Process Debottlenecking and Retrofit of Palm Oil Milling Process via Inoperability Input-Output Modelling

In recent years, there has been an increase in crude palm oil (CPO) demand, resulting in palm oil mills (POMs) seizing the opportunity to increase CPO production to make more profits. A series of equipment are designed to operate in their optimum capacities in the current existing POMs. Some equipment may be limited by their maximum design capacities when there is a need to increase CPO production, resulting in process bottlenecks. In this research, a framework is developed to provide stepwise procedures on identifying bottlenecks and retrofitting a POM process to cater for the increase in production capacity. This framework adapts an algebraic approach known as Inoperability Input-Output Modelling (IIM). To illustrate the application of the framework, an industrial POM case study was solved using LINGO software in this work, by maximising its production capacity. Benefit-to-Cost Ratio (BCR) analysis was also performed to assess the economic feasibility. As results, the Screw Press was identified as the bottleneck. The retrofitting recommendation was to purchase an additional Screw Press to cater for the new throughput with BCR of 54.57. It was found the POM to be able to achieve the maximum targeted production capacity of 8,139.65 kg/hr of CPO without any bottlenecks.