3.

9 ENEGRY BALANCE
3.9.1 Power Balance
Due to the availability of oil palm biomass, palm oil mill itself is able to generate
electricity for domestic usage and manufacturing purpose. In the designed mill, mesocarp fiber
and palm shell are used as boiler fuel to generate steam. These two solid fuels alone are able to
generate more than enough energy to meet the energy demands of a palm oil mill. The steam
generated from boiler is sends to turbine for generating electricity. The exhaust steam is then
sends to back pressure vessel for production usage. The details power consumption of each
station with the total power generated from turbine in the designed palm oil mill is shown in next
section.
3.9.1.1 Power Consumption
The power consumption of each station is determined based on the equipment
specification. Additional 200 kWh is allocated for domestic usage including power usage in
POME treatment plant and raw water treatment plant. Table X shows the power consumption for
each station. The estimated total power consumption for a 30 ton FFB/hour palm oil mill is
1312.1 kWh.
Table X: Power Consumption for Each Station.
N

MACHINERY

QUANTITY

O
FRUIT RECEPTION
1.
Road Weighbridge
2.
Fruit Loading Ramp
STERILIZATION STATION
3.
Tilting Sterilizer
THRESHING STATION
4.
Thresher
DIGESTION STATION
5.
Digester
6.
Screw Press
CLARIFICATION STATION
7.
Sand Trap Tank
8.
Vibrating Screen

POWER (kWh)

TOTAL POWER (kWh)

2
1

30
5.6

60
5.6

23

46

50

100

3
3

33
29

99
87

1
2

4
2

4
4

Separator
9.
Crude Oil Tank
1
10.
Continuous Settling
1
Tank
11.
Hot Water Tank
1
12.
Pure Oil Tank
1
13.
Oil Purifier
2
14.
Oil Holding Tank
1
15.
Vacuum Oil Dryer
1
OIL STORAGE TANK
16.
Oil Storage Tank
1
17.
CPO Daily Storage
2
Tank
SLUDGE SEPARATION STATION
18.
Sludge Buffer Tank
1
19.
Desander
1
20.
Sludge Drain Tank
1
21. Rotary Brush Strainer
1
22.
Sludge Separator
2
23.
Sludge Oil Tank
1
DEPERICARPING STATION
24.
Cake Breaker
1
Conveyor
25. Depericarper Vertical
1
Column
26.
Nut Polishing Drum
1
27.
Pneumatic Fiber
1
Transport System
KERNEL STATION
28.
Nut Silo
1
29.
Ripple Mill
2
30.
Claybath
1
31.
Bulk Kernel Silo
1
32.
Wet Shell Bunker
1
BOILER STATION
33.
Boiler
1
POWER STATION
34.
Fuel Tank
1
EFB STATION
35.
EFB Shredder
1
Machine
36.
EFB Fiber Press
1
37.
Hammer Mill
1
Machine

4
9

4
9

4
4
7.5
4
11

4
4
15
4
11

7.5
7.5

7.5
15

4.5
11
4.5
11
15
4

4.5
11
4.5
11
30
4

15

15

48

48

7.5
75

7.5
75

4
11
85
4
4

4
22
85
4
4

35

35

7.5

7.5

75

75

45
56

45
56

38.
Rotary Dryer
1
75
39.
Baler Machine
1
60
DOMESTIC USAGE AND WATER TREATMENT PLANT
40.
Office, Laboratory,
1
200
Storage Room,
Workshop, POME
Treatment Plant, Raw
Water Treatment Plant
TOTAL POWER

75
60
150

1312.1

3.9.1.2 Power Generation

Steam turbine is using steam from boiler to generate electricity. The exhaust steam from
steam turbine will store in backpressure vessel for processing. Before running the boiler, diesel
generator is used to supply electricity for palm oil mill. The amount of power generated for the
designed mill is shown in Table X.
Table X: Power Generation.
Steam Turbine

Total Power Consumption

Output Power of Steam Turbine
Actual Output Power of Steam Turbine
Steam Required for Steam Turbine
Total Steam Required

Exhaust Steam for Processing

= 1312.1 kWh
= 1500 kWh
= 1500 kWh X 90% = 1350 kWh
= 25 kg steam/kWh
= 25 kg steam/kWh X 1500 kWh
= 37,500 kg Steam
= 37,500 kg Steam X 90% = 33,750 kg
Steam

Diesel Engine Set

Output Power per Engine Set

Total Diesel Engine Set Required

= 450 kW
=3

3.9.1.3 Boiler Selection

Steam Boiler is any closed vessel in which for any purpose steam is generated under
pressure and include any economizer used to heat water being feed to the boiler and any super

heater used for heating steam and any pipes and fitting connected there to. Table X shows the
calculation of the required boiler plant for the designed mill.
Table X: Steam Boiler Selection.
Data
Mill Throughput
Raw Water Temperature
Boiler Feed Water
Boiler Safe Working Efficiency
Steam Required for Turbine
Boiler Steam Capacity Capabilities

= 30 ton FFB/hour
= 27C
= 80C
= 85%
= 37,500 kg Steam/hour
= 45 ton of Steam/hour X 0.85
= 38.25 ton of Steam/ Hour

From the above calculation, the mill needs 37.5 ton of Steam/hour for steam turbine to
generate electricity. But in term of long term planning, the mill was installed boiler with capacity
of 45 tons steam/ hour. The working pressure of boiler is 22 bar with processing temperature of
260C.
3.9.1.4 Fuel Availability
For this mill, EFB will not be used as boiler fuel as it will further processed to become
value added by product. The fuel source for boiler is mainly for mesocarp fiber and palm shell.
The calorific value of mesocarp fiber and palm shell is 19,000 kJ/kg and 18,836 kJ/kg
respectively. The amount of boiler fuel required is calculated as shown in Table X.
Table X: Boiler Fuel.
Data
Amount of Palm Shell
= 30 ton FFB/hour X 5.2% = 1,560 kg shell/hour
Calorie Value of Palm Shell
= 19,000 kJ/kg
Amount of Mesocarp Fiber
= 30 ton FFB/hour X 19.25% = 5,775 kg fiber/hour
Calorie Value of Mesocarp Fiber
= 18,836 kJ/kg
Heat Required to Heat 1 kg of Steam at 22 bar in Boiler

From Steam Table

At 22 bar, hf = 930.562 kJ/kg & hfg = 1869.4 kJ/kg
Let assume steam is 0.9 dry, x = 0.9

h = hf + xhfg
h = 930.562 kJ/kg + [0.9 X 1869.4 kJ/kg]
h = 2613.022 kJ/kg
Heat Already Present in Water
Q = cp X T
Q = 4.187 kJ/kg. C X 80C
Q= 334.96 kJ/kg
Heat Required to Generate 1 kg of Steam
h = 2613.022 kJ/kg - 334.96 kJ/kg
h = 2278.062 kJ/kg
Steam Required For Boiler
= 38.25 ton of Steam/hour
Heat Required to Generate Steam

= 38,250 kg of Steam/hour X 2278.062 kJ/kg.kg Steam

= 8.71 X 107 kJ/kg.hour

Amount of Fuel Required to Generate Steam

Palm Shell
Let assume heating efficiency of 70%
h = 1,560 kg shell/hour X 19,000 kJ/kg X 0.7
h = 2.075 X 107 kJ/kg.hour
Mesocarp Fiber
Let assume heating efficiency of 70%
h = 5,775 kg shell/hour X 18,836 kJ/kg X 0.7
h = 1.08 X 108 kJ/kg.hour
Total Heat Generated
h = 2.075 X 107 kJ/kg.hour + 1.08 X 107 kJ/kg.hour = 1.288 X 108 kJ/kg.hour

From the above calculation, burning of palm shell and mesocarp fiber is enough to
generate sufficient steam for processing of CPO.
3.9.1.5 Summary of Power Balance
Table X: Overall Power Balance.
Power Generation
1350 kWh
Steam Generated
38,250 kg/hour

Power Consumption
1312.1 kWh
Remaining Steam
33,750 kg/hour

Power Loss
37.9 kWH
Steam Loss
4500 kg/hour