conclusions & recommendations

CONCLUSIONS & RECOMMENDATIONS

The key conclusions and recommendations of the study with respect to the analyses that were conducted and observed in the detailed audit are presented in this section. For the convenience of the reader the conclusions and recommendations were divided in to sub-sections with respect to the key areas of the research been performed.

EFFLUENT (POME) TREATMENT & DISCHARGE STANDARDS

• The test results of the effluent in the wet and dry seasons indicate inadequate retention times in the treatment ponds. Regular de-sludging and maintaining the bunds of the ponds in good condition could easily improve the retention time and therefore the effluent treatment efficiency.

• Adding a maturation pond at the end would increase the retention time and immensely improve the final treated effluent quality.

• It is deemed necessary to implement an industry specific effluent discharge standard for palm oil industry in Sri Lanka. A proposed standard is given in Table 4.13.

• Bio gas generated in POME treatment could be captured and used as an energy source. However, this needs some further studies to be carried out before implementation.

THERMAL ENERGY UTILISA TION

• The measured moisture free base calorific values of EFB, PPF & PKS indicate that it is possible to have a cogeneration plant onsite which could fulfil the Plant's electrical and heat (steam & hot water) requirements.

• To have a cogeneration plant the, whole steam generation system should be changed and therefore a detailed assessment should be carried out into the economic viability and technical feasibility.

• The direct use of EFB in the boiler furnace is difficult because of its high moisture content and physically bulky nature. Therefore, this option is also recommended for further study.

• The flue gas analysis carried out in the factory boiler indicates that the excess air percentage is higher than the recommended value. Inlet air control damper should be regulated according to the amount of fuel being burnt in the boiler. This will increase the boiler efficiency as the flue gas losses decrease.

• Complete burning of the fuel will decrease the amount of hazardous pollutants being emitted into the surrounding environment.

• According to the measured values and the boiler heat balance carried out it is seen that there is a possibility of using flue gas heat to preheat inlet air to the boiler.

• It is also possible to use this flue gas heat in the process of kernel heating instead of using steam.

• Blow-down losses could be further reduced by treating (reducing TDS) inlet water to the boiler. It is recommended to re-implement

Cleaner production in Palm Oil Industry, Sri Lanka 81

the boiler water treatment system again which is not operated currently.

• The thermal losses due to un-lagged steam/hot water pipes and steam leaks are huge and kept un-notified as the factory produces steam from freely available waste sources. It is recommended immediately repair the defective places and to have a proper maintenance programme specially looking at places where thermal losses could be arrived.

• The steam released from each sterilisation batch goes wasted and this could be used as an energy source in processes where non-contact heating is done with steam, e.g. clarifier tank heating.

ELECTRIC ENERGY UTILISA TION

• As a result of the electric power analysis of almost all the plant electrical machinery it is seen that most of the machines (over 60%) are operated less than half load conditions which contributes to low operation efficiencies, low power factors and due to all these huge losses in electrical consumption.

• It is recommended that the plant installs variable speed drives to match the capacities of the machines.

• At the time of investing on replacements, it is recommended to go for premium efficiency machines with matching capacities.

• According to the analysis performed on the six stage capacitor bank unit, it was revealed that, the losses due to malfunctioning of the capacitor bank unit could be overcome by fixing a back-up capacitor bank.

ALTERNA TIVE PRODUCTS FROM WASTE

• Waste generated in the factory can be used in various activities generating an additional income. Table 4.15 summarises the current and potential uses from the seven waste streams of the palm oil mill.

• This approach it will also mitigate the environmental impacts of current disposal methods of the factory's waste streams.

• Potential uses from the waste streams indicate that these can be used in the same industry to make the operations self sufficient and also in various other agricultural and industrial applications as an additional income source.

PRODUCTION SCHEDULING AND FINAL PRODUCT QUALITY

• Modifications to the general house keeping practices and operational schedule, that would not need any additional investment, could improve the final product quality, as poor processing and storage affects hydrolysis, oxidation and contamination of the final product. Such improvements to the final product quality would generate more income per tonne and ultimately further enhance economic viability of implementing CP options.

82

6.0 RECOMMENDATIONS FOR FURTHER STUDY

The scope of the research was limited due to constraint of time and resources. The areas that should need further studies, which are identified by our current study, are presented in this section.

6.1 USE OF EFB AS A FUEL

Moisture content of EFB is very high and therefore not suitable as a fuel to be used directly in the boiler. If EFB can be used as a fuel and the factory goes for co-generation system, more electric power could be generated which will be an additional income for the organisation. Therefore removing moisture from EFB and make it an efficient fuel is one of the areas that further study should be carried out.

6.2 CONVERTING INTO A CO-GENERA TION SYSTEM

To go for a co-generation system, the heat generation and distribution system should be changed and have to install steam turbines of relevant capacities. This would be a costly change to start with and it should be studied in depth on financial & Technical feasibility before making the final decision.

6.3 BIOGAS FROM POME Raw POME generated from mill activities does have very high COD & BOD. In the anaerobic ponds huge amounts of biogas is generated and as it is not covered the gases being released to the environment. This is not only a

* loss of a energy source to the factory but also pollutes the environment as CFLt & CO2 are identified as green house gases. Because of all these factors, it is recommend to carry out further studies in capturing the gases from anaerobic ponds, purify them and used as a energy source in the proposed co-generation system.

6.4 IMPROVING HARVESTING TECHNIQUES

Final product quality of CPO and KO determine the product price and therefore the revenue. It was observed that the harvesting techniques used currently being the main culprit of lesser quality final product. Therefore, it is recommended to study harvesting techniques in detail, which will include cutting the bunch from the tree at the correct time, collection of bunches and transporting them to the factory.

6.5 Bio FUELS FORM PALM FRUITS

As all fossil fuels face extinction most of the countries are researching on alternative fuels. Bio Diesel from palm fruits is one of the best alternative sources for petroleum base fuels. Currently Malaysia exports Bio Diesel to Europe where it does have a tremendous demand for alternative fuels. It is recommended to carry out further studies on this aspect and find out whether it is more economical to produce Bio Diesel than extracting Palm Oil from palm fruits.

Cleaner production in Palm Oil Industry, Sri Lanka 83

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LIST OF REFERENCES

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Mahlia T.M.I., Abdulmuin M.Z., Alamsyah T.M.I., Mukhlishien D., "An Alternative Energy Source from Palm Wastes Industry for Malaysia and Indonesia", Journal of Energy Conversion and Management, Vol.42, No. 18, pp. 2109-2118, 2001.

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2002

A n n e x A

Report on Analysis of Wastewater Carried Out for Palm Oil Mill, Nakiyadeniya

(Dry Season)

By University of Moratuwa

Report on analysis of wastewater carried out for Palm Oil Mill,

Nakiadeniya i

D e p a r t m e n t o f C i v i l E n g i n e e r i n g

UNIVERSITY OF MORATUWA SRI LANKA


Nakiadeniya

Report No: E N / 0 4 / W Q / 3 9 / I November 2004

University of Moratuwa, Department of Civil Engineering

Moratuwa, Sri Lanka

Background

The University of Moratuwa undertook the testing of wastewater samples and solid waste samples for Mr. H.M.Weerasekara, Research Student, Department of Civil Engineering, University of Moratuwa.. Samples were brought to the laboratory by the laboratory personnel on 26.02.04. Number of samples and number of parameters to be tested were selected by the client.

Objective

4 The main objective of the study was to perform analysis of (i) solid waste quality of solid samples and (ii) wastewater quality of water samples provided in order study the reusability of waste and to evaluate the existing treatment process.

Methodology

I. Wastewater samples

4

Parameter Method

BOD 5 " u Standard Methods for Examinations of Water and Wastewater (1995) - Azide modification

COD Standard Methods for Examinations of Water and Wastewater (1995)- Open reflux method

TSS Standard Methods for Examinations of Water and Wastewater (1995)-dried at 103- 105°C

TDS Standard Methods for Examinations of Water and Wastewater (1995) - Evaporation

Oil & Grease Standard Methods for Examinations of Water and Wastewater (1995) -Partition gravimetric method

Total N Standard Methods for Examinations of Water and Wastewater (1995) - Persulfate digestion method

Amonical N Standard Methods for Examinations of Water and Wastewater (1995) - Phenate method

Total P Standard Methods for Examinations of Water and Wastewater (1995)- Persulfate digestion method

Phosphates (P-P0 4 ) Standard Methods for Examinations of Water and Wastewater (1995)- H2SO4 Hydrolysis colorimetric method

Sulphates Standard Methods for Examinations of Water and Wastewater (1995) - Gravimetric method

4 I I . Solid waste Samples

Parameter Method

Total Nitrogen Practical Environmental analysis- Royal society of Chemistry- Persulphate digestion and colorimetry

Total Phosphorous Practical Environmental analysis- Royal society of Chemistry-Dry ashing and colorimetry

Potassium

Practical Environmental analysis -Royal society of Chemistry-Dry ashing and Atomic Absorption Spectrophtometry

Ash Practical Environmental analysis- Royal society of Chemistry- Dry ashing

Moisture Practical Environmental analysis- Royal society of Chemistry- Oven drying

Sampling Locations :

(I) Wastewater samples

Sample Location Description

Sample Number 1 Condensate collection tank Condensate recycle from the sterilizer

Sample Number 2 Factory Operations Raw effluent from the factory

Sample Number 3 Oil traps Effluent after going through oil traps

Sample Number 4 Anaerobic Pond Effluent after the anaerobic pond treatment

Sample Number 5 Facultative Pond Effluent after facultative pond treatment

Sample Number 6 ' Treated effluent holding tank Final treated effluent after maturation pond.

(II) Solid waste samples

PKC DC BA EFB PPF PKS

Palm Kernal Cake Decanter Cake Boiler Ash Empty Fruit Bunches Palm Press Fiber Palm Kernel shells

Results:

I. Solid waste samples

Parameter

Sam\ oles

Parameter PKC DC BA EFB PPF PKS

Nitrogen (N) mg/kg 89,315.07 110,046.08 108,777.57 76,299.00 70,596.33 178,408.05

Phosphorous (P)mglkg 2,387.85 1,580.23 727.17 449.45 928.98 471.70

Potassium (K)mg/kg 10,573.66 13,478.07 8,173.46 14,845.04 5,656.04 3,036.89 Moisture % 56.10 8.20 13.70

II. Wastewater Samples

Parameter Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Sample 6 BOD5

2Umg/l 31,750.00 25,500.00, 22,500.00 22,500.00 1,000.00 1,000.00 COD mg/l 61,252.00 53,747.00 55,328.00 36,358.00 3,161.60 2,371.20 TSS mg/l 17,260.00 29,900.00 30,460.00 32,820.00 15,700.00 16,520.00 TDS mg/l 65,588.00 71,642.00 68,032.00 60,390.00 27,490.00 22,410.00 Oil & Grease mg/l 53.33 55.55 34.45 10.00 7.77 5.55 Total N mg/l 89.01 85.47 68.11 109.39 2.48 19.44 Total P mg/l 30.25 16.60 23.18 15.98 9.34 9.17

v f c Mrs N.SXjunathilake Technical Officer

S. Pathinather Head/ Division of Environemental Engineering

Head/Environmental Bi^ii".'ri"g Department of Civil Engioeerms:;

University of Moratuwa.

Annex B

Report on Analysis of Wastewater Carried Out for Palm Oil Mill, Nakiyadeniya

(Wet Season)

By University of Moratuwa

\

! Report on analysis of wastewater ! carried out for Palm Oil Mill, { Nakiadeniya

Department of Civil Engineering

UNIVERSITY OF MORATUWA SRI LANKA


Nakiadeniya

Report No: EN/04 /WQ/39/II

November 2004

University of Moratuwa, Department of Civil Engineering

Moratuwa, Sri Lanka

Background

The University of Moratuwa undertook the testing of wastewater samples and solid waste samples for Mr. H.M.Weerasekara, Research Student, Department of Civil Engineering, University of Moratuwa.. Samples were brought to the laboratory by the laboratory personnel on 14.07.04. Number of samples and number of parameters to be tested were selected by the client.

Objective

The main objective of the study was to perform analysis of (i) solid waste quality of solid samples and (ii) wastewater quality of water samples provided in order study the reusability of waste and to evaluate the existing treatment process.

Methodology

I. Wastewater samples

Parameter Method

BOD 5"° Standard Methods for Examinations of Water and Wastewater (1995) - Azide modification

COD Standard Methods for Examinations of Water and Wastewater (1995)- Open reflux method

TSS Standard Methods for Examinations of Water and Wastewater (1995)-dried at 103- 105°C

TDS Standard Methods for Examinations of Water and Wastewater (1995) - Evaporation

Oil & Grease Standard Methods for Examinations of Water and Wastewater (1995) -Partition gravimetric method

Total N Standard Methods for Examinations of Water and Wastewater (1995) - Persulfate digestion method

Amonical N Standard Methods for Examinations of Water and Wastewater (1995)-Phehate method

Total P Standard Methods for Examinations of Water and Wastewater (1995)- Persulfate digestion method

Phosphates (P-P0 4 ) Standard Methods for Examinations of Water and Wastewater (1995)- H2SO4 Hydrolysis colorimetric method

Sulphates Standard Methods for Examinations of Water and Wastewater (1995) - Gravimetric method

II . Solid waste Samples

Parameter Method

Total Nitrogen Practical Environmental analysis- Royal society of Chemistry- Persulphate digestion and colorimetry

Total Phosphorous Practical Environmental analysis- Royal society of Chemistry-Dry ashing and colorimetry

Potassium

Practical Environmental analysis -Royal society of Chemistry-Dry ashing and Atomic Absorption Spectrophotometry

Ash Practical Environmental analysis- Royal society of Chemistry- Dry ashing

Moisture Practical Environmental analysis- Royal society of Chemistry- Oven drying

Sampling Locations :

(I) Wastewater samples

Sample Location Description

Sample Number 1 Condensate collection tank Condensate recycle from the sterilizer

Sample Number 2 Factory Operations Raw effluent from the factory

Sample Number 3 Oil traps Effluent after going through oil traps

Sample Number 4 Anaerobic Pond Effluent after the anaerobic pond treatment

Sample Number 5 Facultative Pond Effluent after facultative pond treatment

Sample Number 6 Treated effluent holding tank Final treated effluent after maturation pond.

(II) Solid waste samples

PKC DC BA EFB PPF PKS

Palm Kernal Cake Decanter Cake Boiler Ash Empty Fruit Bunches Palm Press Fiber Palm Kernel shells

Results:

I. Solid waste samples

Parameter

Samples

Parameter PKC DC BA EFB PPF PKS

Total Nitrogen (N) mg/kg 2,721.81 4,742.65 2,557.34 3,520.00 7,448.50 2,721.81

Total Phosphorous (P) mg/kg 2,498.76 1,483.36 1,830.13 773.69 747.99 308.11

Potassium (K) mg/kg 1,103.68 3,675.10 3,031.78 7,332.71 767.70 294.16

Ash (%) 30.08 16.20 1.92 Moisture (%) 72.40 23.55 17.45

II. Wastewater Samples

Parameter Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Sample 6 BOD5

2U mg/l 27,500.00 23,250.00 17,250.00 2,000.00 1,440.00 1,360.00 COD mg/l 79,376.00 66,792.00 65,124.00 44,528.00 5,040.00 2,880.00 TSS mg/l 19,200.00 13,140.00 30,180.00 35,300.00 6,000.00 2,620.00 TDS mg/l 62,260.00 71,938.00 66,830.00 61,470.00 28,300.00 21,800.00 Oil & Grease mg/l 59.49 51.94 46.91 17.80 14.86 6.84 Total N mg/l 1,199.60 1,441.59 917.20 1,487.60 1,923.60 2,824.40 Amonical N mg/l 14.70 45.00 79.70 156.40 140.10 140.50 Total P mg/l 72.18 88.51 94.80 100.46

87.41 102.84 36.64

Phosphates (P-PO4) mg/l . 56.80 82.63 89.07 100.46 87.41 101.96 14.19

Sulphates mg/l 167.9 870.7 1084.7 686.3 548.0 380.2

Mrs N.S.Gp-nathilake Technical Officer

Mr. S. Pathinather Head/ Division of Environemental Engineering

Annex C

Report on Determination of Calorific Value for Palm Oil Mill, Nakiyadeniya

By Industrial Technology Institute

-4

y

DETERMINATION O F CALORIFIC VALUE

Report No. SS - 2374

INDUSTRIAL TECHNOLOGY INSTITUTE (ITI) P.O. Box, 787, 363, Bauddhaloka Mawatha, Colombo 7, Sri Lanka. Telephone: 693807-9,698621/3 Fax: 686567

successor to the Ceylon Institute of Scientific & Industrial Research (CISIR)

-DETERMINATION OF CALORIFIC VALUE


Report to

Mr. Mahesh Weerasekcra. Department of Environmental Engineering (Civil), University of Moratuwa, Katubedda.

07 t h April, 2004.

THE REPORT IS ISSUED SUBJECT TO CONDITIONS MENTIONED OVERLEAF

" P L E A S E A D D R E S S A L L C O V E R S T O T H E D I R E C T O R "

This Report is issued under the following conditions:

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February 2000

... Continuation Sheet

DETERMINATION OF CALORIFIC VALUE


CLIENT Mr. Mahesh Weerasekera, Department of Environmental Engineering (Civil), University of Moratuwa, Katubedda.

REFERENCE Client's letter dated 26 February, 2004. Payment received on 07 April, 2004.

SERVICE REQUIRED Testing three (03) samples of Palm Material for Gross

Calorific Vaiue.

PARTICULARS O F SPECIMEN Client submitted three (03) samples of Palm Material packed in sealed

Package as detailed below :

RESULTS

1. Palm press fibre

2. Palm kernel shells

3. Empty fruit bunches

500 g.

375 g.

800 g.

METHOD O F TESTING Test method give in ASTM 240 D was followed to determine

Gross Calorific Value.

! " t e s t Palm Press Palm Kernel Empty Fruit 1 1 Fibre Shells Bunches

1 { Calorific Value, cal/'g.

4 / 5263 4822

1 (Moisture free basis') 1 " I

Mk^ A M M Atapattu SEN OR TECHNICAL OFFICE

Dr. M G M U Ismail HEAD/MATERIALS TECHNOLOGY DIVISION

y 07 April, 2004. -agv.

Annex D

Report on Boiler Energy Balance for Palm Oil Mill, Nakiyadeniya

By National Engineering Research & Development Centre

E&EMC SERVICES OF NATIONAL ENGINEERING RESEARCH AND DEVELOPMENT CENTRE

Boiler Energy Balance

At

Palm Oil Factory, Nakiyadeniya, Galle.

ENERGY 66 ENVIRONMENTAL MANAGEMENT CENTRE N E R D C E N T R E . E K A L A , J A - E L A , S R I L A N K A .

T e l e p h o n e : 0 1 1 - 5 3 5 4 3 7 4 ( D i r e c t ) , 0 1 1 - 2 2 3 6 2 8 4 ( H u n t i n g ), 0 1 1 - 2 2 3 3 1 5 3 Fax , : 0 1 1 - 5 3 5 4 5 9 7 , 0 1 1 - 2 2 3 6 4 3 4

E m a i l : c c r n c g i n e r c i c l k •• ..

E&EMC / MIS -177- 566 - 2004


At

Palm Oil Factory, Nakiyadeniya, Galle.

BY

ENERGY & ENVIRONMENTAL MANAGEMENT CENTRE

NATIONAL ENGINEERING RESEARCH AND DEVELOPMENT CENTRE

EKALA, JA-ELA, SRI LANKA.

Telephone: 075-354374 (Direct), 236284 (Hunting), 233153 Fax : 075-354597, 236434

Email: [email protected]

mailto:[email protected]


University of Moratuwa, Civil Department.

Department of Civil Engineering,

Moratuwa.

Tel. 011 2 650422

Fax: 011 2 650622

Contact Person:

Mr. Mahesh Weerasooriya

(Research Student)

0:i D.-ile of Measurements : 28 t h April 2004

04 Mi.u-isurement Taken by : Eng. K T Jayasinghe Mechanical Engineer

(Yd lnsliuments Used : Flue gas Analyzer KM 9106

00 MiMsurement & Calculation Please refer table 01 .Appendix A and Appendix B.

01 Organization

0',J Address

(liCliiud

\\\\[\ D P . Ananda Namal K T Jayasinghe

I I n f - i d / E M C Project Engineer

Mule. : June 9 "'-2004

I'ayx I <>/

0 1 . Boiler Energy Test:

T h I ) I o 01 - Boiler Energy Test Results

Parameter Values

f'-'nictinl.ige Bare Surface Heat Losses 0.04 F'ni<:niil.Kje Stack Losses 23.4 l : ,nn;nnl;i(|e Blow Down Losses 0.8 r'nicniil.'ine Total Losses 24.2 Percnnlnye Overall Boiler Efficiency 75.8 Hnml liipt.il (kW) 5984 LUinlul Power (kW) 4533 S'tftttm Goneration Rate (kg/hr) 7123

(Nolo: Ploase refer Appendix & B for details)

a.O Fluo Gas Velocity: - 12.0m/sec

7

http://liipt.il

Appendix A

1.0 Boiler Details:

5'

Tnhlo A - 01 ; Boiler Dimensions

10'

Dimension Feet m L 10 3.048 d 5 1.524

Surface 1 Surface 2 Surface 3

- Furnace Side - Opposite to Furnace Si( - Cylindrical Surface

2.0 Fluo Gas Measurements:

Tablo A - 02 ; Flue Gas Measurements Parameter Measuring Time

15:20:00 15:25:00 16:00:00 16:05:00

(.) •/1 '(ircontage 9.6 10.6 13 14.3

COPorcontager 11.3 10.3 7.8 6.6

CO Porconlage 1.241 3.192 0.012 0.024

@xnnti Air percentage 85 104 167 218

NO ppm 90 115 115 96

NO t Porconlage 94 120 120 100

00 l;,( ircontage 47 24 0 0

Fluo Gun Tamperature (°C) 237 233 223.6 250

l:!tticl(iii(:y (%) 77.4 76.6 74.1 68.2

:i.O I D S Measurements

Table A - 03 ; TDS Measurements

Parameter Value (ppm)

11 >S iii Feed Water 35

TDS in Boiler Water 950

11 )M in Condensate 455

4.0 Fuol Details

I i ml Kate

("lei it!!-; Calorific Value of Fuel

MulMlui't' content of fiber

20.06 kg/min

4773 Cal/gr

10 %

Appendix B

1.0 BOILER EFFICIENCY CALCULATION

Boiler Details

Surface 1:- Furnace Side Surface 2:- Opposite to Furnace Side Surface 3:- Cylindrical Surface

10'

Dimension Feet m L 10 3.048 d 5 1.524

Bare Surfaces Heat Losses

Q U A (Ts - Ta)

U (Ur + Uc)

Ur 5.67 E{[(Ts/100)>4 -(Ta/100)>4]/(Ts -Ta)}

Uc B (Ts - Ta) >0.25 .

Symbol Units Surface 1 Surface 2 Surface 3 Surface Area (Sq.m) (A) Sq.m 0.91 1.82 14.59

Surface Temperature (Ts) K 320 349 323

Ambient Temperature (Ta) • K 309 309 309

Surface Emmisivity , (E) - 0.85 0.85 0.85

Geometrical Shape Factor (B)

Radiant Heat T.C.

Convective Heat T.C

Total Heat T.C

Bare Surface Heat Loss

Total Bare Surface Losses

(Ur)

(Uc)

W/m 2 K

W/m 2 K

(Ur+Uc) W/rrr K

(Q) kW

kW

(Silver)

1.2

6.00

2.19

8.18

0.08

2.52

(Silver) (Silver)

1.2 1.2

6.89 6.09

3.02 2.32 Turbulence Flow D>500mm

9.91 8.41

0.72 1.72

4

flack Losses Trials

i ii iii

Combustion Efficiency (%) 77.4 76.6 74.1 Measured Values

Stack Losses (%) 22.6 23.4 25.9

[jlow Down Losses

IDS in Feed Water SF (ppm) 35

IDS in Boiler Water Sb (ppm) 950

IDS in Condensate Sb (ppm) 455

Percentage Blow Down (%) 3.6

Operating Pressure P (bar) 9

Percentage Blowdown Loss (%) 0.8 (Percentage Efficiency Loss =Percentage Fuel Wasted

(SLEMA energy Audit Manual)

Excess Air

i Firing Stages

ji iii

Percentage of Oxygen 1

9.6 II

10.6 Ml

13

Excess Air 84 102 163

Percentage Efficiency

Fuel Rate (kg/Sec) 0.30

feross Calorific Value of Fuel (Cal/g) 4773

Heat Input H in (kcal/sec) 1429

H in (kW) 5984 (1kcal = 4.187 kJ)

Surface Loss as a Percentage (%) 0.04

Total Losses (%) 24.2 (Surface + Blowdown + Flue Gas)

Useful Energy (kW) 4533.1 (Input - Losses) = 16319 (MJ/Hr)

Percentage Efficiency (%) 75.8

I

llcam Generation Rate

Poed Water Temperature (OC) 70 Enthalpy of Feed water kJ/kg 294

(toiler Operating Pressure Bar 10 (Absolute) (inthalpy of Steam at 10 bar kJ/kg 2585

Heat Gained by 1 kg of Steam kJ 2291

Useful Heat kW 4533

Steam Generation Rate kg/hr 7123 1.98 kg/sec

2.0 FLUE GAS VELOCITY CALCULATION

2.1 Pitot Tube Air (Gas) Velocity Measurement is Given by

V = 1.291{ (1000 * T * P v) / ( B* 289 ) } 1/2

Where T

Pv

B

Air Temperature in K

Velocity Pressure in Pa

Barometric Pressure mbar

2.1 Data & Measurments

Velosity Pressure

Pressure Correction Factor

Corrected Velosity Pressure

Barometric Pressure

Air Temperature

2.3 Calculat ion

Rue Gas Velocity

0.5

0.1

50

1

233

kPa

(Bottom Inclined)

Pa

atm

°C

500 Pa

1013 mbar

506 K

12.0 m/sec

Annex E

Report on Boiler Flue Gas Analysis for Palm Oil Mill, Nakiyadeniya

By National Engineering Research & Development Centre

Y .

DATE 28-84-04 TIME 15:22126 HETT . . C 281 . 3 FLUE . . C 237.3 IHLT NOT FITTED 02 V. 9.6 XRIR •/. . . . . . . 85 CO V. 1.241 C02 y. . . . . 11.3

,£FF <G> 77.4 LOSSES '< 22.6 NO ppn . . . . 98 N02 NOT FITTED NOx ppn . . . . 94 S02 pph . . . . 47 AMBIENT C 36.0

******Nf£Rr j * ***** DATE 28 -04 -04 TIME 1 5 : 2 3 : 2 3 NETT . . C 1 8 3 . 1 FLUE . . C 2 1 9 . 3 INLT NOT FITTED 02 'K 10 .4 XAIR y. 99 CO y. 5 . 7 5 3 co2 y. . . . . 1 0 . 6 EFF X <G> 7 7 . 8 LOSSES Z 2 2 . 2 NO pph . . . 104 N02 NOT FITTED NOx ppn . . . 109 S02 ppn . . . . 26 RMBIENT C 3 6 . 2

******NERn****** DATE 28-04-04 TIME 15:24:41 NETT . . C 183.1 FLUE . . C 219.5 INLT • NOT FITTED 02 y. 11.1 XAIR X 114 CO 14.903 C02 '/. 9.8 EFF '/. <G> 77.0 LOSSES._ Z 23.0 NO ppn . . . 103 N02- NOT FITTED NOx ppn . . . 108 S02 ppn . . . . 22 AMBIENT C 36.4

******HERD**++** DATE £8-04-04 TIME 15:25:39 NETT . . C 196.6 FLUE . . C 233.3 INLT NOT FITTED 02 10.6

a XAIR y. ..... 104 n o y. . . . . . 3.192 /C02 X .... 10.3 ' EFF y. <G> 76.6 LOSSES '/. 23.4 NO pph ... 115 M02: NOT FITTED NOx ppn . . . 123 S02 ppn . . . . 24 AMBIENT C 36.7

• T |<***>(<*NERD**+*** • DATE 28-04-04 TIME 16x00:00 NETT . . C 184.1 FLUE . . C 223.6 INLT NOT FITTED 02 . . . . 13.0 XAIR 'A . . . . . 167

c o y. -0.012 co2 y. ..... 7.8 EFF CG) 74.1 LOSSES '/. 25.9 NO ppn . . . 115 H02 NOT FITTED NOx ppn . . . 120 S02 ppn 0 AMBIENT C 39.5

H < * * * * * f ( ^ R O * * * * * * DATE 28-04^04 TIME 16:01J24 NETT . . . C 198.9 FLU£ . . C 233.7 INLT NOT FITTED 02 'A . . . . . 14.0 XAIR y. . . . . . 205 CO y. 8.017 C02 y. . . . . . 6,9 EFF y. <G) 70.2 LOSSES - '/. 29.8 NO ppn . . . 103 N02 NOT FITTED NOx ppn . . . 108 S02 ppn . . . . . 8 AMBIENT C 39.8

* . * * * * *NERD*** * * * DATE 28-04-04 TIME 16:02:22 NETT . . C 210.2 FLUE . . C £50.1 INLT NOT FITTED 0£ '/. . . . . 14.3 XAIR y. 218 CO 0.024 C02 'K 6.6 EFF y. <G) 68.2 LOSSES 'A 31.8 NO ppn . . . . % N02 NOT FITTED NOx .ppn . . . 100: S02 ppn . . . . . 0 RMBIENT C 39.9

LIBRARY UNIVERSITY OF MORATUWA, SRI LANKA

MORATUWA

Annex F

Photographs of Palm Oil Mill, Nakiyadeniya

87273

PHOTO ANNEX

Wastewater Treatment (Pond System) at Nakiyadeniya Palm Oil Mill

l

Dissertation - Cleaner Production In Palm Oil Industry I

PHOTO ANNEX

Palm Oil Production Process (Wet Extraction) at Nakiyadeniya Palm Oil Mill

Dissertation - Cleaner Production In Palm Oil Industry 2

PHOTO ANNEX

Palm Oil Production Process (Wet Extraction) at Nakiyadeniya Palm Oil Mill (Continued)

Plate 9 : Stripped Fruits Falling From the Threshing Machine

Plate 10: Fruits Being Squeezed in the Screw Press

Plate 11: CPO Filtered Through the Vibrating Screen

Plate 12: Filtered CPO Collection Tank


PHOTO ANNEX


Dissertation Cleaner Production In Palm Oil Industry 4

PHOTO ANNEX


Plate 17: Kernel Oil Extraction through a Screw Press

Plate 16: Centrifugal Nut Cracker

Plate 19: Filtered Kernel Oil Form the Filter Press

Plate 18: Kernel Oil Filtering through the Filter Press


PHOTO ANNEX


PHOTO ANNEX

Waste Streams of the Palm

Plate 22: EFB Lorded to the Tractor Trailer for Disposal

Plate 23: Bagged Kernel Cake Ready to be sold

Plate 24: Dust Collection through Bag Filters

Plate 25: Sludge from the POME Treatment Process


Annex G

Effluent Discharge Standards Appl icable to Palm Oil Industry

EFFLUENT DISCHARGE STANDARDS

SRI LANKA

Wastewater Discharge Standards - Sri Lanka. General standards for discharge of effluent into inland surface Waters ( P a r t 1 , S e c . 1 - G a z e t t e E x t r a o r d i n a r y o f t h e D e m o c r a t i c S o c i a l i s t R e p u b l i c o f S r i L a n k a 0 2 . 0 2 . 1 9 9 0 )

; S . NO. Determinant Tolerance limit

1 . Total suspended solids (mg/l, max) 50

2 . pH value size of total suspended solids

Shall pass sieve of aperture size 850 micro m.

3 . PH value at ambient temperature 6.0-8.5

4 . Biochemical oxygen demand - B0D 5 in 5 days at 20°C

30

5 Temperature of discharge Shall not exceed 40°C in any section of the stream within 15 m downstream from the effluent outlet.

6 . Oils and greases (mg/l, max) 10 . 0

7 . Phenolic compounds (as phenolic OH) (mg/l, max)

1.0

8 . Cyanides as (CN) (mg/l, max) 0.2

9 . Sulfides (mg/l, max) 2.0 '

10 . Fluorides (mg/l, max) 2.0

11 . Total residual chlorine (mg/l, max) 1. 0

12 . Arsenic (mg/l, max) 0.2

13 . Cadmium total (mg/l, max) 0 .1

14 . Chromium total (mg/l, max) 0 .1

15. Copper total (mg/l, max) 3 . 0

16 . Lead total (mg/l, max) 0.1

17. Mercury total (mg/l, max) 0 . 0005

18 . Nickel total (mg/l, max) 3.0

19. Selenium total (mg/l, max) 0. 05

20 . Zinc total (mg/l, max) 5 . 0

21 . Ammoniacal Nitrogen (mg/l, max) 50.0

22 . Pesticides Undetectable

23 . Radio active material

(a) alpha emitters micro curie / ml 10°

(b) beta emitters micro curie / ml 10"8

24 . Chemical Oxygen Demand (COD) (mg/l, max)

250

Note 1 All efforts should be made to remove colour and unpleasant

odour as far as practicable.

Note These values are based on dilution of effluents by at least 8

volumes of clean receiving water. If the dilution is below 8

times, the permissible limits are multiplied by 1/8 of the

actual dilution.

Note 3 The above-mentioned General Standards shall cease to apply with

regard to a particular industry when industry specific

standards are notified for that industry.

Tolerance limits for industrial effluents discharged on land for irrigation purpose (Part 1, Sec. 1 - Gazette Extraordinary of the Democratic Socialist Republic of Sri Lanka 02.02.1990) S. No. Determinant Tolerance limit

l. Total dissolved solids (mg/l, max) 2100

2 . pH value at ambient temperature 5 . 5-9.0

3 . Biochemical oxygen demand -days at 20'C (mg/l, max)

B0D 5 in 5 250

5 . Oils and greases (mg/l, max) 10.0

6 . Sulfate (as SO„) (mg/l, max) 1000

7 . Boron (as B) (mg/l, max) 2 . 0

8 Arsenic (as As ) (mg/l, max) 0 . 2

9 . Cadmium (as Cd) (mg/l, max) 2 . 0

10 . Chromium (as Cr) (mg/l, max) 1. 0

11. Lead (as Ph) (mg/l, max) 1.0

12 Mercury (as Hg) (mg/l, max) 0.01

13 . Sodium adsorption ratio (SAR) 10-15

14 . Residual Sodium Carbonate, (mg/l, max) 2 . 5

15 . Radio active material

(a) alpha emitters micro curie / ml 10'9

(b) beta emitters micro curie / ml io-8

Tolerance limits for industrial & domestic effluents discharged into marine coastal areas (Part 1 , Sec. 1 -Gazette Extraordinary of the Democratic Socialist Republic of Sri Lanka 02.02.1990)

No. Determinant Tolerance Limit 1 Total Suspended Solids (mg / 1 ,

(a) For Process Wastewaters Max)

150 (b) For cooling water effluents Total suspended

matter content Of influent cooling water plus 10

2 Particle size of -(a)Floatable Solids, max (b) Settlable Solids, max

3mm 850 micro m

3 pH range at ambient temperature 6.0 - 8.5 4 Biochemical Oxygen Demand (B0D 5)

at 2 0°C (mg / 1 , Max) in 5 days 100

5 Temperature, max 45°C at the point discharge

of

6 Oils & Grease, (mg / 1 , Max) 20 7 Residual Chlorine,, (mg / 1 , Max) 1. 0 8 Ammonical Nitrogen (mg / 1 , Max) 50.0 9 Chemical Oxygen Demand (COD) (mg / 1 , Max) 250 10 Phenolic compounds (as phenolic

1 , Max) OH) (mg / 5 . 0

11 Cyanides (as CN) (mg / 1 , Max) 0.2 12 Sulfides (as S) (mg / 1 , Max) 5 . 0 13 Fluorides (as F) (mg / 1 , Max) 15 14 Arsenic (as As) (mg / 1 , Max) 0 . 2 15 Cadmium (as Cd) Total, (mg / 1 , Max) 2 . 0 16 Chromium (as CR) Total (mg / 1 , Max) 1.0 17 Copper, (as Cu) Total, (mg / 1 , Max) 3 . 0 18 Lead (as Pb) Total (mg / 1 , Max) 1 . 0 19 Mercury (as Hg) Total, (mg / 1 , Max) 0.01 20 Nickel (as Ni) Total, (mg / 1 , Max) 5 . 0 21 Selenium (as Se) Total, (mg / 1 , Max) 0.05 22 Zinc (as Zn) Total (mg / 1 , Max) 5 . 0 23 Radio active material

(a)Alpha emitters,micro curie /ml, max 10" 8

(b)Beta emitters,micro curie /ml, max io-7

24 Organo - Phosphorus compounds 1.0 25 Chlorinated Hydrocarbons (as CI)

Max) , (mg / 1 , 0.02

Note 1 All efforts should be made to remove colour and unpleasant

odour as far as practicable.

Note 2 These values are based on dilution of effluents by at least

8 volumes of clean receiving water. If the dilution is

below 8 times, the permissible limits are multiplied by 1/8

of the actual dilution.

Tolerance limits for industrial waste water (effluents) discharged into the common wastewater treatment plant (Board of Investment (Bol) of Sri Lanka,1999) Parameters Maximum Tolerance Limit

BOD (5 days at 20 °C ) (mg/1)

COD

PH

Suspended solids

Total dissolved solids (inorganic) (mg/1)

Temperature (°C)

Phenolic compounds (as C GH 50H) (mg/1)

Oil & Grease (mg/1)

Total Chromium (mg/1)

Copper (as Cu) (mg/1)

Lead (as Pb) (mg/1)

Mercury (as Hg) (mg/1)

Nickel (as Ni) (mg/1)

Zinc (as Zn) (mg/1)

Arsenic (as As) (mg/1)

Boron (as B) (mg/1)

Percent Sodium

Ammoniacal Nitrogen (as N) (mg/1)

Sulphides (as S) (mg/1)

Sulphates (as SOJ (mg/1)

Chlorides (as CI) (mg/1)

Cyanides (as CN) (mg/(l)

Free Residual Chlorine (as Chlorine) (mg/1)

200

600

6.0-8.5

500

2100

40

5

30

2 (Chromium VI 0.5)

3

1

0.0005

3

10

0 . 2

2

60

50

2

1000

900

0.2

Nil

Colour- Wave Length Range Maximum Spectral Absorption Coefficient

400 - 499 nm (Yellow Range) 7 m"1

500 - 599 nm (Red Range) 5 m"1

. i 600 - 750 nm (Blue Range) 3 m"1

Radio active Materials

(a) Alpha emitters (/ic / ml) 10 "7

(b) Beta emitters (/ic / ml) 10 "6

mg / = milligrams/litre

^c/ml = microcuries/millilitre

BOD = Biochemical Oxygen Demand

COD = Chemical Oxygen Demand

Nm = nano meter

NOTE The quality of waters discharged into common sewer or collection system

should be such as to ensure that the waste water

1. does not damage the sewer by physical or chemical action

2. does not endanger the health of the workers cleaning the sewer

3. does not upset the processes that are normally used in sewage treatment

4. does not overload the common treatment plant

5. does not damage the crops or affect the soil in case the effluent

after treatment is used for irrigation and

6. does not create fire and explosion hazards due. to certain constituents

present in the effluent

EFFLUENT DISCHARGE STANDARDS

MALAYSIA

ocVTRONMENTAL QUALITY (PRESCRIBED PREMISES) (CRUDE PALM-OIL) REGULATIONS, 1977

ARRANGEMENT OF REGULATIONS

Regulation

:Jrt0W«s8«>

msm.

§§§1

1.

2. 3. 4.

5.

6. 7.

8.

9. 10.

II .

12.

13. 14. 1.5. 16. 17. 18.

Citation and commencement. Interpretation. Periods for purposes of section 18 (2) (a) and (c). Continuance of existing conditions and restrictions in case of change in occupancy. Reporting changes in information furnished for purposes of application. Making changes that alter quality of effluent.

Duty of occupier to provide assistance for action under section 38. Dilution of effluent. Display of licence. Quarterly return. Guide for imposition of limits for parameters of effluent. Limits for parameters of effluent to be discharged into a watercourse.

Limits for parameters of tfflucnl to be discharged onto land. Point of discharge.

Fee for permission under section 19. • - - • • Fee for licence, including renewal of licence. Waiver of fee. Fee for transfer of licence.

FIRST SCHEDULE: Quarterly Return Form.

SECOND SCHEDULE: Parameter Limits for Watercourse Discharge.

THIRD SCHEDULE: Method of Computing Effluent-Related Amount of Licence Fee.

49

ENVIRONMENTAL QUALITY (PRESCRIBED PREMISES) (CRUDE PALM-OIL) REGULATIONS, 1977*

In exercise of the powers conferred by section 51 of the Environmental Quality Act, 1974, the Minister, after consultation with the Environmental Quality Council, makes the following regulations:

1. Citation and commencement.

(1) These regulations may be cited as the Environmental Quality (Prescribed Premises) (Crude Pahn-Oil) Regulations, 1977.

(2) Regulations 2, 3 (1), 5, 11, 12, 13, 14, 15, 16 and 17 shall come into force on the 4th November 1977.

(3) Regulations 3 (2), 4, 6, 7, 8, 9, 10 and 18 shall come into force on the 1st July 1978.

2. Interpretation.

In these regulations, unless the context otherwise requires—

"B.O.D." stands for biochemical oxygen demand, which is the quantity of oxygen utilized, according to laboratory test, in the biochemical oxidation of the organic matter in effluent during a specified period, which for the purposes of these regulations is three days, and at a specified temperature, which for the purposes of these regulations is 30 degrees Centigrade;

"B.O.D. concentration" is the intensity of the biochemical oxygen demand of effluent, measured by reference to the B.O.D. of a standard unit of volume of the effluent, such as a litre; thus effluent is said to have a B.O.D. concentration of, say, 5,000 milligrammes per litre, or 5,000 mg/1, if, its oxygen-consuming potential is such that one litre of it will, according to laboratory test, utilize, during a period of three days and at a temperature of 30 degrees Centigrade, 5 ,000 milligrammes of oxygen in the process of its biochemical • oxidation;

"B.O.D. load" is the total amount of oxygen that, having regard to its B.O.D. concentration, a given amount of effluent can be expected to utilize, during a period of three days and at a temperature of 30 degrees Centigrade, in the process of its biochemical oxidation;

"effluent" means liquid waste or wastewater produced by reason of the production processes taking place at prescribed premises;

"licence" means a licence in respect of prescribed premises, as required by section 18 of the Act;

'Published as P.U. (A) 342/1977. coming into force on 1-7-78 and amended by P.U. (A) 183/82.

51

"parameter" means any of the factors shown in the first column of the Second Schedule, by reference to which the pollution potential, of effluent is determined;

"prescribed premises" means any premises prescribed by the Environmental Quality (Prescribed Premises) (Crude Palm-Oil) Order, 1977, being premises occupied or used for the processing of oil-palm fruit or oil-palm fresh-fruit bunches into crude palm-oil, whether as an intermediate or final product;

"watercourse" includes any reservoir, lake, river, stream, canal, drain, spring, or well, any part of the sea abutting on the foreshore, and any other body or natural or artificial surface or subsurface water.

3. Periods for purposes of section 18 (2) (a) and (c). (1) In connexion with the making of application for a licence, the period

ending on the 31st March 1978 is prescribed for the purposes of section 18 (2) (a) of the Act.

(2) The period of fourteen days after a person became the occupier of prescribed premises is prescribed for the purposes of section 18 (2) (c) of the Act.

4. Continuance of existing conditions and restrictions in case of change in occupancy.

(1) Where a person becomes the occupier of prescribed premises in succession to another person who holds a yet unexpired licence in respect of the premises, then—

(a) for a period of fourteen days after the change in occupancy, or (b) where the new occupier makes application within that period for

the transfer to him of the licence, for the period from the change in occupancy until final determination of his application,

the conditions and restrictions of the licence shall be binding on the new occupier and shall be observed by him, notwithstanding that he is not yet the holder of the licence or that the licence may, during the period specified in sub-paragraph (a) or (b), as the case may be, have expired.

(2) Paragraph ( I ) shall cease to apply the moment the new occupier holds in his own right a licence in respect of the prescribed premises.

5. Reporting changes in information furnished for purposes of application. An applicant for a licence or for the renewal or transfer of a licence shall,

within seven days of the occurrence of any material change in any information furnished in his application or furnished in writing pursuant to a request by the Director General under section 11 (2) of the Act, give the Director General a report in writing of the change.

-si <•

6. Making changes that alter quality of effluent.

(1) An occupier of prescribed premises in respect of which there is a licence shall not make, or cause or permit to be made, any change to the premises or in the manner of running, using, maintaining, or operating the premises or in any operation or process carried on at the premises which change, causes, or is intended or is likely to cause, a material deterioration in the quality characteristics, or a material increase in the quantity, of effluent discharged from the premises, unless prior written approval of the Director General has been obtained for the change.

(2) For the purposes of paragraph (1), changes to prescribed" premises include-

(a) any change in the construction, structure, or arrangement of the premises or any building serving the premises;

(b) any change in the construction, structure, arrangement, alignment, direction, or condition of any channelling device, system, or facility serving the premises; and

(c) any change of, to, or in any plant, machine, or equipment used or installed at the premises.

7. Duty of occupier to provide assistance for action under section 38. Every occupier of prescribed premises shall provide the Director General

or any other officer duly authorized in writing by him every reasonable assistance or facility available at the premises, including labour, equipment, appliances, and instruments, that he may require for the purpose of taking any action that he is empowered by section 38 of the Act to. take in respect of the premises.

8. Dilution of effluent. No person shall dilute, or cause or permit to be diluted, any effluent,

whether raw or treated, at any time or point after it is produced at.any pre-., scribed premises unless prior written authorization of the Director General has been obtained for the dilution and the dilution is done according to the terms and conditions of the authorization.

9. Display of licence. Every -occupier of prescribed premises shall display his licence, together

with every document forming part of the licence, in a prominent position in the principal building of the premises.

10. Quarterly return. (1) For the purposes of this regulation, a quarter means a period of three

months commencing on the 1st January, the 1st April, the 1st July, or the 1st October.

53

(2) Every occupier of prescribed premises shall, within fourteen days after the end of each quarter, submit to the Director General, in the Form in the First Schedule, a quarterly return for that quarter in respect of the prescribed premises.

(3) An occupier of prescribed premises is not required to submit under paragraph (2) a return for any period during which he was not an occupier of the prescribed premises.

(4) Where a person becomes an occupier of prescribed premises on a day other than the first day of a quarter, his first return under paragraph (2) may be submitted within fourteen days after the end of the first full quarter, and in that case the return shall be for the period from the commencement of occupation until the end of the first full quarter.

11. Guide for imposition of limits for parameters of effluent.

In the matter of imposing in respect of a licence conditions limiting the parameters of effluent to be discharged from prescribed premises, the Director General shall be guided by regulations 12 and 13.

12. Limits for parameters of effluent to be discharged into a watercourse. (1) This regulation applies in respect of effluent to be discharged into a

watercourse.

(2) No condition limiting any parameter shall ordinarily be imposed in respect of effluent to be discharged during the period 1.7.1978 - 30.6.1979, but the Director General may, if he considers it necessary in any particular case so to" do, impose such a condition or conditions for all or any of the parameters, and in that event the limits shall ordinarily be as shown in the second column of the Second Schedule.

(3) Every licence issued on or after the 1st July 1979 and ever)' licence issued before but expiring after that date shall contain a condition or conditions limiting the parameters of the effluent to be discharged from the prescribed premises on or after that date and the limits for the respective periods shall ordinarily be as shown in the third, fourth, fifth, sixth and seventh columns of the Second Schedule.

(4) The Director General may in any particular case, if he considers it necessary so to do, impose, in respect of effluent to be discharged during any period, a more stringent limit than the applicable limit shown in the Second Schedule, for any parameter.

(5) The Director General may in any particular case impose, in respect of effluent to be discharged during any period after 1.7.1979, a less stringent limit than the applicable limit for a period shown in the Second Schedule, for any parameter, if he is satisfied —

54

(a) that research on effluent disposal or treatment of a kind or scale that ir. likely to benefit the cause of environmental protection is being ' > r is to be carried out at the prescribed premises and that such a concession is necessary for the conduct of such research; or

(b) that it would not be practicable for the limit shown in the Second Schedule to be observed at the prescribed premises.

13. Limits for parameters of effluent to be discharged onto land.

(1 ) This regulation applies in respect o f effluent to be discharged onto land.

, ( 2 ) No limit shall ordinarily be imposed for any parameter other than the B.O.D. concentration.

(3 ) No condition limiting the B.O.D. concentration shall ordinarily be imposed in respect of effluent to be discharged during the period 1.7.1978 - V s . -30.6 .1979, but the Director General may, if he considers it necessary in any particular case so to do, impose such a condition.

(4) Every licence issued on or after 1.7.1979 and every licence issued before but expiring after that date shall ordinarily contain a condition limiting the B.O.D. concentration of effluent to be discharged from the prescribed premises on or after that date and the limit shall ordinarily be 5,000 mg/1 for any period.

(5) The Director General need not impose any condition under paragraph (4) if he is satisfied that the absence of such a condition will not cause any adverse environmental effect in any material degree. . .. . . . . . . . .

(6 ) The Director General may in any particular case, if he considers necessary so to do, impose, in respect of effluent to be discharged during any period, a more stringent limit than 5,000 mg/1 .

(7) The Director General may in any particular case impose, in respect of effluent to be discharged during any period, a less stringent limit than 5 ,000 mg/1 , if he is satisfied that research on effluent disposal or treatment of a kind or scale that is likeiy to benefit the cause of environmental protection is being or is to be carried out at the prescribed premises and that such a concession is necessary for the conduct of such research.

14. Point of discharge.

(1) In every licence the Director General shall specify, for the purposes of these regulations, the point or points of discharge o f effluent for the prescribed premises to which the licence relates.

(2) Wherever the point of .discharge is mentioned in these regulations in

55

connection with any prescribed premises, the references is to the point or points of discharge specified for the prescribed premises pursuant to paragraph (1).

(3) Wherever the B.O.D. concentration or other parameter of effluent discharged or to be discharged is mentioned in these regulations in connection with any prescribed premises, the reference, unless the context otherwise requires, is to the B.O.D. concentration cr other parameter as at the point of discharge specified for the prescribed premises pursuant to paragraph (1).

15. Fee for permission under section 19. The fee for a written permission under section 19 of the Act to carry out

any work on any premises that would cause those premises to become prescribed premises or to construct on any land any building designed for or used for a purpose that would cause the land or building to become prescribed premises is S100.00 and shall not be refundable.

16. . Fee for licence, including renewal of licence.

(1) The fee for a licence, including the renewal of a licence, is SlOO.OO plus an effiuent^related amount computed according to the method prescribed in the Third Schedule.

(2) The amount of $100.00 shall accompany the application and shall not be refundable.

(3) The effluent-related amount shall not become due until called for.

17. Waiver of fee. (1) ' If the Director General is satisfied that research on effluent disposal

or treatment of a kind or scale that is likely to benefit the cause of environmental protection is being or to be carried out at any prescribed premises, he may, with the approval of the Minister, completely or partially waive any effiuent-related amount payable by virtue of regulation 16(1).

(2) In deciding on the extent of waiver, the Director General shall be guided by a consideration of how much of the amount of effluent discharged or to be discharged is involved in the research and by a consideration of the quality characteristics of the effluent discharged or to be discharged.

18. Fee for transfer of licence.

The fee for the transfer of a licence is $30.00.

56

FIRST SCHEDULE (Regulation 10 (2))

QUARTERLY RETURN FORM (Two copies to be completed)

SECTION 1 IDENTIFICATION FOR OFFICE USE

1. (i) Name and Address of Premises. „ _ _ _ _

(ii) Name of Licensee „ ~ (iii) Address of Licensee _ „ _

_ _ „ Telephone: (iv) Licence Number (v) File Reference Number

2 . (i) Name of Reporting OfficaL (ii) Address of Reporting Official.

„ Telephone: „

3. (i) Name of Analytical Laboratory _ _ (ii) Address of Analytical Laboratory

Telephone: (iii) Name of Analyst

4. Quarter of Return:

(i) First Quarter . . (ii) Second Quarter..

' (1 .1 ,19 t o 3 1 . 3 . I 9 ) (1 .4 .19. . . . to 30.6.19. . . . )

(iii) Third Quarter . . (iv) Fourth Quarter. .

(1.7.19. . . . to 30.9.19....) (1 .10 .19 . . . . to 31.12.19. . . . )

SECTION 2 QUARTERLY PRODUCTION DATA

5. (i) Total Crude Palm-Oil Produced (ii) Total P.F.B. Processed

(iii) Total Metered or Estimated Watei Consumption Cubic Metres ( m 3 )

SECTION 3 QUARTERLY EFFLUENT DISPOSAL INFORMATION

6. Effluent Discharge into Watercourse/Effluent Discharge onto Land {Delete whichever not applicable)

NOTE:.

(a) The quantity and quality of theeff luent must be as determined at the point of discharge in accordance with the procedure and standard methods laid down by the Director General

.Metric Tons Metric Tons

57

SECTION 3 QUARTERLY EFFLUENT DISPOSAL INFORMATION

The sampling and flow measurement of the effluent need be done on any one day only in each of the weeks or months indicated by the columns below. The dates must be shown in the spaces provided. Wherever possible, the sampling and flow measurement should be done in the specified weeks rather than the specified months. The analysis for hems (vi), (vii), and (xi) need be done only once in the quarter, on the same sample as that used for the analysis for the other items.

The times Tif sampling for items (iii) to (xi) must also be shown in the spaces provided. The state of the weather at the time of sampling should be recorded as, for example, "dry", "wet", or "heavy rain".

If this is a first return for a period covering more than one quarter, as permitted by regulation 10 (4) of the Environmental Quality (Prescribed Premises) (Crude Palm-Oil) Regulations, 1977, the information required for the period before the first full quarter may be given in a supplementary sheet.

First Week or

First Month

Fifth Week or

Second Month

Ninth Week or

Third Month

Date Time Weather

(i) Total Discharge over 24 Hours; Cubic Metres ( m 3 )

(ii) Maximum Discharge over 1 Hour; Cubic Metres ( m 3 ) . .

o

(iii) Temperature ( C) . . .

O ) pH ' (v) B.O.D., (3-day; 30°C);

mg/1 (vi) C.O.D.; mg/1 . .

(vii) Total Solids; mg/1

(viii) Suspended Solids; mg/1

(ix) Oi land Grease;.mg/1

(x) Ammoniacal-Nitrogen; mg/1 . .

(xi) Total Nitrogen; mg/1

7. If the disposal of the effluent or any quantity of it is neither into a watercourse nor onto land, state mode of disposal:

I hereby declare that all information given in this return is to the best of my knowledge and belief true and correct.

1

Date.. Signature of Reporting Official

58

SECOND SCHEDULE

(Regulation 12 (2) and (3))

PARAMETER LIMITS FOR WATERCOURSE DISCHARGE

Limits According to Periods of Discharge Parameters -

(I)

1-7-1978-30-6-1979

(2)

1-7-1979-30-6-1980

(3)

1-7-1980-30-6-1981

(4)

1-7-1981-30-6-1982

(5)

1-7-1982 31-12-1983

(6)

1-1-1984 and

thereafter (7)

Biochemical Oxygen Demand (B.O.D.) 3-day, 30°C; mg/l . . . 5,000 2,000 1,000 500 250 100

Chemical Oxygen Demand (C.O.D.); mg/l 10,000 4,000 2,000 1,000

Total Solids; mg/l 4,000 2,500 2,000 1,500 — — Suspended Solids; mg/l 1,200 800 600 400 400 400.

Oil and Grease; mg/l 150 100 75 50 50 50

Ammoniacal-Nilrogen; mg/l 25 15 15 10 150* 150*

Total Nitrogen; mg/l 200 100 75 50 300* 200*

PH 5.0-9.0 5.0-9.0 5.0-9.0 5.0-9.0 5.0-9.0 5.0-9.0

Temperature °C 45 45 45 45 45 45

*VaIuc of filtered sample.

THIRD SCHEDULE

. . . . (Regulation 16 (1))

METHOD OF COMPUTING EFFLUENT-RELATED AMOUNT OF LICENCE FEE

1. The amount shall be related to the total amount of effluent to be discharged from the premises, both into a watercourse and onto land, during the period of the licence.

2. (1) Where effluent is to be discharged only into a watercourse, the method of computation in Part A shall apply.

(2) Where the period fo the licence is a complete year, and the amount computed according to the method in Part A is $150.00 or less, the amount to be charged shall be $150.00.

(3) The minimum amount of $150.00 shall be proportionately reduced where the period of the licence is less than a complete year.

(4) For the purpose of sub-paragraph (3), any period of licence of less than one month shall be reckoned and charged for as one month.

3. (1) Where effluent is to be discharged only onto land, the method of computation in Part B shall apply.

59

(2) Where the period of the licence is a complete year, and the amount computed according to the method in Part B is SI50.00 or less, the amount to be charged shall be $150.00.



4. (1) Where effluent is to be discharged both into a watercourse and onto land, the method of computation in Part A shall apply in respect of the effluent to be discharged into a watercourse and the method of computation in Part B shall apply in respect of the effluent to be discharged onto land, and the amount to be charged shall be the total of the two amounts thus arrived

• at.

(2) Where the period of the licence is a complete year, and the total of the two amounts is $150.00 or less, the amount to be charged shall be $150.00.



5. (1) Where no effluent is to be discharged either into a watercourse or onto .land .during the period of thelicence, the amount to be charged -shall be $150.00 per year.

(2; The minimum amount of $150 .00 shall be proportionately reduced where the period of the licence is less than a complete year.


6. In construing this Schedule for the purpose of recovery of fees under section 17 of the Act, references to effluent to be discharged shall be construed as references to effluent actually, or deemed to have been actually, discharged.

PART A

DISCHARGE INTO A WATERCOURSE

Discharge during period 1.7.1978 to 30.6.1979 I. Where the effluent to be discharged has a B.O.D. concentration of 5,000 milligrammes or less per litre, the amount shall be $10.00 per metric ton or part of a metric ton of the B.O.D. load of the total amount of effluent to be discharged.

••m

II. Where the effluent to be discharged has a B.O.D. concentration in excess of 5,000 milligrammes per litre, the B.O.D. load of the total amount of effluent to be discharged shall first be determined on the basis of the actual B.O.D. concentration of the effluent; next shall be determined the BSQ.D. load of the total amount of effluent to be discharged if the effluent were to have a B.O.D. concentration of 5,000 milligrammes per litre; the amount shall then b e -

(a) $10.00 per metric ton or part of a metric ton of the second B.O.D. load, plus

(b) $100.00 per metric ton or part of a metric ton of the difference between the two B.O.D. loads.

III. For the purposes, of paragraphs I and II, the B.O.D. concentration and the total amount of effluent to be discharged shall be as represented by the applicant or, where the Director General limits the B.O.D. concentration and the amount by way of condition of. licence, as so limited.

Discharge on or after 1.7.1979

I. The amount shall be $10.00 per metric ton or part of a metric ton of the B.O.D. load of the total amount of effluent to be discharged, determined on the basis of the B.O.D. concentration limited by the Director General by way of condition of licence.

II. For the purposes of paragraph I, the total amount of effluent to be discharged shall be as represented by .the applicant or, where the Director General limits the amount by way of condition of licence, as so limited.

PART B

DISCHARGE ONTO LAND

Discharge during period 1.7.1978 to 30.6.1979 I. Where the effluent to be discharged has a B.O.D. concentration of 5,000 milligrammes or less per litre, the amount shall be $50.00 per thousand metric tons or part of a thousand metric tons of the total amount of effluent to be discharged. II. Except as provided in paragraph IV, where the effluent to be discharged has a B.OJ). concentration in excess of 5,000 milligrammes per litre, a further amount determined in accordance with paragraph III, shali be charged.

III. The B.O.D. load of the total amount of effluent to be discharged shall first be determined on the basis of the actual B.O.D. concentration of the effluent; next shall be determined the B.O.D. toad of the total amount of effluent to be discharged if the effluent were to have a B.O.D. concentration of 5,000 milligrammes per litre; the amount shall then be S100.00 per metric ton or part of a metric ton of the difference between the two B.O.D. loads.

61

IV. Where the effluent to be discharged has a B.O.D. concentration in excess of 5,000 milligrammes per litre, and the Director General is satisfied that the discharge of such effluent will not cause any adverse environmental effect in any material degree, he may, with the approval of the Minister, completely or partially waive the amount determined in accordance with paragraph III.

V. For the purposes of paragraphs I, II and III, the B.O.D. concentration and the total amount of effluent to be discharged shall be as represented by the applicant or, where the Director General limits the B.O.D. concentration and the amount by way of condition of licence, as so limited.

Discharge on or after 1.7.1979

The amount shall be $50.00 per thousand metric tons or part of a thousand metric tons of the total amount of effluent to be discharged, as represented by the applicant or, where the Director General limits the amount by way of condition of licence, as so limited.

811$ Made this 21st day of October 1977.

TAN SRI ONG KEE HUI, Minister of Science, Technology and

Environment

GENERAL EFFLUENT DISCHARGE STANDARDS

THAILAND

Indiistrial Effluent Standards Parameters I nits Standard Vames

1. pH - 5.5-9.0

2. Total Dissolved Solids (TDS)

mg/l • not more than 3,000 mg/l depending on receiving watefor type of industry under consideration of FCC but not exceed 5,000 mg/l

• not more than 5,000 mg/l exceed TDS of receiving water having salinity of more than 2,000 mg/l or TDS of sea if -discharge to sea

3. Suspended solids (SS) mg/1 not more than 50 mg/l depending on receiving water or type of industry or wastewater treatment system under consideration o f PCC but not exceed 150 mg/l

4. Temperature °C not more than 40

5. Color and Odor - not objectionable

(>. Sulphide ( as l l .S) n ig 1 not more than 1.0

7. Cyanide ( as i l( 'N) mg 1 not more than 0.2

8. Fat, Oil & Grease (FOG)

mg/l not more than 5.0 mg/l depending of receiving water or type of industry under consideration of PCC but not exceed 15.0 mg/l

9. Formaldehyde mg/l not more than 1.0

10. Phenols mg/l not more than 1.0

11. Free Chlorine mg/l not more than 1.0 1 2. Pesticides mg 1 not detectable

13. Biochemical Oxygen Demand (HOD)

mg/l not more than 20 mg/l depending on receiving water or type of industry under consideration of PCC but not exceed 60 mg/l

14. Total Kjedahl Nitrogen (TKN)

mg/l not more than 100 mg/l depending on receiving water or type of industry under consideration of PCC but not exceed 200 mg/l

15. Chemical Oxygen Demand (COD)

mg : not more than 120 mg/l depending on receiving water of type of industry under consideration of PCC but not exceed 400 mg/l

1<>. Heavy metals 1. Zinc (Zn) mg/l not more than 5.0

2. Chromium (Hexavalent)

mg/l not more than 0.25

3. Chromium (Trivalent) mg : not more than 0.75

4. Copper (Cu) mg 1 not more than 2.0

5. Cadmium (Cd) mg 1 not more than 0.03

6. Barium (Ba) mg 1 not more than 1.0

7. 1 ead(I'b) mg/l not more than 0.2

s. Nickel (Ni) mg 1 not more than 1.0

9. Manganese (Mn) 111!' 1 not more than 5.0

10. Arsenic (As) mg/l not more than 0.25

11. Selenium (Se) mg/l not more than 0.02

12. Mercury (Hg) mg 1 not more than 0.005

•

Remark: 1) PCC: Pollution Control Cornmittee 2) The standards were summerized from the Notification of the Ministry of Science, Technology and Environment, No. 3, B.E. 2539 (1996) and it specifies that pollution sources that the above standards are to be applied are factories group II and III issues under the Factory Act B.E.2535 (1992) and every kind of industrial estates. 3) Notification of the Pollution Control Committee, No. 3, B.E. 2539 (1996) dated August 20, B.E. 2539 (1996) has issued types of factories (category of factories issued under the Factory Avct B.E.2535 (1992) that are allowed to discharge effluent having different standards from the Ministerial Notification No. 3 above as follows :

1. BOD up to 60 mg/l o animal furnishing factories (category 4(1))

o starch factories (category 9 (2))

o food from starch factories (category 10)

o textile factories (category 15)

o tanning factories (category 22)

o pulp and paper factories (category 29)

o chemical factories (category 42)

o pharmaceutical factories(category 46)

o frozen food factories (category 92) 2. COD up to 400 mg/l

o food furnishing factories (category 13 (2))

o animal food factories (category 15 (1))

o textile factories (category 22)

o pulp and paper factories (category 38) 3. TKN

- o 100 mg/l - effective after 1 year from the date published in the Royal Government Gazette of the Ministerial Notification No. 4

o 200 mg/l - effective after 2 year from the date published in the Royal Government Gazette of the Ministerial Notification No. 4 for the following factories:

1. food furnishing factories (category 13 (2))

2. animal food factories (category 15(1)) Sources:

1. Notification the Ministry of Science, Technology and Environment, No. 3, B.E.2539 (1996) issued under the Enhancement and Conservation of the National Environmental Quality Act B.E.2535 (1992), published in the Royal Government Gazette, Vol. 113 Part 13 D, dated February 13, B.E.2539 (1996)

2. Notification the Ministry of Science, Technology and Environment, No. 4, B.E.2539 (1996) issued under the Enhancement and Conservation of the National Environmental Quality Act B.E.2535 (1992), published in the Royal Government Gazette, Vol. 113 Part 13 D, dated February 13, B.E.2539 (1996)

3. Notification of the Pollution Control Committee, No. 3, B.E. 2539 (1996) dated August 20, B.E. 2539 (1996) issued under Factory Act B.E.2535 (1996), published in the Royal Gazette, Vol. 113, Part 75 D, dated September 17, B.E. 2539 (1996)

Regulations of Industrial Pollution Control Facilities 1. The following industrial plants must have supervisors and machine operators take

responsibility for the system of prevention of pollution. Qualifications for these individuals are specified in section 2 below. a) An industrial plant discharging waste water at a rate of more than 60 cubic meters/hour (with the exception of cooling water) or having a BOD load of influent higher than 100 kilograms/day. b) An industrial plant using heavy metals in its production process discharging wastewater at higher than 50 cubic meters/day and having a heavy metal content in the discharged waste water at the following values:

1. Zinc higher than 250,000 milligrams/day

2. Chromium higher than 25,000 milligrams/day

3. Arsenic higher than 12,500 milligrams/day

4. Copper higher than 50,000 milligrams/day

5. Mercury higher than 250 milligrams/day

6. Cadmium higher than 1,500 milligrams/day

7. Barium higher than 50,000 milligrams/day

8. Selenium higher than 1,000 milligrams/day

9. Lead higher than 10,000 milligrams/day

10. Manganese higher than 250,000 milligrams/day c) An industrial plant dealing with iron and steel:

11. Using dry furnaces or acids or other substances which may be polluting the environment in the production process with capacity of more than 100 tons/day.

12. Using steel smelters with the total capacity of 5 tonsfaatch. d) An industrial plant producing 100 tons/day petrochemicals from the raw materials obtained as by-products of the oil refinery in the production process. e) An industrial plant of any size separating or producing natural gas. f) An industrial plant producing chloralkali, using sodium chloride (NaCI) as a raw material in the production of soda ash (Na2C03), caustic soda (NaOH), hydrochloric acid (HCI), chlorine (Cl2),and bleach (NaOCl) with separate or combined production more than 100 tons/day. , g) An industrial plant of any size producing cement.

h) An industrial plant engaged in ore smelting or production of metals with production of more than 50 tons/day. i) An industrial plant producing paper pulp with production more than 50 tons/day. j) An industrial plant of any size engaged in crude oil refining.

2. The supervisor and machine operators responsible for pollution control system shall meet the following qualifications: a) The supervisors must be holders of a bachelor degree in engineering or chemistry or other branches of study with experience in the the field of environment, and who has been approved by the Department of Industrial Works. In the case of an Engineering Consulting Firm, it must be operated by person(s) having the above qualifications. b) Machine operators must have a secondary education but can be lower than those in (a) above. c) The persons stated in (a) & (b) above must register themselves with the Department of Industrial Works and comply with all regulations and procedures of the Department of Industrial Works.

3. Factories mentioned in article 1.1 to 1.10 above must arrange to create and submit every three months Poisonous Matter Analysis Reports to the Department of Industrial Works according to its standards. Analysis must be carried out by a government laboratory or in a private laboratory approved by the Department of Industrial Works.

Source: Notification of the Ministry of Industry, No. 13 B.E. 2525 (1982), as amended in No. 22 B.E. 2528 (1985), issued under the Factory Act B.E. 2512 (1969), published in the Royal Gazette, Vol. 99, Part 89, dated June 29, B.E. 2525 (1982).

Source: http://www.pcd.go.th/?=65.15893828

http://www.pcd.go.th/?=65.15893828

Annex H

Findings of the Cleaner Production Audit (Nakiyadeniya Palm Oil Mill)

Table 4.1: Palm Oil & Kernel Oil Production Patterns in the Palm Oil Mill

Month FFB

Processed (kg)

CPO (kg)

Kernels Processed

(kg)

Kernel Oil (kg)

Apr-01 1,264,320 274,740 17,990 7,040 May-01 1,591,780 342,410 101,740 38,030 Jun-01 1,530,420 330,000 87,470 34,230 Jul-01 1,449,330 314,660 68,560 27,270 Aug-01 1,541,090 335,210 86,045 33,800 Sep-01 1,505,440 329,180 76,955 30,000 Oct-01 1,650,430 359,860 68,740 26,340 Nov-01 1,548,970 338,170 74,260 28,050 Dec-01 1,525,170 333,160 77,560 30,730 Jan-02 1,252,830 271,795 66,730 26,270 Feb-02 1,184,160 258,520 63,310 24,630 Mar-02 1,522,540 330,500 96,650 36,820 Apr-02 1,556,490 250,160 37,880 13,900 May-02 1,859,410 397,710 94,670 34,060 Jun-02 1,346,600 286,713 74,970 28,420 Jul-02 1,978,650 423,970 103,240 41,000 Aug-02 1,744,550 375,780 88,910 35,090 Sep-02 2,090,000 453,710 103,230 41,255 Oct-02 1,858,770 404,380 97,930 39,180 Nov-02 1,579,020 325,780 91,770 36,830 Dec-02 1,422,110 292,140 65,130 25,930 Jan-03 1,391,260 294,290 49,770 20,155 Feb-03 1,312,240 282,100 93,070 37,745 Mar-03 1,737,980 364,110 103,710 42,210 Apr-03 1,357,145 287,830 70,950 28,480 May-03 1,597,080 338,500 82,600 32,930 Jun-03 1,740,800 365,940 116,070 45,405 JuI-03 1,439,795 292,510 78,800 31,055 Aug-03 968,392 196,380 61,320 24,670 Sep-03 2,292,745 470,420 108,570 43,650 Oct-03 1,713,290 353,210 91,705 36,700 Nov-03 1,735,875 358,300 117,885 45,670 Dec-03 1,573,835 336,700 70,260 25,230 Jan-04 1,264,320 274,740 61,900 24,260 Feb-04 1,657,930 357,250 82,735 32,415 Mar-04 2,283,535 493,863 154,722 60,400 Total 57,068,302 12,094,691 2,987,807 1,169,850 Average 1,585,231 335,964 82,995 32,496

Cleaner production in Palm Oil Industry, Sri Lanka Annex H - 1

Table 4.2: Monthly Electrical Consumption of the Palm Oil Mill

Month kWhr kWhr kWhr Monthly Bill (Peak) (Off Peak) (Total) (Rs)

Apr-01 5,070 28,410 33,480 285,313 May-01 7,880 44,300 52,180 409,003 Jun-01 5,740 34,990 40,730 319,152 Jul-01 2,150 19,880 22,030 182,444 Aug-01 1,610 19,300 20,910 176,441 Sep-01 2,830 30,710 33,540 250,250 Oct-01 1,470 19,380 20,850 167,623 Nov-01 940 25,160 26,100 225,314 Dec-01 2,480 23,790 26,270 211,036 Jan-02 1,930 27,200 29,130 220,360 Feb-02 1,130 19,800 20,930 187,088 Mar-02 1,150 21,350 22,500 187,665 Apr-02 600 16,640 17,240 147,765 May-02 2,040 33,750 35,790 359,165 Jun-02 1,340 18,200 19,540 133,452 Jul-02 2,510 30,960 33,470 353,376 Aug-02 2,800 34,560 37,360 394,416 Sep-02 2,080 30,800 32,880 355,471 Oct-02 1,890 31,730 33,620 359,048 Nov-02 2,610 31,410 34,020 334,097 Dec-02 1,850 23,970 25,820 302,082 Jan-03 1,990 21,450 23,440 258,322 Feb-03 1,960 24,980 26,940 277,312 Mar-03 2,150 24,440 26,590 286,175 Apr-03 2,720 32,370 35,090 352,384 May-03 2,090 24,300 26,390 281,152 Jun-03 1,060 18,960 20,020 269,711 JuI-03 2,350 26,320 28,670 306,906 Aug-03 1,660 21,060 22,720 244,763 Sep-03 2,580 31,120 33,700 340,347 Oct-03 2,020 27,510 29,530 318,856 Nov-03 2,390 29,460 31,850 320,389 Dec-03 1,910 28,630 30,540 308,783 Jan-04 2,050 22,560 24,610 275,879 Feb-04 2,150 29,660 31,810 334,138 Mar-04 2,340 30,120 32,460 372,253 Total 83,520 959,230 1,042,750 10,107,931 Average | 2,320 26,645 28,965 280,776

Cleaner production in Palm Oil Industry, Sri Lanka A n n e x H - 2

Table 4.4: Plant Electrical Machinery and Their General Working Performance

No. Details of the rn/c Coupling

Type Rated Capacit

(kW)

Operational Details

Phases Section No. Details of the rn/c Coupling

Type Rated Capacit

(kW) Voltage (V) Current (A) Power (kW) PF Phases Section

1 Condensate water pump BC 4 401 2.9 1.22 0.84 3 Phase CPO Extraction 2 Winch m/c BC-GB 7.5 401 1.94 0.914 0.68 3 Phase CPO Extraction 3 Hoist DC-GB 7.5 400 16 8.2 0.7 3 Phase CPO Extraction 4 Fruit auto feeder DC-GB 2.2 400 2.7 0.65 0.34 3 Phase CPO Extraction 5 Threshing Unit DC-GB 7.5 400 9 2.2 0.4 3 Phase CPO Extraction 6 Fruit screw conveyor (Lower) DC-GB 3 400 3.6 1 0.3 3 Phase CPO Extraction 7 Fruit bucket elevator DC-GB 3 401 3.23 1.2 0.53 3 Phase CPO Extraction 8 Fruit screw conveyor (Upper) DC-GB 2.2 401 2.66 0.721 0.39 3 Phase CPO Extraction 9 Digester DC-GB 22 401 15.6 6.83 0.63 3 Phase CPO Extraction 10 Empty bunch conveyor DC-GB 3 403 3.07 0.428 0.2 3 Phase CPO Extraction 11 Press DC-GB 22 402 25.1 15 0.86 3 Phase CPO Extraction 12 Vibrator screen DC 5.5 401 2.26 1.46 0.93 3 Phase CPO Extraction 13 Press hydorlic system DC 1.5 402 1.93 0.506 0.38 3 Phase CPO Extraction 14 Crude oil pump BC 2.2 404 2.33 1.28 0.78 3 Phase CPO Extraction 15 Cake breaker DC-GB 11 404 7.85 2.29 0.42 3 Phase CPO Extraction 16 Pneumatic conveyor blower BC 11 403 11.4 6.78 0.85 3 Phase CPO Extraction 17 Nut vibrator screen BC 1.5 404 3.19 0.684 0.31 3 Phase CPO Extraction 18 Fibre cyclone fan BC 11 405 13.3 7.07 0.76 3 Phase CPO Extraction 19 Air lock DC-GB 1.5 405 2.31 0.37 0.23 3 Phase CPO Extraction 20 Fibre feeding screw DC-GB 3 404 3.19 0.634 0.28 3 Phase CPO Extraction 21 Nut cracker DC-GB 4 403 7.05 3.14 0.64 3 Phase CPO Extraction


22 Nut door discharger DC-GB 1.1 404 2.57 0.457 0.25 3 Phase CPO Extraction 23 Crush mixture screw conveyor DC-GB 3 404 3.09 0.673 0.31 3 Phase CPO Extraction 24 •Cernel separator feeding screw BC 2.2 404 1.63 0.504 0.44 3 Phase CPO Extraction 25 Kerner separator fan BC 7.5 404 4.91 1.17 0.34 3 Phase CPO Extraction 26 kernel bucket elevator DC-GB 3 409 2.38 0.411 0.24 3 Phase CPO Extraction 27 Kernel sheet discharger BC-GB 2.2 403 2.45 0.917 0.54 3 Phase CPO Extraction 28 Kernel Dryer BC 11 404 12.8 3.11 0.35 3 Phase CPO Extraction 29 Boiler flue gas fan BC 15 410 15.2 10.1 0.94 3 Phase Boiler 30 Boiler feed water pump DC 15 403 23 16 1 3 Phase Boiler 31 Oil Dryer DC 0.75 402 1.6 0.378 0.34 3 Phase CPO Extraction 32 Water treatment plant pump BC 4 402 4.73 3.26 0.99 3 Phase Boiler 33 Wastewater pump BC 5.5 398 6.6 3.78 0.83 3 Phase CPO Extraction 34 Decanter BC 30 400 41.3 24.2 0.85 3 Phase CPO Extraction 35 Decanter oil pump BC 2.2 399 4.35 2.52 0.84 3 Phase CPO Extraction 36 Sludge screw DC - GB 0.75 On Repair 3 Phase CPO Extraction 37 Decanter air compressor BC 2.2 246 6.66 1.13 -0.4 Single Phase CPO Extraction 38 Finish oil pump BC 2.2 402 4.04 2.23 0.79 3 Phase CPO Extraction 39 CPO loading pump DC 2.2 Not In Opera. 3 Phase CPO Extraction 40 Water well pump DC 2.2 403 2.73 1.62 0.85 3 Phase CPO Extraction 41 Kernel Transport Blower BC 7.5 409 8.63 4.47 0.73 3 Phase CPO Extraction 42 Kernel expeller 1 BC 37 407 44.5 26.2 0.83 3 Phase KO Extraction 43 Kernel expeller 2 BC 37 On Repair 3 Phase KO Extraction 44 Filtering pump BC-GB 2.2 409 3.07 0.917 0.42 3 Phase KO Extraction 45 Finish oil pump (Kernel) BC 2.2 407 6.27 3.73 0.84 3 Phase KO Extraction 46 Kernel oil loading pump BC 2.2 Not In Opera. 3 Phase KO Extraction


47 Drinking water pump DC 1.1 250 3.06 0 .283 -0.21 Single Phase General

48 Sludge pump BC 2.2 Not In Opera 3 Phase ETP

49 Tube well water pump DC 1.1 404 1.31 0 .209 0.23 3 Phase ETP

50 Submersible pump DC 1.5 230 4.1 0 .886 -0.54 Single Phase ETP

51 Effluent loading pump BC 2.2 407 3.35 2.16 0.91 3 Phase ETP

52 Aerator Fan DC 2 402 2.84 1.76 0.89 3 Phase ETP

53 Neutraliser D C - GB 0.75 Not In Opera. 3 Phase KO Purifying

54 Bleacher D C - G B 0.75 Not In Opera i Phase KO Purifying

55 Cooler DC - GB 0.75 Not In Opera. 3 Phase KO Purifying

5d Water pump (Vacuum) DC 7.5 408 7.72 4.65 0.85 3 Phase KO Purifying

57 Water pump Cooler DC 7 5 408 9.06 5.56 0.87 3 Phase KO Purifying

58 Final filter DC 1.5 Not In Opera. 3 Phase KO Purifying

59 Vacuum pump DC 7.5 408 11.7 6.89 0.83 3 Phase KO Purifying

60 B.T.R. filter DC 1.5 Not In Opera. 3 Phase KO Purifying

61 Finished nil pump DC 2.2 Not In Opera. 3 Phase KO Purifying

Cleaner production in Palm Oil Industry, Sn Lanka Annex H - 5

conclusions & recommendations

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