Improved Oil-Bearing Material Extraction Device And System
20240042718 ยท 2024-02-08
Inventors
Cpc classification
B30B9/16
PERFORMING OPERATIONS; TRANSPORTING
B30B9/12
PERFORMING OPERATIONS; TRANSPORTING
International classification
B30B9/16
PERFORMING OPERATIONS; TRANSPORTING
B30B9/12
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A commercial-scale oil-bearing material expeller press having an oil-bearing material inlet, an oil-bearing material press cake outlet and an oil outlet in a temperature-controlled barrel; said barrel housing a compression screw; said compression screw having a central shaft and a plurality of continuous or discontinuous screw flights wherein there are one or more compression zones along the direction of travel of said oil-bearing materials from said oil-bearing material inlet to said oil-bearing material outlet, wherein said central shaft increases in diameter in said direction of travel; and wherein at least said barrel is adapted to be cooled in a plurality of cooling zones.
Claims
1. A commercial-scale expeller press for extracting oil from oil-bearing material; said expeller press comprising: an oil-bearing material inlet, an oil-bearing material outlet and an oil outlet; said expeller press having a temperature-controlled barrel; said barrel housing a compression screw; said compression screw having a central rotating shaft having a plurality of continuous or discontinuous screw flights; wherein there are one or more compression zones in said barrel along the direction of travel of said oil-bearing materials from said oil-bearing material inlet to said oil-bearing material outlet; wherein said central shaft increases in diameter in said direction of travel thereby to produce said compression zones; and wherein said barrel has an internal cage and internal linings and said linings and/or cage that are adapted to be cooled in a plurality of cooling zones; and wherein at least some of said cooling zones and said compression zones are collocated.
2. The expeller press of claim 1, wherein at least one of said cooling zones is located at the final compression zone before the oil-bearing material press cake outlet.
3. The expeller press of claim 2, wherein said cooling zone incorporates an internally cooled choke ring.
4. The expeller press of claim 1, wherein the central shaft incorporates internal coolant flow.
5. The oil-bearing material expeller press of claim 1, wherein the flights of said compression screw have oil-bearing material engagement faces that are angled at between 1200 and 1350 from the centreline of the shaft, where 0 would represent the centreline of the shaft in the direction of travel of the oil-bearing material.
6. The oil-bearing material expeller press of claim 5, wherein the flights of said compression screw have oil-bearing material faces that are angled at between 1250 and 1300 from the centreline of the shaft, where 0 would represent the centreline of the shaft in the direction of travel of the oil-bearing material.
7. The oil-bearing material expeller press of claim 1 wherein at least one of said cooling zones is located adjacent to said oil outlet.
8. The oil-bearing material expeller press of claim 1, wherein said press is adapted to receive oil-bearing materials via said oil-bearing material inlet and wherein said oil-bearing materials are then conveyed by said compression screw into a first cooled compression zone; then a decompression zone wherein the diameter of the compression screw shaft is smaller than the end of the diameter of the first cooled compression zone; then through a second cooled compression zone; then to a cooled oil-bearing material outlet.
9. The oil-bearing material expeller press of claim 1, wherein the internal diameter of the barrel in said compression zones is 1 mm to 20 mm less than in said drainage zones.
10. A method of extracting oil from oil-bearing materials on a commercial scale, said method including the step of pressing said oil-bearing materials in an oil-bearing material expeller press according to claim 1.
11. A method of extracting oil from oil-bearing materials in a commercial scale, said method including the steps of: feeding oil-bearing materials into an oil-bearing material expeller press inlet; subjecting said oil-bearing material to simultaneous compression and cooling a first time; removing said compression and cooling; subjecting said oil-bearing materials to simultaneous compression and cooling a second time; then said oil-bearing materials exit said oil-bearing material expeller press.
12. Oil extracted form oil-bearing materials using the method of claim 10.
13. Oil extracted form oil-bearing materials using the method of claim 11.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0044]
[0045]
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[0050]
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DETAILED DESCRIPTION OF THE INVENTION
[0056] Broadly, the invention can be understood to reside in a novel configuration of the surrounding barrel and the compression screw for a commercial oil-bearing material expeller press that can process oil-bearing materials into oil and press cake in a single pass at temperatures not exceeding 70 C. and over a wide range of outputs, including outputs significantly greater than those of the prior art.
[0057] When processed through an oil-bearing material expeller press according to the invention, the residual oil content in the post-processed press cake (an indication of the efficiency of oil extraction in the process) e.g., for rapeseed (canola) residual oil contents are typically between 4-12% of dry matter basis, but more typically between 6-8%, after a single pass through a screw press on whole rapeseed with an initial oil content of between 38-48% and a moisture content of between 4-12%.
[0058] By contrast, prior art cold pressing technology achieves a result of between 12-16% oil in cake (OIC) on a comparable throughput, see table 1.
TABLE-US-00001 TABLE 1 Technique OIC Throughput* Cold pressing 12-16% 30-40% Shaft cooling 11-15% 30-40% Shaft & jacket cooling 9-11% 35-45% Shaft. Jacket & choke cooling 6-9% 35-45% Shaft, jacket, choke cooling and angular flights 5-8% 65-85% *Throughput is expressed as a percentage of the press manufacturer's rated full press capacity for preconditioned feed material.
[0059] The invention includes a system for cooling the press to control the viscosity of the oil-bearing material via a combination of cooling points that are utilised concurrently, or independently, to optimise press performance in terms of oil extraction efficiency and press throughput.
[0060] The cooling methods cover three areas of the press: shaft cooling; choke cooling and compression or jacket cooling. Compression cooling may be employed at one or more locations along the screw press shaft depending on the press size, length capacity and the oil-bearing material being processed.
[0061] Each cooling zone needs individual temperature control to optimise press performance in terms of oil yield and maintenance of protein quality in the residual fibre/carbohydrate/protein press cake.
[0062] The flights on the compression screw may be segmented or continuous.
[0063] The screw may preferably contain knife/nib bars to aid in the throughput of the material along the press.
[0064] The diameter of the cage surrounding the screw may be of a constant diameter or it may be variable in order to aid press performance. Typically, the sections of cage containing lining bars or rings near the feed end or immediately following a hump or compression zone may be tapered to ensure the internal pressure inside the cage during operation is lowest in these zones to aid the hydraulic pumping of the oil from the areas of high compression to the drainage zones.
[0065] The press screw worm piece/s is/are designed in such a way that the pressure gradient from the feed end or following a compression section is constantly increasing to enhance the hydraulic pumping of the oil from the high compression/hump zones back to the low-pressure zone for ease of oil drainage.
[0066] Turning to
[0067] The screw 5 may be made from a single piece of steel or a shaft with individual replacement flights placed over the main shaft.
[0068] An important feature of the flights (10, 11) is the geometry of the angular face 15 of the leading face of the screw flights (10, 11), i.e., the face that engages the oil-bearing material to force it along. The leading face, rather than having a profile that is the standard 90 to the centreline of the shaft, will according to a preferred embodiment of the invention have an angle of between 120-135 to the centre line in the direction of travel and more preferably in the range of 125-130 to the centre line in the direction of travel where 0 would represent the centreline of the shaft in the direction of travel of the oil-bearing material.
[0069] This is further illustrated in detail in
[0070] It will also be observed that the diameter of the screw shaft 20 increases in diameter in the direction of travel in two sections (25, 30), in order to increase pressure, then release pressure as the press cake passes out of section 25 at point 35, and then is compressed again in section 30.
[0071]
[0072]
[0073] Two matching cooling jackets 55 are placed around the shaft inside the barrel cage and are positioned to: maintain the desired cooled temperature along the process; create a cooler zone to increase oil-bearing material viscosity and therefore oil extraction; and to allow a higher operating pressure in the compression zone as the cooling jackets prevent foots (small pieces of press cake) from escaping from the press, which would allow pressure to be reduced in the compression zone.
[0074] The cooling jacket can have many suitable types of construction and those familiar with the design and construction of cooling membranes or jackets will be able to construct a suitable cooling jacket. The jacket is best placed in a location in the press relative to the compression zone of the screw and is useful for its ability to remove heat from the oil-bearing material that is caused by the friction and pressure the pressing process creates inside the barrel.
[0075] It is envisaged that the cooling jacket may incorporate a wear plate 60 made of suitable material in contact with the oil-bearing material to give good heat transfer properties to remove thermal energy (heat) from the oil-bearing material and high resistance to wear.
[0076] It is envisaged the body of the cooling jacket 65 will be made of a material that provides sufficient strength to resist the forces produced by the process and will be able to conduct the thermal energy away from the wear plate via fins/ribs 70 in its construction efficiently via a thermal fluid that passes though the channel 75 formed by said ribs.
[0077] The temperature that the thermal fluid operates at is determined by several factors: the design of the screw and the friction it creates and hence the amount of thermal energy required to be removed; the type of oil-bearing material being processed and the fibre/carbohydrate to oil ratio in the material being pressed. The temperature will need to be adjusted based on the moisture content of the oil-bearing material (the higher the moisture content of the oil-bearing material the lower the operating temperature is required for efficient oil extraction).
[0078] The temperature of the cooling fluid required tends to be inversely related to the moisture content of the oil-bearing material being processed.
[0079] For example, in the case of canola/rapeseed, the operating range of the cooling fluid is from 0-50 C. when the seed moisture content of the seed is between 4-12%. When the moisture content of the seed is within the range of 5-10%, the thermal fluid operating temperature should be in the range of 15-35 C.
[0080] Turning to
[0081] In
[0082] It allows for greater pressure to be maintained as pieces of oil-bearing material (also known as foots) cannot be squeezed out, as they normally would, through the normal lining bar gaps/shims at this point, as it coincides with the location of the higher pressure zones on the shaft (as per point 35 in
[0083] It allows the oil-bearing material to be cooled at this point, increasing the viscosity of the material, resulting in higher pressure, thereby resulting in better oil yields; and it allows the process to keep the temperature of the press cake <70 C. to reduce heat damage to the amino acids that make up the protein of the press cake. This results in higher availability of protein in the residual press cake due to less heat damage. Thus, this localised cooling is another advantage of the invention.
[0084] The design of the screw is such that the cross-sectional volume of the screw at any point along the shaft from the oil-bearing material fed into the press to the end of the compression section is reduced as it moves along the shaft by several factors: an increase in the diameter of the boss of the shaft; and/or a change in the pitch of the flights. For example, in screws with a plurality of compression zones there may be incorporated sudden local increases in volume created by several factors such as decreased shaft boss and increased flight pitch.
[0085] For those familiar with the design, manufacture and operation of screw presses, it will be understood that these changes are used to create an increase in pressure along the shaft, allowing for: deaeration of the gaps between the oil-bearing material; reduction of operating volume to allow for the concomitant volume reduction that occurs along the shaft due to the oil extraction (and the loss of some foots through the lining bars).
[0086] In the present invention, the press is designed such that the compression/pressure curve, shown in
[0087] In effect, the increases in compression/pressure along the shaft means the oil released in the high compression zones of the press is hydraulically pumped back towards the feed end, counter-current to the direction of the oil-bearing material being pressed so that it can drain from the press in a low-pressure zone.
[0088] To facilitate this hydraulic pumping of the oil in some cases of the invention the first field of lining bars or rings and the fields immediately after a hump/compression zone, may be of a larger diameter and then taper inwards to meet the diameter of the next field towards the discharge end. This creates a low-pressure zone towards which the oil released from the oil-bearing material under higher pressure is pumped/pushed hydraulically.
[0089]
[0090] There is shown a typical lining bar 115 layout, however this can be replaced with rings or lining bars of different length or thickness. Those familiar with screw press operation will be able to fit suitable sized shims between the lining bars to allow for the drainage of oil.
[0091] Typically, the shim settings are wider at the feed end 80 of the press and reduce in thickness as the material moves towards either a compression zone 100 or discharge end 105 of the press. Immediately after a compression zone there will generally be an increase in shim thickness before shim thickness reduction begins again as the material moves towards the discharge end of the press.
[0092] The location of the two cooling jackets (90, 95) within the press are shown. In alternative embodiments the press may incorporate 1, 2 or more cooling jackets depending on the length of the shaft, the diameter of the shaft and the volume of material being pressed. The lining bars 120 are also represented. Note this cage does not have knife bars and is therefore typically used in conjunction with a continuous screw flight as per
[0093]
[0094]
[0095] A feature of this cage is that the field of lining bars or rings 130 immediately following a cooling jacket/section 135, are tapered from the feed end 140 towards the discharge end 145. That is, the diameter of the cage is larger at the discharge end immediately following the cooling section and then tapers back to be the same diameter as most of the cage lining bars/rings after a distance of between 15-50 cm, or more typically 20-40 cm. In this figure, the location of the cooling jackets 150 and the tapered lining bars 130 are an example only, as they may be located anywhere along the shaft depending on the type of oil-bearing material being processed.
[0096]
[0097] The choke piece 160 will utilise cooling techniques familiar with other parts of the inventive process and they are intended to maximise the ability of the choke piece to remove thermal energy from the material in this zone of the press. The example depicted in
[0098] Any choke ring design employed must be capable of withstanding the operating pressures within the zone and maximise the heat/energy removal from the oil-bearing material being processed. As per the figure, a cover plate 170 would be used on both sides of the choke to hold the cooling medium in place and to allow servicing of the choke.
[0099]
[0100] The shaft may have the screw flights fabricated into it or it may have the screw pieces as a whole or in segments attached to it, usually by placing the pieces onto the keyed shaft with matching keyways in the screw flights.
[0101] There has been a coolant channel 185 centrally bored through the centre of the shaft. Depending on the design of the screw press, the cooling fluid can be fed from the feed or discharge ends of the shaft, or in certain cases passed through the complete length of the press. In either method the cooling fluid is fed and removed from the shaft via a suitably designed rotary union.
[0102] The example shown is of a keyed, stepped shaft although other methods for attaching worm pieces to the shaft will be familiar to those skilled in the art.
[0103] The shaft must remain sufficiently strong after boring of the coolant channel to withstand the forces involved in pressing the oil-bearing material.
[0104] In the case of the thermal fluid being only fed and extracted from the same end of the shaft, a suitable fluid rotary union is usually employed for the fluid to be pumped into and extracted from the shaft. Typically, the fluid is fed in from the discharge end of the shaft either through the inside or outside of a pipe that feeds the thermal fluid a suitable distance down the shaft prior before the liquid exits the shaft via the opposite pathway.
[0105] The volume of thermal fluid used should be maximised without compromising the structural integrity of the shaft, in order to maximise thermal energy removal from the shaft.
[0106] In operation the oil-bearing material expeller press according to the invention provides a method for increasing oil yield and producing a press cake of higher quality from non-pre-heated oil-bearing materials by maintaining press cake temperatures below 70 C. during processing.
[0107] The process involves a single press, as described above, processing (pressing) cleaned oil bearing material that typically has not been cooked/conditioned.
[0108] Whole oil-bearing material is feed into the inlet end of the press which may include several sets of lining bars and one or more blank sections of barrel located along the screw, typically at the highest-pressure points compression zones with or without cooling.
[0109] The press may be started with no cooling (ambient) to allow residual material to be conveyed (pushed) through the press. A press may need to be heated with warmer thermal fluid though the cooling zones, prior to operation to soften hard material inside the press to allow initial operation.
[0110] Once the press is feeding continuously, cooling fluid is introduced to the cooling jackets to increase the viscosity of the oil-bearing material/cake. Cooling temperature is a function of oil-bearing material moisture and is an inverse relationship between moisture content and temperature as discussed above.
[0111] The press should be operated so that the press cake temperature does not exceed 70 C., ideally not exceeding 60 C., and within the range of 30-70 C. or more preferably within the range of 50-65 C.
[0112] Ideally the press should be operated with the press cake at the choke section as close as possible to its glass transition temperature, but this would be close to the maximum operating pressure and this could lead to the press stopping operation due to excessive pressure caused by excessive increase in the viscosity of the press cake.
[0113] Therefore, the temperature at the press choke should ideally be maintained just above the cake glass transition temperature in order to maintain a trouble-free operation.
[0114] The process involves controlling the temperature of the press relative to the moisture content of the oil-bearing material being pressed. The higher the oil-bearing material moisture content, the lower the press operating temperature and vice versa. The relationship between the required optimum temperature, (at or just above the glass transition temperature of the press cake), is inversely related to the oil-bearing material moisture content to maximise oil extraction.
[0115] The glass transition temperature (T.sub.g) is the temperature range where an amorphous polymer (or a biopolymer, such as canola press cake), transitions from a hard, glassy material to a soft, rubbery and ductile material.
[0116] A method should be employed for determining pressure inside the press. It may include using amps and torque readings as a proxy for pressure or pressure sensors placed at suitable locations.
[0117] Typically, the operating temperature range is between 60 C. to 20 C. with a moisture content range of 0-15%. Typically, the change in operating temperature of the cake at the choke of the press will vary between 5-10 C. for every 1% change in moisture content of the oil-bearing material.
[0118] In the compression zones and choke sections of the press the temperature should be such that it does not substantially exceed the glass transition temperature of the material (crushed oil-bearing material/press cake).
[0119] The choke section of the screw assembly and parts adjacent to it are designed in such a way that the increase in pressure that occurs through operating the press at or just above the glass transition temperature is not lost through the choke orifice but rather acts as a plug to hold the pressure within the barrel to maximise oil extraction.
[0120] The design of the choke is a factor of the diameter of the shaft, barrel, screw design and required throughput of the press.
[0121] The process according to the invention can achieve residual oil contents in the press cake with single pressing of between 4-12% (typically 5-7%); and throughputs of approx. 50% to 80% of a full expeller pressing. Refer Table 1.
[0122] In table 2 below are shown typical process conditions for the operation of an oil-bearing material expeller press according to the invention carrying out the method according to the invention.
TABLE-US-00002 TABLE 2 Typical Process Conditions Oil Moisture Press Julabo Cooling MI Choke Jacket Shaft In Seed In Seed Speed Set Set Throughput DIC Cake nlet
nlet inlet % % RPM point pt kg/hr % % C. C. C. Comments Auger assembly 5 40.70% 6.60% 35.00 20.00 N/A 90.69 9.10% 10.70% 18.20 11.10 11.10 Total Cooling Speeds at 6.7% 40.10% 6.50% 37.00 20.00 N/A 90.12 9.00% 10.70% 18.80 13.0 13.00 40.10% 6.50% 40.00 20.00 N/A 96.15 9.50% 10.50% 18.90 13.80 13.70 40.60% 6.50% 40.00 20.00 N/A 92.8 9.50% 10.40% 19.20 15.50 15.70 40.60% 6.50% 40.00 20.00 N/A 95.9 9.70% 10.50% 19.00 15.90 17.50 Auger assembly 5 40.40% 6.80% 20.00 N/A N/A 64.64 10.30% 10.30% No Cooling Speeds at 6.5% 40.80% 6.60% 25.00 N/A N/A 76.5 11.70% 10.00% 40.50% 6.70% 30.00 N/A N/A 91.2 11.40% 10.10% 40.10% 6.60% 30.00 N/A N/A 92.4 13.60% 9.60% 39.80% 6.60% 30.00 N/A N/A 97.3 12.80% 9.60% 39.80% 6.40% 30.00 N/A N/A 93.6 12.90% 9.40% Auger assembly 5 41.20% 6.60% 20.00 20.00 N/A 55 6.80% 11.20% 19.80 0.00 12.30 Total cooling Speeds at 6.7% 41.30% 6.70% 20.00 20.00 N/A 43.9 6.20% 11.30% 19.80 13.90 13.90 41.90% 6.90% 40.00 20.00 N/A 100.4 7.90% 11.00% 20.10 16.20 16.50 40.90% 6.90% 40.00 20.00 N/A 103.0 8.00% 10.80% 17.50 17.50 17.80 41.50% 6.60% 40.00 N/A N/A 119.3 12.30% 0.00% 0.00 0.00 0.00 No Cooling Auger assembly 5 40.90% 7.50% 20.00 20.00 N/A 49.45 6.70% 11.90% 19.70 0.00 14.30 Shaft & Choke Speeds at 7.5% 40.90% 7.50% 20.00 20.00 N/A 51.2
6.90% 12.00% 20.10 0.00 15.40 cooling only 39.90% 7.80% 40.00 20.00 N/A 102.82 7.50% 11.
0% 20.80 18.30 18.10 Total Cooling 40.40% 7.80% 40.00 20.00 N/A 96 7.40% 11.80% 20.90 19.50 19.50 40.40% 7.80% 50.00 20.00 N/A 109.46 7.60% 11.80% 21.80 20.40 20.40 40.40% 7.80% 50.00 20.00 N/A 105.42 7.40% 11.60% 21.90 20.40 20.70 Auger assembly 5 40.20% 7.40% 30.00 N/A N/A 103.61 12.00% 11.10% 0.00 0.00 0.00 Endogenous best Speeds at 7.5% 40.00% 7.50% 30.00 N/A N/A 103.58 10.30% 11.00% 0.00 0.00 0.00 39.70% 7.60% 30.00 N/A N/A 103.14 10.90% 11.10% 0.00 0.00 0.00 Auger assembly 5 39.90% 7.50% 35.00 23.00 N/A 91.05 8.10% 11.20% 6.20 6.20 6.00 Total Cooling Speeds at 7.5% 38.30% 7.70% 35.00 20.00 N/A 94.94 7.80% 11.40% 8.00 8.00 7.70 39.90% 7.50% 40.00 20.00 N/A 87.7 7.60% 11.30% 12.40 12.40 12.00 Auger assembly 5 41.30% 7.50% 30.00 N/A N/A 102.17 12.30% 11.20% No Cooling Speeds at 6.5% 41.20% 7.50% 30.00 N/A N/A 107.57 12.30% 11.40% 41.10% 7.60% 30.00 N/A N/A 104.3 11.90% 11.30% 40.90% 7.50% 30.00 N/A N/A 106.0 12.30% 11.30% Auger assembly 42.00% 7.40% 35.00 20.00 N/A 95.
9 8.10% 11.70% 19.00 10.10 9.60 Total Cooling Speeds at 7.5% 42.00% 7.40% 40.00 20.00 N/A 107.85 8.60% 11.70% 20.00 13.20 12.40 41.10% 7.50% 40.00 20.00 N/A 109.18 8.40% 11.60% 20.00 15.10 14.70 41.40% 7.50% 40.00 20.00 N/A 104.7 8.20% 11.70% 19.80 17.30 17.10 Auger assembly
39.60% 8.50% 20.00 10.00 N/A 65.38 7.80% 12.80% 10.30 8.20 8.10 Total Cooling
39.60% 8.60% 20.00 10.00 N/A 6
.14 8.10% 12.70% 11.20 10.20 9.90 39.10% 8.90% 20.00 10.00 N/A 44.74 5.90% 12.60% 11.70 11.90 11.50 38.80% 8.90% 20.00 20.00 N/A 19.12 5.60% 13.10% 12.00 13.40 12.90 38.80% 8.90% 20.00 20.00 N/A 63.4 8.40% 12.60% 20.70 0.00 14.40 38.80% 8.80% 20.00 20.00 N/A 23.6
5.60% 13.07% 20.80 0.00 15.10 38.00% 9.00% 20.00 20.00 N/A 15.53 6.30% 0.00% 20.70 0.00 16.10 Auger assembly 40.10% 8.40% 40.00 20.00 N/A 94.86 7.30% 12.70% 20.20 13.90 13.50 Speeds at 8.5% 40.30% 8.50% 40.00 20.00 N/A 98.15 7.30% 12.60% 20.70 15.60 15.30 40.10% 8.40% 40.00 20.00 N/A 93.9 7.00% 12.50% 20.80 17.80 17.60 38.60% 8.90% 20.00 N/A N/A 69.96 11.20% 11.90% 0.00 0.00 0.00 Endogenous heat 39.10% 8.50% 40.00 N/A N/A 134 10.70% 11.40% 0.00 0.00 0.00 Endogenous heat
indicates data missing or illegible when filed
[0123] It will be appreciated by those skilled in the art that the above-described embodiment is merely one example of how the inventive concept can be implemented. It will be understood that other embodiments may be conceived that, while differing in their detail, nevertheless fall within the same inventive concept and represent the same invention.