Crown Iron Works Company

Transcription

1 Crown Iron Works Company SPC Plant Process & Equipment for Feed, Aqua & Food Richard W. Ozer, PE Sales Manager, Specialty Extraction mobile

2 Soy Protein Concentrates (SPC) True soy protein concentrates contain +65% protein and are made from non toasted white soybean flakes, used for FOOD & CMR. Hi Pro Meal can be used to produce SPC for Aquafeed, FEED, and lower quality CMR & Piglets Milk Replacer. Aqueous alcohol wash process is used to produce AQUA, FOOD, & FEED grade SPC (about 96% of total world SPC production). Acid washed soy protein concentrate < 4% Enzyme modified soybean meal products for feeds ( 60% protein) Hayes General Technology 2

3 Considerations for SPC Plant Design compared to a Hexane Solvent Plant White Flakes and Toasted Meal expand +30% when wetted with hydrous ethanol Wet a protein rich material with water and you have glue! Energy requirements are 4-6 x greater than hexane. Use of sparge steam is discouraged because of its affect on product quality & color Percolation rate is low compared to hexane extraction. Fines in the feed material reduce percolation even more! Prescreening to remove fines is encouraged. 3

4 Basic SPC Flow Diagram Feed & Aqua Pre-Soak Hi Pro Meal Extraction/ Washing Dewatering Desolventization Dryer/ Cooling For Aqua or Feed SPC Fresh Solvent Distillation Stripping Soy Molasses Hayes Hydrous Ethanol Process, First Commercialized in the 1960 s 4

5 SPC Plants, capacity to 1000 TPD Triple Effect Evaporation Stripper w/reboiler TFE for Molasses Hi Pro SBM Soaker Screws DTDC Concentrated Soy Molasses Heat Recovery Scrubber M3 Extractor Screw Press Finished SPC -Soy Molasses concentrated to 35 to 75% solids depending upon end use -Plants this size are most often for Aquafeed using toasted meal. 5

6 Soaker Screws for Pre Wetting SPC Plant Input <200 TPD Plant Multiple Screws for larger capacity Dry White Flakes or Toasted Meal expands when wetted with Hydrous Ethanol 6

7 Model II Percolation Style Extractors SPC Extractor Hexane Extractor Hexane & SPC MII Extractors installed side by side 7

8 MODEL III PERCOLATION STYLE EXTRACTOR Soaker Screw +400 TPD Plant for Aquafeeds 8

9 Weirs, Liquid Distribution & Percolation Percolation rates are much lower than with hexane extraction Typical Hexane Extraction SPC Extraction 9

10 Views around the MIII Percolation Extractor - New screen design with improved release, Extractor stays on line for a longer runs w/o cleaning - New design underscreen wash, no rails - Immersion Extractors available for smaller capacities 10

11 Dewatering Press - Evaporative load on DT is reduced with Dewatering Screw Presses - Multiple presses for larger capacity - Single Press for Food Grade Product 11

12 Screw Press Internals Internal Shafts Twin Screw Single Screw w/cone & Breaker bars External Screen 12

13 Desolventization - Sail for sensing level Desolventizers are sized based upon Indirect heating Minimal sparge steam. - Rotary Valve for level control - pipe stays for hi pressure (Aquafeed plant above) 13

14 Dryer Cooler -For Final Drying & Cooling -Direct Contact Drying cools SPC quickly and preserves color -Minimizes heat input and maintains digestibility -Uses waste heat from DT to preheat air w/ no concern for overheating or boiling. 14

15 Distillation, Stripper, & Thin Film Evaporator Solvent Recovery is more like true Distillation Objective is to reduce ethanol content in Soy Molasses to ppm levels Recirculating design does not require daily CIP Extended times between cleanouts 15

16 Multi Effect Evaporators & Separators 1 st, 2 nd, & 3 rd Effect Heat Exchangers 2 nd & 3 rd Effect Vapor Separators 16

17 Stripper to recover the last Ethanol - Stripper to recover ethanol from soy molasses before discharge. - Uses fixed valve trays which remain clean even in heavily fouling service - In smaller plants Thin Film Evaporator can be used to concentrate Soy Molasses - In larger plants, multiple effect evaporators can be used. 17

18 Miscellaneous Equipment Thin Film Evaporator to increase Molasses Concentration Operates for weeks without cleaning Scrubber to recover Ethanol from non Condensable Gases 18

19 Soy Molasses Byproduct No SPC Plant should start without a plan for the Soy Molasses! Typical analysis of soy molasses on a dry matter basis Soy Sugars 58 65% Typical: Oligosaccharides:» Stachyose 23 26%» Raffinose 4 5% Disaccharides:» Sucrose 26 32% Monosaccharides:» Fructose %» Glucose % Crude Protein [N x 6.25] (including amino acids, peptides, etc.) 5 7% Crude Lipid Material (including phosphotides) 4 7% Minerals (Ash) 3 7% Saponins 3 7% Isoflavones 6 15% Other organic constituents (Including phenolic-acids, leucoanthocyanins, etc.) to 100% Breakdown provided by Hayes General Technology 19

20 Potential Usages for Soy Molasses Liquid feed for ruminant cattle Source of Isoflavones Food additives Source of sugars for fermentation Add back to hulls for cattle feed Boiler feed for heat recovery 20

21 But What if you want Higher Value Products, Like SPC for FOOD Starting material is now a White Flake for improved functionality & color. White Flakes provided by special desolventization technique Higher finished protein is required Lighter color is required Better starting bean w/less color is required End product is generally milled to less than 200 mesh Vacuum Desolventization Step added to limit heat input to product 21

22 Applications for White Flakes Typical Specifications Moisture Max 8% Particle size 95% less 74 microns Flavor Pleasant to Nutty, Odor: Neutral to Nutty PDI Enzyme active Enzyme active Fully Toasted Soy Protein Isolates Soy Protein Conc. Milk Replacer Fermentation Bakery Mixes Meat Products White Bread Bleaching Doughnut Mixes Protein Beverages Adhesives Pasta Hyd. Vegetable Pr Breakfast Cereals Texturized Soy Flour Flavor carrier Hard Biscuits 22

23 Unground White Flakes 90 PDI White Flakes for making SPI. -note thinner flakes & more fines 60 PDI White Flakes for SPC -note thicker flakes & less fines -Typical Specifications - Max PDI reduction: 5 points less than incoming flakes - less than 350 ppm residual hexane 23

24 Flash Desolventizer -Flexible layout & design eliminates needs for mechanical conveyors -Short residence time ensures low protein denaturization -Pneumatic co current pneumatic conveyor with Direct Heat Transfer -High heat with short residence time -High turbulence to ensure good heat transfer and uniform product treatment 24

25 Vacuum Stripper -Provide Tray Steam to maintain product temp during stripping -Add sparge steam as required for stripping to <350 ppm of hexane -Operation under vacuum allows addition of sparge steam without increasing product temp - Discharge system from Vacuum Stripper designed to minimize inleakage of ambient air. - Dryer/Cooler mounted directly beneath the Vacuum Stripper 25

26 FDS & Vacuum Stripper Flow Diagram -Capacities up to 1200 MTPD White Flakes -Indirect Desolventization available for smaller capacities <300TPD 26

27 Soy White Flakes (FOOD another look) 27

28 Basic SPC Flow Diagram Food & CMR HUMAN CONSUMPTION PreSoak White Flakes Extraction/ Washing Dewatering Vacuum Drying Desolventization Dryer/ Cooling Traditional SPC Fresh Solvent Distillation Stripping Soy Molasses Hayes Hydrous Ethanol Process, First Commercialized in the 1960 s 28

29 VACUUM DRYING (Food Grade SPC) -Gentle Drying & Mechanical Fluidization -Natural backmixing prevents sticking -Maximum Heat Transfer area in a Minimum Volume -Short Material Residence Time 29

30 Desolventization & Cooling DTDC for Food Grade Product Small Capacities Desolventizers are sized based upon Indirect heating Minimal sparge steam In tray Rotary Valves provided when precise level control required 30

31 Thank you for your kind attention!! Presenting: Richard W. Ozer, PE mob 2500 West County Road C Roseville, MN USA Crown Argentina Alberto J/ Paz 1065 vis PB Off 5 y 6 Rosario-Santa Fe, Argentina Manager Alejandro Citterio mobile acitterio@crowniron.com Crown Brasil Rua Dr Renata Paes de Barros 714 cj 133/134 Itiam Bibi CEP Sao Paulo, Brasil Marcos Wietzikoski (11) mobile mfelipe@crowniron.com 31