CONTROLLING THE OIL LOST

FIELD OF INVENTION

The present invention relates to use of mineral salt to improve production of crude palm oil and to control the oil lost in a palm oil milling process.

BACKGROUND ART

Palm oil trees [Elaeis Guineensis) was grown early in Africa, exists in the wild and later cultivated on land areas of tropical countries such in Africa, South East Asia and Latin America. Palm oil anatomy can be describe as monocot with tall and wide trunk appearance which can rise up to the 15m - 20m tall with a diameter count of the trunk of between 20- 75cm. The leaves of the palm trees are the pinnate type of leaves where it is divided into segments or leaflets and attached to the leaf rachis. The leaflets are commonly in pairs and stacking side by side in order.

Typically, for optimum yield, palm oil trees require annual rainfall 2000mm and be distributed to the crops throughout the year. The best oil palm yield are obtain in the climate range of temperature between 22°C to 24°C with the maximum temperature within the range of 29°C to 32°C and exposed to additional 5 hours sunlight per day.

The palm oil fruits contain several type of colour variation, starting from black, purple to the red-orange colour, those colours indicate the ripeness of the fruits or variety of the corps. Generally there are around 2000 fruits with a different level of maturity of the fruits in one bunch. The morphology structure of the palm oil fruits can be divided into 4 important parts: exocarp, mesocarp, endocarp and kernel. Among all, the mesocarp contains 45%-50% of oil in it and most of the oils come from this rest. The crude palm oil produced from the mesocarp has several characteristics which can help to differentiate with the other oils. Pressed oil normally can be measure by its density, refractive index, saponification value, unsaponification matters, free fatty acids, iodine value, total carotenoids and Iodine value. Mixture of water and oil, oil in water and water in oil emulsion is the main component in crude palm oil. It is at the clarifier station where the crude palm oil is separated into pure oil and sludge. Nevertheless there is an approximate average composition of screw pressed crude palm oil to be 64% oil, 24% water and 12% non-oil solid. The Oil Extraction Recovery (OER) of the palm oil depends on several factors such as the mechanical factor, environment, crops, weather and human factor. Mechanical factor and human factor are the only factors that millers can control to enhance the production of the crude palm oil at the mills. Other than mechanical factors, several mills intended to increase the OER by controlling the oil lost or by implementing improved extraction technique to bring out a maximum yield while controlling the oil lost can be achieved by increasing the efficiency of the existing mechanical equipment. The extraction technique usually involves heavy modification in the existing plant along with chemical solvent usage; hexane is the common solvent that has been used in extraction activities especially for soy bean oil and olive oil extraction. There have been number of solutions provided for efficient extraction techniques and few of them have been discussed below:

WO2015150372 Al discloses a process which uses an enzyme to help in increasing the crude palm oil yields. The enzymes are among a group of lipid acyltransferase, a phospholipase A2 or a phospholipase Al. The enzyme will be mix together with the palm fruits extract an incubating the mixture for about 45 ^e C to about 95 ^Q C for about 15 minutes to about 6 hours. Thus results in de-emulsification of the palm fruit extract (e.g. pressed palm fruit extract) and significantly improved separation of oil from pressed palm liquid, thus reducing the amount of oil in the waste stream.

US20080178908 describes a process which uses silicon in making a product for the crude petroleum extraction. The document talks about a solution comprising Si02 and Na20 as a main ingredient to make the solution works. US4570713A describes the use of silicon compound in oil well recovery methods specifically for the crude palm oil. Also, the use of the hydride compound in removing oil from oil bearing materials has been discussed therein.

The aforesaid prior art documents may strive to provide efficient extraction techniques, however, they still have number of limitations and shortcomings such as, but not limited to, maintaining the value of Free Fatty Acids (FFA), Deterioration of Bleachability Index (DOBI) and moisture at optimum level during the production of the crude palm oil as these parameters affect the quality of the crude palm oil. Further, these processes fail to provide a a solution to increase the OER without jeopardising the quality of the crude palm oil as well as for health and safety reasons.

Accordingly, there remains a need in the art to have an improved process to produce crude palm oil in order to enhance the quality and quantity of the crude palm oil.

SUMMARY OF THE INVENTION

Accordingly, the present invention aims to provide a palm oil milling process to produce crude palm oil which uses a water-based solution in the steam line to enhance the quality and quantity of the crude palm oil. The water-based solution is made up of a sodium alkaline silicate salt-type solution and processed water which allows reducing free fatty acids value, increase DOBI and OER values.

In accordance with an embodiment of the present invention, the palm oil milling process to produce crude palm oil comprising the steps of injecting a water-based solution in a steam line by using an atomizer, blending the water-based solution with the steam resulting in a mixed steam and permeating the mixed steam through a plant material such that fruits get detached from the plant material. The reaction of the mixed steam with the fruits results in extraction of the crude palm oil from the fruits. Further, the amount of the injected water- based solution is determined by the atomizer. Furthermore, the mixed steam controls free fatty acids value by reaction between the water-based solution and free fatty acids. Also, the mixed steam controls DOBI value of the fruits.

In accordance with an embodiment of the present invention, the amount of injected water- based solution depends on the weight of the plant material. Preferably, the amount of injected water-based solution is 22 L/Hr.

In accordance with an embodiment of the present invention, the free fatty acid value is reduced by, but not limited to, 0.3%-1.0% and the DOBI value is increased by, but not limited to, 0.5% - 1.5%. In accordance with an embodiment of the present invention, the step of permeating enables to increase the OER by, but not limited to, 0.5%-1.0%.

In accordance with an embodiment of the present invention, the water-based solution having a sodium alkaline silicate salt-type solution and processed water. Further, the sodium alkaline silicate salt-type solution comprises of, but not limited to, a silicon, processed water and caustic soda.

In accordance with an embodiment of the present invention, the processed water having the conductivity between, but not limited to, 0.00 S/m to 0.02 S/m and μ5/πι to 5 μ5/πι.

In accordance with an embodiment of the present invention, the caustic soda is sodium hydroxide with a concentration between 45%-50%. Preferably, the sodium hydroxide having specific gravity between, but not limited to, 1.5 -1.7.

In accordance with an embodiment of the present invention, the step of injecting the water- based solution is performed at a temperature of, but not limited to 90°C.

In accordance with an embodiment of the present invention, the process further comprising a step of steaming the plant material through the mixed steam is performed for about 20- 90 minutes at a temperature of, but not limited to 80°C to 100°C. Preferably, the step of steaming the plant material through the mixed steam is performed for about 60-90 minutes at a temperature of, but not limited to 80°C to 100°C. Further, the step of steaming is performed at a pressure of 3-5 bars. In accordance with an embodiment of the present invention, the water-based solution is separated from the extracted oil in a sludge pit.

In accordance with an embodiment of the present invention, the water-based solution facilitates extraction of the oil from mesocarp of the fruit.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may have been referred by embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawing illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments. These and other features, benefits, and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein:

Fig. 1 illustrates a process palm oil milling process to produce crude palm oil in accordance with an embodiment of the present invention;

Fig. 2 illustrates experimental results of a water-based solution in accordance with exemplary embodiment of the present invention; and Fig. 3 illustrates experimental results of the sodium alkaline silicate salt-type solution of the water-based solution in accordance with exemplary embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described, and are not intended to represent the scale of the various components. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claim.

As used throughout this description, the word "may" is used in a permissive sense (i.e. meaning having the potential to), rather than the mandatory sense, (i.e. meaning must). Further, the words "a" or "an" mean "at least one" and the word "plurality" means "one or more" unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes.

In this disclosure, whenever a composition or an element or a group of elements is preceded with the transitional phrase "comprising", it is understood that we also contemplate the same composition, element or group of elements with transitional phrases "consisting of, "consisting", "selected from the group of consisting of, "including", or "is" preceding the recitation of the composition, element or group of elements and vice versa.

The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only, and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary, and are not intended to limit the scope of the invention.

Generally, the present invention provides a sodium alkaline silicate salt-type solution, wherein the solution comprises 6 w% of silicon, 59 w% of processed water and 35 w% of caustic soda to provide the solution high pH properties and the solution undergoes diffusion by ultraviolet to allow transition metals from periods 4, 5 and 6 of the periodic table. The caustic soda may be a sodium hydroxide with a concentration between 45%- 50%. The sodium hydroxide may have a specific gravity between 1.5 -1.7.

The solution may be used to extract more carotene and may reduce the food fatty acid (FFA) value in a process of producing a crude palm oil. The solution as claimed in claim 4, wherein the solution is used in the in process of producing a crude palm oil to increase the Deterioration of Bleachability Index (DOBI] by extracting more carotene. The solution may reduce the FFA value by reacting with the FFA using a hydrolysis method between fats and oils and may reduce foul odour surrounding palm oil mills. Furthermore, the present invention, generally provides a p^lrn oil milling process to produce crude palm oil using the solution as claimed in any one of claims 1 to 7, the process comprising the steps of:

(a) injecting a water-based solution in a steam line by using an atomizer;

(b) blending the water-based solution with the steam resulting in a mixed steam; and

(c) permeating the mixed steam through a plant material such that fruits get detached from the plant material;

wherein reaction of the mixed steam with the fruits results in extraction of the crude palm oil from the fruits;

wherein the amount of the injected water-based solution is determined by the atomizer; wherein the mixed steam controls free fatty acids value by reaction between the water- based solution and free fatty acids;

wherein the mixed steam controls DOBI value of the fruits.][WUl] The amount of injected water-based solution depends on the weight of the plant material.

Under this process, the FFA may be reduced by 0.3%-1.0% whereas the DOBI value may be increased by 0.5% - 1.5%. The step of permeating enables the OER to be increased by 0.5%-1.0%. The water-based solution comprises the sodium alkaline silicate salt-type and processed water.

The processed water may have conductivity between 0.00 S/m to 0.02 S/m, preferably 0

The step of injecting the water-based solution may be performed at a temperature of 90°C.

A further step of steaming the plant material through the mixed steam may be provided and may be performed for about 20-90 minutes at a temperature of 80°C to 100°C. The step of steaming the plant material through the mixed steam may be performed for about 60-90 minutes at a temperature of 80°C to 100°C and may be performed at a pressure of 3-5 bars.

The water-based solution may be separated from the extracted oil in a sludge pit and the water-based solution may facilitate extraction of the oil from mesocarp of the fruit.

Referring to the drawings, the invention will now be described in more detail. Figure 1 is a flow chart illustrating the process [100) palm oil milling process to produce crude palm oil in accordance with an embodiment of the present invention.

At step 102, a water-based solution is injected in a steam line. In accordance with an embodiment of the present invention, the water-based solution is introduced into the steam line by using an atomizer. Preferably, the water-based solution is continuously injected to the steam line while a plant material is kept in a bin or bucket inside a sterilization chamber. In accordance with an embodiment of the present invention, amount of injected water- based solution depends on the weight of the plant material. Preferably, the amount of injected water-based solution is 22 L/Hr.

Further, the step 102 is performed at a temperature of, but not limited to 90°C. At step 104, the water-based solution is blended with the steam and results into a mixed steam.

At step 106, permeating of the mixed steam is performed through the plant material resulting into extraction of fruits from the plant material.

In accordance with an embodiment of the present invention, at the step 106, everything is permeated including the plant material. The continuous supply of the water-based solution helps to detach the fruits from the plant material and also allows sufficient contact time for optimum performance.

Further, the reaction of the mixed steam with the fruit's enables to extract of the crude palm oil from the fruit's. In accordance with an embodiment of the present invention, Continuous supply as claim (e) will also help in controlling the free fatty acid (FFA) value by allowable reaction between Apollo 59 with the free fatty acid in the oil and the enzyme in the fruits.

Further, the mixed steam controls the free fatty acids and DOBI values. This happened by carrying out the reaction between the water-based solution and the free fatty acids which helps to extract higher carotene from fibre. By this reaction the free fatty acid value is reduced by, but not limited to 0.3% - 1%, while the DOBI value is increased between, but not limited to 0.5% - 1.5%.

In accordance with an embodiment of the present invention, the reduction of the free fitty acids value is cause by the water-based solution reacting with the free fatty acids produce by the hydrolysis of the fats and oils.

In accordance with an embodiment of the present invention, the process further comprising a step of steaming the plant material through the mixed steam is performed for about, but not limited to 20-90 minutes, preferably about 60-90 minutes, at a temperature of, but not limited to 80°C to 100°C. Also, the step of steaming is performed at a pressure of, but not limited to 3-5 bars.

Lastly, the water-based solution is separated from the extracted oil in a sludge pit and the water-based solution facilitates extraction of the oil from mesocarp of the fruit.

Also, the step 106 enables to increase the OER by 0.5% - 1.0% by using the water-based solution. In accordance with an embodiment of the present invention, the water-based solution having a sodium alkaline silicate salt-type solution and the processed water.

The sodium alkaline silicate salt-type solution is developed by using a silicon, processed water and caustic soda. The silicon used comprises of Titanium (Ti) as part of the main ingredient and contain other traces of metal elements such as iron and copper. Further, the processed water of the sodium alkaline silicate salt-type solution is a specific processed water having conductivity of the water between, but not limited to, 0.00 S/m to 0.02 S/m. This processed water is having a cleansing process through filters and mixed bed before it has been use for the reaction purposes. The medium uses in the mixed bed are cationic resin and anionic resin.

In accordance with an embodiment of the present invention, the specific processed water is use to make the sodium alkaline silicate salt-type solution which is having conductivity between, but not limited to, 0 μΞ/τη to 5 μ5/ι . This processed water having a cleansing process through filters and softener bed resin, RO membrane & demineralized ion exchanged bed resin before it has been use for the reaction purposes.

The caustic soda is, but not limited to, sodium hydroxide, with a concentration between, but not limited to, 45%-50%. The sodium hydroxide also contains several compound and elements to make it stable, the compound include, but not limited to, sodium carbonate and sodium chloride. The specific gravity for the sodium hydroxide is between, but not limited to 1.5 -1.7.

The sodium alkaline silicate salt-type solution is formed by introducing the sodium hydroxide with the Silicon and the processed water. The reaction is vigorous and produces a heat and temperature rise to 90°C for half an hour. Further, the temperature rises up to 93 to 98°C, within 60 minutes. This condition is observed left for 4 hours and first sample for specific gravity is collected. Thereafter, the hot processed water added to the reactor when the temperature of the early reaction is starting to decrease by 10%-30%. The process of adding a hot water is required if the reactor until the desire specific gravity of sodium alkaline silicate salt-type solution is reached.

In accordance with an embodiment of the present invention, along the process addition of hot water is required if the reaction is too fast and addition of sodium hydroxide is required if the reaction is too slow. After the first 4 hours, hourly sampling of the sodium alkaline silicate salt-type solution for specific gravity check collected until the desire specific gravity of the sodium alkaline silicate salt-type solution is reached. In accordance with an embodiment of the present invention, the water-based solution is made from silica mineral type and caustic to provide the high pH properties to the solution which helps in the diffusivity activity of the water-based solution.

Referring to Figure 1, the disclosed process increases quality and quantity of Crude Palm Oil (CPO) in the mills from the normal process by using an alkaline sodium silicate salt type solution i.e. the water-based solution. The main aspect of the disclosed process is injecting the water-based solution to the steam line in existing sterilization process in the mills.

As mentioned above, exothermic process is required to produce one of the main ingredients of the water-based solution i.e. he sodium alkaline silicate salt-type solution. Thereafter, the sodium alkaline silicate salt-type solution is refined into a formulation of sodium alkaline silicate salt-type solution i.e. the water-based solution.

The aforesaid process provides number of advantages over existing solution such as, but not limited to, enables higher yield as well as helps in increasing the quality of the crude palm oil without affecting the quality of the final product of the mill. Sterilization process with the water-based solution helps more fruits to detach from the plant material at the early stage and cause more oil to be release from the fruits even before any pressing activity occur. Further, the disclosed process is safe to use during the sterilization process without harming the fruits. Also, the process helps to maintain the quality of the crude palm oil by controlling the domination of the lipase enzyme during the rupture process and extracting more carotene from the fruits itself.

Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing broadest scope of consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and appended claim.