Toasting and Drying Oilseed Meals. Which is the Best ... · Solvent Extraction . Toasting and Drying Oilseed Meals. Which is the Best Approach ? 1) Desolventization Basic Technology

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


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


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


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


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


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.



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.



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.



DT Unit Processes



10% open area trays

DT Unit Processes

Optimizing both solvent loss & meal quality - CONCLUSIONS


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



AIR HEATER

FAN

CYCLONS

AIR CHAMBER


Air Chamber Inlet and Outlet ducts with circular section

Rotary Valve


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



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 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


Item P46ATM

Steam FromSteam And Condensate

To Solvent RecoveryItem 20B/C

To Dist illat ionItem 60A


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


(OPTIONAL)

DRYING A IR F AN


To Solvent RecoveryItem 23A

Steam FromWaste Water S team

Generation





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 Dist illat ionItem 60A


ATM ATM


HEAT RECOVERYACCUM ULATOR

78/94

94DRYING

AIR HEAT ER


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


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 46ATM

To Meal Siz ing

10ADC DISCHARGE M EAL

CONVEYOR 10CCROSS YARD

MEAL CONVEYOR

10BDC CYCLO NEDISCHARGE

MEAL CONVEYOR

SS

SS

IE

IE


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




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



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 meal :65°C

Moisture meal : 13%

Incoming Air: 20°C

(Ambient)

AIR

SOYA MEAL

Steam Savings : With Rotative Dryer




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


Hot / Wet Gases

E-Comyzer®

Seed Conditiner

Cold / Wet Seed Heat

Water Loop


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


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 ?!


E-comyzer

Exhaust

Fan


E-comyzer

Gases Inlet

How Seed Conditioner Solex looks like ?!

SEED

WATER PLATES

Solex : PHE for solids


SUMMER TIME


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]

Documents

Toasting and Drying Oilseed Meals. Which is the Best ... · Solvent Extraction . Toasting and Drying Oilseed Meals. Which is the Best Approach ? 1) Desolventization Basic Technology