4.1.0 Indexes of Peanut Seeds:
4.1.1 Smell and color: Normal
4.1.2 Moisture: ≤12%
4.1.3 Impurities: ≤1.5%
4.1.4 Oil content of sunflower seed: 40~55%
4.2.0 Main Consumption Indexes:
4.2.1 Electricity consumption: ≤ 38.83 kwh/t
4.2.2 Steam: ≤ 180 kwh/t (sunflower seed)
4.3.0 Crude Pressing Oil Quality Indexes:
4.3.1 Smell,taste: With inherent sunflower oil smell and taste, no off-flavor
4.3.2 Insoluable impurities(%): ≤ 0.20
4.3.3 Peroxide value(mmol/kg): ≤ 7.5
4.3.4 Moisture and volatile matters (%): ≤ 0.20
4.3.5 Acid value(Calculating as per KOH)(mg/g): ≤4.0
4.4.0 Process Description of Sunflower Seed Preprocessing Workshop
4.4.1 Sunflower Seeds Preprocessing and Pre-pressing Process Diagram
husk → to husk warehouse
Oil sunflower → cleaning, stones removal → husking → kernel husk separation → flaking → steam-cooking → oil pressing → crude oil precipitation → filtration → to refining workshop
↓ ↓ ↓
↓ ← oil residue back to press ← oil residue back to press
cake → to cake warehouse
4.4.2 Process Description (Pictures only for reference,goods in kind prevail)
18.104.22.168 Cleaning and stones removal
Adopt high efficiency cleaning sieve and specific gravity stoner,with good cleaning and selection effect, changing screen cloth can use one machine for multi-purpose.
Tooth roller crushing machine is comprised of one pair of husking roller with tooth socket, when materials enter the space between tooth and roller through feeding roller, due to the combined action of velocity difference and constant pressure on two rollers, make sunflower seeds suffer shear and extrusion, husks generate bigger deformation and crush, this machine adopts high strength alloy steel roller, with features of long working life, good wear proof effect, convenient maintenance, cheap accessories.
The purpose of flaking is crushing sunflower seed and soybean cell tissue to separate oil smoothly, configurate alloy tooth roller, as twice life as ordinary roller,automatic hydraulic fastening roller system,to ensure flakes thickness uniform(≤ 0.3mm),complete machine has good sealing effect.
Adopt layer steam cooker,the maximum distance between stirring wings on each layer and the bottom of steam cooker is 5mm,avoid stirring unequally,complete steam cooker is sealed, to keep the space upper flakes have maximum moisture,make flakes be steamed and uniform.
Adopt matured special sunflower seed pre-pressing machine ZY24, residual oil in pressing cake is about 10%~18%, the most important feature is once pre-pressing, low energy consumption,small covering area, is the best choice of national sunflower seed pre-pressing.
Adopt filter with function of automatic discharging oil residue,avoid manual cleaning screen clothes, working efficiency is high, filtered oil residue goes back for pressing automatically,this section also configurates clarification slag salvaging machine, make sure the least oil residue in crude oil,and ensure later degumming section effect.
5.4.1 Extraction Process Diagram:
solvent solvent recovery
Cake → oil extraction → miscella processing → crude extracted oil
solvent recovery← wet meal → desolventizing-toasting → finished meal
5.4.2 Process Description
22.214.171.124 Extraction Process
Cake is conveyed to extractor through scraper conveyor,materials run a circle from inlet to outlet,spray it with miscella with diminishing concentration,before entering draining section, spray it with fresh solvent again,drained wet meal discharges with switch device from material grid of extractor and enters wet met scraper conveyor. Concentrated miscella enters two-stage cyclone hydraulic separator through concentrated miscella pump to remove powder impurities and then enters miscella tank.
★ Rotocel extractor adopts chain transmission, unique rotor balance design,with advantages of low rotate speed, small power,stable operation,no noise, low maintenance cost.
★ Feeding system adjusts rotate speeds of air lock and main machine according to feeding capacity, make material storage tank keep certain material level all the time,beneficial for forming micro negative pressure in extractor,reduce solvent leakage.
★ Advanced miscella circulation theory design is beneficial for reducing input of fresh solvent, reducing residual oil in meal, improving miscella concentration, achieve energy-saving purpose through reducing evaporation capacity.
★ The design of high material level rotate grid of extractor is beneficial for forming immersion extraction and reduce meal powder content in miscella, beneficial for improving crude oil quality and reduce scaling of evaporation system.
★ Especially suitable for all kinds of prepressing cake extraction.
Wet meal with solvent out from extractor is conveyed to preliminary desolventizing layer of DTC desolventizer-toaster with wet meal scraper conveyor via air lock,the bottom uses indirect steam to heat, remove part of solvent; wet meal after preliminary desolventizing enters toasting layer,which sets automatic control to keep certain material layer, steam from the bottom to remove all solvent, at the same time, part of steam congeals in meal,the moisture of meal will increase partly. Desolventized meal material level is controlled by each layer, drying layer keeps certain material level, to dehydration and drying process.Finally control discharging materials with automatic material door, then use meal scraper conveyor to convey meal into meal warehouse.
Mixed vapor of solvent out from the top of desolventizer-toaster and water vapor, goes through solvent catcher ,then enters condenser for cooling recovery.
★ Unique breathable pan design,beneficial for good contact between materials and steam,with good desolventizing effect,small direct steam consumption,low outlet temperature of twice steam.
★ Preliminary desolventizing layer and permeable layer adopt horn mouth discharging materials,with good sealing, uniform discharging materials, stable material layer, adopt automatic material door discharging controlled by this layer.
★ Meal quality is stable,urease activity reaches national standard,color is light yellow and uniform,no clustering phenomenon,moisture is adjustable,temperature is a little higher than room temperature;
★ Reducers of main machines adopt famous brand product, performance is stable,failure rate is low.
Miscella enters the first long tube evaporator tube pass from miscella tank, evaporated solvent enters evaporation condenser through separation chamber,outlet pipelines of separation chamber set liquid level control device to keep liquid seal. Miscella enters disc of tower from the top of steam-stripping tower,fall layer by layer,at the same time inject direct steam from the bottom,remove residual solvent.Top outlet connects evaporation condenser, use high vacuum injection pump to keep steam-stripping tower work under negative pressure,equipped with liquid level controller on the bottom of steam-stripping tower to ensure liquid level and stable flow of finished oil,crude oil is drawn from tower bottom with steam-stripping drawn pump to cool and then enters crude oil tank.
★ Evaporation temperature is low, residual solvent in crude oil is low, color is light,no phospholipids precipitation,evaporator and steam-stripping tower scaling not easy;
★ The advantages of using long tube condenser is high solvent recovery rate,reducing condenser area and saving investment cost.
★ Using boiling tank makes solvent in drained waste water reach the minimum value.
Extraction Process Technical Highlights
1 ;Adopt two-stage purification processing for miscella, concentrated miscella enters one-stage cyclone hydraulic separator firstly to remove meal powder with bigger granules, then enters two-stage cyclone hydraulic separator to remove impurities twice.There is hardly solid impurities in miscella after cyclone hydraulic separation, clean miscella is pumped to miscella temporary storage tank for further precipitation. Sediment on the bottom of miscella tank is pumped to extractor with oil residue pump regularly. Application of twice filtration and negative pressure evaporation process of miscella, reduces scaling of evaporation system greatly,cleaning cycle of evaporation system can extend.
2; Adopt micro-negative pressure technology,save energy,reduce energy consumption
3; Twice steam in condensate tank is used to preheat waste water,reduce steam consumption.
4; Collect all used water in extraction workshop,and pump it into boiler room for re-utilization, utilize waste heat of used water,save production water supply.
phosphoric acid hot water bleaching clay
↓ ↓ ↓
Crude sunflower oil → degumming → water washing → continuous drying → continuous bleaching →
continuous dewaxing → continuous deacidification & deodorization → refined grade 1 sunflower oil
1, Degumming,alkali refining and water washing section
Remove impurities from crude pressing oil with filter,use oil pump to convey it into refining tank in refining workshop, add phosphoric acid to make nonhydratable phospholipids transform into hydratable phospholipids, at the same time, complex plenty of iron ions dissolving in oil in the high FFA production process,add little lye to make them neutralize and generate soap-stock and absorb impurities in oil,add hot water for water washing,discharge and recycle soap-stock,then temporarily store soap-stock in temporary storage tank.
2, Continuous drying section
Use steam to heat oil after water washing,and pump it into continuous drying tower,through high vacuum to remove moisture in oil,then draw dry oil from the bottom into temporary storage tank before bleaching.
3 ,Continuous bleaching section
Add efficient active bleaching clay into oil,under vacuum condition, mix well and heat, make pigment solid tiny particles which suspends in oil absorb on the bleaching clay crystal particles, use leaf filter to remove them. The layout of this system is perfect,performance is reliable, high configuration of key equipments — bleaching tower and leaf filter ensures high quality bleaching and separation for oil.
This technology has the following advantages:
- Bleaching clay and oil mix under vacuum state when bleaching,avoid the effect from air,increase bleaching clay utilization efficiency, with better bleaching effect, at the same bleaching effect,bleaching clay consumption is smaller.
- According to bleaching requirement, precisely and automatically meter bleaching clay addition percentage.
- Continuous perfect mixture process makes all bleaching clay particles contact oil uniformly .
- Temporary storage tank of decolorized oil adopts negative pressure design,effectively avoid oil contacting air, make the quality of intermediate product and final product be more stable.
- Filtration of decolorized oil works in sealed filter with stainless steel filter leafs,residual oil rate of filter cake is low, operation is simple and convenient, equipment failure is low.
6.4.4 Continuous deacidification and deodorization section
Soft tower deodorization technology represents the latest deodorization technology, it solves remaining issues in edible oil industry for years. Its technical process flow: Qualified decolorized oil is recovered most heat through efficient heat exchanger,then use heat conduction oil or high pressure steam to heat oil up to required technical temperature, and enters deodorization tower; deodorization tower is combined, upper layer is structure fillers,mainly used to remove FFA and other odor component,lower layer is board type structure,mainly plays hot bleaching role,and make product quality be more stable.Oil from deodorization tower is stored after series of heat exchanging and cooling.Volatile matters such as fatty acid out from deodorization,catch through packing catcher and become by-product.
Soft tower deodorization technology has the following features:
- Technology is advanced and reliable,it’s widely adopted by big oil plants,and gain better effect.
- Energy consumption is low, product quality is good, adopting combined deodorization tower and optimized heat exchanging system design,gave effective guarantee.
- Deacidification ability is very strong,it can decrease the acid value of qualified oil ready for deodorization from 10mgKOH/g to 0.2mgKOH/g in short time.
6.4.5 Continuous winterization dewaxing section
Dewaxing is an important step to improve edible oil quality.Existing of wax mainly affect palatability of oil, therefore, the main purpose of dewaxing is improving palatability of oil,and its sensuality such as transparency and brightness.Different wax content for different oil,dewaxing is nearly necessary for corn oil,rice bran oil,sunflower oil and linseed oil,etc.This technology adopts counterflow type continuous process method, make oil crystallize thoroughly, use special filtration oil pump when filtering, shear force is small,filtration effect is good,wax and oil separate thoroughly, later adopts twice polishing filtration, further improve oil transparency.
1, Higher mechanization,automation,control,reduce labor cost.
2, More advanced process configuration, continuous drying,continuous bleaching, continuous deacidification & deodorization,continuous dewaxing.
3 ,Bleaching clay automatic metering and addition,high vacuum,save steam,save energy, reduce processing cost.
Finished sunflower oil standards(GB/T10464-2003)
|Item||Grade 1 Sunflower Oil|
|Color(Lovibond 133.4mm Color Slot)≤||Y15 R1.5|
|Moisture and volatile matters % ≤||0.05|
|Acid Value(KOH)/(mg/g) ≤||0.20|
|Smell and taste||No smell, good taste|
|Content of Insoluble Impurities(%)≤||0.05|
|Freezing Test(0ºC store for 5.5 hours)||Clear, transparent|
|Solvent Residues(mg/kg)||Not detected|
Part of Project Achievements
|1||Tajikistan||50T/D Cottonseed Cake Extraction Project|
|2||Kazakhstan||3T/D High-class Cooking Oil Refining Project|
|3||Kazakhstan||120T/D Sunflower seed prepressing, extraction and refining project|
|4||Uzbekistan||80T/D Sunflower Seed Cake Extraction,50T/D Sunflower Oil Refining Project|
|5||Uzbekistan||50T/D Sunflower Seed,Soybean,Cottonseed Making Oil Project|
|6||Uzbekistan||100T/D Sunflower Seed Prepressing, Soybean Pretreatment, 100T/D Micro-negative Pressure Extraction and 20T/D Grade 1 Oil Refining Project|
|7||Uzbekistan||100T/D Sunflower Seed Prepressing, Soybean Pretreatment, 100T/D Micro-negative Pressure Extraction and 30T/D Oil Refining Project|
|8||Russia||50T/D Soybean Pretreatment, 50T/D Solvent Extraction and 10T/D Soybean Oil Project|
|9||Russia||10T/D Rapeseed Oil Pressing Project|
|10||Estonia||10T/D Biodiesel Distillation Project|
|11||Sri Lanka||30T/D Chicken Oil Pressing, 20T/D Chicken Refining Project|
|12||Indonesia||20T/D Coconut Oil Pressing,10T/D Oil Refining Project|
|13||Indonesia||3T/D Fragrant Sesame Oil Project|
|14||Indonesia||3T/D Oil Refining Machine|
|15||Thailand||10T/H Palm Oil Renovation Project|
|16||Thailand||45T/H Palm Fruit Sterilization Tank|
|17||Thailand||2T/D Palm Oil Refining Project|
|18||Bangladesh||30T/D Rice Bran Making Oil Project|
|19||Bangladesh||100T/D Rice Bran Making Oil Project|
|20||Bangladesh||30TPD Sunflower Seed, Mustard Seed Making Oil Project,30T/D Fully Continuous Oil Refining Project|
|21||Bangladesh||15T/D Rapeseed Oil Refining Project|
|22||Cambodia||30T/D Rice Bran Making Oil Project|
|23||Philippines||30T/D Corn Germ Pressing and Refining Project|
|24||Philippines||15T/D Corn Processing Project|
|25||Myanmar||3T/D Cottonseed Oil Refining Machine|
|26||Solomon Islands||3T/D Coconut Oil Deacidification & Deodorization Project|
|27||Bolivia||60T/D Soybean Oil Refining Project|
|28||Peru||50T/D Palm Oil Refining Project|
|29||Peru||50T/D Palm Oil Deacidification & Deodorization Project|
|30||Peru||150T/D Soybean/Palm/Sunflower Oil Refining Project|
|31||Egypt||100T/D Soybean Pretreatment and Extraction Project|
|32||Egypt||20T/D Soybean Oil Refining Project|
|33||Egypt||10T/D Cottonseed Oil Refining Project|
|34||Sudan||30T/D Peanut Oil Pressing, 15T/D Peanut Oil Refining Project.|
|35||Ethiopia||50T/D Soybean Oil Refining Project|
|36||Ethiopia||100T/D Corn Processing Project|
|37||Ethiopia||15T/D Peanut and Sunflower Seeds Pressing,5T/D Oil Refining Project|
|38||Djibouti||2T/D Sunflower Oil Dewaxing Machine|
|39||Nigeria||5T/H Palm Fruit and Kernel Pressing Project|
|40||Nigeria||20T/D Palm Oil Refining and Fractionation Project|
|41||Nigeria||50T/D Peanut Pressing, 15T/D Peanut Oil Refining Project|
|42||Ghana||20T/D Corn flour production line|
|43||Cameroon||5T/D Palm Oil Stirring Tank|
|44||Congo||0.5T/H Palm Oil Making Soap Project|
|45||Rwanda||10T/D Palm Oil Refining Project|
|46||Tanzania||20T/D Sunflower Seeds Pressing, 5T/D Refining Project|
|47||Malawi||2T/D Oil Refining Machine|
|48||Swaziland||30T/D Oil Refining Machine|