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Green Productivity Demonstration Program (GPDP) in Soybean Processing Industry (M/s Rama Phosphates Ltd., Indore, INDIA) (March 2002) Asian Productivity Organisation, Japan Prepared by Environment Division National Productivity Council, India Rik Rik n Rkk Rkk i fj fj "k "k ; ; "Vªh "Vªh GREEN PRODUCTIVITY Sponsored by GREEN PRODUCTIVITY MEASURES TO REDUCE HEXANE LOSS IN SOY PROCESSING INDUSTRY GREEN PRODUCTIVITY MEASURES TO REDUCE HEXANE LOSS IN SOY PROCESSING INDUSTRY
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Page 1: GREEN PRODUCTIVITY MEASURES TO REDUCE HEXANE LOSS IN …parasnis.net/update181004/31pagpdp/rama/hexane_loss.pdf · the various causes and their effect for hexane loss. The outcome

Green Productivity Demonstration Program (GPDP) in Soybean Processing Industry

(M/s Rama Phosphates Ltd., Indore, INDIA)

(March 2002)

Asian Productivity Organisation, Japan

Prepared by

Environment Division

National Productivity Council, India

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G R E E N

P R O D U C T I V I T Y

Sponsored by

GREEN PRODUCTIVITY MEASURESTO REDUCE HEXANE LOSS

IN SOY PROCESSING INDUSTRY

GREEN PRODUCTIVITY MEASURESTO REDUCE HEXANE LOSS

IN SOY PROCESSING INDUSTRY

Page 2: GREEN PRODUCTIVITY MEASURES TO REDUCE HEXANE LOSS IN …parasnis.net/update181004/31pagpdp/rama/hexane_loss.pdf · the various causes and their effect for hexane loss. The outcome

Large quantityof hydro carbons discharged into atmosphere.

Inadequate DTDC

Inadequate steam supply in SEP

High moisture in collets

ENVIRONMENT

Machine

Man

Method

Material

Poor recovery of Hexane

Inadequate recovery facility

Inadequate recuperation system

High bed thickness

Inadequate Design

Insufficient contact betweenDOC and steam

Less heating surface area for indirect steam

Less absorption of hexaneby Mineral oil

Fouling of condenser

Absence of rotary valveat out let

Air ingressmentImproper Condensation

Inadequate recuperation system

Fluctuation in steam pressure

Insufficient Boiler capacity

Improper Extractor Less drainage time for miscella

Mind set InadequateVacuum

Leakage through Extractor Sealing

Work instruction not duly followed

Negligence of plant periodicmaintenance

Shortage of skilled manpower

Hexane retention by residual oil

High residual oil in DOC

Power interruption

Damaged / green seed

High moisture in seed

Inadequate cooking

Improper seed preparation

Inadequate Cracking & Flaking

Improper flake thickness

Worn out flaker rollers

Insufficient plasticity

Common condensation of vapour

Improper Cleaning

Presence of foreign matter,which is being considered as seed

High solvent seed ratio

Improper flaking

Faulty quality control of flake thickness

Considering average thickness instead of standard deviation

CAUSE & EFFECT ANALYSIS FOR HEXANE LOSSES

Hexane Loss

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G R E E N

P R O D U C T I V I T Y

PROBABLE CAUSES

Inadequate vacuum in DTDC & distillation

Inadequate steam supply

Inadequate condenser cooling

Inadequate size of condenser

.

.

.

EFFECTS

Inadequate vacuum leads to

Poor separation of hexane in distillation &

Desolventisation

The Quality of Crude Oil & DOC may further

degrade due to high concentration of hexane.

.

.

Inadequate desolventisation in DTDC

Inadequate steam quantity & pressure

Inadequate heating surface area

Low retention time in DT

.

.

.

Inadequate desolventisation leads to

Hexane carryover along with meal dryer air,

resulting high hexane loss

.

Inadequate drainge in extractor

Inadequate drainage time

High hexane concentration in wet DOC

.

.

Inadequate drainage in extractor leads to

Additional hexane carry over with wet DOC

More load to the DT

.

.

BACKGROUND:

CAUSE EFFECT ANALYSIS

India is the fifth largest producer of Soybean in the world. However, India's share in world production of

soybean is only 3%. It is evident from the statistics, that the specific raw material and chemical consumption in

Indian Soybean Processing Industries is very high compare to developed countries. This resulting in high

production cost which is great bottleneck for the survival in the competitive international market. Looking in

potential of improvement in this sector, Asian Productivity Organisation, Japan entrusted a project titled

. Subsequently, M/s Rama Phosphates

Ltd.-Oil Division (RPL), Indore was selected for detailed study. Lots of areas were identified for improvement.

The hexane loss is one of the critical areas where in-depth study was carried out to identify causes for high

consumption of hexane and their possible Green Productivity Measures to bring down the specific

consumption of hexane to the minimum possible level.

Various tools were applied to know the causes of hexane loss in soybean processing industry to produce

refined oil. The well-known Ishikawa Diagram (Fish-Bone Diagram) was prepared, as shown in figure, show

the various causes and their effect for hexane loss. The outcome of the study at M/s RPL is discussed below:

The hexane is used as a solvent for the extraction of oil. In India, on an average, the hexane loss is 3.0~5.0

lit/Ton of seed process. However, it can be reduced to 2.0~3.0 lit/Ton of seed process. The high hexane loss

results in high production cost, high fugitive gas emission, poor quality of DOC and crude oil. The major areas

of hexane exits in the SEP are: (I) Carryover along with crude oil, (ii) Uncondensate vapour going through final

vent of recuperation unit, (iii) Carryover with meal drying air in DTDC, (iv) Carryover with DOC and (v) hexane

emission from leakages.

There are number of reasons for high hexane loss in SEP. The possible causes of high hexane loss in SEP and

their effect are discussed below.

"Green Productivity Demonstration in Edible Oil Industry in India"

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G R E E N

P R O D U C T I V I T Y

GREEN PRODUCTIVITY OPTIONS TO REDUCE EXCESS OIL CONTENT IN DOC

The possible solutions for reducing high hexane loss in SEP are:

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Ensure adequate steam supply (quantity & pressure) without interruptions by providing adequate sized

boiler(#)

Provide cold/chilled water for effective condenser cooling

Maintain optimum bed thickness and steam pressure in the desolventisation compartment of DT.

Increasing heating surface area in DT by providing more limpets

Increase the hexane drainage time in extractor

Increase mineral oil flow rate to improve recuperation (#)

Increase heating surface area of PHE to improve recuperation (#)

PROBABLE CAUSES EFFECTS

Inadequate recuperation

Inadequate absorption/release of hexane

Inadequte condenser size

.

.

Recover of hexane from recuperation system may

be poor. More fugitive hexane loss.

Inadequate crude oil stripping

Inadequate steam & Vacuum

Inadequate condenser size

.

.

Poor oil stripping leads to more hexane carryover

with crude oil resulting in more hexane loss and poor

quality of crude oil.

Increased Heat Surface Area of Plate Heat Exchange (PHE)

Page 5: GREEN PRODUCTIVITY MEASURES TO REDUCE HEXANE LOSS IN …parasnis.net/update181004/31pagpdp/rama/hexane_loss.pdf · the various causes and their effect for hexane loss. The outcome

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Increase chilled water flow rate in vent condenser to improve recuperation (#)

Install separate condenser with steam ejector in stripper to increase vacuum (#)

Additional Steam Ejector installed for increasing vacuum in the Stripper

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COST BENEFIT ANALYSIS

OTHER BENEFITS

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The solvent ratio (solvent:seed) should be in the range of 0.8~0.9

The miscella concentration should be in the range of 26~35%

The hexane concentration in wet DOC should be in the range of 30~33%.

Retention time in DT should be more than 60 minutes

o

The temperature at top of DT should be 70~72 C.

o

The temperature in stripping should be 105 C

o

The flash point in crude oil should be more than 100 C.

Periodic replacement of spent mineral oil with fresh mineral oil

The Demonstration Unit (DU) in India having capacity to crush 400~450- TPD soybean seed, implemented five

options (marked as #) and invested directly Rs. 1.95 lakh (US$ 4,150) in SEP and indirectly Rs. 120 lakh (US$

2,55,360) for installing new higher capacity FBC Boiler. The unit gained financial saving of Rs. 12.7 lakh (US$

27,000) per annum as a result of reduction of hexane loss of 12.2% (from 4.93 lit/T to 4.3 lit/T). By installing

higher capacity boiler, the unit gained further in the reduction of oil content in DOC, high capacity utilisation in

SEP, increase in power generation & saving in steam cost and coal.

Implementation of GP options resulting in following additional benefits:

Productivity enhancements as a result of low production cost.

Better capacity utilisation of plant

Prevention of fire hazard

Higher recovery of uncondensed hexane

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For Further details Contact:Director, Environment Division

NATIONAL PRODUCTIVITY COUNCIL

5-6, Institutional Area, Lodhi Road New Delhi- 110 003.

Ph. 91-11-4611243 Fax:91-11-4625013/4615002

E-mail: [email protected] Web-Site: www.npcindia.org

The inverse relationship between productivity and pollution prompted NPC to develop its expertise in the

field of Industrial Pollution Prevention & control.

Environment Division of NPC (ED-NPC) initiated the Industrial Pollution Prevention & Control (IPPC) services

in 1983. Through a network of 40 plus trained professionals stationed at Chennai, Delhi, Gandhinagar, Kolkata

and Mumbai, ED-NPC is providing quality Environmental services to the industrial diaspora. The application of

Waste Minimisation and Pollution Prevention techniques and principles has been a major thrust area, amongst

a range of service that ED-NPC provides for enhancing profitability and environment performance of industrial

enterprises.

The Environment Division offers complete services for planning, evaluation and execution of environmental

programmes. We understand the importance of cost effective and publicly acceptable solutions to

environmental problems.

ENVIRONMENT DIVISION OF NPCENVIRONMENT DIVISION OF NPC


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