INTRODUCTRY TO CHEMICAL INTRODUCTRY TO CHEMICAL ENGINEERINGENGINEERING

EXTRACTIONEXTRACTION

Extraction is one of the most useful and Extraction is one of the most useful and widely used chemical seperation widely used chemical seperation

methods.methods.

There are two types of extraction There are two types of extraction process:process:

•Solid – Liquid ExtractionSolid – Liquid Extraction

•Liquid – Liquid ExtractionLiquid – Liquid Extraction

Solid – Liquid ExtractionSolid – Liquid Extraction

Leaching generally refers to the Leaching generally refers to the removal of a substance from a solid removal of a substance from a solid via a liquid extraction media.  The via a liquid extraction media.  The

desired component diffuses into the desired component diffuses into the solvent from its natural solid form.solvent from its natural solid form.

Some usage examples:Some usage examples:

Examples of leaching include the Examples of leaching include the removal of sugar from sugar beets removal of sugar from sugar beets with hot water and the removal of with hot water and the removal of

nickel salts or gold from their natural nickel salts or gold from their natural solid beds with sulfuric acid solid beds with sulfuric acid

solutions. solutions.

Types of EquipmentsTypes of EquipmentsThere are many different types of equipment used for There are many different types of equipment used for

leaching.  Most of these pieces of equipment fall leaching.  Most of these pieces of equipment fall into one of two categories:into one of two categories:

• Percolation....."Liquid Added to Solids“ Percolation....."Liquid Added to Solids“ The solvent is contacted with the solid in a The solvent is contacted with the solid in a

continuous or batch method.  This method is continuous or batch method.  This method is popular for in-place ore leaching or large scale popular for in-place ore leaching or large scale

"heap" leaching.  Popular for extreme amounts of "heap" leaching.  Popular for extreme amounts of solids.solids.

• Dispersed Solids....."Solids Added to Liquid“Dispersed Solids....."Solids Added to Liquid“ The solids are usually crushed into small pieces The solids are usually crushed into small pieces

before being contacted with solvents.  This is a before being contacted with solvents.  This is a popular leaching method when an especially high popular leaching method when an especially high

recovery rate can economically justify the typically recovery rate can economically justify the typically higher operating cost (Ex/ gold extraction)higher operating cost (Ex/ gold extraction)

Figure for LeachingFigure for Leaching

Liquid – Liquid ExtractionLiquid – Liquid Extraction

Liquid extraction (or solvent extraction) refers to an Liquid extraction (or solvent extraction) refers to an operation in which the components of a liquid mixture operation in which the components of a liquid mixture are separated by contacting it with a suitable are separated by contacting it with a suitable insoluble liquid solvent which preferentially dissolves insoluble liquid solvent which preferentially dissolves one or more components.one or more components.

In this operation, the separation of the components In this operation, the separation of the components depends upon the unequal distribution of the depends upon the unequal distribution of the components between the immiscible liquids. The feed components between the immiscible liquids. The feed solution represents one phase and the solvent to be solution represents one phase and the solvent to be used to effect separation represents the second used to effect separation represents the second phase.  The mass transfer of the solute liquid takes phase.  The mass transfer of the solute liquid takes place from the feed solution to the solvent phase.place from the feed solution to the solvent phase.

Basic StepsBasic Steps

Typical liquid-liquid extraction operations Typical liquid-liquid extraction operations utilize the differences in the solubilities of utilize the differences in the solubilities of the components of a liquid mixture. The the components of a liquid mixture. The basic steps involved include:basic steps involved include:

1. Contacting the feed with the extraction 1. Contacting the feed with the extraction solvent.solvent.2. Separation of the resulting phases, and 2. Separation of the resulting phases, and 3. Removal/recovery of solvent from each 3. Removal/recovery of solvent from each phase. phase.

Typical liquid-liquid Typical liquid-liquid extraction operations extraction operations utilize the differences in utilize the differences in the solubilities of the the solubilities of the components of a liquid components of a liquid mixture. The basic steps mixture. The basic steps involved include:involved include:

1. Contacting the feed 1. Contacting the feed with the extraction with the extraction solvent.solvent.

2. Separation of the 2. Separation of the resulting phasesresulting phases

3. Removal/recovery of 3. Removal/recovery of solvent from each phase. solvent from each phase.

Some Basic Steps & Extractor DesignSome Basic Steps & Extractor Design

LET’S START TO EXTRACT LET’S START TO EXTRACT SOME OIL!!!SOME OIL!!!

Selecting the best system for type of

oilOILSEED

PROCESSING

Getting your seeds into useful

sizesSIZE

REDUCTION

Removing dust,sand etc.

SEED CLEANING

Removing tough outer shells

DECORTICATION

Clean some mess out

CONDITIONING

Improve the surface areaROLLING

Need some oil?

EXTRACTIONGetting pure

oilREFINING

PREPERATION OF OIL PREPERATION OF OIL EXTRACTIONEXTRACTION

• Oilseed processingOilseed processing

• DecorticationDecortication

• Seed cleaning Seed cleaning

• Size reduction Size reduction

• RollingRolling

• ConditioningConditioning

• Oilseed processingOilseed processing Various small-scale techniques are available to Various small-scale techniques are available to

enable people in rural areas to process their own enable people in rural areas to process their own oilseeds locally. Careful consideration is needed oilseeds locally. Careful consideration is needed to select the system that will best suit the local to select the system that will best suit the local circumstances. These circumstances include circumstances. These circumstances include the the scale of operation required, the availability of a scale of operation required, the availability of a power sourcepower source, and , and a number of other factorsa number of other factors..

• Decortication Decortication Some oilseeds have a hard outer shell which Some oilseeds have a hard outer shell which

must be removed before processing. This process must be removed before processing. This process is called decortication. Palm kernel is an example is called decortication. Palm kernel is an example of a seed that must be decorticated prior to of a seed that must be decorticated prior to processing. The extraction of oil from other processing. The extraction of oil from other oilseeds which can be processed without oilseeds which can be processed without decorticating them first, such as sunflower, may decorticating them first, such as sunflower, may be aided by removing a proportion of the hulls be aided by removing a proportion of the hulls before processing. before processing.

• Seed cleaning Seed cleaning It is essential to winnow and sieve oilseeds, prior to It is essential to winnow and sieve oilseeds, prior to

expelling, to remove as much dirt, dust, sand and expelling, to remove as much dirt, dust, sand and small stones as possible. The presence of sand small stones as possible. The presence of sand results in high wear on critical components of results in high wear on critical components of expellers such as cages, wormshafts and chokes. expellers such as cages, wormshafts and chokes. Using clean oilseed for expelling will greatly increase Using clean oilseed for expelling will greatly increase the time that the expeller can be used before the time that the expeller can be used before replacement parts are needed. replacement parts are needed.

• Size reduction Size reduction Generally, small oilseeds (such as sesame or Generally, small oilseeds (such as sesame or

rapeseed) can be processed directly, while larger rapeseed) can be processed directly, while larger seeds (such as copra or shea nuts) need to be seeds (such as copra or shea nuts) need to be ground before processing. At the domestic level, ground before processing. At the domestic level, grinding is usually carried out with a pestle and grinding is usually carried out with a pestle and mortar (Plate I) while larger quantities may be mortar (Plate I) while larger quantities may be ground in a village maize mill (Plate II). Hand-ground in a village maize mill (Plate II). Hand-operated meat mincing machines can also be used operated meat mincing machines can also be used in certain circumstances. The most common type of in certain circumstances. The most common type of powered mill used for small-scale operations is the powered mill used for small-scale operations is the hammer mill. hammer mill.

• Rolling Rolling Rolling a seed generally results in an Rolling a seed generally results in an

improvement in oil extraction by increasing the improvement in oil extraction by increasing the surface area of the seed while at the same time surface area of the seed while at the same time retaining channels for the flow of oil. The flakes retaining channels for the flow of oil. The flakes should be very fine and preferably thinner than should be very fine and preferably thinner than 0.1 mm. Rolling before processing in a bridge 0.1 mm. Rolling before processing in a bridge press is said to increase oil yields by 10% for press is said to increase oil yields by 10% for palm kernel, groundnut and sunflower.palm kernel, groundnut and sunflower.

• ConditioningConditioning Oilseeds are nearly always conditioned before Oilseeds are nearly always conditioned before

large-scale expelling. Small-scale expellers large-scale expelling. Small-scale expellers minimize the need for pre-treatment by using a minimize the need for pre-treatment by using a relatively fast wormshaft speed which shears the relatively fast wormshaft speed which shears the oilseed as it passes through the expeller and oilseed as it passes through the expeller and produces frictional heating within the expeller produces frictional heating within the expeller barrel. This assists oil expulsion by raising the barrel. This assists oil expulsion by raising the temperature of the oilseed. temperature of the oilseed.

VEGETABLE OIL EXTRACTIONVEGETABLE OIL EXTRACTION• The "modern" way of processing vegetable oil is by chemical The "modern" way of processing vegetable oil is by chemical

extraction, using solvent extracts, which produces higher yields extraction, using solvent extracts, which produces higher yields and is quicker and less expensive. The most common solvent is and is quicker and less expensive. The most common solvent is petroleum-derived hexane. This technique is used for most of petroleum-derived hexane. This technique is used for most of the "newer" industrial oils such as soybean and corn oils.the "newer" industrial oils such as soybean and corn oils.

• Another way is physical extraction, which does not use solvent Another way is physical extraction, which does not use solvent extracts. It is made the "traditional" way using several different extracts. It is made the "traditional" way using several different types of mechanical extraction. This method is typically used to types of mechanical extraction. This method is typically used to produce the more traditional oils (e.g., olive), and it is preferred produce the more traditional oils (e.g., olive), and it is preferred by most "health-food" customers in the USA and in Euroby most "health-food" customers in the USA and in Europpe. e. Expeller-pressed extraction is one type, and there are two Expeller-pressed extraction is one type, and there are two other types that are both oil presses: the screw press and the other types that are both oil presses: the screw press and the ram press. Oil seed presses are commonly used in developing ram press. Oil seed presses are commonly used in developing countries, among people for whom other extraction methods countries, among people for whom other extraction methods would be prohibitively expensive. The amount of oil extracted would be prohibitively expensive. The amount of oil extracted using these methods varies wideusing these methods varies widely.ly.

Wet extraction methods:Wet extraction methods:

In wet extraction methods In wet extraction methods water water is used to extract oilis used to extract oil from oilseeds. from oilseeds. The distinction should be made The distinction should be made between wet methods and water-between wet methods and water-assisted methods of oil extraction.assisted methods of oil extraction.

Wet extraction methods involve Wet extraction methods involve the use of a relatively large amount the use of a relatively large amount of water so that the oilseed is of water so that the oilseed is suspended in the water and the suspended in the water and the extracted oil floats on the surface. extracted oil floats on the surface.

WATER-ASSISTED WATER-ASSISTED METHODSMETHODS

Involve the addition of a small Involve the addition of a small quantity of water to the oilseed before quantity of water to the oilseed before the oil is extracted by manual the oil is extracted by manual kneading. These methods are kneading. These methods are discussed later. They are not classified discussed later. They are not classified as wet methods because all the water as wet methods because all the water used is absorbed by the oilseed and no used is absorbed by the oilseed and no separate water layer is apparent. separate water layer is apparent.

HOT WATER FLOTATION (HWF) HOT WATER FLOTATION (HWF) METHOD METHOD

The hot water flotation (HOOF) method of edible The hot water flotation (HOOF) method of edible oil extraction is traditionally used in the rural areas of oil extraction is traditionally used in the rural areas of many developing countries. Usually, decorticated many developing countries. Usually, decorticated oilseed is used. The oilseed kernels are heated and oilseed is used. The oilseed kernels are heated and ground by pounding in a pestle and mortar. The ground by pounding in a pestle and mortar. The ground seed is then suspended in boiling water and ground seed is then suspended in boiling water and boiled for at least 30 min. Liberated oil floats to the boiled for at least 30 min. Liberated oil floats to the surface. Further quantities of water are sometimes surface. Further quantities of water are sometimes added after boiling to replace that lost by evaporation, added after boiling to replace that lost by evaporation, and to encourage the oil to float to the surface. The oil and to encourage the oil to float to the surface. The oil is carefully scooped from the surface of the water is carefully scooped from the surface of the water using a shallow dish and is then heated over a fire to using a shallow dish and is then heated over a fire to remove residual moisture. remove residual moisture.

• The advantage of the HWF method over other The advantage of the HWF method over other small-scale oilseed processing techniques, such as small-scale oilseed processing techniques, such as those using expellers or ghanis, is its simplicity. those using expellers or ghanis, is its simplicity. The equipment required (pestle and mortar, boiling The equipment required (pestle and mortar, boiling pans, etc.) is readily available. However, oil yields pans, etc.) is readily available. However, oil yields tend to be low and the process can be time tend to be low and the process can be time consuming and arduous. This is especially true if consuming and arduous. This is especially true if traditional pestle and mortar methods are used to traditional pestle and mortar methods are used to grind the oilseed kernel. If long boiling times are grind the oilseed kernel. If long boiling times are used, fuel consumption will also be high. used, fuel consumption will also be high.

• The above method may be applied to most oilseeds The above method may be applied to most oilseeds with varying degrees of success. Sources of oil, with varying degrees of success. Sources of oil, such as coconut and oil palm fruits, can be such as coconut and oil palm fruits, can be processed by traditional methods which make use processed by traditional methods which make use of the water already present in the seed. of the water already present in the seed.

OIL EXTRACTION MACHINEOIL EXTRACTION MACHINE

SOYBEAN MEALS’ STORAGESOYBEAN MEALS’ STORAGE

OIL EXTRACTION PLANTOIL EXTRACTION PLANT

OIL EXPELLERSOIL EXPELLERS

Series of small scale oil expeller Series of small scale oil expeller These small scale screw type oil expeller are These small scale screw type oil expeller are

advanced oil processing machinery, advanced oil processing machinery, characterized by their characterized by their high oil output rate high oil output rate

with good quality, with good quality, simple designsimple design, , easy to useeasy to use and and continuous operationcontinuous operation. They can use for . They can use for

various raw material, such as peanut, beans, various raw material, such as peanut, beans, rape and cotton seeds, sesame, olive, rape and cotton seeds, sesame, olive,

sunflower, coconut, grass seed etcsunflower, coconut, grass seed etc

Oil expellersOil expellersExpellers are continuous in Expellers are continuous in

operation and work by grinding operation and work by grinding and pressing the raw material as and pressing the raw material as it is carried through a barrel by a it is carried through a barrel by a helical screwhelical screw..The pressure inside The pressure inside the barrel, and hence the yield of the barrel, and hence the yield of oil, are adjusted using a ‘choke’ oil, are adjusted using a ‘choke’

ring at the outlet. The equipment ring at the outlet. The equipment has higher production rateshas higher production rates than than similar sized presses similar sized presses but is more but is more expensive to buy and operateexpensive to buy and operate..

PRESS TYPES OF THE OIL PRESS TYPES OF THE OIL EXTRACTION PROCESSESEXTRACTION PROCESSES

• Manual presses Manual presses

• The wedge press The wedge press

• The plank press The plank press

• Cage presses Cage presses

• Curb pressesCurb presses

• Bridge pressBridge press

• Bridge-type Cage pressBridge-type Cage press

• Scissor pressScissor press

• Hydraulic pressHydraulic press

• Ram pressRam press

• GhaniGhani

These presses are used in the rolling stage of the oil These presses are used in the rolling stage of the oil extraction. They help the extraction by widening extraction. They help the extraction by widening

the extraction surface area.the extraction surface area.

CURB PRESSCURB PRESS

BRIDGE PRESSBRIDGE PRESS

SCISSOR PRESSSCISSOR PRESS

HYDRAULIC PRESSHYDRAULIC PRESS

RAM PRESSRAM PRESS

POWER GHANI POWER GHANI

INFORMATION ABOUT SOME INFORMATION ABOUT SOME TYPES OF OILSEEDSTYPES OF OILSEEDS

• COCONUTSCOCONUTS Coconuts grow in the Coconuts grow in the

coastal areas of the coastal areas of the tropics.tropics.

Major producing Major producing countries are: The countries are: The Philippines, Indonesia, Philippines, Indonesia, Malaysia, Sri Lanka, Malaysia, Sri Lanka, India, C’ote d'Ivoire, India, C’ote d'Ivoire, Mozambique, Tanzania, Mozambique, Tanzania, and the Pacific Islands. and the Pacific Islands.

USAGE EXAMPLES OF COCONUTUSAGE EXAMPLES OF COCONUT

• As a cooking oil and in the As a cooking oil and in the preparation of oil and fat blends for preparation of oil and fat blends for the food industry.the food industry.

• Soap-making Soap-making

GROUNDNUTS:GROUNDNUTS:

• The groundnut is an The groundnut is an annual plant. annual plant.

• Varieties are grown Varieties are grown as two types, either as two types, either as a bushy bunch or as a bushy bunch or as a runner.as a runner.

• Groundnuts grow in Groundnuts grow in tropical and tropical and subtropical regions, subtropical regions, and in warm parts of and in warm parts of temperate regions. temperate regions.

USAGE EXAMPLES OF GROUNDNUTSUSAGE EXAMPLES OF GROUNDNUTS

• Using a diesel-powered CeCoCo H54 Using a diesel-powered CeCoCo H54 expeller expeller

OIL PALMSOIL PALMS::

• The oil palm The oil palm requires a rainy requires a rainy tropical climate tropical climate

• begin to fruit begin to fruit after 10 yearsafter 10 years

• do not give a full do not give a full crop for about 20 crop for about 20 years years

USAGE EXAMPLES OF OIL PALMSUSAGE EXAMPLES OF OIL PALMS

• Used in commercial agriculture in the Used in commercial agriculture in the production of palm oil. production of palm oil.

RAPSEED & RAPSEED & MUSTERDSEED:MUSTERDSEED:

• Rape and mustard Rape and mustard are similar species are similar species and for the and for the purposes of this purposes of this manual can be manual can be treated as one treated as one oilseed. Rape is one oilseed. Rape is one of the most widely of the most widely cultivated oilseed cultivated oilseed crops crops

SUNFLOWER SEED:SUNFLOWER SEED:

• Sunflower is an Sunflower is an annual plant that annual plant that thrives in the thrives in the tropics at medium tropics at medium and high elevations and high elevations and, under suitable and, under suitable conditions, in conditions, in temperate climates. temperate climates.

SOYA:SOYA:

• The soyabean, or The soyabean, or soybean, is an soybean, is an annual, and with annual, and with the selection of the selection of the appropriate the appropriate variety, can be variety, can be grown in a wide grown in a wide range of range of conditions conditions

SOYBEAN (SOYABEAN) OILSSOYBEAN (SOYABEAN) OILS

USAGE EXAMPLES OF SOYABEANUSAGE EXAMPLES OF SOYABEAN

• Widely used as a food crop Widely used as a food crop

• Raw material in the manufacture of Raw material in the manufacture of 'textured vegetable protein' used for 'textured vegetable protein' used for human consumption human consumption

TAKE LOOK AT OILSEEDS :)TAKE LOOK AT OILSEEDS :)

MEANING OF SOME MEANING OF SOME OILSEEDS :))OILSEEDS :))

• Palm : Palm : PalmiyePalmiye

• Sesame: Sesame: SusamSusam

• Rapeseed: Rapeseed: Kolza Kolza tohumutohumu

• Mustardseed: Mustardseed: Hardal tohumuHardal tohumu

• Linseed: Linseed: Keten Keten tohumutohumu

• Cottonseed: Cottonseed: pamuk tohumupamuk tohumu

• Soyabean: Soyabean: SoyaSoya

• Groundnut: Groundnut: yerfıstığıyerfıstığı

• Castorseed: Castorseed: keneotu tohumukeneotu tohumu

• Sunflower: Sunflower: ayçiçeğiayçiçeği

• Copra: Copra: kurutulmuş kurutulmuş hindistan cevizihindistan cevizi

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PALM SESAME RAPESEED MUSTARD LINSEED COTTONSEED SOYABEAN PALM FRUIT GROUNDNUTCASTORSEEDSUNFLOWER COPRA

% OIL

TEAM “E”TEAM “E”

Aslı IşıkAslı Işık

Mustafa SeçkinMustafa Seçkin

Vasfi GündoğduVasfi Gündoğdu

Erdal SazErdal Saz

Gökhan BulutGökhan Bulut