MECPRO supplies either the continuous neutralising installation
with centifugal separation of the Soap Stock or Batch
Physical Refining
Physical refining is a modern alternative for processing
crude edible oil by steam stripping of the free fatty
acids instead of chemical neutralisation. The advantages
of this new system are :
Better yields
High Quality of fatty acids
as by-products
Good oil stability
Simultaneous distillation of
fatty acids and deodorisation (Our deacidifier-deodoriser
is perfectly adapted for this operation)
Lower cost of equipment
Simplicity of operation
Prevention of ecological problems
The first stage in the physical refining process is the
complete removal of all phosphatides, resins and metals
out of the crude oil. In addition to the well known degumming
method applied to crude oils containing low amounts of
gums like palm, palm kernel and coconut oil, we have developed
our special wet degumming system to treat most of the
crude oils having a high content of gums such as soyabean,
rapeseed, sunflower and groundnut in order to suit them
for the next stages of physical refining i.e. bleaching
and deacidification-deodorisation.
Combined
Physical / Caustic Refining
The oil produced from our Solvent Extraction Plants
is ideally suitable for water degumming which results
in reduced oil losses and utility consumption in degumming
processes and the by-product can be converted easily
into lecithin which is a high value product.
Continuous
Bleaching
Our continuous bleaching line is delivered complete with:
Optional addition
of silica absorbants
Optional deaeration system
for bleaching earth
Vertical leaf filters with
automatic cake drop
Optional complete automation
of the filtration cycle
Safety filtration
Continuous
Deacidification-Deodorosation
The main feature of our Deacidification-Deodorisation
system is its low steam consumption which is obtained
due to the following factors :
No steam heating of the oil is required because of the
high economy in heat transfer between the hot discharged
refined oil and the cold incoming degummed and bleached
oil, 80% of the total heat required is recovered in a
special heat exchanger supplied in the deacidification-deodorisation
system.
The low amount of stripping steam 1-1.5% of the oil processed
results in a considerable reduction of the steam required
for the vaccum equipment.
LAYER ESTERIFICATION
Layer esterification is a process, which converts Free Fatty Acid in the crude oil to triglycerides and diglycerides by adding glycerine without any catalyst. This does not cause any quality problem. The glycerine requires 10 to 11% of Fatty Acids to be present in the oil. This newly developed Layer esterification System will make your existing unit more profitable after you add some additional equipment.
Process
The bleached oil with 30% FFA is taken into a Layer Esterifier and the required quantity of glycerine is added in different stages giving the required retention time. Thereafter the oil will continuously flow to the Deodorizer. In this newly developed process, no catalyst is needed and the FFA will be converted into Diglycerides. About 40% of glycerine by weight gets added to the processed oil. The glycerine escaping will be controlled and re-fed to the Layer esterifier installed in the condenser system. In this process, any traces of fatty acid escaping the Layer esterification are continuously re-fed to the Layer esterifier and this will make sure that there will not be any FFA produced in the plant.
In this process, 60% of the fatty acid will be converted into triglycerides and 40% to diglycerides.
LAYER ESTERIFICATION
RCO2H
CH2OH
CH2O2CR
RE-ESTERIFICATION
R’CO2H + CHOH
CHO2CR + 3H2O
FAT SPLITTING
R’’CO2H
CH2OH
CH2O2CR
FATTY ACID
(282x3)
846
GLYCERINE
92
TRIGLYCERIDE
884
WATER
54
WEIGHT GAIN 40% OF THE GLYCERIN QTY
BENEFITS
BASIS
1000 KG
FFA
30%
CONVERSION CHARGES
A) GLYCERIN
30 KG
B) COST
0.9 US$
C) PRODUCT GAINED
1012 KG
COSTING
A) COST OF 330 KG FATTY ACID
A
B) GLYCERINE COST
B
C) TOTAL COST
(A + B)
D) FINISHED REFINED OIL COST
C
E) NET GAINED
[C – (A+B)]
BASED ON 1 MT
Current Process
Input of Deodorizer
FFA
1000 Kg
15%
Product
Refined Oil
Fatty Acid
Loss with order
835 Kg x 46 = Rs.38410
164 Kg x 34 = Rs. 5576 Rs.43986
MECPRO supplies either the continuous neutralising installation
with centifugal separation of the Soap Stock or Batch
The oil produced from our Solvent Extraction Plants
is ideally suitable for water degumming which results
in reduced oil losses and utility consumption in degumming
processes and the by-product can be converted easily
into lecithin which is a high value product. 