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High Capacity Vacuum Systems For Edible Oil De-odourization

A PROJECT REPORT ON

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Introduction:

M/s. Everest Blower Systems did a typical study on De-odourisation of Edible oil in a company which is into Refining of Edible.

The company manufactures and export of all kinds of edible oils, cotton seed, maize oil, soyabin oil, groundnut oil, cotton seeds etc.

Particularly we did study on two plants:-

(a.) 200 ton per day capacity plant for Cotton seed oil .
(b.) 400 ton per day capacity plant for Palm Oil.

In existing plant they made vacuum from 2-stages Booster and 2-stages steam jet ejector combination.

Principle of process: Removal of Free Fatty Acid from oil under Vacuum by sparging steam into the oil. (Deodorization of Cotton seed oil & Palm oil).

Nature of process: Continuous process cycle.

Case Studies: Study of Cotton Seed Oil Deodorization.

Process: Refining & Deodorization of Crude Cotton Seed Oil.
Nature of Process: Continuous type.
Existing Vacuum System: 2-stage Booster & 2- stage Steam jet ejector.
Existing Vacuum Recorded: 60 torr (on Dial gauge)
Steam Pressure in Boiler: 8.5 Kg/cm2 (Working Pressure: 10.5 kg/cm2)

Raw material: Crude Cotton Seed Oil.
Percentages of FFA in Crude Cotton Oil: 0.1 -0.2
Percentages of FFA in Refined Oil: 0.04

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Boiler Details:

In Cotton Seed Oil Refining they are using manually Hand Firing Boiler.

Raw fuel: Coal
Boiler Make: Vashpa.
Capacity of Boiler: 3 ton.
Working Pressure: 10.5 Kg/cm2.
Coal Consumption: 11.5 ton per day.
I.D Fan Rating: 30 H.P
Water Feeding Pump into boiler motor Rating: 20 H.P.
Steam generation time: 4 hrs.
Pressure Variation: 8.5 Kg/cm2 – 10.5 Kg/cm2
Problem: Vacuum level is not achieved properly.

In Palm Oil Refining they are using Fluidized Bed Combustion Boiler

Raw Fuel: Meshed Coal or Powdered Coal.
Boiler Make: Thermax
Capacity: 6 ton
Working Pressure: 10.5 Kg/cm2
F.D fan motor Rating: 12.5 H.P

Barometric Condenser Details:

In Cotton Seed Oil Refining

Primary Barometric Condenser:
Water flow rate: 125 m3/hr
Secondary Barometric Condenser:
Water flow rate: 4 m3/hr

In Palm Oil Refining

Primary Barometric Condenser:
Water flow rate: 172 m3/hr
Secondary Barometric Condenser:
Water flow rate: 6 m3/hr.

Cooling Tower Details:

Circulation Pump details:
Flow rate: 143 m3/hr.
Head: 40 mtr.
Power: 14.8 kw
R.p.m=2900 r.p.m
Make: Johonson Pump India Ltd.
∆T=5 0c.
Win=280c Wout=330c
Capacity of Cooling Tower:236 TR.

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Calculation of Steam Flow Rate

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Calculation:
Conversion Factors:
1 Kg/cm2 = 14.19 Psig.
1 lb/hr = 0.45 Kg/hr.

Steam Pressure: 0.5 Kg/cm2 (0.5 Kg/cm2 = 7 psig.)

Given Data:

Numbers of orifices of different diameter are as following:

Placement & Number of orifices Diameter of Orifices (mm) Steam Pressure (Psig.) Steam Flow Rate (Kg/hr)
Deo. Column(5 no.s) 2.5 7 13.6
Deaerator top 2.8 7 2.7
Deaerator bottom 2.8 7 11.36
Packed bottom 2.8 7 3.6

Total Steam Consumption by Graphical Method: 35 Kg/hr (approx.)
Total Non-Condensable Load: 8 Kg/hr.
Free Fatty Acid Load: 10 Kg/hr.

Calculation of System Volume of Cotton Seed Plant

Deodorizer: 35.32 m3 …..……..………………… Height: 7.2 mtr.Diameter: 2.5 mtr.
Packed Column: 2.08 m3 ………………………..Height: 1.7 mtr. Diameter: 1.43 mtr.
Stripping Column: 6.4 m3 …………………………Height: 7 mtr. Diameter: 1.08 mtr.
Deaerator: 7.6 m3 …………………………………Height: 4.6 mtr. Diameter: 1.25 mtr.
Duct Length: 9.65 m3 ………………………………Height: 38 mtr. Diameter: 0.6 mtr.
Fatty Scrubber: 5.2 m3………………………………Height: 3 mtr. Diameter: 1.5 mtr.
Total System Volume = 65 m3 (approx.)

Cost Analysis

In Cotton Seed Oil Plant.
Steam Consumption: 800-900 Kg/hr
Coal Rate: Rs 4500 per ton (imported)
Crushed Coal Rate: 3500 per ton.
I.D fan Motor rating: 30 H.P
Water Feed motor rating: 20 H.P
Blow down time for Boiler to ETP plant: 500 Kg/hr
Boiler Cost of Maintenance: Rs10 /ton/hr.
Boiler Certification Cost: Rs 1, 00,000+
Electricity Rate : Rs. 6 per unit.

Problem with Existing System

  • Very huge pressure fluctuation in their steam boiler(8.5-10.5 kg/cm2)
  • Vacuum level is not achieved properly. (60torr).
  • Maintenance of Steam jet ejector is costly.
  • They are using manually hand coal firing boiler which includes labor cost to feed coal.
  • Boiler running cost will very high.
  • Due to not achieving of proper vacuum process refined oil is not good.
  • Process Cycle time is more by using Steam Jet Ejector system.
  • Due use of Barometric condenser the load on cooling tower will increases.

Benefits of Everest Vacuum Pumping System (E.V.P.S)

  • By using EVPS their High Boilers are stopped.
  • Maintenance of EVPS is easy.
  • No waiting for Steam generation and as well as steam pressure to achieved proper vacuum.
  • Easy to start and easy to operate.
  • No vacuum fluctuation in our system.
  • Place where we did the study electricity supply was very good means there is no shortages of electricity.
  • Labor cost and Plant running cost are also saved.

Client list

aloka-oil

Aloka Oil Industries

api

Agrosolvent Products Ltd.

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Indo MAines ltd.

poi

Pawan Oil Indsutries