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Energy efficiency improvement and cost saving for oilseeds processing
Iven Li
M.A. Sc. Lipid and vegetable protein, Jiangnan University.
R&D of FAMSUN Oils&Fats
2
SolventSteam ElectricityWater
3
Stem Consumption Distribution (Solvent Extraction)
Distillation System
Effluent boiling
DC system
MOS
28.5%
5%
3.7%
2%
60.8%
DT system
Desolventizing
4
Steam Consumption
64.5% 28.5% 10.7%
D T D C D i s t i l l a t i o n O t h e r s
The DT system, that is, the remaining solid parts after extracting (spent/ wet meal), consumed almost 65% of the steam in the whole
workshop. The main determinant is the amount of liquid solvent contained in the spent meal. Therefore, reducing the solvent carried
by the spent meal is the key factor to reduce the steam consumption.
Oleaginous
materialsin
Marcout
Fresh solvent : Hexane
1
1
2
345
6 9 10 11
Miscella
out
5
EX-1, Force-draining design extractor
The advanced force draining design:
in the final draining section set a vacuum design, Condenser + Steam ejector.
7 8
6
EX-1, Force-draining design extractor
Draining Condenser
Steam Ejector The 1st
Evaporator
Extractor
Condensate solvent
Steam
DT Vapor
Fresh
solvent
Negative
pressure
Oleaginous
materials IN
Miscella
OUT
Marc to DT
Cooling
water IN
7
EX-1, Force-draining design extractor
20%
carried solvent
↓
1/3
cooling water
↓
Due to the reduced amount of solvent (from 30% to 25% ,approximately reduce 20%) that
the spent meal is brought into the desolventizer (DT), the amount of heat required for
desolventizing will also be reduced by approximately 20%.
The load of DT and evaporation condensate will be significant reduced. Through theoretical
calculation, even if a small temp. difference between inlet and outlet of cooling water is
adopted, such as 4℃, the circulation volume of cooling water is only 2/3 of the original. Less
recirculating cooling water means less power consumption and less supplementary water
consumption, and less equipment investment for the entire recirculating water system.
8
DT-2, DT vapor heat exchanger
Wet
scrubber
The 1st
Evaporator
DT vapor
Cooling water
Evaporation vaporVent from
Extractor
Stripping vapor
Miscella IN
OUT
Condensate
solvent
Cold fresh
solvent
Heated fresh
solvent to
Extractor
DT vapor
Replace the vapor contactor with shell and
tube interchanger (2-pass on shell side and
4-pass on tube side) to heat the cold fresh
hexane before entering Extractor, which
can save 6~7kg/ton steam.
Solvent is heated from 35℃ to 55℃
Cooler
Fresh hexane
Vapour contactor
9
DT-3, Sparge steam super-heater for DT
Use the super-heating sparge steam will reduce the condensate in
meal (use 8~10 barg steam to heat the sparge steam (3 barg)),
compare to the normal steam will save 5%, almost 4kg/ton.
Super-heating reduce the DC drying required steam, not DT steam.
DTDC
DT vapor
OUT
ATM
ATM
ATM
Meal to PRP.
Steam
3 barG
Steam
8 barG
Steam Super HeaterSteam
3 barG
Steam
8 barG
DT Sparge tray
10
DT-3, DC Cyclone Vent Control
SteamDust
ATM
ATM
Dryer
Cyclone
#1
Cooler
Cyclone
Dryer
Cyclone
#2
Bag
filter
DC
Steam
3 barG
Steam
form Dryer cyclone #1- Heat recovery.
Dust
from Dryer cyclone #2 and Cooler cyclone
- Environmental protection
11
DT-3, DC Cyclone Vent Control
ATM
ATM
Process: wet vapor from cyclone after cleaning by hot water can be used for heating the air of DC or adding one interchanger to
get the hot water as heating source of 1st and 2nd tray of conditioner in preparation.
sump
Cooler
Cyclone
Dryer
Cyclone
#2
Dryer
Cyclone
#1
DC waste vapor recovery includes:
• vapor cleaning system
• slag re-back system
• heat exchanging system
• working liquid recycle system
12
DS-4, Vacuum system-water-ring pump
Wet
scrubber
The 1st
Evaporator
DT vapor
Cooling water
Vent from
Extractor
OUT
DT vapor
Cooler
Evaporation vapor
Stripping vapor
Adopts water-ring pump to replace the traditional steam ejector can reduce 7 kg/ton steam.
Set 2 pumps or 1 pump, bypass piping, adjust separately, or 1 for standby.
13
DS-5, Stripping pre-condenser
Stripping Condenser Pre-Condenser
Water
Hot Water
Stripping
Column
Dryer
Steam
Steam
Miscella IN
Crude Oil
OUT
Pre-condenser set before the stripping condenser, can be
placed on the top of condenser or alone.
Hot water can be used for heating the air of DC or
conditioner in preparation.
By calculation, approx. 5~6kg steam can be saved.
14
DS-6, Pre-stripping and screen type stripper
Concentrate
dMiscella
Concentrated oil
Steamin
Steam in
Ventgas
Pre-stripping
Steam and
vapor
Miscella
Disc
Countercurrent flow
direct steam from
bottom
v a p o r
Concentrated
Miscella
Concentrated
oil
Steam in
Vent out
Miscella
Screen
Countercurrent flow
direct steam from
bottom
Depth of liquid approx.
15mm
15
DS-6, Pre-stripping and screen type stripper
Advantage of Pre-stripping
• Reduce hexane saturated partial pressure, result in de-solvent easier in stripper.
• Premixing the steam and miscella before stripping.
• Reuse the flash steam from vacuum.
Advantage of screen type stripper
• Reduces the potential for fouling.
• Easier to clean when fouling does occur.
• Sparge steam rate reduced from 1.75 to about 1.2 kg steam per kg of hexane, almost 30%, 4kg/ton.
16
DS-7, Waste-water pre-heater
Wastewater heat exchange
The temperature of the wastewater in reboiler is about 90~95℃, and inlet wastewater is about 50℃, can be exchanged through a
horizontal tube heat exchanger.
In summer, the outlet temperature of wastewater can be reduced to about 65℃, and the inlet wastewater temperature can also be
increased by about 10℃ compared with that without heat exchange.
Water/hexane separator
W-water re-boiler
ATM
Steam
Pre-heater
17
DS-7, Waste-water pre-heater
• 2-pass shell and 4-pass tubes for improved performance.
• Flat-sided vessel and full face covers design for easy cleaning.
• Gravity flow without pump.
• Save about 1 kg/ton steam.
18
P-8, Conditioning tower
• On the top of conditioner, set 1~3 heating trays use hot
water to replace the steam.
• Air heater of conditioner use both hot water and steam.
• Dehulling suction air circulation design.
• Air heater of dehulling use both hot water and steam.
19
P-9, Expanding cooling-dryer
• Air heater of cooling-dryer use both hot water and
steam.
• vent air from the fan can be reused.
20
O-10, Others
• Hot condensate can be used to heat air directly, miscella or hexane.
• Hot condensate can be collected and storage in a flash tank, or by a heat pump to produce flash steam, which
can be used to heat the water etc. or to DT.
• Hot oil from degumming can be used for the oil/miscella economizer or wastewater pre-heater.
• Hot pressed oil from expeller can be used for the oil/miscella economizer.
• Hot vent air from cooker can be used for the conditioner.
... ...
21
Solvent Consumption
Spent meal
(Solid)
Miscella
(liquid)
Collets Hexane
Solvent
Oil
Hexane
Meal
Hexane
Evaporation
Condensation
Meal
Desolventing
Toasting
Drying
Cooling
Crude oil
Hexane
Wastewater
Emission to ATM
22
Solvent Consumption Distribution
Hexane taken out
by the meal
Hexane taken out
by vent air
Vapor leakage
Liquid leakage
Start & Stop
Shut down period
Hexane storage
tank leakage
Carried by
wastewater
Carried by
crude oil
49.5%
17%
11.3%
2.2%0.9%
3.8%
7.5%
4%
3.8%
Items PCT Notes
Hexane take out by the meal 49.50% Based on hexane residual in meal is 320 ppm
Hexane take out by the crude oil 2.20% Based on hexane residual in oil is 60 ppm
Hexane take out by the W-water 0.90% Based on hexane residual in water is 100 ppm
Hexane take out by the vent air 11.30% Based on hexane residual in vent air is 10 g/m3
Hexane out from hexane storage tank 3.80% Normal operating of breather valve
Workshop equipment vapor leakage 17.00% Based on can't smell the hexane
Workshop equipment liquid leakage 7.50% No obvious solvent leakage point in workshop
Start and stop 4.00% No frequent start and stop
Shut down period 3.80% for mantainence
Total 100%
23
S-1, Vent air control
Most of solvent consumption is based on meal,
vent gas and workshop vapor/liquid leakage.
Therefore, in order to reduce the solvent
consumption, we should first solve the basic,
non-technical problems leakage in the
workshop, and then reduce the technical
factors such as meal residue and exhaust
emission.
Set 1 hydrocyclone
separator to remove
foggy liquid hexane.
Set 1 more vent gas
condenser with chilling
water for Summer season.Chiller
MineralOilAbsorptionColumn
MineralOilDesorptionColumn
Question ?
Thank You
Contact us:
FAMSUN OILS&FAT ENGINEERING CO., LTD.
http://famsungroup.com
Iven Li
liwj@famsungroup.com
Simon Chen (Sales Country head)
+92(0)3125888890(Pakistan)
cheny@famsungroup.com
© 2011-2019 FAMSUN

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Paper 5 iven li Energy Efficiency Improvement and Cost-Saving for Oilseeds processing.

  • 1. Energy efficiency improvement and cost saving for oilseeds processing Iven Li M.A. Sc. Lipid and vegetable protein, Jiangnan University. R&D of FAMSUN Oils&Fats
  • 3. 3 Stem Consumption Distribution (Solvent Extraction) Distillation System Effluent boiling DC system MOS 28.5% 5% 3.7% 2% 60.8% DT system Desolventizing
  • 4. 4 Steam Consumption 64.5% 28.5% 10.7% D T D C D i s t i l l a t i o n O t h e r s The DT system, that is, the remaining solid parts after extracting (spent/ wet meal), consumed almost 65% of the steam in the whole workshop. The main determinant is the amount of liquid solvent contained in the spent meal. Therefore, reducing the solvent carried by the spent meal is the key factor to reduce the steam consumption.
  • 5. Oleaginous materialsin Marcout Fresh solvent : Hexane 1 1 2 345 6 9 10 11 Miscella out 5 EX-1, Force-draining design extractor The advanced force draining design: in the final draining section set a vacuum design, Condenser + Steam ejector. 7 8
  • 6. 6 EX-1, Force-draining design extractor Draining Condenser Steam Ejector The 1st Evaporator Extractor Condensate solvent Steam DT Vapor Fresh solvent Negative pressure Oleaginous materials IN Miscella OUT Marc to DT Cooling water IN
  • 7. 7 EX-1, Force-draining design extractor 20% carried solvent ↓ 1/3 cooling water ↓ Due to the reduced amount of solvent (from 30% to 25% ,approximately reduce 20%) that the spent meal is brought into the desolventizer (DT), the amount of heat required for desolventizing will also be reduced by approximately 20%. The load of DT and evaporation condensate will be significant reduced. Through theoretical calculation, even if a small temp. difference between inlet and outlet of cooling water is adopted, such as 4℃, the circulation volume of cooling water is only 2/3 of the original. Less recirculating cooling water means less power consumption and less supplementary water consumption, and less equipment investment for the entire recirculating water system.
  • 8. 8 DT-2, DT vapor heat exchanger Wet scrubber The 1st Evaporator DT vapor Cooling water Evaporation vaporVent from Extractor Stripping vapor Miscella IN OUT Condensate solvent Cold fresh solvent Heated fresh solvent to Extractor DT vapor Replace the vapor contactor with shell and tube interchanger (2-pass on shell side and 4-pass on tube side) to heat the cold fresh hexane before entering Extractor, which can save 6~7kg/ton steam. Solvent is heated from 35℃ to 55℃ Cooler Fresh hexane Vapour contactor
  • 9. 9 DT-3, Sparge steam super-heater for DT Use the super-heating sparge steam will reduce the condensate in meal (use 8~10 barg steam to heat the sparge steam (3 barg)), compare to the normal steam will save 5%, almost 4kg/ton. Super-heating reduce the DC drying required steam, not DT steam. DTDC DT vapor OUT ATM ATM ATM Meal to PRP. Steam 3 barG Steam 8 barG Steam Super HeaterSteam 3 barG Steam 8 barG DT Sparge tray
  • 10. 10 DT-3, DC Cyclone Vent Control SteamDust ATM ATM Dryer Cyclone #1 Cooler Cyclone Dryer Cyclone #2 Bag filter DC Steam 3 barG Steam form Dryer cyclone #1- Heat recovery. Dust from Dryer cyclone #2 and Cooler cyclone - Environmental protection
  • 11. 11 DT-3, DC Cyclone Vent Control ATM ATM Process: wet vapor from cyclone after cleaning by hot water can be used for heating the air of DC or adding one interchanger to get the hot water as heating source of 1st and 2nd tray of conditioner in preparation. sump Cooler Cyclone Dryer Cyclone #2 Dryer Cyclone #1 DC waste vapor recovery includes: • vapor cleaning system • slag re-back system • heat exchanging system • working liquid recycle system
  • 12. 12 DS-4, Vacuum system-water-ring pump Wet scrubber The 1st Evaporator DT vapor Cooling water Vent from Extractor OUT DT vapor Cooler Evaporation vapor Stripping vapor Adopts water-ring pump to replace the traditional steam ejector can reduce 7 kg/ton steam. Set 2 pumps or 1 pump, bypass piping, adjust separately, or 1 for standby.
  • 13. 13 DS-5, Stripping pre-condenser Stripping Condenser Pre-Condenser Water Hot Water Stripping Column Dryer Steam Steam Miscella IN Crude Oil OUT Pre-condenser set before the stripping condenser, can be placed on the top of condenser or alone. Hot water can be used for heating the air of DC or conditioner in preparation. By calculation, approx. 5~6kg steam can be saved.
  • 14. 14 DS-6, Pre-stripping and screen type stripper Concentrate dMiscella Concentrated oil Steamin Steam in Ventgas Pre-stripping Steam and vapor Miscella Disc Countercurrent flow direct steam from bottom v a p o r Concentrated Miscella Concentrated oil Steam in Vent out Miscella Screen Countercurrent flow direct steam from bottom Depth of liquid approx. 15mm
  • 15. 15 DS-6, Pre-stripping and screen type stripper Advantage of Pre-stripping • Reduce hexane saturated partial pressure, result in de-solvent easier in stripper. • Premixing the steam and miscella before stripping. • Reuse the flash steam from vacuum. Advantage of screen type stripper • Reduces the potential for fouling. • Easier to clean when fouling does occur. • Sparge steam rate reduced from 1.75 to about 1.2 kg steam per kg of hexane, almost 30%, 4kg/ton.
  • 16. 16 DS-7, Waste-water pre-heater Wastewater heat exchange The temperature of the wastewater in reboiler is about 90~95℃, and inlet wastewater is about 50℃, can be exchanged through a horizontal tube heat exchanger. In summer, the outlet temperature of wastewater can be reduced to about 65℃, and the inlet wastewater temperature can also be increased by about 10℃ compared with that without heat exchange. Water/hexane separator W-water re-boiler ATM Steam Pre-heater
  • 17. 17 DS-7, Waste-water pre-heater • 2-pass shell and 4-pass tubes for improved performance. • Flat-sided vessel and full face covers design for easy cleaning. • Gravity flow without pump. • Save about 1 kg/ton steam.
  • 18. 18 P-8, Conditioning tower • On the top of conditioner, set 1~3 heating trays use hot water to replace the steam. • Air heater of conditioner use both hot water and steam. • Dehulling suction air circulation design. • Air heater of dehulling use both hot water and steam.
  • 19. 19 P-9, Expanding cooling-dryer • Air heater of cooling-dryer use both hot water and steam. • vent air from the fan can be reused.
  • 20. 20 O-10, Others • Hot condensate can be used to heat air directly, miscella or hexane. • Hot condensate can be collected and storage in a flash tank, or by a heat pump to produce flash steam, which can be used to heat the water etc. or to DT. • Hot oil from degumming can be used for the oil/miscella economizer or wastewater pre-heater. • Hot pressed oil from expeller can be used for the oil/miscella economizer. • Hot vent air from cooker can be used for the conditioner. ... ...
  • 21. 21 Solvent Consumption Spent meal (Solid) Miscella (liquid) Collets Hexane Solvent Oil Hexane Meal Hexane Evaporation Condensation Meal Desolventing Toasting Drying Cooling Crude oil Hexane Wastewater Emission to ATM
  • 22. 22 Solvent Consumption Distribution Hexane taken out by the meal Hexane taken out by vent air Vapor leakage Liquid leakage Start & Stop Shut down period Hexane storage tank leakage Carried by wastewater Carried by crude oil 49.5% 17% 11.3% 2.2%0.9% 3.8% 7.5% 4% 3.8% Items PCT Notes Hexane take out by the meal 49.50% Based on hexane residual in meal is 320 ppm Hexane take out by the crude oil 2.20% Based on hexane residual in oil is 60 ppm Hexane take out by the W-water 0.90% Based on hexane residual in water is 100 ppm Hexane take out by the vent air 11.30% Based on hexane residual in vent air is 10 g/m3 Hexane out from hexane storage tank 3.80% Normal operating of breather valve Workshop equipment vapor leakage 17.00% Based on can't smell the hexane Workshop equipment liquid leakage 7.50% No obvious solvent leakage point in workshop Start and stop 4.00% No frequent start and stop Shut down period 3.80% for mantainence Total 100%
  • 23. 23 S-1, Vent air control Most of solvent consumption is based on meal, vent gas and workshop vapor/liquid leakage. Therefore, in order to reduce the solvent consumption, we should first solve the basic, non-technical problems leakage in the workshop, and then reduce the technical factors such as meal residue and exhaust emission. Set 1 hydrocyclone separator to remove foggy liquid hexane. Set 1 more vent gas condenser with chilling water for Summer season.Chiller MineralOilAbsorptionColumn MineralOilDesorptionColumn
  • 25. Thank You Contact us: FAMSUN OILS&FAT ENGINEERING CO., LTD. http://famsungroup.com Iven Li liwj@famsungroup.com Simon Chen (Sales Country head) +92(0)3125888890(Pakistan) cheny@famsungroup.com © 2011-2019 FAMSUN