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Steam Requirements and Mass Balance in Digesters and Screw Presses at Palm Oil Mill

This research analyzes steam requirements and mass balance in digesters and screw presses at a palm oil mill to optimize crude palm oil (CPO) production. The study found that the optimal steam requirement was 359,870 kg/hour, and corrective actions reduced oil losses to 1.57%, improving efficiency and product quality. The methods employed include energy and mass balance calculations to address issues related to steam supply and oil extraction efficiency.

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0% found this document useful (0 votes)
12 views12 pages

Steam Requirements and Mass Balance in Digesters and Screw Presses at Palm Oil Mill

This research analyzes steam requirements and mass balance in digesters and screw presses at a palm oil mill to optimize crude palm oil (CPO) production. The study found that the optimal steam requirement was 359,870 kg/hour, and corrective actions reduced oil losses to 1.57%, improving efficiency and product quality. The methods employed include energy and mass balance calculations to address issues related to steam supply and oil extraction efficiency.

Uploaded by

Riska Indira
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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JEMMME (Journal of Energy, Mechanical, Material, and Manufacturing Engineering)

Vol. 9, No. 2, 2024

ISSN 2541-6332 | e-ISSN 2548-4281


Journal homepage: http://ejournal.umm.ac.id/index.php/JEMMME

Steam requirements and mass balance in digesters


and screw presses at palm oil mill
Zulfatri Ainia, Tengku Reza Suka Alaqsab, Sri Basriatic
a,b,c
Universitas Islam Negeri Sultan Syarif Kasim Riau, Riau, Indonesia
Jalan HR. Soebrantas Km 15, Pekanbaru, Indonesia
e-mail: [email protected]

Abstract

Fresh Fruit Bunches (FFB) are the primary component in Crude Palm Oil
(CPO) production. Palm oil mills face challenges in optimizing CPO yield,
particularly in reducing oil losses during processing, which affects efficiency
and profitability. The pressing station, including the digester and screw press,
plays an important role in oil extraction. The digester uses steam to heat and
soften the fruit for better oil release, while the screw press performs the
mechanical extraction of oil. Insufficient steam can hinder oil separation,
leading to increased losses. This research aimed to analyze steam
requirements for the digester and evaluate the mass balance of the screw
press. Using energy and mass balance methods, the optimal steam
requirement was 359,870 kg/hour with a mass balance error of 6.58%.
Corrective actions in steam valve settings reduced oil losses to 1.57%, which
improved processing efficiency and product quality.

Keywords: steam, mass balance, digester, screw press, palm oil mill

1. INTRODUCTION
Fresh Fruit Bunches (FFB), the primary component in the production of Crude Palm
Oil (CPO) and its derivatives, are produced by palm oil mills, which continually strive to
optimize CPO yield (1)(2). A challenge in this process is reducing oil losses, as high
levels of oil loss can affect processing efficiency and lead to financial losses. Within the
palm oil mills, the pressing station plays an important role in extracting oil from the fruit,
utilizing key tools such as the digester and screw press (3). The operation in the digester
begins by loading the processed fruit to about three-quarters of its capacity, followed by
stirring and opening the line press. This vertical cylindrical tube is equipped with stirring
arms at six levels by an electric motor. The crushing process facilitates the important
heating, which is achieved by directly injecting steam (4).
The operation of the screw press follows the exit of raw materials from the digester,
where these materials are fed into the screw press for further processing. The screw
press, also referred to as a mechanical press, facilitates the mechanical extraction of
palm oil through its pressing process (5). During operation, the digester requires steam
injection from the boiler to heat and soften the fruit flesh, which accelerates the softening
time and eases the release of oil cells from the mesocarp, as well as the separation of the
mesocarp from the palm nut (6). This direct steam injection is essential for reheating the
palm fruit with multiple processing stages, raising the working temperature to 90-95°C
and maintaining it throughout the crushing process. Consequently, higher temperatures in
the digester yield better chopping results, reducing the workload of the screw press and
minimizing kernel damage (7). However, challenges arise if the steam supply is
inadequate, as it may prevent the necessary temperature from being reached. It leads to
suboptimal oil separation from the palm fruit and insufficient release of kernel fibers,
which can result in losses for the company. Conversely, excessive steam heating may
cause an over-evaporation of oil and lead to losses.

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All materials exiting the digester are subsequently transferred to the screw press for
pressing and processing into oil and cake, where the tool operates by rotating and
pushing the fruit bunches. The pressing process occurs under hydraulic pressure of
approximately 45-50 bar, with the electric motor set to around 29-36 amperes to increase
the likelihood of oil extraction. During this process, water is added to the screw press to
dilute the pressed material, preventing it from becoming too dense and avoiding the
formation of high-viscosity liquids that could hinder separation and cause oil losses.
Therefore, mass balance calculations are essential to determine the balance between
input materials and the products exiting the screw press (8). Insufficient steam heating
supply can result from several factors, including disruptions in the steam processing
system, such as damage to pipes that transport steam from the boiler to the digester (9).
Other potential issues include low steam pressure caused by fuel problems, temperature
control issues, mechanical failures in the boiler components, and leaks in the valves
during the steam distribution process. All contribute to inadequate steam heating supply
to the digester.
Calculating the mass balance is essential to ensure that the balance between the
input materials and the products exiting the screw press does not experience significant
discrepancies. If the heating steam supply is insufficient after exiting the digester, the
required temperature may not be reached. Therefore, it results in a considerable amount
of oil remaining in the cake in liquid form, which cannot be accommodated in the oil gutter
and leads to losses. Moreover, an optimal steam supply conversely reduces losses and
enhances the separation of fiber and palm nuts, preventing broken nuts that diminish
production quality. Insufficient steam heating supply to the digester will lead to suboptimal
softening of the palm fruit, creating difficulties in separating the oil from the flesh and
kernel fibers, thereby increasing the risk of higher oil losses detrimental to the company
(7). Additionally, this inadequate steam supply can affect the separation of fiber and palm
nuts, potentially reducing production quality and raising the risk of broken nuts. A lack of
balance between the input materials and products exiting the screw press indicates
problems in the oil extraction process, which can leave significant amounts of oil
unextracted in the cake, decreasing the efficiency of the process and the quality of the
final product (8).
The solutions to these issues based on previous research include routine
inspections of the boiler to detect and repair disruptions or damages (10), which were
prompted by disturbances in the combustion system affecting the auxiliary boiler's
operation. Regular inspections of the combustion system are necessary to identify and
rectify any disruptions in the steam boiler. Another solution involves regularly adjusting
the steam injection in the palm oil digester and its mechanical components (11),
identifying appropriate methods can guide the adjustment of steam injection valves at the
digester and pressing station, thereby reducing losses in the CPO production process.
Additionally, repairing or replacing damaged components in the pipes and steam
processing equipment is vital for ensuring a smooth heating supply (12), However,
conducting a steam requirement analysis before taking action is a more effective solution
(7). Previous research demonstrated that calculating the steam needed during the
softening stage of palm fruit at PT. Perkebunan Sumatera Utara PMKS Tanjung Kasau
led to an adjustment of steam temperature to 135°C, maximizing the softening process
before moving to the screw press and optimizing oil separation from the palm fruit flesh
and kernel fiber release. To address the balance issue between input materials and
products exiting the screw press, calculating the mass balance on the screw press is
optimal, allowing for further action if discrepancies between input and output are
identified, such as adjusting hydraulic pressure and the settings of the press electric
motor (8).
This research utilizes two primary methods: energy balance and mass balance
(7)(8). Based on the first law of thermodynamics, the energy balance method calculates
the steam needed in the digester by equating the heat in a system to the energy change
plus the work done, ignoring kinetic and potential energy (13). The mass balance method
employs the law of conservation of mass, stating that in a closed system, mass remains
constant, with mass entering equaling mass exiting (14). These methods are
advantageous as they yield accurate results, provide a systematic approach to analyzing

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complex systems, can be applied to various industrial processes, and enhance energy
efficiency and quality control (15). After determining steam requirements, corrective
actions are implemented by adjusting digester valve settings to optimize steam use while
minimizing openings. Balancing energy efficiency, operational flexibility, and precision
control utilized four-valve opening methods for allowing accurate steam flow regulation
according to process needs (7).
This research took place at a palm oil mill in Pantai Cermin Village, Tapung District,
Kampar Regency, Riau, which processes 45 tons of Crude Palm Oil (CPO) daily with a
16.6% oil extraction rate (16). The mill has 8 digesters of various types, each with a
cylindrical capacity of 3,000 to 3,500 liters and a total capacity of 12 tons, operating at
temperatures between 90 and 95 degrees Celsius. It also features 8 screw presses that
can produce 15 to 17 tons per hour at a pressure of 40 Bar, facilitating the separation of
crude oil from fiber and seeds, with 7% hot water added based on the fresh fruit bunches
processed (16). The operations in the mill revealed that the pressing station faces
significant oil losses, with a press cake loss rate of 5.83% from January to February 2024,
exceeding the acceptable standard of less than 4%. Insufficient steam heating and
inadequate fruit mashing contribute to these losses. Therefore, an analysis of steam
requirements for the digesters and a mass balance calculation for the screw press are
essential to identify corrective actions. The objective of this research is to analyze the
steam requirements for the palm oil digestion process, evaluate the mass balance
entering and exiting the screw press, and identify corrective actions based on the steam
demand and mass balance analysis. This research contributes to optimizing steam usage
and improving production efficiency at palm oil mills. It aims to enhance the quality and
quantity of palm oil production while minimizing losses.

2. METHODS
This research was conducted at the Palm Oil Mill in Garuda Sakti, Pantai Cermin
Village, Kampar Regency, Riau. The study utilized one of the digesters at the palm oil
mill, specifically the sixth digester, as well as the sixth screw press. Data collection for
further analysis was carried out in September 2024, following initial findings in February
2024 that revealed an issue with palm oil losses in the laboratory exceeding the standard
threshold (>4%) in the fiber, with a recorded value of 5.83%. This problem was identified
as stemming from the suboptimal mashing of fruit in the digester before being transferred
to the screw press, along with insufficient heating steam supply injected from the boiler to
the digester.
This study combines two main methods to identify and analyze oil losses in palm oil
mills, the mass balance method and the energy balance method (7)(8). The study began
with measuring the oil losses produced by the screw press machine. Oil losses that
exceed the standard (> 4%) indicate a problem in the squeezing process that needs to be
followed up with further analysis. If high oil losses are found, the next step is to evaluate
the digestion performance. It plays an important role in determining the quality of palm
fruit processing. This digestion performance is closely related to the steam temperature
used to soften the palm fruit before processing, which if not optimal, it can cause the fruit
to be processed improperly and result in high oil losses in the screw press machine.
The first method used in this study is the energy balance, which is based on the first
law of thermodynamics to calculate the steam requirements in the reactor (13). In this
case, this analysis aims to determine the amount of energy the system requires to heat
and compact the palm fruit. This heating process is crucial because if the steam
temperature is not high enough, the fruit crushing process will be less effective, which
causes problems separating oil from the fruit flesh and fiber, thus increasing oil losses in
the pressing stage. The data on the temperature and pressure of the steam used to heat
the reactor and calculations to ensure that the resulting temperature was sufficient to
maximize the crushing process, under the optimal temperature determined in previous
literature.
Next, the mass balance method was applied to initiate the success of the pressing
process (14). The mass balance was used to ensure that there was no discrepancy
between the incoming material and the output from the screw press machine. This
discrepancy could indicate undetected oil losses or errors in the verification process. In

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this context, the mass balance calculation was used to verify whether the amount of oil
extracted followed the amount that should have been based on the input of raw materials
(oil palm fruit) and output (oil and fiber). In this way, the study identified the oil losses and
provided a clearer picture of the efficiency of the overall pressing process.
After the analysis was carried out using the mass and energy balance methods,
corrective measures were subsequently applied. One of the main corrective measures is
the valve settings on the digester to optimize steam usage while minimizing valve
openings that can cause energy waste. Here, four-valve opening methods are applied to
achieve energy efficiency, operational continuity, and precision control balance in steam
flow regulation. Adjusting the valve setting is expected to optimize the palm oil fruit-
crushing process. It will reduce oil losses and increase the quality and quantity of CPO
production.
This research begins with identifying the problems through direct interviews and
observations at the palm oil mill. Operators provided insights into high fiber losses in the
screw press which enabled a focused investigation of issues, particularly in the digester
section. Secondary data collection includes gathering specifications for both the digester
and screw press machines, along with data on digester performance, such as mass,
pressure, temperature, composition of the fruit bunches, and crude palm oil prices.
Additionally, production data from the pressing stage, including the input and output rates
of the press, are collected. The next step involves measuring oil losses to determine if
they align with standard thresholds. If the losses exceed acceptable levels, the analysis
proceeds by calculating the steam requirements based on the mass composition of the
fruit bunches entering the digester which assesses the heat absorbed by the fruit
bunches and determines the total steam needed for optimal digester operation. Following
this, a mass balance calculation for the screw press is performed by evaluating the input
and output rates of the screw press and its components. Then, corrective actions are
implemented regarding the steam injection process to address the identified
inefficiencies. The flowchart of this research is further explained in Figure 1.

Start No
If Losses
> 4%?
Problem Identification
Yes

Literature Review Calculate Steam Demand

Data Collection Mass Balance Calculation

Corrective Actions
Measure Oil Losses

End

Figure 1. Research Flowchart

2.1 Data Collection


Various data are required in this research from the beginning to its final stages.
Some of the primary data directly obtained from the research objects include the
specifications of the digester and screw press machines at the palm oil mill, which are
utilized in this study.

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Table 1. Digester specifications at the Palm Oil Mill


Component Description Specification
Digester Brand and Type Apindo AP 12
Cylinder Capacity 3000-3500 liters
Digester Capacity 12 tons
Temperature 90-95oC
Blade Rotation Speed 22-25 rpm
Cylinder Diameter 1,27 meters
Cylinder Height 3,5 meters

Table 2. Data of screw press specifications at the Palm Oil Mill


Component Description Specification
Screw Press Brand and Type Apindo AP 12
Capacity 15 tons
Pressure 40 bar
Temperature 90oC
Rotation Speed 20-13 rpm
Machine Length 4970 mm
Machine Width 1200 mm
Machine Height 1050

Table 3. Data on the Palm Oil Mill's fruit mash process in the digester
Data Palm Oil Bunch Steam Oil Fraction
M T1 T2 PS TS TF
(Kg/hour) (oC) (oC) (Kg/cm2) (oC) (oC)
1 11880,5 62 95 2,8 135 95
2 11880,5 65 95 2,8 135 95
3 11880,5 64 94 2,8 135 94

Table 4. Composition of the fruit bunch feed for the digester unit at the Palm Oil Mill
No. Content Composition
(%)
1 Oil 24.98%
2 Water 12,84%
3 Fiber 12.71%
4 Nut 13.00%
5 Shell 7.02%
6 Sludge 29.45%

Table 5. Data on specific heat (Cp) of palm fruit components


No. Content Specific Heat (Kcal/KgoC)
1 Oil 0.35
2 Water 1.00
3 Fiber 0.43
4 Nut 0.38
5 Shell 0.45
6 Sludge 0.53

Table 6. Mass balance components for the screw press at the Palm Oil Mill
No. Content Composition
(%)
1 Dilution Water 9
2 Dilution Crude Oil 50
3 Press Cake 25

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2.2 Oil Losses Measurement


The purpose of measuring oil losses in the screw press is to determine whether
there are any issues related to the steam requirements in the digester. If the losses
exceed the standard limit of 4%, a steam requirement analysis for the digester becomes
necessary. The steps for calculating oil losses in the screw press using the Foss NIRS
DA 1650 in the laboratory are as follows:
a. Prepare a sample of 30 grams to be analyzed, ensuring the sample is homogenous.
b. Place the sample into the large cup, spreading it evenly and compactly to ensure no
light gaps are visible from below.
c. Open the instrument lid, insert the large cup properly, and close the instrument.
d. Press the process button on the instrument to select the type of product to be
analyzed. The product is fiber.
e. The oil loss result will be displayed in approximately 2 minutes.

2.3 Calculation Steam Demand


In this study, the calculation of steam demand begins with determining the
composition of fresh fruit bunches (FFB) entering the digester. Several variables are
required, including FFB mass composition and FFB feed composition in the digester
(percentage composition). Using equation (1), the mass composition of the FFB
components, such as oil, water, fiber, nut, shell, and sludge, is determined. The mass
values are obtained from Table 3, while the percentage compositions are derived from
Table 4. Equation (1) calculates the composition of fresh fruit bunches (FFB) entering the
digester.

M = mpalmoilbunch . composition (1)

where M is mass composition based on percentage content (kg/hour), mpalmoilbunch is the


mass of the fruit bunch unit (kg/hour) and composition is the percentage of unit content
(%). The next step is calculating the sensible heat. It measures water before and after the
water reaches its boiling point. When a substance absorbs sensible heat, its temperature
increases. Inversely, when the substance releases sensible heat, its temperature
decreases. This heat effect is closely related to the substance's heat capacity. Sensible
heat transfer can be calculated using the following equation (2).

Q = m. Cp. ∆t (2)

where Q is the heat transfer rate (kcal/hour), m is the mass flow rate (kg/hour), Cp is heat
capacity (kcal/kg°C), and ∆t is temperature difference (°C)
Then, the calculation for the required steam in the digester unit is based on the
principle that the heat absorbed by the fresh fruit bunches equals the heat released by
the steam. This calculation will be performed using equation (3).

Q = m (∆H + ) (3)

where Q is heat released by steam (kcal/hour), m is the mass of steam (kg/hour), ∆H is


heat due to temperature change (kcal/kg) and  is the enthalpy of vaporization (kcal/kg).
Meanwhile, the mass balance calculation for the screw press is represented by
equation (4).

Input = Output (4)

where Input is the summation of digested fruit bunches and dilution water (kg/hour) and
Output is the summation of press cake and dilution crude oil (kg/hour). If there is an
imbalance between the input and output in the mass balance calculation, the error is
calculated using the equation (5).

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Input−Output
error = | | . 100% (5)
Input

where the error is the percentage of discrepancy (%), Input is the summation of digested
fruit bunches and dilution water (kg/hour) and Output is the summation of press cake and
dilution crude oil (kg/hour).

3. RESULT AND DISCUSSION


3.1 Oil Losses Measurement in the Palm Oil Laboratory
This measurement is conducted to determine if there are issues with the steam
requirements in the digester. If oil losses exceed the standard of 4%, a steam
requirement analysis in the digester is necessary. The oil loss measurement starts with a
30-gram homogenous sample placed in a large cup, ensuring even distribution to
eliminate light gaps. The cup is then inserted into the instrument, and the lid is closed.
The product type, press fiber, is selected using the process button, with results displayed
in about two minutes. Figure 2 shows a 30-gram weighed fiber sample in the large cup
from screw press number 6 under investigation is being processed.

Figure 2. The 30-gram weighed fiber sample in the large cup

After the sample was inserted into the Foss Nirs DA 1650, the test results were
obtained as shown in Table 7.

Table 7. The results of fiber losses screw press number 6


Parameter Results
(%)
Oil/WM 4.04
Oil/DM 6.55
VM (Volatile Matter) 38.31
NOS (Non-Oil Solids) 57.65

The result of 4.04% shows oil losses exceed the acceptable limit of 4%, necessitating an
analysis of the steam requirements in the digester. Calculation analysis is important to
assess the steam needed for the digester and to perform mass balance calculations on
the screw press. Such evaluations will help identify corrective actions to mitigate losses.

3.2 Process Calculation of Steam Demand


As the oil losses remain above 4%, analysis of the steam demand will be conducted.
First, the mass composition of the fresh fruit bunches entering the digester is calculated
using equation (1). The results of the calculations are summarized in Table 8, which the
mass of each component contained within the fresh fruit bunches.

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Table 8. Summarized mass composition

Component Mass Composition


(kg/hour)
𝐌𝐨𝐢𝐥 2967.75
𝐌𝐰𝐚𝐭𝐞𝐫 1525.46
𝐌𝐟𝐢𝐛𝐞𝐫 1510.01
𝐌𝐧𝐮𝐭 1544.47
𝐌𝐬𝐡𝐞𝐥𝐥 834.01
𝐌𝐬𝐥𝐮𝐝𝐠𝐞 3498.81

The next step is calculating sensible heat, or the heat absorbed by the fresh fruit
bunches, using equation (2) for all components. The initial temperature (T1) is 62°C, and
the final temperature (T2) is 95°C, as obtained from Table 3. The total heat absorbed by
the fresh fruit bunches will be calculated by summing from each component, including oil,
water, fiber, nut, shell, and sludge. The results are presented in Table 9.

Table 9. Total heat absorbed by fresh fruit bunches


No. Content Heat Absorbed
(Kcal/hour)
1 QOil 33427.50
2 QWater 48928.65
3 QFiber 21427.06
4 QNut 22935.31
5 QShell 10458.50
6 QSludge 61194.14
QTOTAL 199221.16

After determining the total heat absorbed by the fresh fruit bunches, the next step is
calculating the amount of steam required in the digester unit using Equation (3). Table 10
presents the results of calculating heat due to temperature change. It is denoted as ∆H
which can be referenced from the saturated water table.

Table 10. The heat due to temperature change

No. Temperature Saturated Vapor


(°𝐂) (kJ/kg)
1 95 2667.6
2 135 2726.9

Based on Table 10, the value for ∆H can be determined by subtracting 2667.6 kJ/kg
from 2726.9 kJ/kg, resulting in 59.3 kJ/kg of ∆H. It is 14.17304 kcal/kg after it is converted
into kilocalories. After obtaining the value of ∆H and converting it to kcal/kg, the next step
is to find λ. The enthalpy at a temperature of 100°C is 2257 kJ/kg, which converts to
539.423 kcal/kg. The following step involves calculating the amount of steam required in
the digester using equation (3).

199221.16 Kcal/hour = m (14.17304 kcal/kg + 539.423 Kcal/kg)


199221.16 Kcal/hour = m (553.59604 kcal/kg)
199221.16 kcal/hour
m =
553,59604 kcal/kg
m = 359.870 kg/hour

Thus, from the equation above, the amount of steam required for the palm oil bunches
crushing process in the digester unit is 359.870 kg/hour.

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3.3 Process Mass Balance Calculation


The input consists of the summation of digested fruit bunches and dilution water,
measured in tons, while the output is the summation of press cake and diluted crude oil.
The percentages for each component are detailed in Table 6. The mass of the digested
fruit bunches is taken from the total palm oil bunch mass of 11,880.5 kg/hour. According
to the research in (7), this represents 90% of the total mass, yielding 10,692.45 kg/hour.
This value is then applied to equation (4).

Table 11. Mass balance in the screw press

No. Component Results


(kg/hour)
1 Input 12042.45
2 Output 11250

After calculating, the mass input is 12042.45 kg/hour, and the mass output is 11250
kg/hour. Therefore, the error can be calculated by equation (5).

Table 12. Total error mass balance in screw press

Description Result
(%)
Error 6.58

3.4 Corrective Actions for Steam Injection Settings


Since an error of 6.58% was obtained, corrective measures were implemented in the
steam injection settings of the digester to ensure optimal fruit crushing and prevent oil
losses. Repairment was adjusted to meet the maximum steam required while the opening
valve reached 100%. Four valve-opening methods were adjusted: The first method
involved setting the valve at level 1 with 90-100% opening. The second method involved
setting the valve at both level 1 and level 2 with 90-100% opening at each level. The third
method involved setting the valve opening at levels 1, 2, and 3, each with 90-100%
opening. Lastly, the fourth method involved setting the valve to a 90-100% opening at
level 1 and a 50% opening at level 2. After conducting the adjustments, it was determined
that the best performance was achieved with the second method, which involved setting
the valve at both level 1 and level 2 with a 95% opening at each level. The following
illustrates the experiment conducted on the steam injection in the digester in Figure 3.

Figure 3. Setting the valve at both level 1 and level 2 with a 95% opening at each level

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Corrective action to adjust the steam injection setting involves optimizing steam
usage to ensure efficient fruit digestion and minimize oil losses. This action focuses on
regulating the steam injection to meet the required levels. The steam injection setting
fine-tuned by controlling the valve opening to ensure the optimum amount of steam is
supplied at each process. To validate that the valve setting is correct, samples were
taken from the fiber screw press to see the losses shown in Table 13.

Table 10. The result losses after optimizing steam injection with valve levels 1 & 2 set 95%

Parameter Results
(%)
Oil/WM 1.57
VM 55.46
Oil/DM 3.52
NOS 42.97

Figure 4 illustrates the reduction in oil loss in the palm oil mill before and after the
optimization of the steam injection process. Initially, oil loss was recorded at 4.04% before
implementing corrective actions. After adjusting the steam injection settings, specifically
optimizing the valve opening to 95% at levels one and two, oil loss dropped drastically to
1.57%. This reduction shows the effectiveness of the implemented corrective actions
identified during the initial assessment phase. The study began with a thorough problem-
identification process through interviews and direct observation at the palm oil mill, which
allowed for a targeted approach to address core issues.
4,4%

Oil/WM
38,31% VM
57,65% Oil/DM
NOS

6,55%

(a)
1,57%

Oil/WM
42,97% VM

55,46% Oil/DM
NOS

3,52%

(b)

Figure 4. (a) Oil Losses Before Optimization, (b) Oil Losses After Steam Injection Optimization

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4. CONCLUSION
This research analyzed the steam requirements for the palm oil digestion process
and evaluated the mass balance at the screw press. The findings revealed that the
amount of steam needed for crushing palm oil bunches in the digester unit was 359,870
kg/hour. The calculated mass input was 12,042.45 kg/hour, while the mass output was
11,250 kg/hour, resulting in an error of 6.58%. Upon implementing corrective actions, the
optimal performance was achieved through the second method, which involved setting
the valve at both level 1 and level 2 with a 95% opening at each level. This adjustment
led to a significant reduction in oil losses, measured at 1.57%, indicating substantial
improvement, as it is below the acceptable threshold of 4%.

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