Practical Guide to Palm Oil Refining Energy Efficiency: Achieving Steam Consumption Under 300 kg/t Oil

For technical managers and production supervisors in palm oil processing plants, mastering energy efficiency in refining isn’t just about cutting costs—it’s about elevating your enterprise’s competitiveness and sustainability footprint. This guide delves into actionable strategies for optimizing your refining process to reduce steam consumption below 300 kg per ton of oil, without compromising product quality.

Identifying Core Energy Consumption Points in the Refining Process

Refining stages such as degumming, neutralization, bleaching, and deodorization consume the lion’s share of steam energy. Understanding the energy distribution across these phases allows you to target the highest impact areas effectively.

Key Variables Influencing Steam Consumption

You can substantially reduce steam use by honing in on three critical control parameters:

• Temperature Curve Settings: Smooth, stable temperature ramps reduce overshoot and unnecessary steam bursts. Aim for less than 2°C fluctuation during steady states.
• Vacuum Stability: Maintaining vacuum levels between −650 mmHg to −700 mmHg ensures efficient steam condensation and accelerated deodorization without excess consumption.
• Oil Retention Time: Optimizing contact time to minimal thresholds prevents energy loss while ensuring sufficient treatment. Benchmark retention between 30 to 45 minutes.

Leveraging PLC-based Intelligent Control Systems

Modern PLC automation allows dynamic adjustment of heating rates and vacuum pumps in real time, precisely balancing process parameters to minimize steam input.

For instance, by integrating temperature sensors and condensate flow meters, you can configure your PLC to modulate steam valves during non-critical phases, thereby cutting off excess supply instantly. Enhanced control over the bleed-off and condensate return loops further improves heat recovery, lowering net steam demand.

Case Study: Energy Savings from Refinery Retrofitting in Nigeria

At a Nigerian palm oil refinery operated by Pengu Group, implementing the above practical steps and integrating PLC modifications yielded remarkable outcomes:

• Pre-retrofit Average Steam Consumption: 350 kg/t oil
• Post-retrofit Steam Consumption: 285 kg/t oil (18.5% reduction)
• Monthly Steam Savings: Approximately 180 tons, translating to ~25,000 USD in energy cost reductions
• Product Quality: No compromise, with acidity levels consistently below 0.1%

These results highlight that operational excellence and energy conservation are not mutually exclusive.

Sustaining Energy Efficiency Through Maintenance

Your energy gains depend on rigorous ongoing maintenance. Equipment aging—especially boiler scaling, vacuum leaks, and worn valves—can deteriorate steam efficiency rapidly. Implement scheduled preventive maintenance routines focused on:

• Descaling and cleaning of heat exchangers and boilers
• Tightness checks on vacuum systems
• Valve calibration and steam trap inspections
• Periodic PLC system audits and software updates

With a solid maintenance strategy, steam consumption under 300 kg/t oil becomes not a one-time achievement but a sustained operational standard.