soyabeans oil production chart
TRANSCRIPT
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Edible Oil Making Plant
l-----------------_j (Continuous Type Expeller Extraction and Refining Plant)
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1 Introduction
Fats and oils, like proteins and carbohydrates, are necessary life
sustaining ingredients in man's diet. Food use accounts for more
than two-thirds of total world consumption of oil.
Refining of vegetable and animal oils improves their keeping
quality. The separation of oils and fats from oil-bearing animals and
vegetables constitutes a distinctive and specialized branch of food
processing technology. Crude oils and fats are 90% make up of
esterstriglycerides and triglycerols. These esters, called neutral oils,
are purified during the edible oil refining process. There is, however, a significant amount of
nonglyceride impurities such as free fatty acids, tocopherols, sterols, phosphatides, hydrocarbons,
pigments, oxides, waxes, moisture, proteins, carbohydrates, dirt, bagging fiber, cellular tissue, gum
and resins that need to be removed during processing. These impurities generally find their way into
the oil during the refining process. They produce the dark-color and cause oil to foam, smoke or
precipitate when heated. Subsequent processing might result in an unpleasant taste and odor when
the oil is exposed to atmospheric conditions.
Fats and oils are not only essential to the diet of man and animals but also play an important role in
the manufacture of numerous products, such as paints, varnishes, soap, cosmetics hardened fats,
textiles, leather, paper, pharmaceuticals and lubricants. They are also often used or converted into
edible medicinal.
The widely different characteristics of oil-bearing materials from diverse resources have given rise to
different extraction and refining processes. But the system most commonly used in the refinement of
edible oils today consists of neutralization, washing, bleaching, deodorization of other processes for
special purposes or which produce new products to meet changing market demands. However, to
choose the best process for an oil extraction and refinement plant, some common objectives must be
considered. These include the need to obtain uninjured fats and oils, which are as free as possible from
undesirable impurities, to obtain the fats and oils in as high a yield consistent with economical
processing, and to produce an oil cake residue (by-product) of the highest value.
In the current world industrial situation of energy resource shortage, rising wages, demand for higher
quality from consumers and stiffer competition, investors must tread carefully in making their
investment plans in and management of a whole plant business. How to make an economical
investment, save labor expenses and energy resources, and how to produce high value products and
by-products are points, which must be considered when investing in an edible oil plant. The investor
must consider that there are many inherent disadvantages to processing edible oil by the solvent
extraction method. These include the large amount of investment and energy costs, the complex and
dangerous processing, difficult maintenance and repair of machinery and equipment, large solvent
leakage during the manufacturing process, and high personnel expenses for high-tech engineers, all of
which make the cost of solvent-extracted products at least twice higher than the alternative continuous
type oil expeller-extraction method (although the former extracts about 2-5%more oil). Today unlike
the low oil content materials such as soybeans, oil from rice bran must be extracted using the solvent
extraction process. Contrarily, for other high oil content materials such as peanuts, copra, palm kernel,
rapeseed, etc., the continuous type oil expeller process is used to extract oil, so that the management
and profitability of the plant will be much more efficient and competitive.
Among all kinds of oil extraction plants, the continuous type oil expeller-extraction and refining process
is the most economical investment because:
1.1 The manufacturing process is easy.Itis easy to manage and control, and there is a
minimal need for high-tech engineering personnel
1.2 The cost of machinery and equipment and the occupation of the plant are not very high.
1.3 The production capacity is stable, and there is less likelihood of unit equipment failure
and job interruption.
1.4 Due to simple machinery design, it is easier to repair
1.5 There is lower leakage and loss of raw materials, Products, and energy during
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manufacturing
1.6 Because of the low content of gum and wax, it is easy to refine crude oil from the
continuous type oil expeller-extraction process, and
1.7 It is easy and safe to operate the plant because no volatile materials are involved.
2 General Processing Information
2.1 Flow Chart
2.1.1 Expeller Extraction Section
2.1.1.1 The Process for Peanut, Rapeseed, Cotton Seed, and corn palm kernel, copra, Sunflower Seed,
etc., Material.
2.1.1.2 The Process For Palm Kernel Material
2.1.1.3 The Process For Copra Material
2.1.2 Refining Section
2.1.2.1 The Process of physical Refining System:
2.1.2.2 The Process of Batch Type Refining System
2.1.2.3 The Process of Semi-Continuous Refining System
2.2 Process Description:
2.2.1 Pressing
2.2.1.1 Any raw material such as peanut, rapeseed, cotton seed, corn, palm kernel, copra, or sunflower
seed that is stored in the warehouse in bulk form is loaded by using wheel loaders and dumped into
the receiving hopper where labor will push the raw seed grain through the static screen into the
receiving hopper.
2.2.1.2 Through vibrating feeders, the raw seed grain is fed into the bucket elevator and transported to
the vibrating screen which magnetically removing part of the dehulling equipment.
2.2.1.3 After being crushed, the dehulled seeds are separated from the hulls by a screening device. The
hulls thus removed are sent to storage for eventual use as roughing in animal feeds.
2.2.1.4 The seeds are rolled into thin flakes to make them easily permeable to steam in the cooking
operation and are next cooked or conditioned in a 5-stage automatic steam kettle at 1200( for 20
minutes before pressing to rupture the oil lands and to coagulate the proteins.
2.2.1.5 The conditioned vegetable seeds are then places in an oil pressure expeller, which remove the
oil from the seeds. The oil removed by the presses is screened, cooled, filtered and stored for refining.
2.2.1.6 The expressed meal cake extruded from the expellers consists of approximately 8-10%
vegetable oil, which could be recovered through a secondary mechanical pressure expeller, which
recovers up to 95%-98%of oil from the raw vegetable seed. The cake residue could eventually be
consumed as animal feed.
2.2.2 Refining: The overall refining process of crude vegetable oil usually involves neutralization, water
washing and drying, bleaching, and deodorization.
2.2.2.1 Neutralization is carried out to remove the free fatty acid present in the oil. This is the most
delicate and difficult stage in the refining cycle because this is the stage with the highest loss of
neutral oil. In this process, the oil is heated in jacketed kettle fitted with a heating cell set at a
temperature of 500(-600( and agitated. Sodium hydroxide solution is added to the oil in excess of
stoichiometric requirements. Agitation is continued when the soap flocks are well flocculated. Soap
stock or foots is settled, and then pumped to the holding tank.
2.2.2.2 The soap stock is then steamed with phosphoric acid, the fatty acids and the neutral oil thus
liberated rise to the surface. A thorough washing is required to remove the traces of soap, which always
remain in the oil. After washing, the surface of the oil mass and water are settled and drained off
separately.
2.2.2.3 The dehydrated oil is brought into intimate contact with the bleaching materials. The mixture is
then heated by steam while the contents are maintained under vacuum by the barometric condenser
and vacuum pump. When the required temperature is reached, the moisture present in the oil is
completely removed upon completion of bleaching; The oil-bleached suspension is pumped to the
filtration section where the two component are separated. Neutralization, bleaching and filtration
remove coarse suspened free acids and coloring matter from the extruded oil.
2.2.2.4 The purpose of deodorization is to remove unpleasant odor and flavour to oils. The operation
should be operated at lower temperatures. The deodorizer is fitted with heating coils, and a vacuum is
applied. Measured amounts of oil are charged into it, and the oil is heated to the desired temperature
at which deodorization is carried out. Steam is injected in the operating coils. At the end of this
operation, oil is dumped by gravity into a cooling tank, which is maintained at the same pressure as
the deodorizer. After this final step of refining, the odorless, transparent and neutralized oil is ready for
packaging.
3 Plant Description
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3.1 Production capacity:
The plant equipped with the machinery and equipment outlined in section 3.4 of this proposal,
operating 24 hours (3 shifts) a day, 25 days a month, is capable of producing 1500-5000 tons of high
quality vegetable oil per month.
3.2 Raw Materials:
Copra, seasame seed, palm fruit, ground nut (peanut), rapeseed, sunflower seed, safflower seed,
corngern,cotton and soybean.
The oil content of the oil-bearing vegetable materials is as follows:
I Oil Bearing Material I Oil content 10/0
ICol2ra 65-68
ISeasame Seed 50-55
IPaim Kernel 45-50
IGroundnut (Peanut) 45-50
IRal2eseed 40-45
ISunflower seed 35-45
Icorngern 35-45
ICotton Seed 18-20
3.3 Manpower Required:
IRaw Material
I
Input Capacity Persons/Shift(Tone/24hrs) O~erator I Engineer I Total
I 50 5 I 1 I 6
Palm Kernel100 6 1 I 7
150 8 1 I 9
200 10 1 11
~P,"
I 50 8 1 I 9
100 10 1 11
150 12 1 13
200 14 1 15
Peanut Cotton Seed 100 10 1 11
Sunflower Seed150 12 1 13
Castor nut
Rapeseed 200 14 1 15
3.4 Machinery & Equipment:
I Item I Set
IBucket Elevator
IVibrating Screen 2
IVeqetable seed Crusher 1
15-Staqe Automatic Steam Kettle 1-2
ICrude Cake or Residue Cooker 1
IScrew Convel'or 6
ID!:l(Run Bin 1
IFloat Level Control Puml2 1
IFeed Puml2 1
IWater SUl2l2ll' and Drainage Facilitl' 1
ICooling Tower 1
IHeating Sl'stem 1
IHot Water Tank 2IAgitator and Motor 3
IBeit Convel'or 2
IElectroaqnetic Discharqe Belt 1
INeutralization Tank 1
ICentrifugal Sel2arator 1
ICentrifugal Sel2arator 1
INeutralized Oil Tank 1
ISoalLWashiD_gTank - 1 -
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I Item I Set
IWashed Oil Tank 1
Ivacuum S::,'stem 1
IBleaching Tank 1
IFilter Press 2
IBleached Oil Tank 2
IDeaerator Tank 1
IDeodorization Vessel
ISlurl}' Tank 1
IDirt::,'Oil::,'Tank 1
IDeodorized Oil Tank 1
IAcid Oil Storaqe Tank 1
3.5 Information Required for the Set Up of An Oil & Fat
Expelling and Refining Processing Plant:
3.5.1 Raw material quality analysis information
3.5.2 The plant civil structure design drawing.
3.5.3 The flow chart design of manufacturing process.
3.5.4 The flow chart and storage layout for raw material and finished products.
3.5.5 The layout of whole plant equipment.
3.5.6 The electricity supply and installation diagram.
3.5.7 The foundation diagram of equipment.
3.5.8 The operation frame mechanism design.
3.5.9 The water supply and piping system installation diagram.
3.5.10 The steam boiler and system and installation diagram.
3.5.11 The manpower arrangement information.
3.5.12 The electricity power arrangement information.
3.5.13 The investment and cost analysis information.
3.5.14 The market analysis information.
3.5.15 The operation instruction and trouble shooting in processing and technical information.
3.5.16 The maintenance technical information.
3.5.17 To be visited the production plant to understand the actual practice.
3.6 Plant Site Planning:
The location of the plant can have a crucial effect on the profitability of the project and the scope for
future expansion. Many factors must be considered when selecting a suitable site. The principle ones to
consider are:
3.6.1 Proximity of material supply market and product consumer market.
3.6.2 Transportation facilities.
3.6.3 Availability of utilit ies: Water, fuel, electric power
3.6.4 Availability of labor
3.6.5 Location not too close to metro area.
For the purpose of economical investment, the plant should be built with steel frame or with concrete
but be ready for reconditioning for future development. The height between every two stairs should
consider piping engineering and air flow system and should be at least 4.5M. In order for the future
development, the area of the oil refining plant should have enough unoccupied area for development of
twice of the capacity. The plant should have good drainage system to avoid contamination of water,
good air flow system to avoid wetting and a suitable width of aisle space for convenient processing.
3.7 Electricity Power Requirement:
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IRaw Material
Input Capacity
IElectricity Power (Kw)
(Tons/24hrs)
I " , m Kernel
50 I 405
100 I 703
I 150 I 974
200 I 1381
r ' "I 50 I 463
100 I 974
I 150 I 1320
200 I 1800
Peanut, Cotton seed 100 I 913
Sunflower seed,150
I1267
Castor nutRapeseed 200 I 1725
3.8 Layout for the Package Plant
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H' ;PO.
'To F'ackgo
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4 Suppliers Information
Shanq Jer Industries Co.. Ltd
Taiepe World Trade Center
RM.3C16,No.S, Sec.S, Hsinyi Rd.,
Taiepei, Taiwan., R.O.C.
Tel:886-02-27234300, 886-2-87809087
Fax:886-2-88622723
E-Mail:[email protected]
http://www.shang-jer.com.tw
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333 Keelung Rd., Section 1, 5-7 Fl., Taipei 11003, Taiwan ROC
Tel: +886 (2) 2725-5200 Fax: +886 (2) 2757-6245 E-mail: [email protected]
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