCS ii. The extra collectable oil from sludge centrifuge
Corporate Achievement Award in April 2013 (Fig. 12). returns another 2.00-3.00 kg/T FFB
Tai Tak mill is never ‘rich’ on OERs and over the years,
Use of Megasonic in Palm Oil Mills
process yearly some 100,000 T FFB - own FFB of old-
It is not one size that fits all. It is advisable to audit your age palms and substantial 100,000 T FFB from Traders
own mills and establish the need for this Megasonic to maintain processing continuity and acceptable
tool. milling costs for her 45 TPH FFB plant.
In comparison to previous data with no Megasonic
Key Issues Best Answered by the Mill: intervention in months of Nov 2012 – Oct 2013 to
• Are there frequent oil clarifier upsets requiring current months of Nov 2013 – Oct 2014 with Megasonic
discharges or complete empty-outs? intervention, the mill had an increase of 0.56% oil
extraction rate of FFB and on 211,449 T FFB processed,
• Are there frequent high collectable oils in the mill’s translating to some higher earnings gain of RM2.9
sludge pits or de-oiling tank? million. And to cream the top, Kai Tak mill had the
• Is there high oil in the ETP acidification ponds? highest OER achievement in Y2014 in comparison to
previous 30 years since Y1984.
• Is there poor ripeness of FFB?
Megasonic intervention assists in:
Achievements of Tai Tak Mill i. Dislodging oil droplets trapped in the suspended
and dissolved non-oil solids.
At Tai Tak mill we had complete mass balance and
analytical data for 277 run days covering 15,000 ii. Agglomerating emulsified and tiny oil droplets
from sludge centrifuge returns.
Malaysian Oil Science and Technology 2018 Vol. 27 No. 2 89DEVELOPING INNOVATIVE TECHNOLOGIES FOR PALM OIL MILLING: CHALLENGING - ENRICHING - PROFITABLE JOURNEYS
iii. Agglomerating emulsified oil from the pressed
crude oil; all these coalesced into bigger droplets
which are then collectable in the oil clarifier tank.
Food for Thought
• Low oil at the centrifuge discharge is not good
enough
• Recoverable centrifuge oil still has to be totally
converted into collectable oil.
Quality & Loss Laboratory: Introduction of Near
Infrared (NIR) Spectrometer
Classical laboratory although with standard procedures
takes too long for plant operations correction. The NIR
spectrometer can also now analyse for many other
critical chemical parameters. This was installed and
tested during the period of July – Nov 2011 (Fig. 13).
Figure 14. Replacing the old turbines (1968-1998) with
new ones (1999-2012)
More Power - Less Steam Consumption with Lower
Biomass Boiler Fuel Use
The multistage condensing steam turbine generates
power at 90KWe/T FFB. Boiler provides process steam
consumption of 350kg/T FFB and lower.
• Operational skills were acquired in early 2013 to run
independent steam for power and process.
Figure 13. NIR spectrometer monitors quality and
oil loss • Installed process steam supply systems were for 350
kg/T FFB
Condensing Turbine • Improved sterilizing steam supply and use without
The next continuing project is a smart partnership sacrificing cooking efficiency & throughput
to power with renewable energy from conversion of • Improved boiler super heater design and
biomass waste to reduce GHG emissions and power installation, had continuous monitoring of superheat
other down-stream activities. This looks at updating temperature and improve proper start-up and shut-
the steam turbine which was developed in the early down procedures
years (1880s) whereby steam was expanded in piston
engines (Fig. 14). The vertical motion was then • Condensing (3 stage) turbine installed in Sept 2013
converted to rotary motion to generate power. In 1884 • The steam boiler and steam turbine stations run well
Charles Parsons developed the first practical, modern since Mar 2014
high-speed steam turbine. The single stage back-
pressure turbines for integrated supply of steam for
power and process in Tai Tak mill (1999-2012).
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