Detailed Project Report on soyabean solvent extraction unit with vegetable oil refinery
Detailed Project Report on soyabean solvent extraction unit with vegetable oil refinery
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SOYABEAN SOLVENT EXTRACTION UNIT WITH VEGETABLE OIL REFINERY
[CODE NO.4042]
Soybean seeds contain 18% to 20% oil. Normally soya bean seeds are not subjected to mechanical pressing but the entire oil is extracted after preparation of the seeds in the solvent and Soybean Extraction Plant. Preparation of soya bean seeds includes seed cleaning, destoning, cracking, husk separation (if required), cooking, flaking, expanding and drying
Oil extraction, isolation of oil from animal by-products, fleshy fruits such as the olive and palm, and oilseeds such as cottonseed, sesame seed, soybeans, and peanuts. Oil is extracted by three general methods: rendering, used with animal products and oleaginous fruits; mechanical pressing, for oil-bearing seeds and nuts; and extracting with volatile solvents, employed in large-scale operations for a more complete extraction than is possible with pressing.
Soybean oil is produced from the seeds of the soybean plant. Plant sterols, chemicals derived from soybean oil, are used to lower total cholesterol and “bad” low-density lipoprotein (LDL) cholesterol. Specially processed soybean oil is used to treat osteoarthritis.
Some people apply soybean oil directly to the skin to repel mosquitoes and other insects.
Soybean oil is also used as a nutritional supplement in intravenous feedings.
EFFECTIVE FOR...
Use as a nutritional supplement in intravenous feedings.
LIKELY EFFECTIVE FOR...
Preventing mosquito bites when applied to the skin. Soybean oil is an ingredient in some commercial mosquito repellents. It seems to work about as well as some other mosquito repellents including some products that contain a small amount of DEET.
POSSIBLY EFFECTIVE FOR...
Lowering cholesterol levels in people with high cholesterol. Soybean oil plant sterols used in margarine seem to help lower total cholesterol and “bad” LDL cholesterol without affecting “good” HDL. The FDA has allowed the makers of the products Take Control and Benecol to include this claim on their labels.
Osteoarthritis, when a specific processed part of the oil (unsaponifiable fractions) is used in combination with avocado oil. This combination seems to significantly improve pain and overall disability. It appears to work better for osteoarthritis of the hip than the knee.
PRIMARY RAW MATERIAL
Soybean is a leguminous vegetable of the pea family that grows in tropical, subtropical, and temperate climates. Soybean was domesticated in the 11th century BC around northeast of China. It is believed that it might have been introduced to Africa in the 19th century by Chinese traders along the east coast of Africa.
Soybean is among the major industrial and food crops grown in every continent. The crop can be successfully grown in many states in Nigeria using low agricultural input. Soybean cultivation in Nigeria has expanded as a result of its nutritive and economic importance and diverse domestic usage. It is also a prime source of vegetable oil in the international market. Soybean has an average protein content of 40% and is more protein-rich than any of the common vegetable or animal food sources found in Nigeria. Soybean seeds also contain about 20% oil on a dry matter basis, and this is 85% unsaturated and cholesterol-free.
The rapid growth in the poultry sector in the past five years has also increased demand for soybean meal in Nigeria. It is believed that soybean production will increase as more farmers become aware of the potential of the crop, not only for cash/food but also for soil fertility improvement and Striga control. The market for soybean in Nigeria is growing very fast with opportunities for improving the income of farmers.
Currently, SALMA Oil Mills in Kano, Grand Cereals in Jos, ECWA Feeds in Jos, AFCOT Oil Seed Processors, Ngurore, Adamawa State, and PS Mandrides in Kano all process soybean. IITA along with partners has developed improved technologies for soybean production. This handbook outlines crop production practices that farmers may use to grow soybean profitably in Nigeria
PRODUCTION
It consists of more than 36% protein, 30% carbohydrates, and excellent amounts of dietary fiber, vitamins, and minerals. It also consists of 20% oil, which makes it the most important crop for producing edible oil.
Malnutrition, particularly protein deficiency, is prevalent in many parts of Africa as animal protein is too expensive for most populations. Many leguminous crops provide some protein, but soybean is the only available crop that provides an inexpensive and high quality source of protein comparable to meat, poultry and eggs.
A by-product from the oil production (soybean cake) is used as a high-protein animal feed in many countries. Soybean also improves soil fertility by adding nitrogen from the atmosphere. This is a major benefit in African farming systems, where soils have become exhausted by the need to produce more food for increasing populations, and where fertilizers are hardly available and are expensive for farmers.
More than 216 million tons of soybean were produced worldwide in 2007, of which 1.5 million were in Africa. Africa imports nearly as much soybean as it produces. Africa exports about 20,000 tons annually.
Nigeria is the largest producer of soybean in sub-Saharan Africa (SSA), followed by South Africa. Low yields (<1 t/ha in tropical Africa) and a shortage of fertilizer constrain the ability of some countries to increase production. In Nigeria the haulms and post-processed pulp (soybean meal) serve as important sources of animal feed. A 30% annual growth in the poultry industry from 2003 to 2008 fuelled such a dem and for soybean meal that an increase in imports was required.
Commercial soybean production on large farms takes place in Zambia, Zimbabwe and South Africa. However, it is mostly cultivated by small-scale farmers in other parts of Africa where it is planted as a minor food crop among sorghum, maize, or cassava.
Harvesting
Nearly 95 million hectares of soybeans were harvested worldwide in 2007, with 19 million in Asia, 3.5 million in the USA, and 1.2 million in Africa.
Depending on the variety, soybeans can be harvested between 100 and 150 days after planting. Labor requirements in Africa are high since most cultivation and harvesting are done manually.
Consumption
Worldwide consumption of soybean is nearly 11 million tons. Africa consumes about 618,000 tons annually, and uses another 4,800 tons for animal feed. Nigeria is the largest consumer of soybeans in SSA followed by Ug anda.
In Africa dry soybean is used to produce milk substitutes and flour. The bean curd is fried and eaten as a snack or breakfast food. Mature beans are not easily digested and contain toxic compounds, which require soaking and prolonged cooking.
COST ESTIMATION
Plant Capacity 210 Ton/Day
Land & Building (24,420 sq.mt.) US$ 4.99 Lac
Plant & Machinery US$ 20.18 Lac
Working Capital for 1 Month US$ 63.97 Lac
Total Capital Investment US$ 99.61 Cr
Rate of Return 68%
Break Even Point 57%
INTRODUCTION
EFFECTIVE FOR...
LIKELY EFFECTIVE FOR...
POSSIBLY EFFECTIVE FOR...
PRIMARY RAW MATERIAL
PRODUCTION
PRODUCTION
HARVESTING
CONSUMPTION
PRESENT MANUFACTURERS/SUPPLIERS
SOY OILS
PALM OIL
USES AND APPLICATIONS
FOOD FOR HUMANS
FEED FOR ANIMALS
OTHER USES
BENEFITS
1. HIGH SMOKE POINT
2. RICH IN HEART-HEALTHY FATS
3. MAY SUPPORT BONE HEALTH
4. CONTAINS OMEGA-3 FATTY ACIDS
5. PROMOTES SKIN HEALTH
6. VERSATILE AND EASY TO USE
MARKET POSITION
GLOBAL SOYBEAN OIL MARKET DRIVERS:
BREAKUP BY END-USE:
REGIONAL INSIGHTS:
COMPETITIVE LANDSCAPE:
SOYBEAN OIL FUTURES – QUOTES
SOYBEAN OIL MAR '21 (ZLH21)
PROPERTIES AND APPLICATIONS
ON THE BASIS OF END USE, THE INDUSTRY IS DIVIDED INTO:
RAW MATERIALS - SEGMENT ANALYSIS
APPLICATIONS - SEGMENT ANALYSIS
GEOGRAPHY - SEGMENT ANALYSIS
DRIVERS – SOYBEAN OIL MARKET
CHALLENGES – SOYBEAN OIL MARKET
SOYBEAN OIL INDUSTRY OUTLOOK
ACQUISITIONS/PRODUCT LAUNCHES
LIST OF KEY VEGITABLE OIL COMPANIES IN NORTHERN NIGERIA
TOTAL DEMAND OF EDIBLE OIL IN THE NATION
AVERAGE LOCAL PRODUCTION:
GAP AND IMPORT FIGURES
PROSPECT OF LOCAL PRODUCTION
CURRENT POLICY ON THE SECTOR
SOLVENT EXTRACTION PROCESS
PROCESS DESCRIPTION
PREPARATION OF SOYA BEAN SEED
NOTE ON EXTRACTION PLANT EXTRACTOR
DESOLVENTIZER
DISTILLATION
HEXANE RECOVERY
SOYA PREPARATORY SECTION
EXTRACTION SECTION
CONSISTING OF:-
MEAL DESOLVENTISING SECTION
MEAL DESOLVENTISING AND TOASTING SECTION
MEAL CONDITIONING SECTION
DISTILLATION SECTION
DISTILLATION SECTION
ABSORBER SECTION
ABSORBER SYSTEM
PUMPS
PIPING AND INSTRUMENTATION
ONE LOT ALL WATER VALVES.
THE EQUIPMENT SUPPLY INCLUDES:
WATER COOLING TOWER
PROCESS STORAGE
PERFORMANCE AND CONSUMPTION DATA
DESCRIPTION OF INPUT MATERIAL:
DESCRIPTION OF OUTPUT MATERIAL
A. SOLID MATERIAL PHASE
B. IN THE LIQUID PHASE
CONSUMPTION OF UTILITIES
FEATURES OF THE PRODUCTS FROM THE EXTRACTION PLANT
FEATURES OF THE WASTE DISPOSAL FROM THE PLANT
WASTE WATER (PROCESS WATER FROM THE WATER STRIPPER)
EXHAUST AIR FROM THE ABSORPTION PLANT
SPECIFICATION OF EXTRACTION MATERIAL TO SEP.
TECHNICAL SPECIFICATION OF AUXILIARY & OPERATING MEDIA FOR THE PROCESS
C. COOLING WATER
D. STEAM
REFINING PROCESS
CONTINUOUS SPECIAL ACID DEGUMMING SECTION
CONTINUOUS BLEACHING PLANT
PROCESS
CONTINUOUS DEODORIZATION / DEACIDIFIER
CONTINUOUS DEGUMMING, NEUTRALIZATION AND WASHING SECTION
ONTINUOUS BLEACHING
CONTINUOUS DEODORIZATION
WATER COOLING AND DISTRIBUTION
HEAT INSULATION
PERFORMANCE AND CONSUMPTION DATA
BLEACHER PERFORMANCE GUARANTEE
FEED
CONSUMPTION OF UTILITIES
DEODORIZATION / DEACIDIFICATION
CONSUMPTION OF UTILITIES
FILLING LINE
PROCESS FLOW DIAGRAM
UTILITIES
WATER
WATER QUALITY PARAMETERS FOR PROCESSED WATER:
STEAM
POWER
EFFLUENT TREATMENT AND DISPOSAL
STANDARDS
TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
WASTE TREATMENT
PRIMARY TREATMENT
ANAEROBIC TREATMENT
SECONDARY TREATMENT
TERTIARY TREATMENT
SOLIDS CONCENTRATION
TYPICAL WASTE SOLIDS CHARACTERISTICS
EQUIPMENT REQUIREMENT
EQUIPMENT REQUIREMENTS
QUALITY CONTROL
1.0 DETERMINATION OF SAPONIFICATION VALUE
2.0 PREPARATION OF TEST SAMPLE
3.0 DETERMINATION OF MOISTURE CONTENT
4.0 DETERMINATION OF SPECIFIC GRAVITY
5.0 DETERMINATION OF THE REFRACTIVE INDEX
6.0 DETERMINATION OF FLASH POINT.
7.0 DETERMINATION OF COLOUR
8.0 DETERMINATION OF MELTING POINT OF FAT
MANPOWER
GENERAL
BASIS OF ESTIMATION
PROCESS FLOW DIAGRAM OF SOLVENT EXTRACTION PLANT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
COMPLETE PLANT AND MACHINERY SUPPLIERS FOR SOLVENT EXTRACTION PLANT
MACHINERY SUPPLIER
FOOD AND AGRO PROCESSING CONSULTANTS
SEED OIL MANUFACTURER
MACHINERY LIST
LIST OF LABORATORY EQUIPMENTS
RAW MATERIAL PHOTOGRAPHS
PRODUCT PHOTOGRAPHS
SOYA CRUDE OIL
SOYA DE OILED MEAL
REFINED SOYA OIL
SOYA GUM
SOYA SOAP STOCK
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)
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