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SOLVENT EXTRACTION FROM OILSEEDS

Table of Content

1 Processes and Process Steps

2 Lurgi - Sliding Cell Extractor

3 Desolventizing Toasting

®
4 ALCON Process

5 Selected References
Introduction

SOLVENT EXTRACTION FROM OILSEEDS

Lurgi has built about


200 solvent extraction plants
world wide for the capacity
range of 100 to 3000 tpd.
Processes and Process Steps
DIFFERENT PROCESSES TO DEOIL OILSEED

SEED Process Steps Advantage

18% oil 18% oil 0,6% oil


SOLVENT
1.) Soya PREPARATION Standard for Soya
EXTRACTION PLANT

2.) Soft Seeds with 44% oil PREPARATION 18% oil 1% oil
SOLVENT
high Oilcontent High Oil Yield
PREPRESSING EXTRACTION PLANT
(Rape)

3.) Soft Seeds with 44% oil PREPARATION AND FINAL PRESSING 8% oil
Simple Authority
high Oilcontent
(2 x PRESSING) Approval
(Rape)

Remark: The investmentcosts for item 2.) and 3.) are almost similar if the capacity is below 1000 t/d seed,
above 1000 t/d the investmentcosts for final pressing will unproportional increase.
Processes and Process Steps
Oil Seed Extraction
OIL SEEDS

SILO

CLEANING
WEIGHING

CRUSHING
FRONT END
DEHULLING
CRUDE PRESS OIL
CONDITIONING PREPRESSING

FLAKING

ALCON HEXANE
EXTRACTION
CONDITIONING

VAPOURS MISCELLA HEXANE


DESOLVENTIZING DISTILLATON RECOVERY

TDC MEAL DRYING DEGUMMING

TAIL END LECITHIN


DEHULLING MEAL COOLING RECOVERY

HIGH PROTEIN MEAL MEAL CRUDE OIL LECITHIN


Processes and Process Steps
PROCESS SECTIONS OF THE SEED PREPARATION
Processes and Process Steps
PROCESS SECTIONS OF A SOLVENT EXTRACTION PLANT
Processes and Process Steps
PREPARATION STEPS FOR VARIOUS OILSEEDS
Oilseed Seedcleaning Production Delintering Dehulling Crushing Conditioner Flaking Conditioner Prepressing Pelletizing Expander Cake Extraction
Scale Grinding Cooling Crushing

Soya Beans
       
Rapeseed
       
Sunflower
        
Corngerms direct
    
Corngerms prepressed
        
Grape kernel
     
Rice Bran
   
Groundnut dehulled
       
Palmkernel direct
     
Palmkernel prepressed
        
Cotton Seed
        
Sesam
       

 = Standard Preparation Step


 = Additional or Alternative Preparation Steps
Processes and Process Steps
FLOW SHEET OF THE EXTRACTION SECTION
Processes and Process Steps
FLOW SHEET OF THE EXTRACTION SECTION
WITH PREDESOLVENTIZER

EXTRACTION
WITH PREDESOLVENTIZER
Processes and Process Steps
FLOW SHEET OF THE EXTRACTION SECTION
WITH PREDESOLVENTIZER
Processes and Process Steps

FLOW SHEET OF THE EXTRACTION SECTION


WITH PREDESOLVENTIZER
Table of Content

1 Processes and Process Steps

2 Lurgi - Sliding Cell Extractor

3 Desolventizing Toasting

®
4 ALCON Process

5 Selected References
Lurgi - Sliding Cell Extractor

Suitability for Multi Seed Purposes


• The continous series of
cells moving on roller rails
to transport the oilseeds
across the upper and lower
stationery screen plates
• The extractor design
assures complete counter-
current operation of
solvent/ miscella and flakes
• Low height of the shallow
extractor bed assures large
contact areas between
solvent and flakes and
maximum drainage
• Long drainage zone prior
to extractor discharge
assures low solvent carry-
over into extracted meal
• Design of the double bed
construction allows for
shop assembly and easy
transportation to the job
site as on compact unit.
Lurgi - Sliding Cell Extractor
Extractor Systems
TO EXTRACT OILSEEDS PRODUCTS DESIGN PRINCIPLE EXTRACTOR SCREEN PLATE
SUCH AS:
• crude oils for food industry EXTRACTOR FEEDING DEVICE • The continous series of cells moving on • Flakes are drained on heavy- duty-
• soybeans, • meal for animal consumption roller rails to transport the oilseeds self cleaning V-bar screen plates
• A uniquely designed feeding device
• rape seed • meal for human consumptionCV across the upper and lower stationery resulting in maximum drainage and
automatically controls feeding and
• sunflower kernels screen plates long life
assures a vapour tight seal to the
• cottonseed
PROCESS PRINCIPLE atmospere • The extractor design assures complete CELLS
• corn germs
counter- current operation of solvent/
• peanuts • the oil contained in the solid feed is • Feeding screws with variable speed • The liquid- tight cells provide the
miscella and flakes
• linseed extracted by a liquid solvent (n-hexane) drives provide uniform distribution into abbility of maintaining a level of
• palm kernels in a countercurrent flow each cell over the entire width and allow • Low height of the shallow extractor bed miscella on top of the feed in each
• copra the flexibility to vary the fill level assures large contact areas between cell optimizing the soaking and
• castor beans solvent and flakes and maximum percolation rate
• rice brain drainage
MISCELLA STAGES
as well as cakes of these
• Long drainage zone prior to extractor
oilseeds from mechanical • Product redistribution from upper to
discharge assures low solvent carry-over
pressing processes lower cells prevents channelling
into extracted meal (Solvent content in
resulting in low and uniform residual
Alcon® conditioned soybean flakes is as
oil content in extracted meal.
low as 23%)
• Clean miscella additionaly
• Design of the double bed construction
Typical sizes selffiltrated in the extractor bed
allows for shop assembly and easy
protects the distillation equipment
transportation to the job site as on
capacity length width height compact unit. • A number of extraction stages each
tpd approx. mtr. mtr. mtr. containing several spray pipes are
100 13 1,4 3,5 one of the primary advantage of the
SC-Extractor when processing feed
200 16 1,8 4,0 products with low quality and poor
500 20 2,6 4,7 percolation

1000 21 3,0 4,7 • Cells and miscella collecting


hoppers are positioned such that
2000 28 3,5 4,7 separtion of individual extraction
3000 38 3,5 4,7 stages is assured

4000 38 4,5 4,7

Lurgi has been one of the pioneers of We entered the solvent extraction field The SC- Extractor is now the most Our reference list shows extractors and
the edible oil industry since 1927. of oilseeds with the Bollmann Extractor advanced alternative to all existing complete plants built all over the world.
New processes and equipment have (built until 1956) followed by the FB- systems.
Contact Lurgi, for Lurgi has
been developed to industrial maturity in Extractor (the horicontal frame belt
experienced specialists and the right
our own research center. extractor).
equipment for you as well.
Lurgi - Sliding Cell Extractor

Principle Sketch
Lurgi - Sliding Cell Extractor

PRODUCT REVERSING STATION


Lurgi - Sliding Cell Extractor

MISCELLA FEEDING TO EXTRACTOR STAGES


- EXTRACTION TIME / DRAINAGE TIME
Lurgi - Sliding Cell Extractor

Design Advantage

MOVING CLOSED MOVING CHAIN


OILSEED BUCKETS WITH FLIGHTS

EXTRACTOR HOUSING FRICTION FRICTION

CHAIN
NO FRICTION
FIXED FIXED MOVING
SCREEN PLATE SCREEN PLATE SCREEN PLATES
WITH MESH SCREEN

THIS DESIGN GIVES NO FRICTION BETWEEN EXTRACTOR THESE DESIGNS GIVE FRICTION BETWEEN EXTRACTOR
HOUSING AND THE OILSEED. LESS WEAR AND TEAR HOUSING AND THE OILSEED. MUCH WEAR AND TEAR,
LONGER LIFE TIME. WHICH CAUSE SHORTER LIFE TIME.
Lurgi - Sliding Cell Extractor

Design Advantage
SELF- CLEANING SCREEN PLATES
THE SREEN PLATES ARE MADE OF STURDY V-PROFILED SCREEN WIRES WITH A LARGE WEDGE TYPE OPENING
AT THE BOTTOM FACE AND SOME SUPPLIERS USE AN ADDITIONAL TAPER OF THE SCREEN OPENING IN THE
CONVEYING/ SLIDING DIRECTION; THIS WILL SAFELY AVAOID ANY CLOGGING OF THE SCREEN PLATES.

THE „TAPER“ OF THE SCREEN PLATES IS SELECTED AS A FUNCTION OF THE OILSEED; BEEING NORMALLY 0,4 - 0,6 mm,
TO AVOID STICKING OF MATERIAL AT THE SCREEN PLATES.
Lurgi - Sliding Cell Extractor

Design Advantage STAGE 7 STAGE 6 STAGE 5

STAGE 7
SEVERAL SOLVENT OILSEEDS OR CAKES WITH
AND MISCELLA FEED TUBES HIGH FINE CONTENTS
GIVES A BETTER FLEXIBILITY NEED LONGER DROPPING TIME
FOR THE DIFFERENT TYPE OF THAN OIL SEEDS WITH LOW
OIL SEEDS FINE CONTENT
STAGE 6
STAGE 5

STAGE 6 STAGE 5 MISCELLA

GRAIN

HEXANE

CAN CHANGE EXTRACTION TIME (ET) THIS EXTRACTOR TYPE HAS ONLY ONE FEED TUBE
AND DROPPING TIME (DT) WHEN CLOSING PER STAGE.
SOME TUBES RESP. OPEN TUBES IT IS NOT POSSIBLE TO CHANGE EXTRACTION AND
DROPPING TIME
Lurgi - Sliding Cell Extractor

Design Advantage
BUCKETS, BASKETS, CELLS NO BUCKETS, BASKETS, CELLS

MAINTENANCE OF MISCELLA BATH IS POSSIBLE DESIGN A)


AND BETTER EXTRACTION EFFICIENCY
NO CELLS ONLY FLIGHTS WITH CHAIN

MISCELLA CHAIN
OILSEED SCREEN
SCREEN PLATES

DESIGN B)
NO CELLS MOVING SCREENBELT
MISCELLA MOVING
SCREEN MESH

NO MAINTENANCE OF MISCELLA BATH;


MISCELLA CAN FLOW DIRECTLY TO THE NEXT STAGE AND
TO THE MEAL DISCHARGE:
LESS EXTRACTION EFFICIENCY AND DANGEROUS OF
OVERCARRYING TO MUCH SOLVENT TO THE TOASTER
Lurgi - Sliding Cell Extractor

Design Advantage

LOW MATERIAL BED HIGH MATERIAL BED

LARGE EXTRACTION SURFACE A1 = 2 x A2 EXTRACTION AREA IS 2-TIMES BIGGER IN CASE OF


LOW MATERIAL BED
Lurgi - Sliding Cell Extractor

Comparison of the different extractor types


Design advantages Which extractor type has these Design Advantages

Carusell Extractor Belt Extractor without Sliding Cell Extractor


buckets / cells Belt Extractor with
buckets / cells

1. Buckets, Baskets, Cells yes no yes

2. Several miscella feed points per extraction stage no yes yes

3. Self-cleaning slotted rod-type screen belts or plates yes no yes


rod type available,
price increase

4. Material loosening stage no no yes


standard equipment

5. Large extraction surface no yes yes

6. No friction between oilseed and extractor housing no no yes

7. 2-stage (level) Extractor no no yes

8. Low material bed 800 - 1100mm no no yes


very high bed to high

9. Mechanical moving parts little many little

10. Meal is covered by miscella yes no yes

11. Dimension of extractor at 250 t/d, 900 mm bed height same 7,5 m  L = 30 m L = 16 m
retention time, and residual oil content, same quality of cake

12. Feeding by automatic controlled screws no no yes


Lurgi - Sliding Cell Extractor

Residual Oil Content in Extracted Meal


- depending on oil content in seed or cake and grade of
preparation
Seed Type of Oil Content Extraction time Residual Oil Content
Preparation approx. approx. in Meal after Extractor
% min. approx. %
Soya flaked 19 35 0.6

Rapeseed Presscake 20 60 1
Sunflower Presscake 18 40 0.8
Corngerms flaked and prepressed 20 40 0.9-1.0
Wet process
Corngerms from Dry Process crushed and pelletized 14 35 0.8-0.9
Grapekernels flaked and pelletized 19-20 35 0.6-0.7
Cottonseed flaked and repressed 17 40 0.6-0.7
Groundnut flaked and prepressed 17 35 0.6-0.7
Palmkernel direct craked, crushed and flaked 48 70 0.8-1.0
Palmkernel pressed flaked and prepressed 20 40 0.8-1.0
COPRA flaked and prepressed 20 45 1
Lurgi - Sliding Cell Extractor
Prepared Oilseed prior to Solvent Extraction
Moisture Oil Flake Temp. Presscake Pellets
% % Thickness °C Granulate mm
mm mm

Soya Beans

a) nondehulled flakes 11-12 18-19 0,28-0,3 55-60 - -

b) dehulled flakes 10,5 18,5-19,5 0,28-0,3 55-60 - -

c) nondehulled flaked expanded 10,5 18-19 45-50 - 14x14

Rapeseed prepressed 7-8 18-19 - 60-65 6-8 -

Sunflower prepressed 7-8 17-18 - 60-65 6-8 -

Corngerms direct 8-9 13-14 - 45-50 5x5

Corngerms prepressed 7-8 18-19 - 55-60 6-8 -

Grapekernel pelletized 10-12 18-19 (0,3) 60-65 - 5x5

Rice Bran pelletized 7-8 14-20 - 55-60 - 5x5

Groundnut prepressed 6-7 17-18 55-60 6-8 -

Palmkernel flaked 7-8 48 0,3 45-50 - -

Palmkernel prepressed 7-8 17-18 - 55-60 6-8 -

cottonseed prepressed 7-8 17-18 - 55-60 6-8 -

Sesam prepressed 7-8 17-18 - 55-60 6-8 -


Lurgi - Sliding Cell Extractor

Assembly and Delivery in one Piece


Lurgi - Sliding Cell Extractor

Assembly and Delivery in one Piece


Table of Content

1 Processes and Process Steps

2 Lurgi - Sliding Cell Extractor

3 Desolventizing Toasting

®
4 ALCON Process

5 Selected References
Desolventizing Toasting

Desolventizer/ Toaster/ Drier/ Cooler


Desolventizing Toasting

Desolventizer/ Toaster/ Drier/ Cooler with Predesolventizing


Desolventizing Toasting

Sectional View of a Toaster Vapour Duct Tray

VAPOUR DUCT

STEAM HEATED PLATE

TOASTER VAPOUR
Desolventizing Toasting

Predesolventizer with Toaster / Drier / Cooler

Steam Savings
up to 20%
compared to the
usual DT-Systems
Desolventizing Toasting

Steam Consumption of a Solvent Extraction Plant


and Influence of Predesolventizing
Consumer Extraction Extraction Extraction
+ Toaster + Toaster with + Toaster
PD-Stages + sep. PD-System
Steam Consumption per t and extraced seed

ca. kg/t ca. kg/t ca. kg/t

Extractor
Hexane + Miscella Preheating 48 48 48
Miscella Distillation
Absorption / Solv. Recovery
Subsidiary Equipment
Waste Water-Stripper
Sep. Predesolventizer - - 54
Toaster Predesolventizer stages - 17 -
Toastersteam Tray-heating 129 108 67
Toaster live steam
Meal drying 48 38 10 *
Total Consumption approx. 225 211 179
*)Steam for heating the air for meal drying up to 50 -60 °C

Basis: Processing 1000 t/d Soyaflakes


Seed Moisture 11%
Meal Moisture 12,5%
Table of Content

1 Processes and Process Steps

2 Lurgi - Sliding Cell Extractor

3 Desolventizing Toasting

4 ALCON® Process

5 Selected References
ALCON® Process

Preparation - Conventional Process


ALCON® Process

Preparation/ Prepressing with Alcon Conditioning


ALCON® Process

Preparation - Conventional Process


ALCON® Process

Preparation with Alcon Conditioning


ALCON® Process
With the ALCON® Process, Lurgi gives you the right recipe.
Lurgi has all the right utensils e.g. processes for making the most of soybeans, one of the world`s
major sources of human and animal food. With the ALCON Process, Lurgi has the right recipe, too,
for the conditioning of soybean flakes, extraction and physical refining.
Advantages of the ALCON Process
for extraction for refining

 Greater bulk density  Elimination of degumming step

 Greater extraction throughput capacity  Elimination of neutralization step

 Higher percolation rates  Elimination of washing step

 Lower hexane retention  Elimination of soapstock splitting

 More lecithin  Elimination of sour water neutralization

 Better hydration of phosphatides  No acid oil

 Lower residual phosphatidescontent  Lower neutralization losses

in crude oil  More condensate from deodorization

 Good meal quality (containing tocopherol)


Lurgi.
The leading source of plants and technology for modern soybean processing.
Table of Content

1 Processes and Process Steps

2 Lurgi - Sliding Cell Extractor

3 Desolventizing Toasting

®
4 ALCON Process

5 Selected References
Selected References

Customer: Deutsche Cargill GmbH


Salzgitter, Germany
Plant: Rapeseed Extraction Plant
Location: Salzgitter
Capacity: 1600 TPD Rapeseed

Lurgi Services:
 Project Management
 Basic Engineering
 Detail Engineering
 Architectural and Building Design
 Procurement
 Construction Supervision
 Commissioning and Start-up Special Features:
 Operator Training  shallow bed sliding cell extractor
 self cleaning screen plates
Start of Engineering: 1992  low hexane content in crude oil
Start-up: 1993  bio filter for low odor emission
Selected References

Customer: Shenzhen Nantian Oilmills Co. Ltd.


P.R. China
Plant: Soybean Crushing and Extraction
Plant with ALCON-Process, Water
Degumming and Lecitin Production
Location: Shenzen
Capacity: 1200 TPD

Lurgi Services:
 Basic Engineering
 Detail Engineering
 Procurement
 Construction Supervision
 Commissioning and Start-up
Special Features:
 Operator Training
 with separate predesolventizing for low steam
consumption
 shallow bed sliding cell extractor
Start of Engineering: 1993  self cleaning screen plates
Start-up: 1994  miscella degumming to prevent gum deposits in
miscella distillation
Selected References

Customer: Yingkou Bohai Oils & Fats Co. Ltd.


P.R. China
Plant: Soybean Crushing Plant, Rapeseed
Prepressing Plant, Extraction Plant
and Water Degumming
Location: Yingkou
Capacity: 800 TPD Soybeans, 600 TPD Rapeseed
Lurgi Services:
 Basic Engineering
 Detail Engineering
 Procurement
 Local Supply of Process Equipment
 Construction Supervision
 Commissioning and Start-up
 Operator Training Special Features:
 Project Execution: Cooperation with our JV  with separate predesolventizing for low steam
consumption
Lurgi Engineering SDN. BHD. (JLE), Malaysia
 shallow bed sliding cell extractor
Start of Engineering: 1993  self cleaning screen plates
Start-up: 1995/1996  low hexane content in crude oil
Selected References

Customer: Shangdong Bohai Oils & Fats Co. Ltd.


P.R. China
Plant: Soybean Crushing and Extraction
Plant with Water Degumming
Location: Boxing
Capacity: 2000 TPD
Lurgi Services:
 Basic Engineering
 Detail Engineering
 Procurement
 Local Supply of Process Equipment
 Construction Supervision
 Commissioning and Start-up
 Operator Training Special Features:
 Project Execution: Cooperation with our JV  with separate predesolventizing for low steam
consumption
Lurgi Engineering SDN. BHD. (JLE), Malaysia
 shallow bed sliding cell extractor
Start of Engineering: 2000  self cleaning screen plates
Start-up: 2001  low hexane content in crude oil
Selected References

Customer: Shining Gold Foodstuffs Co. Ltd.


P.R. China
Plant: Soybean Crushing and Extraction
Plant with ALCON-Process, Tail End
Dehulling and Water Degumming
Location: Ningbo
Capacity: 2500 TPD
Lurgi Services:
 Basic Engineering
 Detail Engineering
 Procurement
 Local Supply of Process Equipment
 Construction Supervision Special Features:
 Commissioning and Start-up  with separate predesolventizing for low steam
 Operator Training consumption

 Project Execution: Cooperation with our JV  shallow bed sliding cell extractor
Lurgi Engineering SDN. BHD. (JLE), Malaysia  self cleaning screen plates
 miscella degumming to prevent gum deposits in
Start of Engineering: 2000 miscella distillation
Start-up: 2001  low hexane content in crude oil
Selected References

Customer: Shantou Free Trade Zone Zhongxing


Fat Co. Ltd. / P.R. China
Plant: Soybean Crushing and Extraction
Plant and Water Degumming
Location: Shantou
Capacity: 2000 TPD
Lurgi Services:
 Basic Engineering
 Detail Engineering
 Procurement
 Local Supply of Process Equipment
 Construction Supervision Special Features:
 Commissioning and Start-up  with separate predesolventizing for low steam
consumption
 Operator Training
 shallow bed sliding cell extractor
 Project Execution: Cooperation with our JV Lurgi
Engineering SDN. BHD. (JLE), Malaysia  self cleaning screen plates
 miscella degumming to prevent gum deposits in
Start of Engineering: 2000 miscella distillation
Start-up: 2002  low hexane content in crude oil
Selected References

Customer: Liaoning Fuhong Co. Ltd. / P.R. China


Plant: Soybean Crushing and Extraction
Plant and Water Degumming
Location: Guangdong
Capacity: 3000 TPD
Lurgi Services:
 Basic Engineering
 Detail Engineering
 Procurement STILL IN PROGRESS
 Local Supply of Process Equipment
 Construction Supervision
Special Features:
 Commissioning and Start-up
 with separate predesolventizing for low steam
 Operator Training consumption
 Project Execution: Cooperation with our JV Lurgi  shallow bed sliding cell extractor
Engineering SDN. BHD. (JLE), Malaysia  self cleaning screen plates
 miscella degumming to prevent gum deposits in
Start of Engineering: 2003
miscella distillation
Start-up: 2003/2004
 low hexane content in crude oil