SOYA EXTRACTION PLANT
[EIRI/EDPR/4595] J.C.: 2812US$
INTRODUCTION
Primitive mills and presses for extraction of oils from seeds have been in use sevice long. Mechanization came with the introduction of the hydraulic press by the end of the 18th Century. This too was replaced by the more efficient screw press or expeller towards the end of the last century.
The first chemical process applied to fats and oils (excluding oxidation in burning) was saponification for making soap. Industrialization of oils and fats began with the installation of a cotton seed oil mill in South California in about 1826.
The methods were crude and the product was impure in 1850 the use of caustic soda to remove free acids from the oil was introduced in France. About this time the millers became aware of the value of linters (fibre) that clung to the Hulls and also of the Hulls themselves as cattle feed.
By 1887 more scientific methods of refining were introduced. In 1983 it was learned that the oil could be deodorized by blowing steam through it at high temperatures. In 1900 the discovery that oils could be hydrogenated to produce fats of different consistencies revolutionised the entire oil and fat industry. So far no comprehensive and absolute classification of vegetable fats and oils is made though various schemes have been used based on origin, physical characteristics, composition or use, or combinations of these factors.
They are more commonly classified according to their capacity for absorbing iodine i.e. Iodine value. Those with a high proportion of double bonds are called drying oils, those intermediate in capacity are called semidrying and those of low capacity non-drying. In general the non-drying and semi-drying oils are used as foods and as lubricants and the drying oils as paint and varnish ingredients. This distinction has never been a very precise one and is becoming less so as oils formerly classified as semi-drying such as soyabean are being used more and more in paints varnishes and other products that dry in a highly satisfactory way.
COST ESTIMATION
Plant Capacity 50 MT/Day
Land & Building (10 Acres) US$ 19.01 Lac
Plant & Machinery US$ 46.01 Lac
Working Capital for 1 Month US$ 23.51 Lac
Total Capital Investment US$ 94.30 Lac
Rate of Return 96%
Break Even Point 26%
CONTENTS
INTRODUCTION
USES AND APPLICATIONS
PROPERTIES
COMPOSITION OF SOYBEANS
TABLE 1: TYPICAL COMPOSITION (WT%.) OF SOYBEANS (DRY WEIGHT BASIS)
TABLE 2: TYPICAL COMPOSITION OF CRUDE SOYBEAN OIL
B.I.S. SPECIFICATION
PRODUCTION, IMPORT & CONSUMPTION OF EDIBLE OIL IN THE LAST FIVE YEAR
INDIA’S DEPENDENCY
CONSUMPTION ON RISE
GOVERNMENT’S EFFORTS
MARKET OVERVIEW OF VEGETABLE OIL
INDIA’S VEGETABLE OIL IMPORTS TO HIT 14 MILLION TONNES IN 2022-23
DOMESTIC CONSUMPTION
INDIA’S DEPENDENCY
CONSUMPTION ON RISE
GOVERNMENT’S EFFORTS
YIELD GAP ANALYSIS
FUTURE OF INDIA EDIBLE OIL
IMPORTANCE OF EDIBLE OIL IN THE COUNTRY ECONOMY
TYPES OF OILS COMMONLY IN USE IN INDIA
CONSUMPTION PATTERN OF EDIBLE OILS IN INDIA
MAJOR FEATURES OF EDIBLE OIL ECONOMY
EXPORT IMPORT POLICY ON EDIBLE OILS
E-GOVERNANCE INITIATIVES
STATUS OF THE VEGETABLE OIL INDUSTRY (AS ON 22.06.2021)
LIST OF CUSTOMERS FOR SOYBEAN OIL
PROCESS DESCRIPTION OF SOLVENT EXTRACTION
WE HAVE EXPLAINED EVERY SECTION IN DETAIL BELOW:
1. SEED PREPARATORY SECTION
2. SOLVENT EXTRACTION SECTION
A. EXTRACTOR
B. DESOLVENTISING SECTION
C. DISTILLATION SECTION
D. SOLVENT RECOVERY SECTION
PROCESS DETAILS OF OIL REFIING
DEGUMMING
LONG MIX NEUTRALISATION
BLEACHING
DEODORIZATION
STANDARD REQUIREMENT FOR AUXILLARY ITEMS
A) STEAM
B) COOLING WATER
C) CONTROL AIR
D) POWER
SOYABEAN OIL PRODUCTION METHODS
SOYBEAN OIL PRODUCTION PROCESS
ADVANTAGES OF EXPANDER -EXTRUDER - COOKER
SOYABEAN OIL EXTRACTION
CLEANING OF SOYBEANS
EXTRACTION OF SOYBEAN OIL
PURIFICATION OF SOYBEAN OIL
HYDROGENATION OF SOYBEAN OIL (OPTIONAL)
SEQUENCES IN SOYABEAN OIL EXTRACTION
PREPARATION AND DEHULLING
EXTRACTION
DESOLVENTIZING
OIL REFINING AND PROCESSING
DETAILS OF SOYABEAN OIL EXTRACTION & REFINING
STRUCTURE OF OIL BODY (WASCHATKO ET AL., 2012)
MECHANICAL EXTRUDING-EXPELLING PROCESS
HEXANE EXTRACTION
TABLE: PHYSICAL PROPERTIES OF N-HEXANE AND EXTRACTION HEXANE (NFPA-36 STANDARD, 2009)
SCHEMATIC FLOW OF OIL SOLVENT EXTRACTION
ENZYMATIC ASSISTED AQUEOUS EXTRACTION (EAEP)
SCHEMATIC FLOW OF ENZYMATIC ASSISTED AQUEOUS EXTRACTION PROCESS
PROCESS FLOW DIAGRAM OF SOYABEAN OIL EXTRACTION & REFINING
RECOVERY OF OIL FROM SOYBEANS
FIGURE 1: PROCESS FLOW DIAGRAM FOR SCREW PRESSING SOYBEANS.
FIGURE 2: PHOTOGRAPH INSIDE A MODERN SOYBEAN SCREW-PRESS PLANT
FIGURE 3: PROCESS FLOW DIAGRAM FOR DIRECT SOLVENT-EXTRACTING SOYBEANS
FIGURE 4: DEPICTION OF EQUIPMENT AND PROCESS FLOW DIAGRAM FOR DIRECT SOLVENT-EXTRACTING SOYBEANS
FIGURE 5: PHOTOGRAPH INSIDE A MODERN DIRECT SOLVENT-EXTRACTION PLANT PROCESSING SOY
FIGURE 6: PROCESS FLOW DIAGRAM FOR EXTRUDING-EXPELLING SOYBEANS
FIGURE 7: PHOTOGRAPH INSIDE A MODERN EXTRUDING-EXPELLING PLANT PROCESSING SOYBEANS
QUALITIES OF SOYBEAN OILS AND MEALS EXTRACTED BY DIFFERENT METHOD
TABLE 1: QUALITY CHARACTERISTICS OF SOYBEAN MEALS PRODUCED BY DIFFERENT OIL-EXTRACTION PROCESSES.
TABLE 2: QUALITY CHARACTERISTICS OF SOYBEAN OILS RECOVERED BY DIFFERENT PROCESSES.
BASIC PROCESSING OPERATIONS
DEGUMMING
FIGURE 8: DIAGRAM OF CONVENTIONAL SOYBEAN OIL REFINING
DEGUMMING SEPARATOR
NEUTRALIZATION
NEUTRALIZATION SEPARATOR
BLEACHING
BLEACHING STEP
TABLE 3: EFFECT OF PROCESSING ON CONTENT OF TOCOPHEROLS, STEROLS AND SQUALENE
IN SOYBEAN OIL
HYDROGENATION
DEODORIZATION
DEODORIZATION STEP
TABLE 4: EFFECT OF PROCESSING STEPS ON QUALITY OF SOYBEAN OIL
FRACTIONATION AND WINTERIZATION
WINTERIZATION FILTERS
FLOW SHEET OF SOYBEAN OIL PRODUCTION
ALTERNATIVE REFINING METHODS
ALTERNATIVE REFINING METHODS
COPRODUCTS AND UTILIZATION
LECITHIN
TABLE 5: COMPOSITION OF COMMERCIAL SOY LECITHIN IN COMPARISON WITH EGG LECITHIN, WT %
TABLE 6: TYPICAL COMPOSITION (%) OF COMMERCIALLY REFINED SOY LECITHIN PRODUCTS
DEODORIZER DISTILLATE
SOAPSTOCK
CONFECTIONERY AND IMITATION DAIRY PRODUCTS AND LOW-CALORIE FAT SUBSTITUTES
PRIMARY SOYBEAN PRODUCTS FOR ANIMAL FEEDING
FIG. 1: PROCESSING OF SOYBEANS INTO SOYBEAN PRODUCTS
FULL-FAT SOYBEANS
SOYBEAN MEAL
SOYBEAN PROTEIN CONCENTRATE (SPC)
SOYBEAN OIL
TABLE 1A: COMPARATIVE AMINO ACID COMPOSITION (G/KG PROTEIN BASIS) OF SOYBEAN MEAL WITH PALM KERNEL MEAL AND MAIZE
TABLE 2A: COMPARISON OF DIGESTIBILITY AND METABOLISABLE ENERGY VALUES OF TRIGLYCERIDES IN BROILER CHICKENS FED SOYBEAN OIL AND SELECTED DIETARY FATS/OILS
TABLE 2B: COMPARISON OF FATTY ACID COMPOSITION OF SOYBEAN OIL WITH SELECTED DIETARY FATS/OILS (G/KG TOTAL FATTY ACIDS)1
CHEMICAL COMPOSITION OF COMMONLY USED SOYBEAN PRODUCTS IN ANIMAL DIETS
TABLE 3: PER CENT COMPOSITION OF SOME SOYBEAN PRODUCTS USED IN ANIMAL FEED
ANTI-NUTRITIVE FACTORS
TABLE 4: ANTI-NUTRITIVE FACTORS IN SOYBEANS
UTILISATION OF SOYBEAN IN ANIMAL PRODUCTION
TABLE 5A: UTILISATION OF SOYBEAN MEAL BY LIVESTOCK IN THE UNITED STATESTABLE 5B. SOYBEAN MEAL USED IN TYPES OF ANIMAL COMPOUND FEED IN THE EUROPEAN UNION
TABLE 5C: SOYBEAN ACREAGE NEEDED FOR LIVESTOCK CONSUMPTION IN THE EUROPEAN UNION AND BY COUNTRY OF ORIGIN
FUTURE CHALLENGES OF SOYBEAN UTILISATION IN ANIMAL DIETS
BY PRODUCTS OF REFINING
BY PRODUCTS RECOVERY
MANUFACTURING PROCESS OF CATTLE FEED
PROCESS FLOW DIAGRAM FOR CATTLE FEED
SWOT ANALYSIS OF SOYA PROCESSING INDUSTRY
STRENGTH
WEAKNESS
OPPARTUNITIES
THREAT
TECHNICALSPECIFICATION OF PREPARATORY SECTION
PP- EL 1 BUCKET ELEVATOR 1 NO.
PP- SC 1 SEED CLEANER – SUITABLE FOR 250 TPD 1 NO.
PP- EL 2 BUCKET ELEVATOR 1 NO.
PP- EL 3 BUCKET ELEVATOR 1 NO.
EDGE GRINDING
PP-TC 1 TEMPERING CONVEYOR 1 NO.
PP-EXP1 EXPANDER – SUITABLE FOR 200 TPD SOYABEAN 1 NO.
PP-HADC HORIZONTAL DRIER COOLER: 1200MM DIA X 9 MTR LONG 1 NO.
ANNEXURE – 2.2
TECHNICAL SPECIFICATION FOR PREPARATORY SECTION ADDITIONAL EQUIPMENTS FOR 200 TPD SOYA HI PRO
PP- EL 1 BUCKET ELEVATOR 1 NO.
PP-DH 1 HULLER – 1ST STAGE 1 NO.
PP-CON 1
PP-CON 2
PP-CON 3
PP-DH DEHULLER – 2ND STAGE 1 NO.
PP- EL 3 BUCKET ELEVATOR 1 NO.
PP-ZZ ZIG ZAG CHANNEL 1 NO.
TECHNICAL SPECIFICATION FOR MAIN SOLVENT EXTRACTION PLANT SUITABLE TO PROCESS 200 TPD SOYABEAN
PARTICULARS QTY
EX – 2 ROTARY AIR LOCK: 1 NO.
EFFECTIVE BED WIDTH OF THE EXTRACTOR IS 1200 MM.
EX-5A PLUG O SEAL CONVEYOR: 1 NO.
EX – 8 DESOLVENTISER TOASTER 1 NO.
EX-8A PLUG O SEAL CONVEYOR: 1 NO.
EX-9 DUST CATCHER 1 NO.
MOC OF BODY STAINLESS STEEL 304
EX - 9A VAPOUR DUCTING 1 NO.
EX-10 HORIZONTAL TUBULAR CONDENSER 1 NO.
EX-10A HORIZONTAL TUBULAR CONDENSER 1 NO.
EX-11 SEALING DEVICE: 1 NO.
EX-12 VAPOUR COOLER: 1 NO.
EX- 13A/B
EX-14 WATER SOLVENT SEPARATOR: 1 NO.
EX-16A SEPARATOR: 1 NO.
EX-17 MISCELLA EVAPORATOR: 1 NO.
EX-17A SEPARATOR: 1 NO.
EX-19 SEPARATOR: 1 NO.
EX-20 HORIZONTAL TUBULAR CONDENSER: 1 NO.
EX-21 OIL STRIPPING COLUMN: SPECIAL DESIGN 1 NO.
EX-21A HEATER 1 NO.
EX-21B VACUUM DRIER 1 NO.
EX-21C FINAL OIL COOLER : 1 NO.
EX-21 D PHE: 1 NO.
EX-22 HORIZONTAL TUBULAR CONDENSER: 1 NO.
EX-23 OIL HOLDING TANK: 1 NO.
EX-26 HEAT EXCHANGER: 1 NO.
EX-27 FINAL VERTICAL STRIPPER 1 NO.
EX-28 MINERAL OIL COOLER: 1 NO.
EX-28 A PHE: 1 NO.
ACCESSORIES
2. INSTRUMENTATION SECTION:
3. ELECTRICAL SECTION
4. DRIVE SECTION:
ANNEXURE – 2.4
TECHNICAL SPECIFICATION FOR MEAL FINISHING SECTION
ITEM CODE
MF-OC OUTGOING CONVEYOR: 1 NO.
MF-MLC MEAL COOLER
MF-LS LUMP SEPARATOR – ROTARY TYPE 1 NO.
MF-HM HAMMER MILL: 1 NO.
MF – AB AUTOMATIC ELECTRONIC WEIGHING AND BAGGING SYSTEM CONSISTING OF FOLLOWING:
ELECTRICALS
LIST OF MAKES
TECHNICAL SPECIFICATION OF OIL REFINING PLANT
TECHNICAL SPECIFICATION FOR DEGUMMING & LYE REFINING 50 TPD SOYA OIL REFINING PLANT
T01 CRUDE OIL TANK 1 NO.
F101 FILTERS 2 NOS.
P1 OIL FEED PUMP 2 NOS.
IM INLINE MIXER 1 NO.
HT HYDRATION TANK 1 NO.
PD1 OIL FEED PUMP 1 NO.
S1 CENTRIFUGAL SEPARATOR (ALFA LAVAL) MODEL VO – 5 1 NO.
T41 GUMS STORAGE TANK 1 NO.
P41 GUMS CONVEYING PUMP 1 NO.
E2 OIL HEATER 1 NO.
M1 MIXER (DYNAMIC) 1 NO.
RT1 RETENTION TANK 1 NO.
PD2 OIL FEED PUMP 1 NO.
S2 CENTRIFUGAL SEPARATOR (ALFA LAVAL – VO 5) 1 NO.
T22 TANK FOR CAUSTIC SOLUTION 1 NO.
P22 CAUSTIC DOSING PUMP 1 NO.
T21 CAUSTIC SODA PREPARATION TANK 1 NO.
P21 CAUSTIC SODA CONVEYING PUMP 1 NO.
P33 HOT WATER PUMP 1 NO.
P42 SOAP STOCK CONVEYING PUMP 1 NO.
T6 SLOPE OIL TANK 1 NO.
P6 SLOPE OIL PUMP 1 NO.
M4 FINAL WATER WASHING (DYNAMIC MIXER) 1 NO.
E4 OIL HEATER 1 NO.
S3 CENTRIFUGAL SEPARATOR (ALFAL LAVAL VO 5) 1 NO.
CT CLEANING TABLE 1 NO.
T02 NEUTRAL OIL TANK (NOT) 1 NO.
INSTRUMENTS
F131 WATER FLOW INDICATOR METER 1 NO.
TIC1 TEMPERATURE CONTROLLER VALVE 1 NO.
F133 FLOW INDICATOR FOR WATER 1 NO.
F135 FLOW INDICATOR FOR WATER 1 NO.
TIC2 TEMPERATURE CONTROLLER VALVE 1 NO.
LC LEVEL CONTROLLER FOR SLOPE OIL TANK TO INDICATE HIGH LEVEL FOR PUMP ON/ OFF
TIC33 TEMPERATURE CONTROLLER FOR HOT WATER TANK 1 NO.
LI T02 LEVEL INDICATOR FOR THE NEUTRAL OIL TANK 1 NO.
TECHNICAL SPECIFICATION FOR BLEACHING 50 TPD SOYA OIL REFINING PLANT
PARTICULARS QTY
E601 OIL HEATER 1 NO.
P611 ACID DOSING PUMP (METERING TYPE) 1 NO.
T611 PHOSPHORIC ACID TANK FOR BLEACHER 1 NO.
M601 DYNAMIC MIXER 1 NO.
RT601 RETENTION TANK 1 NO.
T601 BLEACHING EARTH TANK 1 NO.
P602 FILTER FEED PUMP 2 NOS.
E601 PRESSURE LEAF FILTERS 2 NOS.
PF 601
POLISHING FILTERS 2 NOS.
V 600 VACUUM SYSTEM 1 NO.
T 606 CLOUDY OIL TANK 1 NO.
P606 CLOUDY OIL PUMP 1 NO.
MT 601 MOISTURE SEPARATOR 1 NO.INSTRUMENTS
FIC601 FLOW INDICATOR 1 NO.
TIC601 TEMPERATURE CONTROLLER FOR THE HEATER E 601 1 NO.
PI 600 PRESSURE INDICATOR FOR THE REACTOR 1 NO.
LIC 602 LEVEL CONTROL LOOP FOR THE BLEACHER 1 NO.
LAHB60 1
LAL 606 HIGH AND LOW LEVEL ALARM FOR THE CLOUDY OIL TANK 2 NOS
PAH 601
PRESSURE INDICATION OF THE PRESSURE LEAF FILTER 2 NOS.
BLEACHING EARTH POWDER CONVEYING SYSTEM
BF 633 BAG FILTER
DEOD5ORIZATION
PARTICULARS QTY
P 802 OIL FEED PUMP 1 NO.
E801 HEAT EXCHANGER FOR BLEACHED OIL 1 NO.
E 802.1 (HE2)
E802.2 DEARATOR 1 NO
E802.3 DEARATOR PUMP
BRAND FLOWSERVE / EQUIVALENT
P803 DEODORISED OIL PUMP 2 NOS.
D 804 SCRUBBING SECTION 1 NO.
P 804 FATTY ACID CIRCULAION PUMP 1 NO.
E 804 FATTY ACID COOLER 1 NO.
E 805 DEODORIZED OIL COOLER (SHUT DOWN) 1 NO.
FINAL POLISHING FILTERS 2 NOS.
VS 800 VACUUM SEALING SYSTEM 1 NO.
B 806 FINAL OIL COOLER 1 NO.
V 800 VACUUM SYSTEM 1 NO.
P811 CITRIC ACID DOSING PUMP 1 NO.
T811 TANK FOR THE STORAGE OF REAGENT 1 NO.
PRS 3 PRESSURE REDUCING VALVE 1 NO.
INSTRUMENTS
THERMIC FLUID HEATER
PARTICULARS
SOYA GUMS DRYING (LECITHIN PLANT) – 5 TPD – (OPTIONAL)
CONTROL PANEL WITH REMOTE SYSTEM
CP 1000 CONTROL PANEL WITH REMOTE SYSTEM 1 NO.
CT 2 COOLING TOWER FOR THE CLEAN WATER 1 NO.
PARTIAL AUTOMATION
PARTICULARS
GUARANTEE
IF COMES MECHANICAL DEFECT IN OUR EQUIPMENT WITHIN 18 MONTHS FROM THE SUPPLY OR 12 MONTHS FROM THE DATE OF COMMISSIONING WHICHEVER IS EARLIER
ALL THE FIGURES HEREWITH APPLY SIMULTANEOUSLY WITH +/- 5% TOLERANCE PROVIDED THAT THE PLANT IS OPERATED WITH THE SAME FEED STOCK CONTINUOUSLY FOR AT LEAST 24 HOURS UNDER NORMAL OPERATED CONDITION. THE METHODS OF THE DETERMINATION OF THE GUARANTEE SHALL BE WORKED OUT BEFORE COMMERCIAL PRODUCTION DURING COMMISSIONING OF THE PLANT. THE CRITERIA HAS TO BE DISCUSSED FOR THE PROCESS PARAMETERS
B. FEED OIL SPECIFICATION:
D: TOTAL OIL LOSSES IN THE PROCESSING:
WE GIVE BELOW CONSUMPTION OF UTILITIES AND CHEMICALS DURING STEADY STATE OPERATION PER MT OF OIL PROCESSED.
CONSUMPTION OF UTILITES AND CHEMICALS PER MT OF THE OIL
4. OUR SERVICES
SUPERVISION, COMMISSIONING SERVICE AND START UP OF THE PLANT
5. BATTERY LIMITS AND EXCLUSIONS
PROCESS
BATTERY LIMITS FOR THE UTILITIES: CONTAMINATED WATER
CLEAN WATER:
STEAM:
PROCESS WATER:
INSTRUMENT AIR:
EXHAUST:
POWER:
EXCLUSIONS IN GENERAL
EXCLUSIONS FOR LABOUR:
ADDRESSES OF PLANT & MACHINERY SUPPLIERS
OIL EXPELLER
FILTER PRESS
BABY BOILER
OIL STORAGE TANK
OIL PACKAGING MACHINE
BAG STITCHING MACHINE
DIGITAL WEIGHING SCALE
LABORATORY EQUIPMENTS
SUPPLIERS OF RAW MATERIALS
TIN CONTAINERS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
