Soya Extraction Plant (50 MT/Day)

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)