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Palm oil mill plant

Palm oil, as the world's largest vegetable oil, occupies a major position in edible oil and industry. It is currently mainly planted in tropical regions, mainly distributed in Southeast Asia, South America, and West Africa. Among them, Indonesia and Malaysia account for 80% of the world's production, and West Africa and South America have great development space.Overview of palm oil pressing project: After picking, the fresh fruit bunches (FFB) of palm are sorted and enter the closed container (fermentation tank) for sterilization with high-temperature steam; the ripe fruit bunches (SFB) after high-temperature cooking are repeatedly dropped by the cage drum thresher to separate the fruit grains from the fruit bunches. After the empty fruit bunches (EFB) pass through the empty fruit bunch cutter and the empty fruit bunch press, the remaining residual oil is obtained and the moisture of the empty fruit bunch is reduced, and it is provided as fuel to the steam boiler for the plant area.After the palm fruit is separated, it enters the crushing tank for secondary cooking, and the fruit grains are crushed into pulp and then enter the palm oil press. The press uses a twin-screw arrangement and hydraulically controls the discharge port to squeeze out the oil as much as possible and keep the palm kernel intact without breaking.The squeezed palm oil is subjected to oil-water sedimentation, centrifuge, vacuum drying and other main processes to reduce the moisture and impurities in the crude oil to obtain standard crude palm oil (CPO).The pressed palm kernel is polished, de-stoned, graded, crushed, air-selected, washed and dried to obtain palm kernel and palm shellThe entire factory uses steam turbines to achieve self-sufficiency in electricity. The factory area is equipped with raw water treatment, boiler water treatment, sewage treatment and other facilities.After the fresh palm fruit bunches are picked from the tree, they should be sent to the oil mill for oil processing within 48 hours as far as possible to ensure that the FFA index of the product crude palm oil (CPO) is low and improve the quality of crude palm oil (CPO).The palm oil pressing project mainly consists of site selection, earthwork, civil engineering, steel structure plant, power and water conservancy, and production process equipment.Large-scale palm fruit oil pressing plants can achieve self-sufficiency in electricity supply and recycling of water and sewage.The main process steps of the crude palm oil factory are as follows:1. Weighing: The fresh palm fruit bunches entering the factory are weighed together with the transport vehicles. After unloading, the empty vehicles are weighed again to calculate the net weight of the materials. Main equipment: truck scale and weighing identification calculation system. 2. Fresh fruit bunch receiving platform: The fresh fruit bunches after unloading are first sorted manually, and the stones, spoiled fruits and debris that do not meet the requirements are cleaned up. These debris will be sent back and deducted from the weight. At the same time, it also ensures that the equipment is not damaged and improves the quality of the oil. The sorted fresh fruit bunches are stacked on the inclined slope by the loader, and enter the fresh fruit bunch conveying scraper through the opening of the hydraulic device door. Main equipment: unloading platform, unloading slope, hydraulic gate, palm fresh fruit bunch scraper conveyor. 3. Sterilization: Fresh palm fruit bunches are loaded into the sterilization tank by the scraper conveyor and cooked for 80-90 minutes under high temperature 145℃ steam conditions, thereby reducing the activity of enzymes and inhibiting the increase of free fatty acids (FFA). The quality of palm crude oil is guaranteed and conditions for subsequent processes are provided. The main equipment includes: fresh fruit bunch scraper conveyor, sterilization tank, Indexer control system, and cage tipping car.4. Fruit threshing station: The cooked fruit bunches (SFB) after steaming and sterilization are separated from the palm fruit and empty fruit bunches by drum-type rotary beating.The empty fruit bunches contain a certain amount of oil and water, which are reduced in water content and residual oil after passing through the empty fruit bunch shredder and empty fruit bunch press. After the size and water content of the empty fruit bunches are reduced, they are transported to the boiler as fuel. Main equipment: empty fruit bunch scraper conveyor, palm fruit threshing machine, empty fruit bunch scraper conveyor, empty fruit bunch shredder, empty fruit bunch press, and rotary vibrating screen.5. Pressing station: After sterilization and de-fruiting, the fruit particles enter the crushing tank, where the fruit particles are stirred and crushed into a paste state, and steam is used for sterilization at the same time. Then they enter the double-screw press for extrusion, the oil and water are squeezed out, and the pressed cake including the palm kernel and pulp fiber is separated and crushed and spirally conveyed to the next section. Main equipment: screw conveyor, crushing tank, double-screw press, spiral crusher.6. Oil clarification station: The oil clarification station is to reduce the moisture and impurities in the crude oil after pressing, so that its quality meets the market sales standard. After pressing, the crude oil is filtered, settled, sanded, centrifuged, vacuum dried and other processes to remove moisture and impurities in the palm crude oil. The main equipment includes sand settling tank, double-layer rotary vibrating screen, continuous vertical oil clarification tank, sand clarifier, three-phase horizontal screw centrifuge, disc centrifuge, vacuum dryer, etc.7. Kernel & shell separation: The fiber in the pressed cake is separated and removed, and the kernel shell after the palm kernel is crushed is separated and stored.The fiber of the cake from the double screw oil press is separated by wind, and the palm kernel is polished, de-stoned, crushed, air-selected, washed and separated to separate the palm kernel and palm shell. The palm kernel and palm shell are dried and stored, and the fiber part is transported to the boiler fuel bunker as boiler fuel. Main equipment: fiber sachets, polishing drums, de-stone separation columns, 1,2-level kernel and shell separation columns, water-washed sachets, kernel drying bunkers, kernel and shell screw conveyors and elevators.8. Boiler room: The boiler is the steam source and power source of a factory. The high-pressure and high-temperature steam generated by the biomass boiler using palm fruit as fuel is provided by the back-pressure steam turbine generator. The discharged steam is used to provide heat source in the production process, realizing biomass reuse, power self-sufficiency, and steam self-sufficiency, reducing the production cost of the factory and improving the environmental protection effect. Main equipment: biomass steam boiler, fuel bunker, deaerator, boiler feed water tank, fuel scraper conveyor.9. Power room: The power room provides power output for the factory. Emergency power uses diesel generator sets, and production power uses steam turbine generator sets, and the two can be switched. Main equipment: steam-water separator, steam turbine generator set, steam separator, diesel generator set, diesel storage tank.10. Raw water treatment system: production water is introduced from nearby rivers to the reservoir. After water purification, it is filtered, dosing, clarified, softened, and RO system before being provided to production, boiler water, fire water, and domestic water.Main equipment: raw water pump, raw water pipeline, high-level water tank, pressure sand filter, clarified water tank, dosing system, softened water system.11. Sewage treatment system: The sewage generated by the palm oil factory contains many harmful substances and recyclable oil. After condensation and sedimentation, the upper oil layer of the discharged sewage is recovered, and the bottom sewage BOD, COD, solid suspended matter SS, etc. are high. Through aerobic, anaerobic, aeration, filter press, filtration, chemical treatment, etc., the sewage meets the government's emission standards.Main equipment: pump, belt filter press, aerator, MBR water treatment system.

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Palm Kernel Oil Extrusion Plant

Palm kernel oil is a byproduct of palm oil pressing plant. The oil content of palm kernel after drying is about 48%. Palm kernel oil is rich in lauric acid C12 and myristic acid C14. It is the main source of high-end detergents and surfactants. The market demand for palm kernel oil is increasing year by year, and the supply is in short supply. It is widely used as an organic raw material for health foods, medicines, cosmetics, detergents and other products, and has a relatively high market value.Overview of palm kernel oil pressing process: Palm kernels collected from palm oil pressing plants are dried and pressed twice to obtain crude palm kernel oil (CPKO) and palm meal (PKM). Palm kernel meal is crushed, fermented and packaged as animal feed ingredients.After the pressing, the oil residue of the palm kernel oil is filtered and recovered after sedimentation and re-pressed. The palm kernel oil is filtered and dried and stored. The main equipment includes: kernel drying bin (optional), palm kernel spiral & scraper conveyor, slag remover, disc filter, air compressor, palm kernel oil storage tank.The secondary pressing process is widely used in the market, but the palm meal after the secondary pressing still contains about 8-10% oil. If it is not considered as animal feed, the single pressing + leaching process can be used, which can greatly increase the output, and the residual oil in the meal can be controlled to ≤1%. Customers can choose different processes according to their needs.

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Palm oil refining and fractionation process

The crude palm oil (CPO) produced by the palm fruit bunch in the pressing plant contains a lot of impurities, mainly including cellulose, moisture, insoluble matter, free fatty acids(FFA), phospholipids, trace metals, oxidation products and odorous substances. Therefore, most crude palm oil must be refined before being eaten or used as an ingredient to make it more stable and non-irritating RBD oil.Physical refining is mainly used for palm oil refining. The difference between the two is the different methods of removing FFA from palm oil.The main processes of physical refining are: degumming, decolorization and filtration, deacidification, and deodorization. Deacidification and deodorization are completed in a stainless steel pressure vessel.Palm oil refining process flow and pollution-generating link diagram  (1) Pretreatment      Pretreatment refers to the process of adding concentrated phosphoric acid to palm oil to condense and precipitate non-hydratable phospholipids in the oil. In the refining of edible vegetable oils, vegetable oils with a high content of non-hydratable phospholipids are often accompanied by more metal ions. The presence of these metal ions will cause the vegetable oil to become corrupt and give the product an unpleasant taste.  In order to obtain satisfactory flavor quality of vegetable oil, various phospholipid substances must be removed, i.e. degumming. For palm oil, it can directly enter the decolorization stage after a simple acid treatment, which is called dry degumming.(2) Decolorization     Decolorization is an indispensable step in the refining process of vegetable oil. Generally, the crude oil processed contains pigment substances: natural pigments such as carotenoids and chlorophyll; pigments produced by oxidation, degradation and polymerization of sugars, vitamins and other substances during processing; pigments produced by metal derivatives of iron and copper.    After pretreatment, palm oil is added with bleaching clay for decolorization treatment, and the temperature is basically controlled at around 110°C. In the decolorization tower, the oil is depressurized and stirred to make the pigment and other substances fully contact with the adsorbent, so that the adsorbent is evenly distributed in the oil. The decolorization time is controlled at around 1 hour, and after complete adsorption, it enters the filter for filtration. (3) Deodorization     Deodorization is the process of distilling free fatty acids, volatile odor substances and oxides in palm oil out of the deodorization tower under suitable temperature and steam stirring. Deodorization is a process of removing odor substances and volatile substances such as free fatty acids from oil under high temperature and high vacuum by means of the stripping effect of water vapor. The deodorization temperature is controlled at 240-250℃ by high-pressure steam, and the steam pressure is 50barg. After the oil is fully in contact with the steam, the gas stripped from each layer of the deodorization tower is discharged through the central exhaust pipe. The gas is partially condensed by the sprayed fatty acids at the top, and the uncondensed gas is extracted by the vacuum system. In the process of oil deodorization, many of the volatile components stripped are substances with high utilization value, such as free fatty acids and vitamin E.  In order to recover these components, a fatty acid trap is connected to the exhaust channel coming out of the deodorization tower to capture them. When deodorizing oils with low free fatty acid content, the trap can be connected behind the first-stage jet pump, and when the free fatty acid content is high, it can be connected in front of the first-stage steam jet pump. The gas after passing through the fatty acid trap enters the vacuum system, which consists of a 2-stage condenser and a 4-stage steam jet pump. After the volatile gas is mixed with the steam, it is condensed by the condenser. After cooling the oil coming out of the deodorization tower, refined finished oil is obtained. Table 5.2-1 Comparison table of raw materials, energy consumption, water consumption, etc. of the project with other processesProject ValuePOF yield of palm oil refining (%)  99.0Fatty acid yield (t/t oil)  0.0018Clay consumption (kg/t oil)  10Steam consumption (t/t oil) 0.17Fresh water consumption (t/t oil)0.25Electricity consumption (kWh/t oil)  12Palm oil fractionation project:The carbon chain lengths of fatty acids in palm oil triglycerides vary, and the degree of unsaturation is also different, so that palm oil contains triglycerides with different melting points. By controlling the cooling crystallization process of palm oil and separating it, palm oil is separated into low melting point (palm olein) and high melting point solid (palm Stearin). The factors affecting the crystallization process of palm oil are mainly: oil composition, homogeneous crystals, and cooling conditions. The purpose of palm oil fractionation:  separate liquid oil (olein) and solid oil (stearin) by physical process to increase the value of the product.Palm oil is a mixture of multi-component fatty acid glycerides with a melting point range of -30 to +70°CSelectively cool and crystallize the triglyceride components with higher melting points to form crystals, thereby achieving separation. The selectivity of crystallization is achieved by temperature control during the cooling process.The crystallization process consists of four parts: pre-cooling, nucleation, crystal growth, and final conditioningPre-cooling period: the oil is supercooled to the process temperatureNucleation period: catalyzed by supercooling conditions and stirring conditionsCrystal growth period: proportional to supercooling conditions and inversely proportional to viscosityFinal conditioning: adjust the oil slurry mixture and prepare for filtration.The main equipment for palm oil fractionation includes: crystallization tank, condensate system,Membrane press filter.

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Oleochemicals

The main components of all animal and vegetable oils are triglycerides and glycerol. The oils are hydrolyzed under high temperature and high pressure to separate fatty acids and glycerol. The crude fatty acids obtained are distilled and fractionated to produce fatty acid products of different components. Glycerol as a by-product is concentrated and purified to obtain 99.7% refined glycerol.Fatty acids, as the basic products of oil and fat industry, are widely used in various industrial fields, with broad market prospects, and are an important direction for investment in oil and fat industry refining.The raw materials of the oil and fat fatty acid industry come from a wide range of sources. Palm crude oil, coconut oil, palm kernel oil, UCO, stearin, and other oil products of various qualities can be used as raw materials.The products vary according to the different components of the oils. Palm oil and palm kernel oil, as the main raw material sources of fatty acid products, occupy an absolute position in the fatty acid industry.Introduction to the main processes of fatty acid engineering:Hydrolysis chemical equation1. Oil hydrolysisHydrogenated oil (oil) is input from the bottom of the high-pressure hydrolysis kettle by a high-pressure feed pump, and condensed water is input from the top of the hydrolysis kettle by a high-pressure water inlet pump.  Since hydrogenated oil (grease) or hydrolyzed fatty acids are lighter than water or sweet water, hydrogenated oil (grease) or hydrolyzed fatty acids move upward, while water or sweet water (dilute aqueous solution of glycerol) moves downward. The two are in countercurrent contact in the tower kettle, and high-pressure steam replenishes steam and energy from different positions in the middle of the high-pressure hydrolysis kettle, thereby reaching the temperature and pressure of the reaction between oil and water, and realizing the process of continuous hydrolysis. The hydrolyzed crude stearic acid (fatty acid) enters the crude acid storage tank through a pump after flash evaporation, vacuum dehydration and cooling from the top of the tower, and the sweet water enters the pre-concentration first effect kettle for concentration after flash evaporation.  2. Fatty acid distillationAfter the hydrolyzed crude fatty acids or hydrolyzed black soap stock crude acid reach a certain degree of hydrolysis, they are pressed into the crude acid storage tank. After the water separated by the crude acid is discharged, the material is pumped into the crude acid metering pot, and after heat exchange with the collected material, it is heated by the heater and enters the distillation tower. The tower kettle material is circulated and heated by the pump through the re-boiler.  After the collected materials are condensed by the condenser, part of them flows back to the tower , and part of them are heat exchanged in the crude acid metering pot, and then collected in the metering pot through the cooler. According to the quality requirements of the finished product, they can be input into different storage tanks or directly pumped into the packaging workshop through the collection and delivery pump. Fatty acids are adjusted and mixed in the fatty acid finished product tank and then pumped into the fatty acid storage tank, and then canned or filtered by the filter and input into the user tank.Hydrolyze crude fatty acids, cut out the part below C14 at the top of the first tower, enter the buffer tank, and can be pumped into the palm kernel oil distillation section; the bottom product enters the second tower, and the second tower separates C16\C18; the top C16 product (1690) of the tower, the bottom C18 product enters the third tower, the top of the third tower is the C18 product (1865), and the bottom of the tower is the black foot entering the black soap stock storage tank.3. Sweet water concentrationThe treated sweet water is pumped from the storage tank through the preheater and the three-effect residual gas, and then input into the first-effect evaporator. The first-effect liquid is pumped to the first effect for circulation; the steam heater is used for circulation heating. The first effect enters the second-effect evaporator through the liquid level automatic control system. The second-effect liquid is pumped and circulated with the first-effect secondary steam. The second effect enters the three-effect evaporator through the liquid level automatic control system. The three-effect liquid is pumped and circulated with the second-effect secondary steam; the pump is pumped and circulated with the glycerol cooler and the black foot cooling tank. After the three-effect liquid level reaches the specified value, the pump is discharged to the glycerol feed storage tank through the three-effect liquid level automatic control system.The concentrated four-effect evaporator is fed from the treated crude glycerol storage tank, and can also be fed from the first, second, and third effects. The liquid is pumped through the tail gas heat exchanger for circulation heating, and the gas phase is connected to the three-effect vacuum system through the condenser. The discharge concentration is controlled by controlling the discharge speed, and the material is discharged to the glycerol feed storage tank. 4. Glycerol distillationThe concentrated crude glycerol is preheated from the glycerol feed pump through the finished product heat ex-changer, then enters the fraction second heat ex-changer and enters the vacuum degassing tank. Part of the condensed water and other impurities are cooled by the condenser, and the crude glycerol raw material is fed to the glycerol distillation tower through the circulating feed pump, heated and evaporated by the re-boiler, and the heating heat transfer oil is circulated through the heat transfer oil circulation pump. The bottom material is circulated and heated by the circulation pump. The top steam of the tower is condensed by the condenser and enters the collection tank to remove the sweet water treatment section. The glycerol collected from the upper part of the distillation tower passes through the buffer tank and then through the re-flux pump to the top of the distillation tower for re-flux. In this process, it passes through the heat ex-changer and cooler to cool to about 100℃. The glycerol collected in the middle part flows into the re-flux liquid storage tank, and then part of it is pumped into the lower part of the tower for re-flux; the rest is input into the decolorization buffer tank and decolorized by the decolorization delivery pump fixed bed decolorization tower.  After decolorization, it first passes through a bag filter and then a precision filter. The finished glycerin enters the packaging intermediate tank, and the problematic product returns to the decolorization intermediate tank. The glycerin black feet discharged from the glycerin tower are input into the glycerin black foot distillation kettle. The heating system consists of a steam generator, a water replenishment plunger pump, and a soft water storage tank. The distilled fraction of the black foot distillation kettle is condensed by a condenser and enters the crude glycerin degassing tank for re-distillation or collection decolorization and desweetening treatment section according to the actual quality. The steam at the top of the distillation tower is condensed by a condenser, and the cooled material is transported to the sweet water treatment section for treatment.5. HydrogenationThe oils (fatty acid) is heated by the heater from the raw material storage tank to the finished product heat ex-changer after the feed pump exchanges heat with the raw material storage tank. After the material is dehydrated and deodorized in the degassing tank through circulation, a certain amount of material is diverted into the catalyst configuration tank to dissolve the catalyst from the catalyst hopper and the auger. The dissolved catalyst is pumped into the hydrogenation reactor through the catalyst feed pump.  After degassing, another part of the material is sent from the reaction feed pump to the raw material finished product heat ex-changer and then heated by the feed heater and enters the hydrogenation reactor at the same time as the hydrogen from the separation tank. The reacted material is cooled by the raw material finished product heat ex-changer and enters the hot hydrogen separator. The material enters the filter tank from the hot hydrogen separator through the buffer tank. The hydrogen separated by the hot hydrogen separator is separated again by the separator and condensed by the hydrogen condenser before entering the separator. It is then compressed by the hydrogen circulation machine and sent to the separator for recycling. The insufficient hydrogen is sent to the hydrogen buffer tank by the pressure swing adsorption through the hydrogen compressor, and then sent to the separator from the hydrogen buffer tank through the regulating valve. The material in the filter tank is pressed into the sealed filter by the filter press pump and filtered, and then sent to the finished product storage tank, and then sent to the next production section by the finished product delivery pump.6. Oleic acid separationThe fatty acids are pumped into the crystallizers and partially crystallized by cooling to the required temperature, and the remaining liquid portion is separated from the solid portion by a pattern filter press;The fatty acids first flow into one of the crystallizers, where they undergo a full crystallization cycle. Once the liquid level in the crystallizer reaches a high level, the feed is stopped and the fatty acids in the crystallizer are heated to melt the residual crystals inside. This is done to convert the fatty acids in the crystallizer into liquid form in order to ensure uniform nucleation and a controlled crystallization process.Next, crystallization begins with controlled cooling. Each crystallizer is equipped with a water jacket, a stirrer, and a control valve that regulates the cooling cycle.When the cooling cycle is complete, the fatty acid slurry is discharged into a membrane filter press for solid-liquid separation. The crystallized phase or stearic acid fraction remains in the filter tank, while the filtrate or oleic acid fraction flows through the designed channels and is collected in the oleic acid tank.When the back pressure of the filter press increases to a certain set value, the stearic acid mass is squeezed to remove the remaining oleic acid fraction.  Then it is discharged from the filter and enters the stearic acid melting tank for melting operation.7. High tower granulationThe material is pumped into the finished product storage tank through the finished product storage tank in the packaging room, and pumped into the top distributor of the tower by the material pump for spray granulation. The liquid particles are cooled by air and heat exchanged with cooling water to become solid bead particles. The flow is intercepted on the fluidized bed and discharged to the vibrating screen for classification. The qualified products enter the weighing scale for measurement and packaging, and are stored by forklift after the pallet is full. The unqualified products are melted through the pipeline and enter the waste storage tank and return to the system.

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Oil Extraction Process

The oil extraction process is widely used in the field of oil production because it can improve production efficiency and oil yield.The main principle is to mix the pretreated oil with a low boiling point solvent (industrial n-Hexane), extract the oil from the meal, and finally separate the solvent from the meal by evaporation. The mixed solution of oil and solvent is evaporated and stripped to separate the oil and solvent, and finally obtain the oil product, and the solvent is recycled.The extraction process has been widely used in other oils, but it is less used in the palm oil industry. However, the oil extraction process has broad prospects for the extraction of residual oil from palm kernel meal (PKM) and palm fiber after pressing, and can reduce 8-10% residual oil to ≤1%.Because the extraction process has high investment and high explosion-proof requirements, it is more suitable for large-scale production. The main process includes: material extraction, mixed oil desolventization, wet meal desolventization, solvent recovery and exhaust treatmentThe main equipment includes: conveying and metering equipment, extractor, degassing machine (DTDC), suspension separator, collector, evaporator, stripper, condenser, vacuum pump, etc.Introduction to extraction process:1. Material extractionThe pre-treated material to be extracted is transported to the material storage box in the extraction workshop through a conveying scraper, and then the material is sent to the extractor for extraction through an auger. In addition to achieving continuous, stable and controllable feeding to the extractor, the auger also has a key role in sealing, that is, preventing the solvent gas in the extractor from "slipping" to the pretreatment workshop through the conveying equipment.After entering the extractor, the material to be extracted comes into contact with the solvent. Depending on the type of extractor, there are three main contact methods: immersion, spraying and immersion spraying mixed.  The common movement direction of materials and solvents in the extractor is reverse movement, that is, the material moves from the feed end of the extractor to the discharge end of the extractor, and the oil content of the material becomes lower and lower, while the movement of the solvent is just the opposite, that is, it moves from the discharge end of the extractor to the feed end, and the oil content in the solvent becomes higher and higher. This leaching method is called "counter current leaching". The advantage of counter current leaching is that it can reduce the solvent consumption, obtain a larger solvent ratio, and at the same time increase the leaching rate and shorten the leaching time.2. Mixed oil desolventizationThrough reverse leaching, the mixed oil with a higher concentration is pumped into the mixed oil tank for temporary storage through the mixed oil pump. Before entering the tank, it is generally necessary to pass through a set of impurity removal equipment. The most common one is a combination of a self-cleaning filter and a suspension separator. The impurity removal equipment separates most of the meal contained in the mixed oil from the mixed oil. After the cleaner mixed oil enters the mixed oil tank, the meal sinks to the bottom of the mixed oil tank by natural sedimentation, and then the meal is discharged from the mixed oil tank by regular slag discharge.  The mixing oil tank is usually installed above the extractor so that the slag can be discharged directly into the extractor. After the purified mixed oil is evaporated and separated in the first long tube evaporator (first evaporator), the concentration is increased to 70%-80%. After evaporation and separation in the second long tube evaporator (second evaporator), the concentration can be increased to more than 90%. Finally, the content of solvent in the mixed oil is reduced to less than 100ppm by the stripping action of the stripping tower, and qualified crude oil is obtained.The most commonly used mixed oil evaporation equipment in the oil extraction plant is the rising film long tube evaporator, and the most commonly used mixed oil stripping equipment is the layer disc stripping tower. The steam in the shell side of the first and second evaporators quickly heats the mixed oil in the tube and makes it boil. The solvent in the mixed oil evaporates and expands in volume, pushing the mixed oil to the surrounding of the tube wall and entering the top separator as it rises. Due to the increase in the volume of the separator, a large amount of solvent begins to vaporize and is vacuum-pulled into the condensation system to condense into liquid. The mixed oil concentrated by the first and second evaporators is sprayed evenly into the stripping tower from the top of the stripping tower and forms an oil film on the layer disc under the action of gravity. Steam is sprayed from the bottom and the oil flows down from the top. The steam and oil are counter currently contacted and stripped. The solvent and other low-boiling substances contained in the oil are taken out with the stripping steam under vacuum conditions.3. Wet meal desolventizationThe wet meal desolventization equipment commonly used in leaching oil plants is the DTDC desolventizer. According to the functional division, it can be divided into pre-desolventization, desolventization, drying and cooling layers. Different functional areas will be designed with different numbers of layers according to the capacity and requirements.The wet meal enters the DTDC desolventizer through the conveying scraper. In the pre-desolventization, the material is heated and part of the solvent is removed under the action of the interlayer steam. Under the stirring action, the material is pushed to the discharge port and falls to the next layer. The pre-desolventization is generally designed to be two to three layers, and the material layer height is not high. The size of the discharge port can be adjusted by a slider and fixed with bolts. After the material enters the desolventizing layer, direct steam will directly contact the material and strip the material. Direct steam is sprayed from the interlayer of the bottom layer of the desolventizing layer. The upper surface plate of the interlayer is distributed with direct steam holes of specific aperture and number (as shown above). Under the stripping action of direct steam, the solvent in the material is transferred to the steam and moves upward with the steam. The mixed gas mixed with solvent gas passes through the pores of specific number and aperture designed on each desolventizing layer in turn and strips the material. Except for the direct steam layer, the interlayers of the other desolventizing layers are passed through indirect steam to heat the material. The solvent contained in the wet meal after steam stripping is basically removed, and the anti-nutritional factors are also fully destroyed.The meal discharged from the desolventizing layer has a high temperature and a high moisture content, so it needs to be dried and cooled.  The cooling medium used in the drying and cooling layer of the DTDC degassing machine is air provided by a centrifugal fan. In the drying layer, the air is heated to a certain temperature by a heater and then introduced into the interlayer of the drying layer. There are pores with specific apertures and numbers on the upper surface of the interlayer. The hot air is ejected through the pores to contact the material. The material is in a semi-fluid state under the action of airflow and stirring. The centrifugal fan inlet damper is adjusted according to the moisture content of the material to obtain the appropriate air volume. The air temperature can also be adjusted to dry the meal and remove the excess moisture contained in the meal. The air introduced into the cooling layer does not need to be temperature-regulated. It is directly sprayed into the material through the pores on the upper surface of the interlayer to contact the material and cool the material. According to the temperature of the material, the centrifugal fan inlet damper is adjusted to obtain the appropriate air volume so that the material temperature meets the requirements for safe storage.4. Solvent recoverySolvent recovery mainly involves two sources of solvents: DTDC degassing machine and evaporation system.①Recovery of solvents generated by DTDC degassing machineThere is a large pipe on the top of the DTDC degassing machine, called the gas phase pipe, which is the channel for the mixed gas of steam and solvent in the degassing machine to be discharged. Because the mixed gas contains a certain amount of meal, a manhole is generally set at the lowest position of the gas phase pipe to facilitate maintenance and cleaning of the meal deposited inside. Because this manhole is opened only a few times a year, and the steam condensate contained in the mixed gas will also be deposited here. Therefore, every time the manhole is opened to clean the meal, the smell is quite sour and refreshing. I believe that those who have cleaned it have a very deep memory.The temperature of the mixed gas is generally around 80℃, and the heat is huge. If it can be used, it will greatly save steam consumption. Therefore, it can be used to heat up the mixed oil.  However, in order to prevent the meal contained in the mixed gas from entering the first steam shell pass and adhering to the outer surface of the tubes to affect the heat exchange efficiency or reduce the shell space to increase the resistance of the mixed gas flow and affect the negative pressure of the DTDC steam degassing machine, which may cause blockage of the first steam shell pass in severe cases, it is generally necessary to capture the meal in the mixed gas. There are many ways to capture meal. The most common one I have encountered is the wet capture method, which is to use the hot water in the wastewater cooking tank to spray it evenly into the mixed gas through the nozzle. The meal is captured by the water in the wastewater tank, and the clean mixed gas enters the first steam shell pass to exchange heat with the mixed oil. Corresponding to the wet capture method is the dry capture method, which is to capture with solvent liquid at room temperature. Each method has its advantages and disadvantages, which will not be introduced in detail here. If there is still a part of the mixed gas that has not condensed into liquid after heat exchange, it will be passed into a condenser and cooled by cooling circulating water to become liquid.  The mixed liquid that becomes liquid after heat exchange or cooling enters the water separation tank and the solvent liquid obtained after water separation is recycled, but there will still be a small amount of solvent gas that has not been condensed. This part of the gas will enter the exhaust system for recovery. The exhaust fan can make the exhaust treatment system and the equipment connected to it, such as the condenser, in a slightly negative pressure state, which can provide power for the gas flow.② Recovery of solvents produced by the evaporation systemThe leached mixed oil contains a large amount of solvent. After one, two and stripping, the solvent content in the leached crude oil has been reduced to a very low level. The solvent content in qualified leached crude oil is generally less than 100ppm. The solvent vaporized by the evaporation system enters the condensation system, and after heat exchange with cooling water, it becomes condensate and flows into the water distribution tank for water distribution. The solvent after water distribution is recycled again.The vacuum pump draws the gas in the condensation system and the evaporation system to make the inside of the system in a negative pressure state. After the solvent evaporates and becomes gas, it begins to move backward and enters the shell side of the condenser (the space between the outer wall and the tubes is called the shell side), and cooling water is introduced into the tubes in the condenser (referred to as the tube side). The solvent gas in the shell side exchanges heat with the condensed water in the tube side. The solvent gas that loses heat is condensed into liquid and enters the water distribution tank for water distribution and recycling. The cooling water in the tube side takes the heat obtained from the solvent gas to the cooling tower for cooling and then circulates for heat exchange.  Since there is no direct steam in the first and second steaming, and the temperature is not too high, the value of heat recovery is not high, but the amount of solvent gas is relatively large, so the solvent gas from the first and second steaming is combined and directly condensed in a condenser with a large heat exchange area. Although the amount of solvent gas coming out of the stripping tower is small, a large amount of direct steam is used during stripping. The steam temperature is high and contains a lot of heat, which has a very considerable recycling value. If it is directly cooled and condensed, it will cause a waste of heat. It can be used as needed to exchange heat with the material that needs to be heated (a sufficiently large temperature difference is required), and then enter the condenser for cooling and condensation. In addition to the above two main sources of solvents that need to be recovered, there is also a certain amount of solvent in the solvent free gas produced by the extractor and the non-condensable gas in the condenser that needs to be recovered.

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Biodiesel

Bio-diesel is synthesized by esterification or transesterification of animal and vegetable oils with short-chain alcohols. Most animal and vegetable oils are mainly triglycerides. The oil is converted into alkyl lipids of monohydroxy alcohols through chemical processes. The low-viscosity fuel produced can directly replace diesel fuel. The main chemical reaction is transesterification.  Through the transesterification reaction, the glycerin in the oil reacts with the alcohol under the action of a catalyst. The reaction process consumes the glycerin to generate glycerol and short-chain alcohol fatty acid esters.  Bio-diesel is highly valued by countries around the world as a renewable fuel and plays an important role in reducing carbon emissions.The raw materials of bio-diesel are widely available. All animal and vegetable oils, waste kitchen oils, free fatty acids, etc. can be used as raw materials. The products are fatty acid methyl esters (biodiesel) and glycerol. Raw oil → degumming → neutralization → ester exchange → bio-dieselMain process description of acid-base bio-diesel:1. Top-grade degumming of raw materialsUse nano-knife mixer and disc centrifuge to reduce the free fatty acid and phospholipid content in the raw materials through acid and alkali reaction, ensure that the ester exchange reaction and glycerol quality meet the pharmaceutical grade standard, and the phosphorus content in the raw oil can be reduced to below 10 ppm after this process.2. Alcohol neutralizationAlcohol neutralization is one of the core technologies of this process. It is used to purify oil and fat so as to enter the continuous esterification section. It integrates degumming and caustic neutralization of free fatty acids. Alkaline glycerol-methanol-phase is used to neutralize free fatty acids. This is a unique process step to increase the yield of fatty acid methyl ester products—the free fatty acids in the degummed oil are further separated from the oil, and then esterified to generate bio-diesel in the subsequent process. In this way, the conversion rate of degummed oil in bio-diesel products can reach more than 95%. 3. Ester exchange After the alcoholized oil, methanol and sodium methoxide are mixed twice in a dynamic mixer, subjected to two ester exchange reactions and separated by a centrifuge, they are separated by two water washes and then dried to obtain the bio-diesel product. The separated glycerol methanol water enters the next process section. Its process characteristics: The U-type reactor can achieve timely separation of glycerol and improve the reaction speed. The use of a centrifuge for separation can greatly reduce the content of free glycerol, reduce the reverse reaction and improve the conversion rate; Two water washes can ensure the quality of biodiesel;4. Methanol recovery and glycerol concentrationThe excess methanol in the bio-diesel reaction is fractionated and recovered. The mixture of glycerol, methanol and water is first treated with acid to separate fatty acids, and then methanol is recovered by distillation. The methanol purity is greater than 99.9%, and the water content is less than 0.1%. It is recycled and reused, and the glycerol water enters the next process. The glycerol water is concentrated by three evaporations to obtain more than 80% crude glycerol. After heating, the crude glycerol is vacuum dehydrated to reduce its water content.  The glycerin concentration part adopts negative pressure evaporation, secondary steam utilization and condensed water recycling process. After the transesterification reaction is completed, the product needs to be washed twice to meet the standard. The device uses the acidic water evaporated from the glycerin concentration part for the final washing, and the separated water is used for the first washing. The workshop condensed water is used as a supplementary water source to form an internal water circulation system, which fully reflects the design concept of water saving, energy saving and emission reduction.5.  EsterificationDuring the methanol recovery process, 1.5-2% fatty acids can be produced, which can be further reacted to generate biodiesel by acid catalysis, which can increase the bio-diesel yield by about 2%, with significant economic benefits.6.  Glycerol refiningBefore the crude glycerol enters the distillation tower, it is first vacuum dried, then sodium hydroxide is added to adjust the pH value, and then distilled and deodorized under alkaline and vacuum conditions. The distilled part is decolorized with activated carbon, and finally medical-grade glycerol (refined glycerol) is obtained with a purity of more than 99.9%. The residual part is then evaporated at high temperature by a thin film evaporator to recover the residual glycerol. The process design uses a four-stage high-pressure steam ejector heat exchange vacuum device and a glycerol thin film evaporator, which has significant energy-saving and emission reduction effects and a higher yield.7. Water recycling processThe water recycling system makes the most of the acidic wastewater generated by glycerol concentration for washing bio-diesel. Wastewater discharge is limited to the hot wells of the glycerol refining part, with a normal production of about 1.5 tons/hour.  Wastewater discharge 1.5-2.0t/h Workshop condensate Glycerol methanol Degumming oil Alcohol neutralization 1-water washing 2-water washing Triple-effect evaporation Glycerol refining Ester exchange Water storage tank Drying Tail gas recovery Refined glycerol Bio-diesel Vacuum hot well Glycerol methanol acid treatment Methanol recovery8. Wastewater treatment deviceThe production wastewater enters the wastewater regulating tank, where it is homogenized and adjusted. After adjusting the pH value, it enters the oil separation sedimentation tank, and then enters the flotation separation device. After removing most of the suspended matter and organic matter in the water, it enters the hydrolysis acidification tank for acidification treatment. After acidification treatment, it is treated by the contact oxidation tank for oxygen consumption. After oxygen consumption treatment, the effluent is separated into solid and liquid, and the separated effluent meets the discharge standards. The main equipment includes:Transesterification tower, centrifuge, esterification unit, glycerin triple-effect evaporator, vacuum system, storage tankThis process uses waste oil and methanol as raw materials. Through the processes of top-level degumming, alcohol neutralization, transesterification-esterification, methanol recovery and glycerin concentration and refining, under the action of catalyst, oil and free fatty acids are transesterified or esterified with methanol to obtain bio-diesel and glycerin. The process is advanced and highly automated. The concept of safety, low carbon and energy saving is reflected everywhere in the process design. Its main features are as follows: The entire device realizes PLC automatic control to achieve the interlocking of quality, process parameters and safety facilities; Six-time heat exchange measures are used, heat energy is efficiently utilized, and the energy-saving effect is significant; Alcohol neutralization, transesterification-esterification process, bio-diesel yield is higher and quality is better; Workshop process water is recycled, steam condensate is fully reused, and wastewater discharge is small; Because methanol has high flammability and explosiveness, the entire system adopts nitrogen sealing protection, and safety facilities and measures are guaranteed.

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biomass power plant

Palm oil production process, there are a lot of biomass by-products, such as: palm empty fruit bunches, palm tree branches and leaves, palm shells, palm fiber, etc., you can effectively use the above biomass by-products as steam boiler fuel, using steam-driven turbine generator will be converted from biomass to electricity. Effective utilization of biomass not only reduces the pollution of the environment, but also produces electricity can produce economic benefits and national standard of living, is currently one of the many countries to promote the direction of green energy.The main processes for biomass power generation are:The main equipment are: biomass crusher, biomass dryer, conveyor, water treatment system, steam boiler, turbine generator and so on.Our company has been committed to the development of palm oil industry for a long time, and each large-scale palm oil crushing plant is equipped with its own biomass power generation facilities to realize the comprehensive economic benefits of self-sufficiency in electricity and domestic and exported electricity. The main power stations are: 3MV/hour, 7.5MW/hour, 10MW/hour, 15MW/hour, 15MW/hour, 20MW/hour, 30MW/hour, 40MW/hour

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