Unit 1

UNIT 1 NATURAL PRODUCT INDUSTRIES CPT-II 2015-16
UNIT 1 NATURAL PRODUCTS INDUSTRIES
Unit no and Major Learning Outcomes Topics and Sub-topics

name (in cognitive domain)
1a. Define oil and fat 1.1 Basics of oil and fat
1b. Describe physical properties of oil 1.2 Physical properties of oil
1c. Describe carbohydrates 1.3 Introduction to Carbohydrates
Unit-I
Natural 1d. Draw flow diagram explain 1.4 Manufacturing Process of
Product manufacturing process of
Industries (i) Vegetable oil
(i)Vegetable oil (ii) Hydrogenated products of oil
(ii) Hydrogenated products of oil (iii) Sugar from sugar-cane
(iii) Sugar from sugar-cane (iv) Starch from maize
(iv) Starch from maize (v) Dextrin from starch
(v) Dextrin from starch
1e. Distinguish chemicals available from 1.5 Chemicals from sea

the sea
1f. Draw flow diagram describe 1.6 Production of bromine from sea
manufacturing process of bromine from water
sea water.
VIKASSINGH B CHAUHAN
LECTURER IN CHEMICAL ENGINERING
KJ POLYTECHNIC BHARUCH Page 1
1.1 Basics of Oil and Fat /1.2 Physical Properties of Oil
 Oils and fats are organic molecule of carbon, hydrogen, oxygen and sometimes nitrogen
and sulfur.
 They are mixture of glycerides of fatty acids where R1, R2 & R3 are not necessarily same.
 Oils like caster oil, linseed oil are non edible and oils like ground nut oil, coconut oil are
edible .
 By terminology of the industries, oils are all liquids and fats are solid at normal
temperatures.
 Oil is used in producing vanaspati ghee, soaps and detergents, cosmetics, medicines,
polymers, paints and varnishes and in many other applications.
 Number of double bonds in the fatty acid radical(R) controls the melting point and
chemical reactivity as shown in the table.
SR NAME (R) COMPOSITION NO.OF MELTING REACTIVITY TO

NO DOUBLE POINT OXYGEN
BONDS
1 Stearic acid C17 H35 0 69 Nil
2 Oleic acid C17 H33 1 14 Fair
3 Linoleic acid C17 H31 2 -5 Rapid
4 Linolenic acid C17 H29 3 -11 Extremely Rapid
 The ability to react with oxygen enhances the use of unsaturated fatty acids as film
forming vehicles for paints.
 It also is the cause of rancidity in edible fat products which can be avoided by the use of
1. Hydrogenation: removes reactive double bonds
2. Antioxidants : Compounds which oxidized preferentially to fats without much
increase in color or odour.
1.3. Introduction To Carbohydrates

 All carbohydrates consist of carbon, hydrogen, and oxygen atoms and are poly-
hydroxyaldehydes or ketones or are compounds that can be broken down to form such
compounds.
 Examples of carbohydrates include starch, fiber, the sweet tasting compounds called
sugars, and structural materials such as cellulose.
 The term carbohydrate had its origin in a misinterpretation of the molecular formulas of
many of these substances. For example, because its formula is C6 H12 O6, glucose was
once thought to be a “carbon hydrate” with the structure C6·(H2O6)6.
 Carbohydrates are classified into three major groups:
1. Monosaccharides
2. Oligosaccharides
3. Polysaccharides
a. Monosaccharides
 The simplest carbohydrates—those that cannot be hydrolyzed to produce even smaller
carbohydrates—are called monosaccharides.
 Two or more monosaccharide can link together to form chains that contain from two to
several hundred or thousand monosaccharide units. Prefixes are used to indicate the
number of such units in the chains.
 Disaccharide molecules have two monosaccharide units, trisaccharide molecules have

three units, and so on.
 They are low molecular weight carbohydrates and can not be hydrolysed further.
 They are crystalline, soluble in water, and sweet in taste.
 Classified into triose, tetrose, pentose, hexose (glucose & fructose) and heptose
depending upon the number of carbon atoms.
 They may be either aldoses or ketoses depending upon whether they contain a free
aldehyde or ketone group, respectively.
 All monosaccharides are reducing in nature.
b. Oligosaccharides
 They contain two to ten monosaccharide units joined by glycosidic linkages that can be
easily hydrolyzed.
 They are Low molecular weight carbohydrates which can be hydrolysed by enzymes or
acids to yield mono-saccharides. Powdery or crystalline,soluble in water & sweet in
taste.
 Classified into disaccharide, trisaccharide, tetrasaccharide and pentasaccharide
depending upon the number of monosaccharides they contain.
 Some of them are reducing and some of them are non reducing in nature.
 Examples are Maltose, Lactose ,Sucrose.
c. Polysaccharides
 They are high molecular weight polymers containing more than ten monosaccharides.
 They are either linear or branched in structure.
 Polysaccharides are further classified based on
A. The kind of monosaccharides present as:

1. Homopolysaccharides: when made from a single kind of monosaccharide.
Eg starch, cellulose, glycogen
2. Heteropolysaccharides are made up of more than one type of monosaccharides.
Eg. Hemicellulose, Mucopolysaccharides – Chondroitin sulphate, Hyaluronic acid
Heparin and Keratan sulphate
B. Functional aspect as:
1. Storage Polysaccharide
eg. Starch, glycogen, Galactomannan
2. Structural Polysaccharide
eg. Cellulose, Hemicellulose
1.4 (i) Manufacturing Process of Vegetable oil
 Raw material
 Seeds of oilseed plant
 Process Flow Sheet
 Functional Role of Various Processes
(a) Cleaner and dehulling:
 Mechanical cleaning is done to remove stones and other undesirable material.
 Dehulling remove hulls, dry outer covering of seed.
(b) Cracking rolls:
 Crushing rolls crush the oil seeds and gets flacked seeds.
(c) Digester:
 100 parts of flaked seeds are thoroughly mixed with 5-10 parts of water by rotating
blades.
 Softening by means of heat and moisture is done here.
 Steam is added for heating purpose.
 Acid is formed by hydrolysis of ester.
 The seeds get swollen up.
(d) Expeller:
 The swollen seeds are crushed under great pressure.
 Cells of seeds get ruptured and oil is released.
 The tapering shape ensures more application of pressure on the seeds
 The oil depleted cake is either sent for solvent extraction or used as animal feed.
 Oil is sent for purification.
(e) Mix tank:
 The extracted oil is treated with alkali like NaOH or Na2CO3 to remove fatty acids.
 It also removes heavy metals, which can start oxidation of oil.
(f) Centrifuge:
 Acids are separated in centrifuge separator.
 These separated acids are used as foots for soap manufacturing.
(g) Rotary filter:
 The clear oil is treated with some bleaching agent like”Fullers Earth Carbon” in filter aid
before rotary filter.
 Rotary drum filter is used for removal of seed particles which may be present.
 This finished oil is produced.
 From this process around 1-2% oil content remains in the meal.
(h) Extractor:
 The flaked seeds or oil extracted seeds from crushing rolls are fed on a moving bed.
 Oil depleted cake is also added in extractor.
 The solvent extracts oil from the seeds.
 The wet meal (the left seed part) is collected in the middle and is sent for solvent
removal.
(i) Solvent removal:
 Steam is used to extract solvent carried by the oil seeds.
 The rotating blades ensure better exposure to steam.
 The solvent free meal is sent to dryer and then used as animal feed.
 Solvent is collected from top and is recycled after cooling it in heat exchanger.
(j) Flash film evaporator:
 The solvent is preheated by steam.
 Oil is concentrated here by evaporating the more volatile component (hexane).
 The hexane is recycled back to extractor after heat recovery.
 The use of flash evaporator reduces the cost of vacuum stripping column.
(k) Vacuum stripping column:
 The oil from flash evaporator is fed here.
 The stripping is done by steam i.e. steam carries away the hexane.
 And it is under vacuum for the reason that the boiling point of hexane and oil are close
to each other.
 Jet ejector is used here to generate vacuum.
 The hexane is recycled again.
 Oil produced here is either directly used or sent for purification.
1.4 (ii) Hydrogenated Products of Oil

 Hydrogenation process is used to remove double bonds and to make fats and oil
saturated.
 Hydrogenation also raises its melting point and improves its resistance to rancid
oxidation.
 The most common end product of hydrogenation is Vanaspati ghee.
 Other products include vegetable ghee, hardened industrial oils and partially
hydrogenated liquid oil.
 Raw material:
 Oils which is to be saturated and pure hydrogen.
 Chemical Reactions: (* indicates activated catalytic state) Ni* catalyst

(a) Hydrogenation process
R1(C=C)xR2 + (x-y)H2 → R1(C=C)yR2

(b) Nickel catalyst preparation: 190˚C
Ni(HCOO)2.2H2O Ni* + 2CO2 + H2 + 2H2O
 This produces a finely divided catalyst which is preferred for well-stirred hydrogenation
reactors.
(c) Nickel catalyst preparation (reduced Ni on inert catalyst support) \
Ni(OH2) + H2 → Ni* + H2O \

NiCO3 + H2 →Ni* + H2O + CO2
 Nickel salts are precipitated on inert porous carrier such as kieselguhr or diatomaceous
earth and reduced at high temperature in a hydrogen atmosphere.
(d) Nickel catalyst preparation
2Al.Ni + 6NaOH Ni* + 2NaAlO3 + 3H2

 Alloy Raney nickel Produces spongy, high-surface area catalyst when the sodium
aluminate is washed with water.
 Process Flow Sheet
(a) Hydrogenator:
 Oil is fed to the hydrogenator.
 Hydrogen, and steam is introduced in it.
 The catalyst oil slurry of concentration 5 to 15 kg per ton of oil is also put.
 The reaction is slightly exothermic so steam is sometimes turned off.
(b) Deodorizer:
 The hydrogenated oil is now fed to vacuum steam deodorizer.
 It operates in continuous basis.
(c) Finishing
 Oil colour is removed by treating with fuller’s earth or carbon.
 It is then filtered, mixed with some vitamins.
 Now the finished oil is sent for packaging and storage.
1.4(iii) Sugar From Sugar-Cane
 Introduction
 Sucrose is a disaccharide that occurs naturally in most fruits and vegetables. Sugar
occurs in greatest quantities in sugarcane and sugar beets from which sugar is separated
economically and commercially.
 Chemical formula – C 12H22O11.
 Molecular weight – 342 Density = 1.58 kg/m3
 Sucrose is soluble in water but slightly soluble in methyl alcohol and ethyl alcohol.
 Raw material:
 Sugar cane , Water, SO2, Lime, CaHPO4
 Process Flow Sheet:

(A). Cutter
 The cutter consists of knives on a cylindrical shaft which rotate at a velocity of 400 to
500 rpm.
 The knives cut the canes into small pieces.
(B) Crusher
 Canes are shredded here.
 It consists of two rollers rotating in opposite direction.
(C) Series of Pressure mills
 Crushed canes are passed through four pressure mills to extract juice.
 Each pressure mill is made up of cast iron rolls.
 Rolls are grooved and the width decreases from first roll to the last.
 Make up water added in the third and fourth mill is recycled back to the first two mills.
 About 85-90% of juice present in cane is extracted.
 Bagasses are produced as byproduct.
(D) Clarifier
 In general two methods of clarification are available for the manufacture of white sugar,
namely, Sulfitation process and Carbonation process.
 The juice now comes to thickener.
 To precipitate the colloids, calcium phosphate(CaHPO4) is added followed by milk of

lime.
 The milk of lime used has 9 to 10% strength and about 400mg CaO/litre alkalinity.
 Apart from maintaining pH about 7, SO2 gas also acts as a bleaching agent.
 Phosphoric acid or CO2 can also be substituted as acidifying agent depending upon the
type of extracted juice.
 At the bottom of clarifier, mud (impurities) are settled and drained.
 Steam is used to slightly heat the juice.
(E) Rotary filter
 The underflow mud from the bottom of thickener is passed to a continuous rotary filter
press to recover sugar solution.
 This sugar solution if it is clear, is passed to multieffect evaporator or otherwise recycled

back to clarifier.
 The filter cake produced is used for fertilizer.

(F) Multieffect evaporator
 The clarified liquor overflows to the 3-4 forward feed multieffect evaporator.
 Here juice is concentrated from 80-85% H2O to 40% H2O to make juice ready for
crystallization.
 A vacuum of 63cm is maintained in the last effect.
(G)Crystallizer
 The clarified concentrated sugar solution comes to crystallizer.
 The sugar solution is further boiled in vacuum pans at vapor temperature of 57˚C until
fine cloud of crystals is seen.
 Crystallization is completed in vacuum pan unit.
(H) Centrifuge
 The mixture of crystals and syrup is called masscuite.
 The masscuite from crystallizer is centrifuged in basket type centrifuged to basket type
to centrifuge remove mother liquor (molasses) which is a byproduct.
 The high grade sugar crystals are obtained here.
 The centrifuge speed is maintained at 800 to 1000 rpm.
1.4 (iv) Starch from maize

 Introduction
 Starch consists of a chain of D-glucopyranosyl units.

 It is used in the manufacture of textiles, paper, adhesives, insecticides, paints, soaps,
explosives, and derivatives as dextrins, nitrostarch and corn sugar. Chemical
formula- C6H10O5
 Starch gets hydrolysed by acids, alkalis and enzymes giving dextrin, dextrose. Starch
forms gels with water within several minutes at 60-80˚C.
 The major source of starch is maize kernels.
 Raw Masterials
 Maize, Air, Water

(a) Air cleaner:-
 At first, maize kernel containing 60-65% starch is introduced in air cleaner.
 Air is passed through the bottom of cleaner.
(b) Steeped tank:-
 Air cleaned maize kernel is passed to steeped tank to make it soft.
 50-55˚C water and 0.15-0.3% SO2 is added.
 Here SO2 acts as a bacteriostatic.
 Steeping is done to yield high production and quality of starch.
 The residence time is 40-50 hours.
(c) Grinding mill:-
 The soft grains are passed through coarse grinding mill to rupture the cells.
 The floating germ oil from the tank is removed.
(d) Buhrstone mill:-
 The kernel is then wet ground in buhrstone mill.
 This mill completely disrupts the cells of endosperm and release starch granules.
(e) Nylon screen:
 The wet ground kernel is then passed through nylon cloth.
 Water washes the starch through the screens.
 The fibre and hulls is left over on the nylon screen.
(f) Two stage centrifuge:
 The gluten is water insoluble protein.
 Gluten is a light fraction which is separated in two-stage centrifuge.
(g) Rotary filter:
 Water starch mixture is then passed then passed to continuous rotary filter.
 Starch is separated as filter cake which is of yellow colored and contains high amounts
of protein.
 Other products can also be made by hydrolysis of starch.
(h) Dryer:
 Starch as filter cake is dried and powdered in dryer with the introduction of steam in
dryer and produced as pearl starch.
1.4 (v) Dextrin From Starch

 Introduction
 Heating and acid depolymerisation of starch yields a water soluble carbohydrate gum
which is known as dextrin used in adhesives and gum.
 Raw Materials
1. Starch 2. HCL Vapour 3. Air
 Chemical Reaction
(C6H10O5 )n → (C6H10O5 )x
 Process flow sheet:
 Process Description
 A batch operation charges 5-10 µ starch to an air suspended fluidizer.
 Heat is added via rectangular-shaped plate coils, using steam,in the upper section of
fluidizer.
 The charges reaches 65-170 °C, depending on the degree of hydrolysis desired, within
30 minutes.
 HCL vapour is introduced into the recirculating air stream and depolymerisation
continued for 1-8 hours.
 The reaction can be stopped by ammonia addition and/or by using H 2O in plate- coil
exchangers.
 Starch agglomerates during hydrolysis, so allowing fluidisation without excessive carry
over of fines.
1.5 Chemicals From Sea

 Ocean covers over 70% of the earth surface.
 The sea is still our important source of food but it is also a dumping ground for sewage,
radioactive wastes and a supplier of raw materials for a host of chemical industries.
 The oceans contains on an average about 35 parts per 1000 dissolved salts.
 Major salts can be found from sea are
1. Chlorine,
2. Sodium
3. Magnesium,
4. Sulfur,
5. Calcium,
6. Potassium,
7. Bromine,
8. Carbon,
9. Oxygen,
10. Strontium,
11. Boron,
12. Silicon,
13. Flourine,
14. Nitrogen, P
15. Phosphorous,
16. Iodine.
 The important commercial products obtained from sea water are common salt,
magnesium compounds, potassium compounds and bromine are extracted from sea
beaches.
 Phosphorite and calcareous deposits from the continental shelves.
 Oil, gas, sulphur, coal and iron are extracted from the subsea floor rocks.
 While clays, manganese, and calcareous oozes extracted from the deep sea floor.
1.6 Production of Bromine From Sea Water

 Introduction
 Bromine is a dark red,low boiling and high density liquid.
 It have intensely irritating odour and it is very reactive chemical.
 It belongs to halogen group of elements.
 In sea water bromine occurs in concentrations between 60-70 ppm.
 Most of bromine is converted into inorganic and organic compounds.
 Ethylene di-bromide and methyl bromide are used for fumigation of food grains, fruits,
seeds, and soil.
 They also used as anti knock fluids in aviation petrol.
 Bromine is also used in the preparation of fire extinguishing compounds and fire
proofing agents and dyes.
 Raw Materials
1. Sea water
2. Cl2
3. Air
4. SO2
5. H2O
 Chemical Reactions
Cl2 + 2 Br- → 2Cl- + Br2
SO2 + Br2 + H2O → 2HBr + H2SO4
2HBr + Cl2 → 2HCl + Br2
 Process Description
1. Blow Out Tower

 The process involves oxidation of bromine ions of or brine to free elemental bromine .
 This bromine is vaporised by air or steam.
 When sea water is used bromine is first concentrated by vaporising chlorinated sea
water with air.
2. HBr Absorption Tower
 SO2 is introduced into dilute bromine laden air and is sent to absorption tower counter
current to water.
3. Steaming Out Tower
 The resulting hydrobromic acid solution from HBr absorption tower is chlorinated and is
steamed to vaporise Br2 .
 By products HCl & H2SO4 are used to acidify the incoming sea water.
4. Condenser
 Br2 vapour from Steaming out tower is condensed to liquid bromine.
ASSIGNMENT 07 Marks Each
1. Define oil & Write its physical properties and Its Uses
2. Describe The Mechanical Extraction Method Of Vegetable Oil With
Neat Flow Diagram.
3. Explains manufactures of vegetable oil by solvent extraction method With
Neat Flow Diagram.
4. Short note on Hydrogenation of oil.
5. Explain manufacturing of glycerin with flow diagram
6. Describe manufacturing process of Starch from Maize with neat flow
diagram.
7. Explain manufacture of dextrin from starch.
8. Elaborate Manufacturing Process of Sugar from Sugarcane with
Flow Sheet.
9. Discuss major engineering problems in manufacturing of sugar.
10. Write a note on chemicals from sea.
11. Explain production of bromine from sea water with its chemical reactions and neat flow
diagram.

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UNIT 1 NATURAL PRODUCT INDUSTRIES CPT-II 2015-16

UNIT 1 NATURAL PRODUCTS INDUSTRIES

Unit no and Major Learning Outcomes Topics and Sub-topics

1b. Describe physical properties of oil 1.2 Physical properties of oil

1c. Describe carbohydrates 1.3 Introduction to Carbohydrates

1e. Distinguish chemicals available from 1.5 Chemicals from sea

1.1 Basics of Oil and Fat /1.2 Physical Properties of Oil

SR NAME (R) COMPOSITION NO.OF MELTING REACTIVITY TO

1.3. Introduction To Carbohydrates

 Disaccharide molecules have two monosaccharide units, trisaccharide molecules have

A. The kind of monosaccharides present as:

1.4 (i) Manufacturing Process of Vegetable oil

 Functional Role of Various Processes

(a) Cleaner and dehulling:

 Mechanical cleaning is done to remove stones and other undesirable material.

 Dehulling remove hulls, dry outer covering of seed.

(b) Cracking rolls:

 Softening by means of heat and moisture is done here.

 Steam is added for heating purpose.

 Acid is formed by hydrolysis of ester.

 The seeds get swollen up.

 The swollen seeds are crushed under great pressure.

 Cells of seeds get ruptured and oil is released.

 The tapering shape ensures more application of pressure on the seeds

 Oil is sent for purification.

(e) Mix tank:

 It also removes heavy metals, which can start oxidation of oil.

 Acids are separated in centrifuge separator.

 These separated acids are used as foots for soap manufacturing.

(g) Rotary filter:

 This finished oil is produced.

 Oil depleted cake is also added in extractor.

 The solvent extracts oil from the seeds.

(i) Solvent removal:

 Steam is used to extract solvent carried by the oil seeds.

 The rotating blades ensure better exposure to steam.

(j) Flash film evaporator:

 The solvent is preheated by steam.

 Oil is concentrated here by evaporating the more volatile component (hexane).

 The hexane is recycled back to extractor after heat recovery.

(k) Vacuum stripping column:

 The oil from flash evaporator is fed here.

 Jet ejector is used here to generate vacuum.

 The hexane is recycled again.

 Oil produced here is either directly used or sent for purification.

1.4 (ii) Hydrogenated Products of Oil

 Oils which is to be saturated and pure hydrogen.

 Chemical Reactions: (* indicates activated catalytic state) Ni* catalyst

R1(C=C)xR2 + (x-y)H2 → R1(C=C)yR2

Ni(HCOO)2.2H2O Ni* + 2CO2 + H2 + 2H2O

Ni(OH2) + H2 → Ni* + H2O \

(d) Nickel catalyst preparation

2Al.Ni + 6NaOH Ni* + 2NaAlO3 + 3H2

 Process Flow Sheet

 Functional Role of Various Processes

 Oil is fed to the hydrogenator.

 Hydrogen, and steam is introduced in it.

 The reaction is slightly exothermic so steam is sometimes turned off.

 The hydrogenated oil is now fed to vacuum steam deodorizer.

 It operates in continuous basis.

 Oil colour is removed by treating with fuller’s earth or carbon.

 It is then filtered, mixed with some vitamins.

 Now the finished oil is sent for packaging and storage.