Sunflower Dehulling - OFI Events · Sunflower Preparation Process Yields Moisture content 8,00 %...
Transcript of Sunflower Dehulling - OFI Events · Sunflower Preparation Process Yields Moisture content 8,00 %...
Sunflower Dehulling
Bühler AG2014
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Oilseeds World Production 2013/2014.Focus: Sunflower and Rapeseed
EU-27 SF RSWorld No 3 1Prod. : 8.53 20.8Growth 2012: +21.8% +8.2%Growth 2011: +2.7% +8.9%
Argentina SB SFWorld No 3 4 Prod. mio.t : 54.5 2.7Growth 2012: +10.5% -13.0%Growth 2011: +35.9% -22%
Ukraine SFWorld No 1Prod. mio.t : 11.5Growth 2012: +27.7%Growth 2011: +9.5%
Russia SFWorld No 2 Prod. mio.t : 10Growth 2012: +25.6%Growth 2011: +4.1%
Canada RSWorld No 2Prod. mio.t : 18Growth 2012: +29%Growth 2011: +23%
India RS SBWorld No 4 5Prod. mio.t : 7.0 11.8Growth 2012: +2.9% +2.6%Growth 2011: +7.6% +7.2%
China SB RSWorld No 4 3Prod. mio.t : 12.2 14.2Growth 2012: -6.9% +1.3%Growth 2011: -15.8% +5.9%
USA SBWorld No 1 Prod. mio.t : 88.66Growth 2012: +7.3%Growth 2011: +5.2%
Brazil SBWorld No 2 Prod. mio.t : 88.0Growth 2012: +7.3%Growth 2011: +32.3%
World Wide Production
Soybeans:Rapeseed:Sunflower:Total oilseeds*:
*Includes: Soybeans, Rapeseed, Cottonseed, Sunflower, Peanut, Palm kernel, Copra
Source: USDA
mio t 284,94
69,9742,43
502,27
2012 + 6,2 %
+ 11,0 %+ 16,5 %+ 5,8 %
2011 + 19,3 %+ 13,6 %
+ 5,3 %+ 13,8 %
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Sunflowerseed Production
Market Outlook
Growth of sunflowerseed production in Europe and Eastern Europe
Demand for high valuable products like animal feed and vegetable oil due to growth of world population and increase of living conditions
Especially important:o High yields of oil (low oil residues and low oil losses)
o High content of protein in meal
o Digestibility of meal due to less fiber content
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Hull ControlSeparation
Dehulling
Dehullingo beating by impactors
ORo crushing by corrugated roller mills
Separationo separation of hulls & kernels
by oscillating sieveso aspiration of hulls by air
Hull Controlo sifting of hulls and kernels
Flakingo flaking of kernels to open oil cells
Sunflower Preparation Processes
Sunflower Seed
Kernels + Hulls
Hulls
Kernels (fine)
Flaking
Flaked Seed
Hulls + Kernels (fine)
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Vertical Impact Dehuller Horizontal Impact Dehuller
CapacitiesSunflower up to 150 - 180 t/24h
* All capacities and performances values are depending on raw material specifications & conditions.
DehullingKey Preparation Technology
CapacitiesSunflower up to 150 - 180 t/24h
CapacitiesSunflower up to 260 - 320 t/24h
Corrugated Roller Mill
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For high capacity multi-seed crushing
- Suitable for multi-seed processes- High capacity - Limited dehulling efficiency
The roller miller assures flexible processing of multiseeds.
DehullingCorrugated Roller Mill
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DehullingWorking Principles of Corrugated Roller Mill
OLCB | Cracking Mill OLCB | 2012
level controlled feeding device
feeder allows consistent distribution over entire roll width
permanent magnet removes ferrous particles in feed
individual roll gap adjustment
scraper knives cleans rolls from seed residues
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1. Inlet bin with product level sensor2. Pneumatic metering slide gate3. Roll feeder with variable speed4. Permanent Magnet5. Product guide plate and roll end sealing6. Cracking rolls with pneumatic driven roll gap7. Scraper knife
sharp to sharp
Differential Speed
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For efficient multi-seed impact dehulling.
- Suitable for multi-seed dehulling- Smooth dehulling for low fines content- Quiet, clean and safe operation
The versatile dehuller adapts to your requirements.
DehullingVertical Impact Dehuller
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DehullingWorking Principle of Horizontal Impact Dehuller.
1. Product feed2. Rotor3. Impact cone4. Outlet5. Dehulling tuner
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Feeder screw for even feed
Level indicator (top/bottom) avoids choking
Permanent Magnet
Grooved rotor for controlled, fines avoiding product impact
Dehulling degree adjustment through adjustable impact cone (spacers)
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DehullingEspecially Suited for Multi-Seed Oil Mills.
Main advantages:Applicable for dehulling of various oilseeds incl. sunflower, cotton seed, and soybeans
High process safety due to screw feeder, magnet and level probes
Continuously adjustable screw and rotor speed allow perfectly controlled process
Alternative impact cone surface characteristic (smooth, fluted) for optimized dehulling
Efficient especially with higher moisture content
1. Rotor2. Wear plates3. Impact paddles
Impact cone characteristicsSmooth: SunflowerFluted: Soy, cotton seed
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For state-of-the-art sunflower dehulling.
- Smooth dehulling for low fines- Long machine lifetime- Easy maintenance of key parts
Applied in the sunflower seed processing industry exclusively.
DehullingHorizontal Impact Dehuller
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DehullingWorking Principle of Horizontal Impact Dehuller.
1. Product feed2. Rotor3. Impact chest4. Outlet5. Dehulling tuner
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Feeder roll with integrated frequency converter
Magnet
Wear resistant and adjustable impact chest
Only applicable for sunflower seeds
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DehullingSimple Way of Dehulling.
Main advantages:Simple and fast adjustment of impact chest and thus excellent dehulling quality
No aspiration required
Simple and easy accessible and exchangeable wear parts
Efficient especially with lower moisture content
Permanent magnets Impact chest adjustment
Impact rotor Impact chest
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DehullingSystem Comparison.
Corrugated Roller Mill
Vertical Dehuller
Horizontal Dehuller
Dehulling Efficiency + ++ ++
Sunflower Suitability + ++ ++
Other oilseeds ++ + N/A
End Product Quality + ++ ++
Integrated Safety Features + ++ +
Aspiration Yes Yes No
Throughput (t/h) ++ + +
Efficiency (kWh/t) ++ 0 +
Space requirement 0 ++ +
Serviceability ++ + ++
* ++ … very good; + … good; 0 … acceptable; N/A … not applicable
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DehullingTechnical Datas - Overview.
Impact Dehuller Corrugated Roller Mill Vertical Dehuller Horizontal
Dehuller
Dimensions (mm)LengthWidthHeight
2.9201.9001.130
2.110550
1.820
2.9232.0031.925
Rotor / Roll diameter (mm)Rotor / Roll length (mm)
3001.600
600-
8002.150
Aspiration needed (m3/min) 20 15 0
Motor power (kW)Feeder driveMain drive
0,7518,5
0.37 (FC optional)15-22 (FC optional)
0.3318
Weight (kg, net) 3.690 825 2’640
Beaters / Throw paddles / Rolls 2 8 16
Throughput (t/24h)SunflowerSoybeanCotton seed (max. 4% lint)
260 – 320500 - 800230 – 260
150 - 180120 - 150120 - 150
150 - 180--
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SeparationHull Separator
Efficient sifter for hull separation.
- Optimal separation of oilseed kernels from hulls- High throughput capacities- Easy operation and maintenance- Designed especially for oilseed separation
Applied in the oilseed processing industry for the dehulling of sunflower seeds and soya.
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Separation Key Preparation Technology
Hull Separator SMA 203-3 OL
1. Proven main hull aspiration systemEasy adjustable, powerful suction nozzles
2. Proven post hull aspiration systemMulti-tunable aspiration channelLarge control window for optimal setting
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fine hullsImpact Dehuller
Cleaning
hulls to sifter
fine seed to flaker
backflow of undehulled seed
dehulled seed to 2nd stage or to flaker
Separation Working Principle and Technical Data
coarse hulls
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Impact Dehuller
fine seed to flaker back
flow
of u
ndeh
ulle
dse
ed
dehulled seed to 2nd stage or to flaker
hulls to hull control
Separation Working Principle and Technical Data
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Sunflower Preparation Processes
Differentiation through the rest of hull content and amount of kernel loss by efficient hull controls
* additional 2,5-3 % botanical oil content in hulls
Objective • reduction of fiber content in meal by hull removal
• increase of final protein content
• highest oil yield
Different Dehulling Processes
2- stage Dehulling
1- stage Dehulling
Hull Removal from 26% to 10%
Hull Removal from 26% to 14 – 12 %
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Sunflower Preparation Processes2- stage Dehulling with Total Hull Control
1. Dehuller2. Separator3. Filter/Cyclone4. Hull Sifter5. Hull Drum Sieve6. Hull Separator
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* additional 2,5-3 % botanical oil content in hulls
10% rest hull
1,0-1,2% oil loss with hulls*
Separation Hull Control
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Sunflower Preparation Process.1- stage Dehulling with Total Hull Control
12% rest hull
0,9-1,1% oil loss with hulls*
1. Dehuller2. Separator3. Filter/Cyclone4. Hull Sifter5. Hull Drum Sieve6. Hull Separator
* additional 2,5-3 % botanical oil content in hulls
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Separation Hull Control
dehulling results
low kernel/ oil losses
high investment
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Sunflower Preparation Process.1-stage Dehulling with Partial Hull Control
14% rest hull
1,0-1,2% oil loss with hulls*
1. Dehuller2. Separator3. Filter/Cyclone4. Hull Sifter
* additional 2,5-3 % botanical oil content in hulls
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Separation Hull Control
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Sunflower Preparation ProcessYields
Moisture content 8,00 %Oil content 43,00 % NSCrude fiber content 17,50 % NS
Protein content 18,00 % NSHull content 26,00 % NSImpurities < 1,00 % NS
YIELDS AFTER DEHULLING
SUNFLOWER INPUT SPECIFICATION
* based on seed input; all figures determined with Bühler Oil Balance calculation
DEHULLING
Rest hull content in dehulled fraction
Capacity prior to dehullingCapacity prior to expeller pressing
YIELD
Total hulls removedAdditional oil loss*
Extraction mealProtein contentCrude fiber contentOil content
Expeller crude oilExtraction crude oil
2 stage
10 %
100 t/24h80 t/24h
18 t/24h0,21 %
37 t/24h44,5 %19 %
1,0 %34 t/24h
7 t/24h
1 stage
partial
14 %
100 t/24h84 t/24h
14 t/24h0,16 %
41 t/24h41 %23 %
1,0 %33 t/24h
8 t/24h
no dehulling
26 %
100 t/24h100 t/24h
0.0 t/24h0.0 %
56.2 t/24h31.4 %29.3 %
1,0 %30 t/24h11 t/24h
1 stage
total
12 %
100 t/24h82 t/24h
16 t/24h0,17 %39 t/24h42,5 %22 %1,0 %
33 t/24h8 t/24h
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Sunflower Preparation Process.Performance Figures
Dehulling Stages
Rest Hull Content
Protein Content
Loss of Oilbased on Hulls
Loss of Oilbased on seed input
1-stage - partial
14 %
41%
1,2 – 1,0 %
0,15 – 0,2 %
2-stages
10 %
44,5 %
1,2 – 1,0 %
0,2 - 0,3 %
1-stage - total
12 %
42,5 %
0,9 – 1,1 %
0,17 – 0,2 %
Moisture content 8,00 %Oil content 43,00 % NSCrude fiber content 17,50 % NS
Protein content 18,00 % NSHull content 26,00 % NSImpurities < 1,00 % NS
SUNFLOWER INPUT SPECIFICATION
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State of the art features
Flake thickness adjustment during operations
Easy access for regular maintenance
Correct roll type and surface
Optimal Sunflower throughput
(at 0.4mm flake thickness, cold, 8% H2O)
capacities of approx. 400 t/24h
Flaking is Key in Achieving Low Rest Oil in Meal.
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www.buhlergroup.com
Bühler’s High Performance Flaking Mill OLFB.
Bühler’s state-of-the-art flaking mill.
- High performance flaking mill- Flake thickness adjustment during operations- Compact and efficient- Easy maintenance, safe operation