toasting and drying oilseed meals. which is the best ... · solvent extraction . toasting and...
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Rosario , Argentina 31st October 2015
Anibal Demarco Crushing , Solvent Extraction
Toasting and Drying Oilseed Meals. Which is the Best Approach ?
1) Desolventization Basic Technology 2) Different types of Meal Dryer and main design parameters 3) Psicometric Chart : bases / application to the process 2) Different types of Meal Dryer and main design parameters 4) Different types of Meal Dryer : Features 5) Different types of Meal Dryer : Steam and Electrical Consumptions 6) Different types of Meal Dryer : Conclusion
What we´ll see?: Minimum OPEX
Meal Dryers : Moisture Levels vs Process Steps
0%
2%
4%
6%
8%
10%
12%
14%
16%
18%
Material Moisture
Trading rule : 12,5%
Meal Desolventizing
DT Unit Processes
Predesolventizing
Desolventizing
Toasting & Stripping
Steam Drying
DT Unit Processes
Predesolventizing
Purpose is to remove a minority of the solvent using indirect steam heat to reduce live steam condensed into the meal and thereby save DC steam 10-20% of solvent removed 57 66°C meal temperature 12% typical meal moisture
DT Unit Processes
Need to maximize meal/tray contact for heat transfer Residence time not important (150 mm meal levels) 5-10 minutes total time Simplistic level control
Predesolventizing
DT Unit Processes
Purpose is to remove the majority of the solvent using live steam 80-90% of solvent removed Mostly direct steam latent heat Some added indirect steam heat 6699°C meal temperature 1220% meal moisture
Desolventizing
DT Unit Processes
Need minimum 1000 mm deep level and consistent level control Approx. 5 minutes time Uniform condensation plane is critical Rotary valve level control
Desolventizing
DT Unit Processes
Uneven steam distribution in the top countercurrent tray causes condensation of the steam in a wide band. Water mixes with 66°C meal, water balls form and encapsulate solvent.
Desolventizing
DT Unit Processes
Poor Steam Distribution (2% open area)
Hollow Staybolt tray
Desolventizing
DT Unit Processes
Even steam distribution in the top countercurrent tray results in condensation of the steam in a narrow band. Fewer “water balls” form. Even steam distribution is critical for good performance.
Desolventizing
DT Unit Processes
Aerodynamic Sweeps
Good Steam Distribution
Desolventizing
DT Unit Processes
10% open area trays
Good Steam Distribution
Desolventizing
DT Unit Processes
Toasting & Stripping
Remove final traces of hexane Deactivate anti-nutritional factors Direct Steam Specific Heat Indirect Steam Heat 99-108°C Meal Temperature 2019% Meal Moisture 20-25 minutes
DT Unit Processes
0.05-0.10 pH rise in urease activity 25-35 PDI protein solubility 20-25 minutes
Optimizing Meal Quality for Poultry & Swine
Toasting & Stripping
DT Unit Processes
0.01-0.05 pH rise in urease activity 15-20 PDI protein solubility 40-50 minutes
Optimizing Meal Quality for Dairy & Beef Cattle
Toasting & Stripping
Meal PDI of U.S. Soybean Processing Plants (2004)
0
5
10
15
20
25
30
35
40
45 3 48
50
46
68
39
22
60 8 6 12 2 36
18
47
31
15
40 9 52
20
24
10
44
49 5 19
35
Standard Deviation = 4.96
DT Unit Processes
Increasing residence time allows more time for solvent to be stripped out. Increasing live steam flow increases the steam density, and therefore the intimate contact between the steam and the meal.
Optimizing solvent loss
Toasting & Stripping
DT Unit Processes
So how do we keep toasting time down to 15-20 minutes and also reduce solvent loss in the meal? The answer is to increase steam density passing through the meal.
Optimizing both solvent loss & meal quality
Toasting & Stripping
DESIGN 3000 tpd soybeans 26 minutes under sparge 579 kg/hr/m2 steam density
TRIAL 1 2400 tpd soybeans 32 minutes under sparge 450 kg/hr/m2 steam density
TRIAL 2 2140 tpd soybeans 36 minutes under sparge 394 kg/hr/m2 steam density
residence time improves initial desolventization
higher steam density improves stripping on sparge Stack
Residual free Hexane in Meal
8 samples tested per Stack at each capacity
DT Unit Processes
Existing DTs with higher steam density have experienced practical operational problems resulting from the pressure drop across each counter-current tray and meal increasing to 37 mbar.
Optimizing both solvent loss & meal quality
Toasting & Stripping
DT Unit Processes
Level control problems arise. Steam short circuits behind the sweeps, the path of lowest resistance. Existing hollow stay-bolt trays with 2% open area will not allow higher steam density.
Optimizing both solvent loss & meal quality
Toasting & Stripping
DT Unit Processes
So how do we reduce pressure drop across the DT counter-current trays to allow higher steam densities? The answer is increased open area for vapors in the counter-current trays design.
Optimizing both solvent loss & meal quality
Toasting & Stripping
DT Unit Processes
Optimizing both solvent loss & meal quality
Toasting & Stripping
10% open area trays
DT Unit Processes
Optimizing both solvent loss & meal quality - CONCLUSIONS
Toasting & Stripping
Taller, smaller diameter DT’s with higher steam density 10% open area Stack s Aerodynamic sweep arms Rotary valves on every Stack
DT Unit Processes
Steam Drying
Purpose is to both dry the meal to save DC steam, and to enable low pressure water vapor heat to be recovered in extraction Half of drying heat is from meal Half of drying heat is from trays Water vapor captured via steam ejector for heat recovery
DT Unit Processes
Steam Drying
Shallow 300 mm meal level 108102°C meal temperature 2019.5% meal moisture Rotary valve level control
Meal Drying and Cooling
Meal Dryers and Coolers Type
– Adiabatics • Vertical or Stack • Conveyor type
– fixed floor – moving floor
• Counterflow
– Non Adiabatics • Rotative • Plates
Meal Dryer Type: Vertical or Stack
Meal Dryer Type: Vertical or Stack
Meal Dryer Type: Vertical or Stack
AIR HEATER
FAN
CYCLONS
AIR CHAMBER
Meal Dryer Type: Vertical or Stack
Air Chamber Inlet and Outlet ducts with circular section
Rotary Valve
Meal Dryer Type: Vertical or Stack
Double Bottom
Meal Dryer Type: Vertical or Stack (DT+DC)
Gum s FromWater Degum mi ng
S team FromSteam And Condensate
To Steam And CondensateItem 46/70
S team FromWaste Water S team
Generation
S team FromSteam And Condensate
S team FromSteam And Condensate
Purge FromWaste Water S team
Generation
Ext racted MealFrom Ext ract ion
Item 4
(OPTIONAL)
SPARGE ST EAMSUPERHEAT ER
49/70
To Steam And CondensateItem 46/70
To Steam And CondensateItem 46/70
To Steam And CondensateItem 46ATM
To Meal Siz ing
10ADC DISCHARGE M EAL
CONVEYOR
10CCROSS YARD
MEAL CONVEYOR
10BDC CYCLO NEDISCHARGE
MEAL CONVEYOR
13DRYER-COOLER
14ADRYING
AIRCYCLONE
14BCOOLING
AIRCYCLONE
ATMATM
DRYING A IR F AN
(OPTIONAL)
DRYING A IRINLET FILT ER
16
(OPTIONAL)
ATM
36A
P78/94
ATM
HEAT RECOVERYACCUM ULATOR
78/94
36BCOOLINGAIR F AN
94DRYING
AIR HEAT ER
1ST TRAY
2N D TRAY
3R D TRAY
8/13DRYER-COOLERFEEDING DEVICE
Steam FromSteam And Condensate
Condensate F romSteam And Condensate
Item P46ATM/94
Condensate F romSteam And Condensate
Item P46ATM
Steam FromSteam And Condensate
To Solvent RecoveryItem 20B/C
To Dist illat ionItem 60A
To Solvent RecoveryItem 20B/C
1ST TRAY
2N D TRAY
3R D TRAY
4TH TRAY
5TH TRAY
6TH TRAY
8TH TRAY
Caust ic AdditonSystem
(OPTIONAL)
VAPOURSCRUBBER
29
HYDRAULICSEAL
FLASH TRAYSTEAM
EJECTOR
41/70
DESOLVENTISED M EALCONVEYOR
9
DESOLVENTISER-TOASTER
70
EXTRACTEDMEAL
CONVEYOR
5
EXTRACTEDMEAL CONVEYOR
SLIDE GATE
52/5(OPTIONAL)
52/70
P29
PT70
PI70
ZS52/5
ZS52/5
IE5
FT70
PI49/70
ATM
XV70
PI70
PT70
XV70
TT5
ZS52/70
ZS52/70
PT70
TI70
PI70
TT70
TV5
LS70
LT70
SC70
LT70
SC70
LT70
SC70
LT70
SC70
LT70
SC70TT
70TI70 LS
70
PI41/70
PCV70
TIP29
PIP29
AT29
LT29
FG29
FI29
XV29
PI29
TI94
PI36A
XCV36A
PI36A
TI94
PI36BXCV
36B
To SolventRecovery Item 23A
From Sol ventRecovery Item 23A
TI94
TT94
TI94
PI94
LS13
LS13
LS13
SS13
SS10A
IE13
FS13
BATT ERYLIM IT
SS10C
IE10A
PT13
PI13
TI13
TI13
TI13
TT13 LT
13SC13
SS8/13
IE8/13
IE9
FT94
IE10C
BATT ERYLIM IT
AT14A
FS70
IE70
SS9
SS70
SS5
TCV70
BATT ERYLIM IT
IE36B
IE36A
LS5
LV29
XV94
XV94
XV94
PRV94
PT13
PI13
PT13
PI13
ATM
PSV70
SN29
SN29
SN29
SN29
PSV70
ATM
DESOLVENTISERSLIDE GATE
TT70
TI70
TI70
TT70
7TH TRAYTT70
TI70 PT
70
TT70
TI70
PT70
Meal Dryer Type: Vertical or Stack (DTDC)
11TH TRAY
7TH TRAY
6TH TRAY
5TH TRAY
4TH TRAY
8TH TRAY
1ST TRAY
2N D TRAY
3R D TRAY
9TH TRAY
10TH TRAY
Gum s FromWater Degum mi ng
S team FromSteam And Condensate
(OPTIONAL)
DRYING A IR F AN
To Steam And CondensateItem 46/70
To Solvent RecoveryItem 23A
Steam FromWaste Water S team
Generation
S team FromSteam And Condensate
S team FromSteam And Condensate
S team FromSteam And Condensate
Condensate F romSteam And Condensate
Item P46ATM/94
Purge From Waste Water S team
Generation
Ext racted MealFrom Ext ract ion
Item 4
(OPTIONAL)
SPARGE ST EAMSUPERHEAT ER
49/70
From Sol vent RecoveryItem 23A
DRYING A IRINLET FILT ER
16
(OPTIONAL)
ATM
36A
P78/94
41/70FLASH TRAY
STEAMEJECTOR
14ADRYING A IR CYCLONE
14BCOOLING A IR
CYCLONE
29VAPOUR
SCRUBBER
HYDRAULICSEAL
P29
(OPTIONAL)
Steam From S team And Condensate
To Solvent RecoveryItem 20B/C
To Dist illat ionItem 60A
To Solvent RecoveryItem 20B/C
ATM ATM
To Steam And CondensateItem 46/70
HEAT RECOVERYACCUM ULATOR
78/94
94DRYING
AIR HEAT ER
EXTRACTEDMEAL CONVEYOR
5
Caust ic Additi onSystem
PTPI
TTTITI
TI
PI
PI
FT
PI
TCV
PI
PTXV
TT PT
TI
TT
PI
PCV
AT
PI
TI
LT
PI
Condensate F romSteam And Condensate
Item P46ATM
FI
XV
FG
AT
PI
ATM
XV
TV
IE
PRV
PI
XV XV XV
IE
PSV
ATM
ATM
PSV
SN
SN
SN
SN
BATT ERYLIM IT
BATT ERYLIM IT
52/70
ZS
ZS
LT
LT
LT
LT
LT
DESOLVENTISERSLIDE GATE
PTPI
PTPI
PTPI
DIM AX TM
DESOLVENTISER TOASTERDRYER COOLER
LS
SC
SC
SC
SC
SC
SCLT
ATM
36BCOOLING A IR F AN
PI
IE
FSIE
SS
BATT ERYLIM IT
70/13
To Steam And CondensateItem 46/70
To Steam And CondensateItem 46ATM
To Meal Siz ing
10ADC DISCHARGE M EAL
CONVEYOR 10CCROSS YARD
MEAL CONVEYOR
10BDC CYCLO NEDISCHARGE
MEAL CONVEYOR
SS
SS
IE
IE
EXTRACTEDMEAL CONVEYOR
SLIDE GATE
(OPTIONAL)
ZS
ZS
SS
LS
XCV
LV
XCV
TI
TI TT
TT
TI TT
TTTI
TTTI
LS
LS
TI
TT
LSTI
TI
PT
PT
LS
FT
BARRINGMOTOR
(OPTIONAL)
PI
PI
PS
Meal Dryer Type: Tunnel (Chain or Belt)
Courtesy : Alloco
Meal Dryer Type: Tunnel (Chain or Belt)
Courtesy : Alloco
Air Inlet
Air Outlet
Meal Transport Chain
Meal Dryer Type: Counterflow
Courtesy : Geelen
Meal Dryer Type: Counterflow
Courtesy : Stolz
Meal Dryer Type: Rotative Bundle
Meal Dryer Type: Rotative Bundle
Meal Dryer Type: Rotative Bundle
Meal Dryer Type: Rotative Bundle
Excentric Feed Concentric Feed
Meal Dryer Type: Plate (Solex)
Meal Dryer : Psichometric Chart
-
0,200
0,400
0,600
0,800
1,000
1,200
1,400
50,0 60,0 70,0 80,0 90,0 100,0 110,0
Air Moisture (kg/kg) vs Temp
100%
90%
40%
10%
TEMPERATURE
AIR
WAT
ER C
ON
TEN
T
Air Temp increase in air heater
Moisture increase in the DC
Humedad Absoluta
Meal Dryer : Psichometric Chart (Adibatic Dryers)
A: Amb Condition B: Dryer Outlet
A
B
Air Temp increase in air heater
Moisture increase in the DC
Humedad Absoluta
Meal Dryer : Psichometric Chart (Adibatic & Non Ad. Dryers)
A
C
A: Amb Condition B: Dryer Outlet (Adibatic) C:Dryer Outlet (Non Adibatic)
B
Meal Dryer : Psichometric Chart (Delta Adiabatic/Non Adibatic)
Courtesy : Solex
ATM
2N D TRAY
3R D TRAY
1ST TRAY
Meal Dryer (Adibatic): Operational Parameters
Temp Amb.25*C HR: 60%
31*C
140*C HR : <1%
54*C HR : 90%
Material Inlet : Temp :100*C Moisture : 18%
Material Outlet : Temp :60*C Moisture : 13%
2N D TRAY
3R D TRAY
1ST TRAY
Meal Cooler : Operational Parameter
Temp Amb. 25*C
31*C
46*C
60*C
42*C
AIR
SOYA MEAL
Meal Dryer (Non Adibatic): Operational Parameters
Temp Amb. 25*C
Temp :90*C HR : 90%
Material Inlet : Temp :100*C Moisture : 18%
Material Outlet : Temp :60*C Moisture : 13%
Meal Dryer : Features
• Vertical or Stack Type – High Material Layer : 900mm – High Air Delta P : 300-400mmH2O – Air Flowrate density : 1200 m3/h /m2
» Or air spead of 21m/h – High Delta Material Moisture – Material quite isolate from ambiente (animal or other
contaminations) – Low potential to have wet spots (Salmonella formation) – For small / medium capacities can be integrated with the DT – Can be done Cooler in one single vessel – Relative low air outlet temperature (low chances of heat
recovery) – Good air separation in between stages – Plant Capacity : all (so far up to 10.000MTPD in a single
vessel)
Meal Dryer Features
• Chain Type – Low Material Layer : 300mm – High Air Delta P : 100-150mmH2O – Air Flowrate density : 1200 m3/h /m2 (about) – High Delta Material Moisture – High contamination potential (animal or other ) – High potential to have wet spots (Salmonella
formation) – Can not be integrated with the DT – Can be done Cooler in one single vessel – Relative low air outlet temperature (low chances of
heat recovery) – Not as good air separation in between stages – Plant Capacity : all (but normally medium)
Meal Dryer Features
• Counterflow – High Material Layer : 700-900mm – Medium Air Delta P : 250-300mmH2O – Air Flowrate density : 1200 m3/h /m2 (about) – High Delta Material Moisture – High contamination potential (animal or other ) – High potential to have wet spots (Salmonella
formation) – Can not be integrated with the DT – Can´t be done Cooler in one single vessel – Relative low air outlet temperature (low chances of
heat recovery) – Air separation in between stages : full countercurrent – Plant Capacity : low /medium
Meal Dryer Features
• Rotative – « Very Low » Material Layer – Minimun Air Delta P (not fan required) – Air Flowrate density : Low – Medium Delta Material Moisture (maximum 5%) – Medium contamination potential (animal or other ) – Low potential to have wet spots (Salmonella formation) – Can not be integrated with the DT – Can´t be done Cooler in one single vessel – High low air outlet temperature (High chances of heat
recovery) – Air separation in between stages : full countercurrent – Plant Capacity : low / medium
Meal Dryer Features
Meal Dryers : « Clouds »
Meal Dryer « Clouds » : Vertical
ATM
2N D TRAY
3R D TRAY
1ST TRAY
Outcoming Air: 53°C
0.091 kg water / kg dry air
Equivalent to : 64kg Steam/ton
28kg/ton
Fans : 1,12kwh/ton
Drive : 0,9kwh/ton
Meal Dryer « Clouds » : Rotative
Outcoming Air: 88 - 92°C
1.02 kg water / kg dry air
Equivalent to : 48kg Steam/ton
Steam 23kg/ton
Drive : 0,9kwh/ton
Meal Dryer « Clouds » : Vertical
ATM
2N D TRAY
3R D TRAY
1ST TRAY
Air Flow : 533kg/ton
Pollution : 47 g/ton
Meal Dryer « Clouds » : Rotative
Air Flow : 37kg/ton
Pollution : 3 g/ton
Design values : Comparative Chart
Vertical Rotative UnitsSteam Consumption : 28 23 kg/ton
Total Drying Air 533 37 kg/tonFAN kw abosrbed . 1,1 0 kwh/ton
Pollution : 47 3 g/tonDrive kw absorbed 0,9 0,9 kwh/ton
Vents Temperature : 54 90 *C
Meal Dryers : Savings
Steam Savings : With Vertical DCs Preheating air with stripper gases Benefits : Steam Saving : 7,0 kg/ton Parameters : -Air to meal dryer : 1.300 kg/ h – m2 -it94S : Air inlet/outlet : 36/55*C -it23A : Gas inlet/outlet : 95/68*C -it23A : Water inlet/outlet : 65/68*C
Steam Savings : With Vertical DCs Preheating air with condensate Benefits : Steam Saving : 4,0 kg/ton Parameters : -Air to meal dryer : 1.300 kg/ h – m2 -it94/B : Air inlet/outlet : 55/62*C -it46ATM : Water inlet/outlet : 100/90*C
Steam Savings : With Vertical DCs Preheating air Benefits : Steam Saving : 7,0 kg/ton Steam Saving : 4,0 kg/ton Total steam Saving : 11,0 kg/ton
Incoming meal :100°C
Moisture flakes : 18%
Outcoming Air: 88 - 92°C
0.89 kg water / kg dry air
Outcoming meal :65°C
Moisture meal : 13%
Incoming Air: 20°C
(Ambient)
AIR
SOYA MEAL
Steam Savings : With Rotative Dryer
Outcoming Air: 88 - 92°C
1.02 kg water / kg dry air
Equivalent to : 48kg Steam/ton
Incoming meal :100°C
Moisture meal : 18%
Outcoming mel :60°C
Moisture meal : 13%
Steam:23kg/ton
Steam Savings : With Rotative Dryer
How to recover that energy ?
Concept
Temp : 105*CMoisture : 18%
Temp : 75*CMoisture : 10,0%
Temp : 20*CMoisture : 12-13%
Temp : 65*CMoisture : 13%
SEEDSTORAGE
CLEANING &WEIGHING
CONDITIONING
FLAKING
MEALPELLET
STORAGE
SOLVENTEXTRACTION
PLANT
MEALTREATMENT
MEALDESOLVENTIZING
OIL DISTILLATION
STEAM
OILSTORAGE
MEALDRYING
DEHULLING(WARM)
STEAM
STEAM
MEALCOOLING
ATMOSPHERE
AIR+WATER
AIR+WATER
Temp. Aprox : 60*C
Temp. Aprox : 85*C
PRE-CONDITIONER
How to recover that energy ?
Hot / Wet Gases
E-Comyzer®
Seed Conditiner
Cold / Wet Seed Heat
Water Loop
How to recover that energy ?
65°C 90°C
0.16
1,02
Temp *C
Absolute Moist
kg/kg Rotary Dryer
Exhaust
0,69
83°C
Stack DC
ATM
P2720
How to recover that energy ?
SB Meal Rotary Dryer
Seed Conditioner
E-Comyzer ®
Stea
m C
ond
ATM
P2720
How much energy do we recover ?
T : 83*C RM: 100%
T : 80*C
Recirc. Flowrate : 80m3/h
T : 82*C
T : 20*C
Cold/Wet Seed
T : 50*C
T : 75*C
T : 62*C
T : 90*C RM: 90%
Hot SB Meal
Hot/Dry Seed
Stea
m C
ond
How E-Comyzer ® looks like ?!
Exhaust
Fan E-comyzer
How E-Comyzer ® looks ?!
How E-Comyzer ® looks like ?!
E-comyzer
Exhaust
Fan
How E-Comyzer ® looks like ?!
E-comyzer
Gases Inlet
How Seed Conditioner Solex looks like ?!
SEED
WATER PLATES
Solex : PHE for solids
How much energy do we recover ?
SUMMER TIME
How much energy do we recover ?
SUMMER Seed :20*C
WINTER Seed :10*C
Saving average: 25,6kg/ton Saving : 9,5 %
Conclusion
For Minimum Opex the more convenient is a combination: *Meal Dryer : Rotary *Meal cooler : Vertical (or eventually a Rotary paddles )
For More compact & Simple installation : *DT & Meal Dryer & Meal Cooler in one piece : Vertical
Thank you!
Anibal Demarco [email protected]