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.

ichsan@astra-agro.co.id
HP : 0811-99-34-10
TYPE OF STERILIZER
 BASIC CONCEPT STERILISASI
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.
RACHIS SYARAT LEPASNYA BRONDOLAN DARI SPIKELET ADALAH DENGAN
MENGGUNAKAN STEAM PADA TEKANAN ATMOSPHERE, TEMPERATUR 100 C
INNER FRUIT SELAMA 20 – 40 MENIT
Mongana Report – hal – 35 – (figure 55)
MIDLE FRUIT
SYARAT MATINYA ENZYM LIPASE YANG MENAIKKAN FFA ADALAH TEMPERATUR
OUTER FRUIT 55 oC
STORK PALM OIL REVIEW – hal – 3
DAYA SERAP PANAS
KONDUKSI SILINDER BERLAPIS pada FRUIT
PRESSURE STERILISATION (PS)
q VS
Lapisan steam
ATMOSPHERIC STERILISATION (AS) :
Lapisan udara film r2
r1 T2
r3
Lapisan mesocarp T3 PS/AS = 166/90 = 1.84
T0
Lapisan shell
A
T1
r4
PS = 1.84 X AS
T4
B

C
“Pressure sterilisation daya serap panas dari
Lapisan kernel
steam lebih effektif 1.84 kali dibandingkan
ΔT ΔT D
dengan Atmospheric Sterilisation”
q= =
Σ Rth RD + RC + RB + RA Inilah mengapa di Atmospheric Sterilisation
132oC to 85o C q=
( T4 - T0 ) untuk mematangkan lagi fruits disterilisasi
ln (r4/r3) ln (r3/r2) ln (r2/r1) ln (r1) di POST HEATING COOKER, sebelum
+ + + 2πk L masuk ke DIGESTER dan PRESSING.
2πkDLD 2πkCLC 2πkBLB A A
 EVAPORATION in STERILISATION Hasil perebusan yang
optimal untuk

Temp in the rachis oC

3 2.8 mendapatkan
pengutipan minyak
130ºC
dimana kandungan
2.2 120ºC
Relative Presure (

moisture di pericarp
2 110ºC
10 % - 14 %.
1.8 100ºC STORK – PALM OIL
90ºC REVIEW hal 15
80ºC
70ºC
1
Kg/cm2)

60ºC
50ºC
40ºC
30ºC
15 30 45 60 75 90
Time (in minutes)

1000
KEBUTUHAN STEAM VS PEMBUANGAN UDARA
32
Kg of steam/hour per tonne of

800

ltr Air/Kg Steam

100Kg of steam

600
8
bunches

Total Consumption : about 260 kg

2
400 Zona of variable troughput
Blowdown

0 to 200 kg/hour
Blowdown trought airvent

n trought
Normal airvent

200
Blowdow
Sweepin
Blowdown

Swe
epin

B
Normal

Blowdo
g

3
g

D
wn

2
Continuous blow off
Kg/Cm2

1
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)
0
A 10
Time (Minute) 10 C 20 20 E 30 30 40 50
40 60 50 70 60 80
 OPERATIONAL IMPROVEMENT
MENAIKKAN THROUGHPUT DARI 30 KE 50 TPH

Cycle Time

Stz #1

Stz #2

Interval
waktu

Stz #3

Interval
waktu
STEAM FLOW
STEAM FLOWCHART
CHART STEAM FLOW
– POM
SATURATED CHART –BOILER
& SUPERHEAT POM
SUPERHEATED BOILER
SATURATED BOILER
P = 21 bar abs P = 21 bar abs
T = 215 OC T = 260 OC
3b 4

SUPER HEATER
21 bar
P = 21 bar abs
abs PP==19
19bar
barabs
abs
3a 100 OOCc
Cc OC
250OC
T = 100 TT==209
545 STEAM
STEAM P = 21 bar abs
SEPARATOR
SEPARATOR T = 260 OC

PP==21
21bar
bar abs
abs
BOILER TURBIN
TURBIN 4
80OOCC
TT==80
22
~~
MAKE
MAKE UP
UP STEAM
STEAM
P = 1 bar abs
TP= =801 Obar
C abs
T = 80 OC11 P = 4 bar abs
T = 143.6 OC
PP==44bar
barabs
abs
T = 150
Camp 90%OC

656 TOTO STERILISER

STERILISER 99
P =64 bar abs
T = 143.6 OC
FEED
FEEDWATER
WATER PUMP
PUMP
P = 1 bar abs STEAM TRAP TOTO PROCESS
PROCESS
T = 80 OCc
7
BACK PRESSURE VESSEL
8
P = 4 bar abs BACK PRESSURE VESSEL
MAKE-UP
T = 80 OC
WATER
PUMP
PROPERTIES SUPERHEATED
SATURATED BOILER FOR
BOILER PROCESSING
FOR PROCESSING

s = konstan

Sensible heat Latent

= m cp Δt Sensible heat =
heat
m cp Δt
2 3a 3b 4

5 s = konstan
8 BPV 4 Bara
6,9
6
BPV 3 Bara (CS)
9

1a Atmospheric Pressure CS
7

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)
hf
hcs hhcs
hz s hsh
hhz
 OPERATIONAL COMPARATION
NO ITEM EVALUASI CONTINUOUS HORISONTAL HORIZONTAL INDEXER VERTICAL/OBLIQUE Keterangan
Preelemeneries, Mechanichal, Earth work and civil,
Building, Elektrical, Workshop equipment, Anciliary
Cost Of Investment 1,125 1,010 1,019 1 (investment index) Building, Piping work, Fire fighthing equipment,
1 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
6 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
10 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
TERIMA KASIH
TOP DOOR OF STERILISER
USED TO FILL FFB
IMPROVEMENT : auger digantikan dgn STEAM FLUSHING
 Y

X
 FROM FFB FEEDING
CONVEYOR

BUNCH
CONDITIONER

TWO DECK
INLET FLAP VALVE LIVE STEAM CONVEYOR
INJECTION

OULET FLAP VALVE

STERILISED
BUNCHES TO THRESHER
 INNER
FRUIT
MIDLE
FRUIT
RACHIS
OUTER
FRUIT

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
PRESSURIZE SYSTEM
INNER
FRUIT
MIDDLE
FRUIT
TS RACHIS
OUTER
FRUIT
TR

Penampang TBS dan Dimensinya

TS – TR 140 - 30
Panas Latent = hfg qCOND = k A =kA
R R
(Panas diberikan steam) (Panas yang diterima oleh buah)
ATMOSPHERIC SYSTEM
INNER
FRUIT
MIDDLE
FRUIT
TS RACHIS
OUTER
FRUIT

TR PIECES OF
CRUSHED FRUIT

Penampang TBS dan Dimensinya

TS – TR 105 - 30
Panas Latent = hfg qCOND = k A = k 2A
R ¼R
(Panas diberikan steam) (Panas yang diterima oleh buah)
HEAT TRANSFER
Horizontal Steriliser

udara isolator

kudara = 0,0285
W/(kg.K), at T = 60 oC STEAM

CAGES
kf = 0,687 W/(kg.K),
at p = 3 barg

BODY STZ
kg = 0,029 W/(kg.K),
at p = 3 barg CONDENSATE
HEAT LOSS
 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)

1000

800
100Kg of steam
Kg of steam/hour per tonne of

600
Total Consumption : about 260 kg
bunches

400 Zona of variable troughput

0 to 200 kg/hour

200

3
Kg/Cm2

0
10 20 30 40 50 60

Time (Minute)
HEAT TRANSFER
Vertical Steriliser

udara isolator

STEAM

BODY STZ

CONDENSATE
HEAT LOSS
HEAT TRANSFER
Continuous Steriliser

udara isolator
Cp, TBS = 0.6 kcal/kg oC

Cp, TBS = 2.52 kj/kg oC

STEAM STORK PALM OIL REVIEW – hal 23

BODY STZ

Cp,f = 4,217 kj/kg oC CONDENSATE

HEAT LOSS
CONTINUOUS STERILISATION
SUPERHEATED BOILER
P = 21 bar abs P = 21 bar abs
T = 215 OC T = 260 OC
3b 4

SUPER HEATER
P = 21 bar abs P = 19 bar abs
T = 100 OCc T = 250 OC
3a 5 STEAM P = 21 bar abs
SEPARATOR T = 260 OC

P = 21 bar abs
BOILER TURBIN 4
T = 80 OC
2
~
MAKE UP STEAM
P = 1 bar abs
1
T = 80 OC
9
P = 4 bar abs
P = 1 bar abs
T = 150 OC
6 TO STERILISER T = 105 OC

FEED WATER PUMP

TO PROCESS

BACK PRESSURE VESSEL

CS - SUPERHEATED STEAM

Sensible heat
= m cp Δt Latent
heat Sensible heat =
m cp Δt
2 3a 3b 4

6
Pressure
drop
1a 9
7 LATENT HEAT FOR
STERILISATION
 CONTINUOUS STERILISATION

P = 21 bar abs
SATURATED BOILER
T = 215 OC
3b

P = 21 bar abs P = 19 bar abs

T = 100 OCc T = 209 OC
3a 5 STEAM
SEPARATOR

BOILER TURBIN
P = 21 bar abs
T = 80 OC
2
~
P = 1 bar abs MAKE UP STEAM
T = 80 OC
1 P = 1 bar abs
T = 100 OC
P = 4 bar abs
Camp 90%
6 TO STERILISER 9
FEED WATER PUMP
STEAM TRAP TO PROCESS

BACK PRESSURE VESSEL

CS - SATURATED STEAM

2 3a 3b

s = konstan

6
Pressure
drop
1a 9

LATENT HEAT FOR

STERILISATION
 JENIS-JENIS PROSES HEAT TRANSFER

KONDUKSI MELALUI KONVEKSI DARI SUATU RADIASI NETTO

BENDA PADAT ATAU PERMUKAAN KE FLUIDA PERTUKARAN PANAS
FLUIDA YANG DIAM YG BERGERAK ANTARA DUA PERMUKAAN

Surface, T1

T1 > T2 Ts > T∞
FLUIDA BERGERAK,
T1 T2 T∞
q1”
q” Ts q2”

Surface, T2

KONDUKSI KONVEKSI RADIASI THERMAL

 EVAPORATION in STERILISATION

3 2.8
Relative Presure ( Kg/cm2)

Temp in the rachis oC

130ºC
2.2 120ºC
2 110ºC
1.8 100ºC
90ºC
80ºC
70ºC
1
60ºC
50ºC
40ºC

30ºC
15 30 45 60 75 90
Time (in minutes)
Pressure Sterilisation
Evaporation 10 % Latent heat diserap buah

TBS out =
85 C
TBS in =
Small vertical stz cap 1 ton
30 C FFB. Max temp of steam
130 C.

Cp = 0.6 kcal/kg oC
Sensible heat diterima buah Cp = 2.52 kj/kg oC
 MOLLIER CHART

T = 130 C
T = 30 C

T = 85 C

∆T Laten heat
diberi
steam
P = 2.7 bar

P = 1 bar

Sensible Latent heat

heat diserap diserap TBS
TBS

h85 hf,130 hg,130

hf,85
Pressure Sterilisation
Evaporation 10 % Latent heat diserap buah
QL = 100 kg x (hg,130 – hf,85) kJ/kg
QL = 100 x (2718.9 – 355.75)
QL = 236,315 kJ

TBS out =
85 C
TBS in =
Small vertical stz cap 1 ton
30 C FFB. Max temp of steam
130 C.

Sensible heat diterima buah Latent heat steam T = 130 C

Qfg = (hg,130 – hf,130) kJ/kg
QS = 900 kg x 2.52 kJ/kg oC x (85 – 30) C
Qfg = (2718.9 - 546.11) kJ/kg
QS = 124,740 kJ
Qfg = 2173 kJ/kg
Pressure Sterilisation
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
=
Latent heat steam T = 130 C

= 361,055 kj / 2173 kj/kg = 166 kgs steam/ton FFB

 Atmospheric Sterilisation

TBS in
30 C

Evaporation 3 %

TBS out
85 C
 MOLLIER CHART

T = 30 C

T = 85 C

T = 100 C

∆T

Laten heat
diberi
steam
P=
P =1
1 bar
bar

Sensible Latent heat

heat diserap TBS
diserap
TBS

hf,130
h85 hg,130
hf,85
Atmospheric Sterilisation
Latent heat diserap buah
QL = 30 kg x (hg,100 – hf,85) kJ/kg
QL = 30 x (2674.9 – 355.75)
Evaporation 3 %
QL = 69,575 kJ

TBS out =
85 C
TBS in =
Actual continues stz. Max
30 C temp of steam 100 C, in 1
ton FFB

Sensible heat diterima buah Latent heat steam T = 130 C

Qfg = (hg,100 – hf,100) kJ/kg
QS = 970 kg x 2.52 kJ/kg oC x (85 – 30) C
Qfg = (2674.9 - 418.87) kJ/kg
QS = 134,442 kJ
Qfg = 2256 kJ/kg
Panas Total yang diterima oleh 1000 kg FFB :

= Sensible heat diterima buah + Latent heat diserap buah

QS = 134,442 kJ QL = 69,575 kJ

= 204,017 kj

Steam Consumption (kgs steam/ton FFB) :

Sensible heat diterima buah + Latent heat diserap buah
=
Latent heat steam T = 100 C

= 204,017 kj / 2256 kj/kg = 90 kgs steam/ton FFB

 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

C C x n C x n S x 60
THROUGHPUT STZ 
cycle time
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.

Menaikkan Throughput Steriliser
C C x n C x n S x 60 TON STEAM
THROUGHPUT STZ  Ratio  0.25  0.30 
cycle time TON TBS

CC = Menaikkan Kapasitas Cage/lorry, (Ton)

= Pengisian lorry yg maksimal, kapasitas lorry diperbesar.

nC = Jumlah Cage/lorry dalam satu steriliser

= steriliser diperpanjang

nS = Jumlah steriliser
= unit steriliser ditambah.

Cycle time = CT = Waktu dari tutup pintu ke tutup pintu stz, (menit)

= cycle time dikurangi dengan cara menambah supply

steam dan by pass steriliser.

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

1. Tentukan Throughput Steriliser

2. Tentukan Cycle Time

CC x n C x n S x 60
Cycle Time  CT 
Throughput Stz

3. Tentukan Interval waktu antara steriliser

CT
Interval waktu 
ns
 Cycle Time

Open - close
Blow off
Deaeration Penetration

Holding Time
 Cycle Time

Stz #1

Stz #2

Interval
waktu

Stz #3

Interval
waktu
GRAFIK BPV SLS2 3.2 BARG KONSTAN
(THROUGHPUT 50 TPH)