TOPIC 2

Sterilization Vertical, Slanting Oblique and Ball Type

1.0 Introduction
Sterilization is the most important process in the production line. Steam is used as the medium to
transfer the necessary heat required to raise the temperature of the oil palms Fresh Fruit Bunch
(FFB). It is used because it is cheap and readily available from the operation of the boilers and
steam turbo-alternators. Moreover, it is convenient and suitable for this purpose.

The FFB delivered and received at Palm Oil Mill must be sterilized as soon as possible to avoid
the rise in Free Fatty Acid (FFA) during prolonged storage. It is of paramount importance that
sterilization is carried out properly and effectively. Otherwise, it will affect the recovery of oil
and kernel.

The present method of sterilization of FFB is a batch process. With well-thought of design and
planning of sterilizer layout, a continuous operation to supply sterilized FFB into the production
line to sustain the designed Mill throughput can be easily achieved.

With poor design of layout, any interruption in the supply of sterilized FFB will result in a
disruption of downstream activities which lead to, not only reduction of throughput but also the
loss of product.

The main objectives of sterilization of FFB are:-

a. Inactivation of Oil-splitting Enzymes Lipolytic enzymes responsible for the oil- splitting action
in FFB can be destroyed by heart treatment. A minimum temperature of 550c is sufficient to
render these enzymes inactive. Enzymes not inactivated will degrade palm oil by
promoting the rise in Free Fatty Acids (FFA).

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 b. Loosening of Fruitlets From The Bunch Sterilization loosens the fruitlets in the bunch and
facilitates their removal from the bunch during the stripping/threshing process.

c. Conditioning the Mesocarp For Good Oil Recovery.

During the process of sterilization, the mesocarp is softened. During digestion and
pressing processes the mesocarp will be separated from the nut which is further polished
in the depericarper drum.

d. Nut Conditioning For Better Cracking

In order to achieve good nut cracking efficiency in the Nut Crackers or Ripple mills, the
nuts must be dried to a given temperature for a given time. Normally, sterilization at a
pressure of over 40 psig for
90 minutes or more will be sufficient to ensure good stripping of fruitlets and good nut
cracking efficiency.

The main machinery in sterilization process is Sterilizer, and it is categorized as unfired

pressure vessels. Sterilizer and its related equipments will be further described in this topic.

2.0 Types of Sterilizer

Currently there are six (6) types of sterilizer available in the palm oil industry such as follows:
a. Horizontal Sterilizer
b. Vertical Sterilizer
c. Oblique Sterilizer
d. Tilting Sterilizer
e. Ball Tipper (Spherical) Sterilizer
f. Continuous Sterilizer

The most common type of sterilizer used in the palm oil industry is Horizontal Sterilizer.

b. Vertical Sterilizer
Vertical Sterilizers are constructed as cylindrical steel vessels, electrically welded, the size of
which is adapted to the capacity required. At the top is a screw down circular door and at the
bottom front a rectangular hinged door fitted with toggle gear for tightening up to cover the
discharge opening.

Both doors are fitted with a spigotted rubber steam joint, which is oil and temperature
resistant. To assist the discharged of the sterilized bunch, the bottom is provided with a
perforated plate, set at an incline towards the discharge opening and installed with an auger
for better discharge of sterilized bunch.

Vertical non fired pressure vessel with diameter ranging from 2.8m to 3.2m and 6m length
complete with hydraulic operated quick action doors for filling and discharging of fresh fruit
bunch.

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Figure 31: Diagram of Vertical Sterilizer

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It uses pressurized steam (45psig) to sterilize fresh fruit bunch which is similar to current technology.
Hot water may be used to displace pockets of air inside for better heat transfer & to avoid bruising of
fresh fruit bunch. Fresh fruit bunch feeding to the sterilizer and sterilized fruit bunch discharge from the
sterilizer is by using scraper conveyors.

Design capacity is 10 to 30 tons fresh fruit bunch per unit and position vertically, use less floor space
and easier to install. The system is designed without the fresh fruit bunches cages and rail-tracks.
Modular and flexible, can be orientated at any position parallel or perpendicular line process. Easy to
fit for rehabilitation project on sterilization station upgrading without interruption to the normal mill
operation. Simpler in design and process that provides automation capability. It used variable speed
drive on the auger to discharge the sterilizer fruit which eliminates manual discharge.

Figure 32: Schematic diagram of Palm Oil Mill _ Front End section using Vertical Sterilizer

Figure 33: Arrangement of Vertical Sterilizer at Palm Oil Mill

Current Vertical Sterilizers have an effective capacity ranging from 10t to 30t FFB. They are
customized cylindrical steel vessels, made of boiler grade materials, fully welded and sized to suit the
capacity needed. Latest generation of Vertical Sterilizer does not use water. Bottom Door could be
horizontal or Sloping Chute Door.

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There are a few different model of Vertical Sterilizer by different Sterilizer manufacturer which
are using different valves per Sterilizer:
3 Steam Valves (Inlet; Exhaust; Condensate).
4 Steam Valves (Main Inlet; Aux. Inlet, Exhaust; Condensate).
5 Steam Valves (Main Inlet; Aux. Inlet, Exhaust; Condensate; Condensate By-Pass).
6 Steam Valves (Main Inlet; Aux. Inlet 1; Aux. Inlet 2; Venting, Exhaust; Condensate;
Condensate By Pass).
7 Steam Valves (Main Inlet; Aux. Inlet 1; Aux. Inlet 2; Aux. Inlet 3, Exhaust; Condensate;
Condensate By Pass).

Figure 34: Schematic view of Vertical Sterilizers arrangement.

Figure 35: Schematic view of the process of FFB feeding into Vertical Sterilizer

Various sterilizer clutched door used: 900-950mm; 1100mm; 1200mm, 2100mm, 2700mm and
3200mmO.D. Hydraulic cylinders supplied are used for door opening/closing with
lock/unlocking device. Auger is either internal or external type.

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Figure 36: Typical (horizontal) type of FFB discharge door at the bottom section of Vertical
Sterilizer.

Figure 37: Sloping Chute type of FFB discharge door at the bottom section of Vertical Sterilizer

Figure 38: FFB feeding door at the top section of Vertical Sterilizer

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Figure 39: Auger drive system and hydraulic power system for door automation of Vertical
Sterilizer

Figure 40: Auger for evacuation / discharge of sterilized fruit bunch.

c. Oblique Sterilizer
Oblique Sterilizer is the latest type of sterilizer design. It uses pressurized steam (45psig) to
sterilize fresh fruit bunch which is similar to current technology. The system is also designed
without the fresh fruit bunches cages and rail- tracks.

Similar to Vertical Sterilizer, its design capacity is 10 to 20 tons fresh fruit bunch per unit, use
less floor space and easier to install. The plant layout for installation of Oblique Sterilizer is
more or less similar to the Vertical Sterilizer. The difference is more to its orientation where
Oblique Sterilizer is designed and installed at 45 degree steep as compared to Vertical
Sterilizer which is installed vertically, refer to figure below.

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Figure 41: Oblique Sterilizer at Palm Oil Mill

Oblique Sterilizer is mounted at fixed structure of 45 degree inclination to distribute evenly the lessen
the impact of gravitational force. Top Sterilizer Door is 1200mm, while Bottom Sterilizer Door is
2100mm. Sterilizer Capacity is 20ton.

Figure 42: FFB feeding door at the top section of Oblique Sterilizer

Figure 43: FFB discharge point at the bottom section of Oblique Sterilizer

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Figure 44: Hydraulic power system for door automation of Oblique Sterilizer

d. Tilting Sterilizer
Tilting Sterilizer is mounted at base structure and resting a horizontal position during cooking
and tilted up 45 to 50 degree inclination for discharging Sterilizer Fruit Bunches and filling.
Top Sterilizer Door is 1200mm, while Bottom Sterilizer Door is 2100mm. Sterilizer Capacity
is 25 to 30ton.

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Figure 45: Tilting Sterilizer at Palm Oil Mill complete with hydraulic system

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Figure 46: Hydraulic cylinder for tilting of sterilizer located at the bottom section.

Figure 47: FFB discharge door of Tilting Sterilizer

e. Ball Tipper (Spherical) Sterilizer

Ball Tipper Sterilizer is a unique design of Sterilizer in Ball Shape operated like Tipper. Each
Sterilizer is about 60 ton Gross Weight and with a diameter of 3.5m that would hold 30ton fruit.

Feeding of FFB is via FFB Conveyor via Chute to one Sterilizer Clutched Door, where when
sterilization is done, sterilizer is rotated to underneath hopper to discharge the Sterilizer Fruit
Bunch.

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Figure 48: Schematic side view of Ball Tipper Sterilizer

Hydraulic system used in this application required a hydraulic power unit (HPU), to rotate the
Ball Tipper as well to operate the sterilizer clutched door.

Figure 49: Schematic front view of Ball Tipper Sterilizer

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Figure 50: Ball Tipper Sterilizer at Palm Oil Mill (side view)

Figure 51: Ball Tipper Sterilizer at Palm Oil Mill (front view)

Figure 52: FFB feeding door also come as discharge door at Ball Tipper Sterilizer

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Figure 53: Hydraulic power system for door automation of Ball Tipper Sterilizer

Figure 54: Hydraulic power system for tipping of Ball Tipper Sterilizer

f. Continuous Sterilizer (Non-Pressure Vessel type)

Unlike conventional sterilization which is a batch- process using pressure vessel at 3 bar steam
pressure, the continuous sterilizer is a continuous sterilization process using steam at
atmospheric pressure in a non-pressurized chamber.

In conventional sterilization, the material flow from the sterilizers to the threshers is by
batches, which is difficult to automate, whereas the continuous sterilizer is a continuous
process, which can be effectively automated. Design capacity is
10 to 30 tons of fresh fruit bunch per unit of continuous sterilizer.

The Continuous Sterilizer system does not require pressure vessel. In general the system is
equipped with a very long scraper bar type conveyor (40m length) fitted with steam injectors. It
sterilizes the fresh fruit bunch at atmospheric pressure steam (not pressurized), 0 psig, 90-100
deg.c.

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To achieve heat penetration into the fruit
bunches, the fruit bunches are passed
through a bunch crusher before entry into
the sterilizer. The system is also designed
without the fresh fruit bunches cages and
rail-tracks.

Continuous Sterilizer offers better safety

and cleaner working environment from
fresh fruit bunch reception to the threshing
station. It is not a pressure vessel and easy
to operate.

Continuous Sterilization steps:

i. Pre-sterilization: Fresh Fruit Bunch is conditioned using bunch conditioner.
ii. Sterilization: Fresh Fruit Bunch is continuously sterilized at atmospheric pressure or with low
pressure.
iii. Post-Sterilization: Further heating of fruitlets using the post-heating vessels and the horizontal
digester.

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Figure 56: FFB is being conditioned using the Bunch Crusher before fed into
Continuous Sterilization

Figure 57: Continuous Sterilization using

Two Deck Conveyor

Figure 55: Schematic diagram of

Continuous Sterilizer

Figure 56: FFB feeding into Continuous

Sterilizer

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Figure 58: Plant layout of Palm Oil Mill using Continuous Sterilizer (top and
bottom pictures)

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