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Development of Palm Oil Extraction System

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 International Journal of Engineering and Technology Volume 5 No. 2, February, 2015

Development of Palm Oil Extraction System

Basil E. Okafor
Department of Mechanical. Engineering, Federal University of Technology,
Owerri - Imo State, Nigeria.

ABSTRACT

This is an improved design of a palm oil extraction system with particular reference to Nigerian experience. Existing design
conditions were carefully examined and necessary improvements made to enhance oil extraction efficiency. A detailed design of the
oil extraction system was therefore done. The screw press design configurations, the effects of lagging, the casing of the press
chamber, as well as optimal heating requirement of the system were carefully examined. A vertical oil palm digester design was
made to feed the screw press by gravity. Detailed design of the screw press hereby presented. Much emphasis was however made in
the use of available local construction materials. Performance test shows that the oil extraction efficiency of the screw press at an
optimal temperature of 98oC is 95.7 percent.

Keywords: Palm oil extraction, improved design, optimal temperature, improved efficiency, lagging.

1. INTRODUCTION its economic importance as a high yielding source of edible

and technical oils, oil palm is now grown as a plantation crop
The oil palm tree is a tropical plant commonly found in warm in most tropical countries with high rainfall (minimum of
climates at altitudes of less than 1600 feet above sea level 1600 mm per year). The palm bears its fruits in bunches
([Link]). It is one of the most economic trees in the varying in weight between 10 ~ 40 kilograms. The individual
world today as virtually every part of the tree is of economic fruit (Fig.1.1) of weight between 6 ~ 20 grams is made of an
importance to man. The tree produces one of the most outer skin (exocarp), a pulp (mesocarp) which entraps the
popular edible oil of high nutritional value. Palm oil is rich in palm oil in a fibrous matrix, a central nut consisting of a shell
carotenoids (a pigment found in plants and animals) from (endocarp) and the kernel-which itself contains an oil quite
which it derives its red colour and its major components of different from palm oil but resembling coconut oil (Poko,
glycerides – a saturated fatty acid (palmitic acid). Hence palm 1998). A typical composition of a Fresh Fruit Bunch (FFB) is
oil is a viscous semi-solid substance even at tropical ambient as shown in Fig. 1.2.
and a solid fat in temperate climates (Poko, 1993). Because of

exocarp

mesocarp

endocarp

kernel

Fig. 1.1 Structure of Palm Fruit

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 International Journal of Engineering and Technology (IJET) – Volume 5 No. 2, February, 2015

Fibre-10%

Empty Bunch Water-13%

27%
Palm Oil-20%
Pericarp
43%

Fresh Fruit Bunch Fruit Palm Kernel

(FFB) 63% 4%
Nut
Cake -1.8%
20%
Shell
Water Kernel Oil -1.5%
16%
10%
Water - 0.7%

Fig. 1.2 Composition of Fresh Fruit Bunch

Conversion of crude palm oil to refined oil will involve the The traditional design is simple, but the process involved is
removal of products of hydrolysis and oxidation, colour and tedious and very inefficient (Poko, 2002). There are many
flavor. After refining, the oil is separated (fractionated) into palm oil extraction methods, but the question is; which
liquids and solid phases by thermo-mechanical means among them is most efficient and economical? According to
(involving controlled cooling, crystallization and filtering), Cornelius (South, 1983), the use of screw press gives an oil
the liquid fraction (olein) being used extensively in the extraction efficiency level as high as 95 per cent. However, a
tropics as cooking oil. Palm oil extractors of all kinds critical examination of the local press system revealed the
incorporate these unit operational stages, differing only in the following problems;
level of mechanisms that make the system batch or 1. High viscosity of the extracted oil caused by low
continuous. The primary interest however is how best to operating temperature and subsequent loss of heat
extract oil from the fruits by use of an integrated design of a during pressing operation.
fruit digester and screw press. 2. Loss of heat while transferring digested palm fruits
from the digester to the press chamber.
The oil content of the palm fruit is about 30 per cent by
weight of the fresh fruit bunch (Hartley, 1977). Under normal
3. Increase in production cost owing to extra labour
required to transfer digested palm fruits from the
conditions, oil extracted from palm fruit is light red. In
digester to the press chamber.
addition to its primary use for edible purposes, it also serves
as a major raw material in the production of margarine and 4. Inefficient extraction of entrapped oil.
soap. This makes its extraction a major concern for large
scale production, considering oil loss arising from use of
inefficient extraction methods. In order to ensure maximum 2. CONCEPT DESIGN
oil extraction, it becomes necessary to consider as follows
(Poko, 2002). Figure 2.1 shows the assembly view of the palm oil screw
press, and Fig. 2.2 shows the orthographic views.
i. The best maturity time to cut the palm fruit bunch
from the tree. 2.1. Description
ii. The optimum period to keep the fresh (harvested)
palm fruit bunch before processing. The screw press consists of a screw in a cylindrical drainage
iii. The optimum oil extraction temperature cage with a main worm shaft which carries a worm assembly
iv. The effect of heat on the screw press surface and and which acts as palm oil expellers. Digested mash is
structure; and hence appropriate material selection. introduced into the press screw via an inlet hopper. The press
v. Appropriate lagging of screw press chamber to assembly has a provision through which hot water is
minimize heat loss. sprinkled to the mash. This helps to keep the system at
vi. Appropriate power selection to ensure optimum desired optimal temperature (can be as high as 98 oC). The
performance. higher the operating temperature, the lower the oil loss
vii. Should the digester be incorporated to the screw
press, considering that heat will be lost while
transferring the digested palm fruits from the
digester to the screw press? Also extra cost will be
incurred. So will the integrated design actually
guarantee higher efficiency?

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 International Journal of Engineering and Technology (IJET) – Volume 5 No. 2, February, 2015

Fig. 2.1 Assembly View of the Screw Press

Fig.2.2 Orthographic View of the Screw Press

and the easier to extract the oil from the mash (South Worth, 3. DESIGN ANALYSIS
1983). This is as a result of reduction in oil viscosity with
increase in temperature. The drainage cage is lagged to 3.1 Power Requirement Considerations
prevent heat loss. The design incorporates a gear box and a
variable speed pulley assembly for easy control of the In the screw press design there are basically four areas where
operating speed. The screw press is powered through a power is needed; these are:
reduction gear box. Power is transmitted from the electric i. Power required to overcome the inertia of the
motor through spur gears to an auxiliary shaft. The roller shaft and screw,
conveyor taps power from the motor through a crossed belt. ii. Power required to convey digested palm fruits
The screw power shaft works both as a conveyor and as a along the entire length of the press,
power element. The screw is welded to the shaft with iii. Power required to effectively press and squeeze
incrementally decreasing pitches. The press receives digested out entrapped oil from the digested palm fruits,
palm fruits from the digester via an inlet hopper and gradually and
moves it forward by aid of the screw threads. The decreasing iv. Power compensation for friction and other
screw pitch and screw height provide the compressing force losses during operation.
needed to squeeze out the entrapped oil. Spur gears were used
in the design of the reduction gear box. In general, screw 3.1.1 Inertia of Drive Shaft
presses are relatively simple in operation and much less
costly to install than the solvent extraction systems. The The shaft is cylindrical and hollow; thus volume, V = πr 2l
screw method is reported to give oil extraction efficiency as Internal radius, ri = 24mm; Outside radius, ro = 30mm;
high as 98 per cent (Hartley, 1977). Length, l = 1400mm
V = 3.142 (0.0009 – 0.0006) x 0.14 = 1.32 x 10-4 m3
Mass of the steel pipe, M = 7850 (kg/m3) x 1.32 x 10-4 (m3) =
1.04 kg
The press screw is made up of ten gradually decreasing
flights cut and drawn to shape with a thickness of 4.9mm.
The diameter of the largest flight is 270mm which
progressively decreases by 9mm.
But the flights are connected by a 60mm hollow drive shaft,

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 International Journal of Engineering and Technology (IJET) – Volume 5 No. 2, February, 2015

Thus net volume of flight = volume of flight – Volume of Where Q is the conveying capacity; L is the projected length
hollow shaft of the screw conveyor (1.2m), and F m is the material factor
per kW.
Flight 1; V1 = π (0.00028) – 0.000014 = 0.0000266m3
P2 = (380.32 x 1.2 x x 480 x 0.8) / 168547 = 1.4 kW
Flight 2; V2 = π (0.0000834) – 0.000014 = 0.000248m3
3.1.3 Power Required to Press the Digested Palm Fruit
Flight 3; V3 = π (0.0000778) – 0.000014 = 0.0023m3
Experiment shows that it requires approximately 322kPa to
Similarly, V4 = 0.00213m3; V5 = 0.000197m3; V6 = crush and press out oil from palm kernel. Since high oil
recovery is desired, a compression pressure slightly less than
0.00018m3; V7 = 0.000166m3; V8 = 0.000151m3 the crushing strength of the kernel is desired. During
operation, the cage and the activities of its accessories (flights
V9 = 0.000137m3; and V10 = 0.000123m3 and the cone) add to the pressure needed to squeeze out the
oil. Thus, let compression pressure required = 200kPa
Total Volume, VT = 0.00191m3
But power required to press oil, P = FVm
Total mass of Flight, MT = 0.00191 x 7850 = 15.001kg
Where F = Force required to squeeze out the oil; Vm = Mean
Mass of Flight + Mass of Shaft = 15.001 + 1.036 = 16.16kg
peripheral velocity of drive shaft
Power to overcome this mass = weight x mean peripheral
But F = Squeezing pressure x Total surface area in contact
velocity, vm
with the palm fruits
But vm = TmN/60 (Spivakousky and
Vm = tmn/60 ; where tm = mean pitch of the screw
Dyachkou, 1983)
Vm = (0.111 x 30) / 60 = 0.056 m/s
Where Tm = mean lead of screw; N = RPM of the screw
Areas in contact with palm fruits are as shown in figure 3.1.
vm = (0.111 x 30) / 60 = 0.056 m/s
Curved surface area of drive shaft = 2πrl = 2 x 3.142 x 0.03 x
Thus power required, P1 = (16.16 x 9.81) x 0.056 = 0.00887
1.2 = 0.226 m2
kW
Considering the flights an approximate circle joined by the
3.1.2 Power Required to Convey Digested Palm Fruits
shaft;
We first determine the throughput capacity of the press
screws. The Throughput Capacity is given by, Area of first flight = π (0.1350)2 – π (0.03)2 = 0.0545m2

Q = (60 π d2tnψρc) / 4 = 47d2tnψρc in t/hr Area of 2nd flight = π (0.1305)2 – π (0.03)2 = 0.0507m2

(Spirakovski and Dyachkov, 1983)

Where d = screw diameter (225mm), t = screw lead (110mm),

n = rotational speed (30rpm), c = correction factor based on

the angle of inclination (0.8), ψ = filling coefficient of the Fig.3.1 Areas in contact with palm fruits

screw cross section (0.125 for high abrasive materials), and ρ

Area of 3rd flight = π (0.12605)2 – π (0.03)2 = 0.0471m2 and
3
= density of digested palm fruit (480kg/m ).
so on up to the 10th flight.
2
Thus, Q = 47 x (0.225) x 0.110 x 30 x 0.125 x 480 x 0.8 =
Total area of flights = sum total area of the ten flights
380.32kg/hr
= 0.391 m2
Power required to convey digested palm fruits,
We however observe that the effective area of the flights is
P2 = QLρFm / 168547
equal to half of the total area therein;

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 International Journal of Engineering and Technology (IJET) – Volume 5 No. 2, February, 2015

Thus, Effective Total Area of Flights = 0.391 / 2 = 0.1955 m 2 Frictional Force, F = µN = 0.035 (174.40 x cos 30) = 5.2862

For the curved surface area of the cone (Fig.3.2); kN

Frictional Power, P4 = 5.2862 x 0.056 = 0.296 kW

180
270 Overall Power Required, P = 0.00887 + 1.4 + 9.76 + 0.296 =
X

1200
11.46 kW

Fig.3.2 Curved Surface Area of the Cone 3.2 Selection of Electric Motor for the Screw Press

(X + 1200) / 270 = X / 180 (similar triangles) Power Required = 11.46 kW

X = 2400mm Considering 10 % addition for compensation;

Area of curved surface of the conical part of the cage = Power Required, P = 11.46 + 1.146 = 12.60 kW =

142[(0.135 x 3.6) – (0.09 x 2.4)] = 0.848m2 12.60/0.746 = 16.8 hp

Effective area = 0.848 x 0.5 = 0.424m2 Use 17 horse power electric motor

Surface area of the end part = πr2 = 3.142 (0.09)2 = 0.026m2 3.3 Design of the Drive Shaft

Both areas become 0.424 + 0.026 = 0.450m2 Forces acting on the shaft include:
i. Weight of digested palm fruits (distributed
Total Contacting Areas = (0.226 + 0.196 + 0.450)m2 = force)
ii. Weight of flights (also considered a distributed
0.872m2 force)
iii. Force acting on the gear (concentrated force)
Total Force Required = Pressure x Total Area = 200 (kPa) x iv. Reactions at the bearings

0.872 (m2) = 174.40kN Figures 3.3 and 3.4 show the load and free body diagrams
respectively. In Fig. 3.4 the distributed forces arising from
Hence, Power required to press out palm oil, P3 = FVm = weights of digested fruits and flights are treated as
concentrated forces. This helps to add to factor of safety of
174.40 x 0.056 = 9.76 kW the design.

3.1.4 Power Required to Overcome Friction

wt. of flights

wt. of digested palm fruits C

1200mm B 200mm
A
Fig. 3.3 Press Screw Shaft Loading

Ff+Fp = 72,210N Fg =
26,644.44

A B C
1200 200
Ra = Rb =
31664.26N 67,190.18N
Fig.3.4 Free Body Diagram of Shaft Loading

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 International Journal of Engineering and Technology (IJET) – Volume 5 No. 2, February, 2015

Force due to weight of digested palm fruits, Fp = 9.81(QL/V)

Flange
Gear Box Pulley
= [9.81 (380.32/60 x 60) x (1.2/0.056)] = 22.21kN

Force due to weight of flights, Ff = 15.001 x 9.81 = 150kN

V-belt
But since it is a distributed force, we choose one third of this
Electric Motor

value which is still very safe. Thus, Ff = 50kN

Thus, Fp + Ff = 22.21 + 75 =72.21kN = 72,210 N is

Fig. 3.5 Power Transmission

considered a concentrated force acting at the centre.

For the first two gears;
Gear force, Fg = T/r where T is the torque generated by
Number of teeth of pinion, N1 = 18; Number of teeth of
the gear wheel, 2398 N-m
driven gear, N2 = 72
Fg = 2398/0.18 x 0.5 = 26,644.44 N
Power = Fv where v is the pitch line velocity of the pinion
Taking moment about A; (26644.44 x 1.4) + (72,210 x 0.6) –
Whole depth of teeth = 2.157 x 4.5 = 9.7mm (where
1.2RB = 0
modulus, m = 4.5)
RB = (26644.44 x 1.4) + (72,210 x 0.6)/1.2 = 67,190.18 N-m
Minimum deddendum = 9.7 – 5.2 = 4.5mm
Also, RB + RA = 72,210 + 26644.44; RA =98854.44 –
Pitch circle, PC = π x 4.5 = 14.137mm
67,190.18 = 31664.26 N
Thus pc = π/14.137 = 0.222
Obviously, the maximum bending moment,(Mb) = 72,210 x
Pitch diameter of pinion, dp = N1 / 2 = 18/0.22 = 81mm
0.6 = 43326 N-m
Pitch diameter of gear, d g = N2 / 2 = 72/0.222 = 324mm
d3 ={16/πSa √[(kbMb)2 + (ktMt)2] (Hall, 1980)
Centre to centre distance of the mating gears, dg/2 + dp/2 =
where d = shaft diameter; Sa = allowable stress; Torsional
324/2 + 81/2 = 202.5mm
moment, Mt = (9550 x kW)/RPM
Pitch line velocity of pinion, vp = πdpn/60 where speed of
Kb and Kt are shock correction factors for bending and
pinion gear = Input shaft speed of gear box = 327.22rpm
torsional moments respectively, kb = kt = 1
vp = (3.142 x 0.081x 327.22)/60 = 1.388 m/s
Mt = (9550 x 12.60)/950 = 126.663N-m
Force acting on pinion, Fp = power / vp = 15.20 /1.388 =
d3 = {(16/3.142 x 120x106)√[(43326)2 + (126.663)2]
10.90 kN
d3 = 0.001838; d = (0.001838)1/3 = 0.120m
Induced stress on the pinion, s = So (3/ (3 x vp) for v < 10
3.4 Gear Design for the Screw Press
m/s where So is the allowable stress
Figure 3.5 shows the power transmission network of the
Induced Stress, s = 800 [3/(3 x 1.3888)] = 576MPa
screw press. Considering 20% power transmission losses,
Since face width should not exceed 4pc (Shigley and Chuke,
Design Power, P = 12.6kW + 0.2 (12.6) = 15.20kW
1989);
Speed of electric motor = 950rpm; motor sheave diameter =
If b is the face width for pinion, then b = 4P c = 4 x 0.014137
180mm
= 0.0565
Input shaft speed of gear box = (62/180) x 950 = 327.22rpm
But whole depth teeth, h = 9.7mm = 0.0097m

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 International Journal of Engineering and Technology (IJET) – Volume 5 No. 2, February, 2015

Induced stress, s = 6Nh/bt2 where t is the thickness of gear 3.5.2 Determination of the Insulation Thickness

teeth Proper insulation of heating equipment is important for

efficient utilization of heat energy. Fiber glass was chosen
t2 = 6Nh/sb = 6 x 18 x 0.0097 / 57600 x 0.0565 = 0.000322; t (with a thermal conductivity of 39 W/moC) because of its
high sensitivity and ability to withstand temperatures up to
= 0.018m = 18mm the envisaged operating temperature. According to Woodcock
and Mason (1987);
Thus, gear thickness of gear teeth, t = 18mm Quantity of heat transferred, Q = KA (t2 – t1)2 / x

3.5 Heat Calculations Where K = Thermal conductivity of the material, 40W/mK; A

Heat conducted through the materials will depend on; = Area through which heat transfer takes place

i. The available time for heat transfer t1 = Initial temperature, 25oC = 298K ; t2 = Final
ii. The type of material
iii. Thickness of the material temperature, 98oC = 371K
iv. The temperature difference, and
v. The area through which the transfer takes place x = Thickness of screw press chamber, 20mm =

3.5.1 Total Area to be Heated 0.02m

The screw press is in form of a frustum of a circular cone Q = 40 x 1.913 (371 – 298) / 0.02 = 27915 W
(Fig. 3.6).
ASSUMPTIONS

r2 i. Steady state heat transfer exists

r1 ii. One dimensional heat flow through the walls
iii. Effects of heat losses through edges and corners
are neglected, and
iv. Material of the wall is considered to have
constant thermal conductivity
L

Fig. 3.6 The Press Chamber

Δx1 = Δx3 = 0.005m where Δx1 and Δx3 are thicknesses of

the inner and outer walls respectively.

Resistance, R = Δx/K

where K is the thermal conductivity.

Resistance of metal walls, R1 = 0.005/60 = 8.33x10-5 W/K

X1 X2 X3
R2 Rc where K for mild steel = 60W/mK
R1 Rh
Resistance of aluminum wall, R3 = 0.005/52 = 9.62x10-5 W/K
Fig. 3.7 Resistance to Heat Flow where K for aluminum = 52 W/mK

Resistance of insulating material (fiber glass), R2 = Δx2/0.143

Area = πhs (r1 + r2)
= 6.993 Δx2 W/K
Where hs = slant height = √ (r2 – r1)2 + L2 = √ (0.270 –
Where K for fiber glass = 39W/moC = 0.143W/mK
2
0.170)2 + 1.380 = 1.384m
Rn is the resistance due to surface conductance of the inner
Area, A = 3.142 x 1.384 x (0.27 + 0.17) = 1.913m2
cage wall, and Rc is the resistance to heat flow of the outside

wall.

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 International Journal of Engineering and Technology (IJET) – Volume 5 No. 2, February, 2015

Rh = 1/hh ; and Rc = 1/hc where h is the heat transfer

Efficiency, η2 = (12.96/14) x 100 = 92.57%
coefficient of the surface with h and c representing hot and
Test3: 13.40kg of palm oil was extracted at an operating
cold sides respectively. temperature of 98oC.

Since heat transfer by convection is free or normal; Efficiency, η3 = (13.40/14) x 100 = 95.71%

hc = hh ; 1/hc = 1/hh = 1/10 = 0.1mK/W 5. CONCLUSION

Total overall heat transfer coefficient, Vc = 1/Rh + R1 + R2 + It is observed that oil extraction efficiency is largely
depended on the flow property of the oil which also depends
R3 + 1/Rc
on the viscosity of the oil and which in turn is a factor of the
Vc = 1/0.1 + 8.33x10-5 + 6.993Δx2 + 9.62x10-5 + 1/0.1 operating temperature. Maximum quantity of oil was
extracted at an optimal temperature of 98oC.
Vc = 20.0001 + 6.993Δx2

Rate of heat loss (Heat Flux), Q/A = VcΔT where ΔT = REFERENCES

temperature difference = (373 – 298)K = 73K
[1] Hall,H.L. (1980). Machine Design. Schaum’s
2 Outline Series. McGraw-Hill Book Company,
A is the total heat transfer surface area = 1.9128m , and Q is
London.
the quantity of heat transferred = 27915W
[2] Hartley, C.W.S. (1977). The Oil Palm. Longman
Group Limited, London.
27915/1.912 = (20.0001 + 6.993Δx2) 73
[3] Poko, K. (1993). Innovations in Village Based Palm
200 = 20.0001 + 6.993Δx2; 179.99 = 6.993Δx2 ; Δx2 =
Oil Processing. Paper presented at the BUROTROP-
AFDPDA seminar on small and medium scale oil
25.7mm
palm and coconut technologies, Accra, Ghana.
Thus, use insulation thickness of 26mm
[4] Poko, K. (1998). Oil Palm Small Holder
Development. Processing Technology Mission
4. PERFORMANCE RESULT report presented on FAO project TCP/MLW/6612.
[5] Poko, K. (2002). Small Scale Palm Oil Processing.
Performance tests were carried out at different operating A paper posted at [Link].
temperature values. Digested fruits were fed into the screw
press by gravity. Sprinkles of water at 100 oC were added to [6] Shigley, J.E. and Ms Chuke (1989). Mechanical
the mash. Percentage of palm oil extracted was recorded at Engineering Design. 10th Edition. McGraw Hill
different operating temperatures. Book Company, Inc. New York.

Efficiency: [7] Spirakovsky, A.D. and Dyachkov, V.K. (1983).

Conveying Machines. Vol.11. Mir Publishers,
The oil extraction efficiency of the press can be defined as Russia.
quantity of oil squeezed out by the press divided by the
maximum oil content in the mash. According to Velayuthan [8] South Worth A. (1983). Palm Oil Extraction by
and Chan (1983), the maximum oil content in palm fruits is Pressing. Workshop on palm oil technology and
35% of whole weight. Thus 40kg of digested palm fruits was effluent [Link] oil research institute,
charged into the press chamber; Malaysia.

Total amount of realizable oil from the mash = (40/1) x [9] Velayuthan, A. and Chan, K.L. (1983). Efficiency of
Palm Oil Extraction and Quality Control. Workshop
(35/100) = 14kg of oil on palm oil mill technology and efficiency
treatment. Palm oil research institute of Malaysia.
Test 1: 12.20 kg of oil was extracted at an operating
temperature of 92oC. [10] Woodcock, C.R. and Mason, J.S. (1987). Bulk Solid
Handling. Chapman and Hall. New
Efficiency, η1 = (12.20/14) x 100 = 87.14% [Link].(2003). The Origin of Palm
Fruits.
Test 2: 12.96 kg of oil was extracted at an operating
temperature of 96oC.

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