PROCESS FOR OBTAINING SOYBEAN MEAL, SOYBEAN OIL AND OILSEED MEAL WITH HIGH PROTEIN CONTENT

Description

1 / 13 SYSTEM FOR OBTAINING SOYBEAN MEAL, SOYBEAN OIL AND OILSEED MEAL WITH HIGH PROTEIN CONTENT BRIEF DESCRIPTION

[001] This patent application relates to a “SYSTEM FOR OBTAINING SOYBEAN MEAL, SOYBEAN OIL AND OILSEED MEAL WITH HIGH PROTEIN CONTENT”, which is achieved through a carbohydrate extraction system that uses anhydrous ethanol at 99.5° INPM to wash rolled soybeans, and a hydroalcoholic solution with a concentration of 50 to 55% to remove carbohydrates present in Hypro meal, resulting in products with high protein content and low moisture content. The present invention has an important technical contribution in that the process employed a single desolventizer, dryer, and cooler, both for the production of Hypro meal and for the production of SPC meal. FIELD OF APPLICATION

[002] The present invention belongs to the processing operations section, to the field of chemical processes, more specifically to separation by extraction, as it refers to a process for obtaining soybean meal, soybean oil and oilseed meal with a high protein content, by means of a carbohydrate extraction system that uses anhydrous ethanol and hydroalcoholic solution as solvents and a single desolventizer, a dryer and a cooler, both for the production of Hypro meal and for the production of SPC meal. CONVINCING

[003] Soybean meal is a product resulting from crushing soybeans to extract oil. Generally, soybean meal is used as animal feed and human food and, in its less rich form, has the following composition: protein (46 to 48% by mass); lipids (16% by mass); carbohydrates (25% by mass) and water (8 to 10% by mass).

[004] Solvent extraction of oil from soybean meal in its less rich form is an efficient method for extracting vegetable oil. The most commonly used solvent is derived from Petition 870260060215, dated 06 / 19 / 2026, page 34 / 50 2 / 13 petroleum, hexane, a mixture of hydrocarbons with a boiling point around 70°C.

[005] Hexane is the most widely used industrial solvent for extracting fatty materials, however, it has several negative factors that encourage the use of alternative solvents for extracting vegetable oils for the following reasons: ✓ Hexane is extremely flammable; ✓ In hexane extraction, gossypol (present in cotton) and aflatoxin (present in peanuts), carcinogenic substances, are not extracted, remaining in the final meal; ✓ It presents greater difficulties in operation and industrial maintenance compared to other solvents that may be used, due to the items mentioned above; ✓ Hexane has a benzene ring chain, making it carcinogenic; ✓ The use of hexane as a solvent does not eliminate the anti-nutrients and antigens from soy.

[006] Optimizations made to the process in question made it possible to use ethanol as a solvent, allowing the extraction of lighter-colored oils, better smell, higher quality bran proteins and also achieving a 2% increase in soybean oil extraction.

[007] The use of ethanol as a solvent also promotes the elimination of antinutrients and antigens present in soybeans, and it is not considered a carcinogenic product, reducing the health risks associated with the operation. The ethanol used in the solvent composition is a vehicle that facilitates the washing of less rich soybean meal and the removal of oils present in it.

[008] Currently, soybean meal with a high protein content is obtained from existing plants by washing the product with a hydroalcoholic solvent with an alcohol concentration of around 60% INPM (INPM = quantity in grams of absolute alcohol contained in 100 grams of hydroalcoholic mixture), where a large part of the carbohydrates contained in the meal dissolves. In this way, the concentration is increased. Petition 870260060215, dated 06 / 19 / 2026, page 35 / 50 3 / 13 of the protein mass in the remaining bran for an index between 60-70% by mass on a dry matter basis.

[009] The ethanol used in the solvent composition is a vehicle that facilitates the washing of the high-protein soybean meal and the removal of the carbohydrates it contains. The product derived from the proposed process, which employs ethanol, has great nutritional and commercial value due to high global demand, and is known as SPC (Soy Protein Concentrate). SPC soybean meal has several advantages over other sources of animal or vegetable protein (normal soybean meal, soy protein, fishmeal, etc.), such as: ✓ High protein digestibility equivalent to that of animal sources, and can be a substitute for other protein sources; ✓ Reduced flatulence factors to levels similar to those of soy protein, due to the removal of 90% of soluble sugars from soy bran; ✓ Enables a greater number of applications in animal feed and nutritional supplements, characterized by a low flavor profile, with the removal of undesirable components; ✓ It does not interfere with osmotic balance due to its low sodium concentration, approximately 25 to 50 ppm; ✓ Due to its higher protein concentration, it offers high functionality in terms of shipping and transportation costs, and is viable for processing into various forms such as flours, granules, or pellets, characterized according to their final application; ✓ It offers greater stability and uniformity compared to fishmeal, mainly due to heat treatments and a moisture content of around 8%, which inhibits the proliferation of microorganisms; ✓ It has low processing costs when compared to other more refined protein sources. BACKGROUND OF THE INVENTION

[010] Currently, the literature describes processes for producing soybean oil and meal in their less rich form, which provide products with the following concentrations: Petition 870260060215, dated 06 / 19 / 2026, page 36 / 50 4 / 13 protein 46 to 48% by mass; lipids 16% by mass; carbohydrates 25% by mass and water 8 to 10% by mass, where the extraction step is carried out using alcohol, as observed below.

[011] In alcohol extraction, it is possible to operate under conditions of infinite miscibility similarly to hexane extraction, with countercurrent contact and complete desolventization of the final micelle by alcohol evaporation. In the extractor, the extruded or laminated agglomerates are partially extracted by the micelle with the highest concentration, which will originate the final micelle, removed from the extractor for desolventization. The material to be extracted moves countercurrently to the solvent flow and is extracted and drained, passing to a desolventizer, where the solvent present is vaporized by heating and contact with direct and indirect steam.

[012] The solvent used in the proposed process is composed of a mixture of water and alcohol, in a proportion of 99.5% alcohol. The ratio for applying this solvent is 2 liters of anhydrous alcohol / ton of mass feeding the extractor. Inside the extractor, the temperature must not exceed the boiling point of the solvent, reducing its evaporation.

[013] The proposed operating temperature should not exceed 73°C and the retention time of the mass inside the extractor will be 1 hour followed by drainage for 15 minutes. To avoid high steam consumption, the final micelle is fractionated by cooling to 15°C to allow separation into 3 layers (free oil, emulsified oil and gums).

[014] The resulting heterogeneous system will be processed in a suitable phase separator (settling column), where the free oil, emulsified oil and gums are separated from the poor micelle of lower specific gravity.

[015] The poor micelle separated in the initial decantation will be recycled to the extractor with a low residual oil content of 3.5%. The oil and gum phase is treated with water and enzymes, transforming the phosphatides into mono- and diglycerides, then centrifuged to give a degummed oil with about 4% volatiles and a fluid sludge formed by gums and some poor micelle. Petition 870260060215, dated 06 / 19 / 2026, page 37 / 50 5 / 13

[016] The sludge obtained, formed by gums and poor micelles, is recycled and incorporated into the solid extraction residue before desolventization. In desolventization, the separated alcoholic vapors will be condensed in shell and tube heat exchangers and returned to the process. The protein meal obtained has a fat content of less than 1%. The degummed oil is then subjected to a desolventization process through a stripping column. In this process, the oil will be separated from the alcoholic vapors, which will be condensed in shell and tube heat exchangers and returned to the process.

[017] The literature also includes the SPC production process, in which the extraction step occurs as follows: in the first step, soybean meal with a protein content between 46-48% is sent to an extractor, where the product is washed in the countercurrent extraction sector with a hydroalcoholic solvent with an alcohol concentration of around 60% INPM. In this step, part of the carbohydrates contained in the meal dissolves in the solvent, which leaves the extractor in the form of an alcoholic micelle, which is then sent to the solvent recovery sector to be reused in the carbohydrate extraction.

[018] The bran washed with hydroalcoholic solution continues to be transported inside the extractor, finally passing through a drainage sector, thus preventing the bran leaving the extractor from having a large amount of solvent. From the extractor, the drained bran, with approximately 55 to 59% solvent and an ethyl alcohol concentration of around 57% INPM, is sent to the mechanical press sector, where part of the micelle composed of water, alcohol, and soluble and insoluble solids is extracted, which returns to the extractor along with the solvent. The bran leaving the presses will have a reduced solvent content of 50%, and the composition of this hydroalcoholic solvent will be around 57% INPM.

[019] In the desolventizing, drying and cooling stages, the bran is sent from the press assembly to a desolventizer equipped with steam-heated trays, the purpose of which is to evaporate all the alcohol and some of the water in the form of hydroalcoholic vapors, without degrading the protein contained in the bran. These vapors are recovered by condensation in the condenser section, generating a hydroalcoholic condensate with an alcohol concentration of around 80-85% INPM. Petition 870260060215, dated 06 / 19 / 2026, page 38 / 50 6 / 13 of which is sent to the recovered solvents tank. The bran that comes out of the desolventizer contains approximately 21% water, requiring it to be dried in a steam dryer and subsequently cooled in the cooler so that the final moisture content is around 8%, preventing the proliferation of microorganisms. The final product temperature should be below 40°C to prevent product degradation. Finally, the alcoholic micelle that leaves the extractor is sent to the solvent recovery sector by evaporation / distillation or by evaporation, these solvents being collected in the recovered solvent tank. In the recovered solvent tank, ethyl alcohol is added as needed to replace process losses and water, if necessary, to adjust the concentration of the hydroalcoholic solvent to around 60% INPM.

[020] In the solvent recovery stage, in the modern solvent recovery system, the recovery of the hydroalcoholic solution contained in the micelle coming from the extractor is done by feeding a second effect of an evaporator, whose hydroalcoholic vapors generated there are condensed in a condenser, generating a hydroalcoholic condensate with a high alcohol content, around 80-85% INPM, which is sent to the recovered solvent tank. The alcoholic micelle remaining from the second effect of the evaporator will feed the first effect of the evaporation, whose hydroalcoholic vapors will be sent to the second effect of the evaporation. The alcoholic micelle that leaves the first effect, already with a low alcohol content, around 10% INPM, will be sent to a distillation column which will generate a dealcoholized micelle that will be sent to another evaporator of five to seven effects, producing a molasses with a high carbohydrate content.The hydroalcoholic vapors generated in the distillation column will be sent to the first effect of the evaporator, where the hydroalcoholic condensate will join the hydroalcoholic condensate produced in the second effect, and then be sent to the recovered solvent tank.

[021] In the conventional solvent recovery system, the recovery of the hydroalcoholic solution contained in the micelle coming from the extractor is done by feeding a first effect of an evaporator, whose generated hydroalcoholic vapors are condensed in the second effect, generating a hydroalcoholic condensate with a high alcohol content, around 80-85% INPM, which is then sent to the recovered solvent tank. The micelle Petition 870260060215, dated 06 / 19 / 2026, page 39 / 50 The 7 / 13 alcoholic residue from the first evaporation process will be sent to a second process, and so on, until the last evaporation process (which may have four to seven effects), resulting in a carbohydrate-rich molasses. The low-alcohol hydroalcoholic condensates generated in the second and subsequent processes, as well as the condensate generated in the final evaporation condenser, will be sent to the recovered solvent tank where the solvent (Sol1) to be used in the extractor will be prepared.

[022] Regarding the preparation of the solvent to be used in the extractor, all hydroalcoholic condensates generated in the solvent recoveries, being those condensates with a high alcohol concentration, are combined with the condensates with a low alcohol content generated in the other effects of evaporation and collected in the tank where, with the addition of water, if necessary, and ethyl alcohol, necessary to replace the process losses, the alcohol concentration of the solvent to be used in the extractor will be adjusted to around 60% INPM.

[023] Current processes have the following main disadvantages in the production of soybean oil and meal in its less rich form for feeding the SPC meal production plant (its richer form): ✓ High electricity consumption, as it becomes necessary to install desolventizers, dryers, and coolers to prepare the bran that leaves the extractor for subsequent feeding into the SPC bran production plant; ✓ High steam consumption due to the fact that today plants desolventize and dry the bran before feeding it into the plant for SPC bran production; ✓ Significant physical space is needed to accommodate the desolventizer, dryer, and cooler, which are necessary for preparing the bran in its less rich form for feeding the SPC bran production plant; ✓ Significant investment is needed for the manufacturing and assembly of the desolventizer, dryer, and cooler; ✓ Another important point to highlight is the need for a high volume of water circulating in cooling towers to condense the vapors generated in the desolventizer. Petition 870260060215, dated 06 / 19 / 2026, pages 40 / 50 8 / 13

[024] In addition to the processes previously presented, the current state of the art also includes several patent documents, some of which are briefly discussed below.

[025] The prior art BR10202100406-7, entitled Process for obtaining soybean meal with high protein content, with a carbohydrate extraction system, and owned by the present inventors, refers to a process for obtaining soybean meal and meal from other oilseeds, through a carbohydrate extraction system, resulting in a product with high protein content and low moisture content. The described process has as a major differentiating factor the installation of a complementary stage for final washing of the meal with a hydroalcoholic solution with a high alcohol content, around 86% INPM, obtained by collecting the condensates from the desolventizer and the solvent recovery sector in a new recovered solvent tank to which the alcohol necessary to replace process losses is added.

[026] The prior art PI0704513-1, owned by the present inventor, entitled Process for obtaining soybean meal with a solvent recovery system with low specific steam consumption per liter of solvent recovered, refers to a process to be applied in plants for the production of protein-enriched soybean meal capable of improving both yield and efficiency in the solvent recovery sector by adding a distillation column that, interconnected to a set of two- or three-stage evaporators, concentrates micelles with hydroalcoholic vapors; on the other hand, the process is also improved in the alcoholic vapor condensation sector, which provides for the installation of a heat regenerator condenser between the desolventizer and water condenser, as well as an absorption column for recovering the remaining alcohol from the product.According to the prior art, in its first execution stage, in extractor 1, soybean oil is extracted with hexane solvent, producing Hypro meal with a protein content of 47%, which will be desolventized in desolventizer 1, dried in dryer 1, and cooled in cooler 1; the oil will then pass through a distillation process to separate the hexane solvent, for subsequent reuse and production of crude oil. In the second stage, the desolventized Hypro meal, with a protein content of 47%, will feed extractor 2 for removal of... Petition 870260060215, dated 06 / 19 / 2026, pp. 41 / 50 9 / 13 carbohydrates using an alcoholic solution with a 60% by weight concentration as a solvent. This carbohydrate-free bran will be desolventized in desolventizer 2, dried in dryer 2, and cooled in cooler 2, thus producing SPC bran with a high protein concentration (62% dry basis). The micelles (carbohydrates + alcoholic solvent) will go to the alcohol recovery sector. The major technical advance of the present invention in relation to the aforementioned prior art lies in the fact that the claimed process employs a single desolventizer, dryer, and cooler for both the production of Hypro bran and the production of SPC bran.

[027] The prior art US11254895B2, entitled 'Oilseed extraction method', refers to improved oilseed extraction methods for producing oilseed meal concentrates with higher protein content and reduced soluble carbohydrate (e.g., sugars) and antinutritional compound content. More particularly, the extraction methods of the present disclosure eliminate the need for a desolventization / roasting step prior to soluble carbohydrate extraction, thus allowing greater oil extraction efficiency compared to prior art processes, while allowing effective removal of about 20% to about 90% of soluble carbohydrates (e.g., sugars) and antinutritional compounds.The oilseed extraction method comprises extracting oil and soluble carbohydrates from flaked oilseed meal in a first extraction step comprising sequential extraction of flaked oilseed meal with a polar organic solvent comprising water to extract soluble carbohydrates and anti-nutritional compounds followed by extraction with a non-polar solvent to extract soluble carbohydrates or vice versa.

[028] In order to overcome the technical problems present in the current state of the art, the present invention relates to a process for obtaining soybean oil, soybean meal in its less rich form (Hypro), soybean meal in its richer form (SPC), through a carbohydrate extraction system, resulting in a product with a high protein content and low moisture content. Petition 870260060215, dated 06 / 19 / 2026, pp. 42 / 50 10 / 13 OBJECTIVE OF THE INVENTION

[029] The present invention aims to provide a system for obtaining soybean meal, soybean oil and oilseed meal in general, with a high protein content from a system that uses a single desolventizer, a dryer and a cooler, both for the production of Hypro meal and for the production of SPC meal, and which uses anhydrous ethanol with 99.5% INPM and a hydroalcoholic solution with a concentration of 50 to 55% as solvents, resulting in products with a high protein content and low moisture content. OF THE INVENTION

[030] The present invention relates to a system for obtaining soybean oil, soybean meal in its less rich form (Hypro), and soybean meal in its richer form (SPC), through a system that employs a single desolventizer, a dryer, and a cooler, both for the production of Hypro meal and for the production of SPC meal, resulting in a product with a high protein content and low moisture content, which, for this purpose, employs anhydrous ethanol with 99.5° INPM for oil extraction and Hypro meal production, and for the production of SPC meal, uses a hydroalcoholic solution with a concentration of 50 to 55% as a solvent to remove the carbohydrates present in the Hypro meal. ADVANTAGES OF THE INVENTION

[031] The present invention has the following main advantages: ✓ To provide a system for obtaining soybean meal, soybean oil, and oilseed meal in general that, through a carbohydrate extraction system using ethanol as a solvent, provides products with high protein content and low moisture content; ✓ To provide a process with lower energy and steam consumption compared to current processes; ✓ To provide a process that requires less physical space and less water volume compared to current processes. DESCRIPTION OF THE FIGURES

[032] In order to facilitate a better understanding of the present invention, reference will be made to the figures described below: Petition 870260060215, dated 06 / 19 / 2026, pp. 43 / 50 11 / 13 ✓ FIG. 1: Illustration of the process for obtaining soybean meal, soybean oil and oilseed meal in general, using a system that employs a single desolventizer, a dryer and a cooler, for both the production of Hypro meal and the production of SPC meal; ✓ FIG. 2: Illustration of the process present in the state of the art for obtaining soybean meal and soybean oil. DETAILED DESCRIPTION OF THE INVENTION

[033] The present invention has as a differentiating and unprecedented point, the Hypro bran to be processed in the SPC extractor to obtain SPC bran, being directly derived from the Hypro extractor, as observed in FIG. 1, without the need to pass through desolventizer toaster 1, dryer 1 and cooler 1, which are currently (FIG. 2) used for the production of Hypro bran and, subsequently, for feeding the SPC extractor and producing SPC bran.

[034] In the proposed process (FIG. 1), a single desolventizer, dryer, and cooler serve both the production of Hypro bran and the production of SPC bran. For this purpose, Hypro bran, coming directly from the Hypro extractor, is fed into the SPC extractor with an alcoholic solution with a concentration of 50 to 55% by weight for the production of SPC bran, which results from the extraction of oil in the Hypro extractor using anhydrous alcohol at 99.5° INPM as a solvent. In current processes, as observed in FIG. 2, the SPC extractor is fed with an alcoholic solvent with a concentration of 60% by weight, while in the process described (FIG. 1), the concentration is 50 to 55% by weight, which ensures the dissolution of part of the carbohydrates contained in the Hypro bran and the production of SPC bran.

[035] Thus, in the proposed process, only a single desolventizer, a dryer and a cooler are used for both Hypro meal production and SPC meal production. In this process, anhydrous alcohol (99.5° INPM) is used as a solvent for separating crude oil and Hypro meal, which has a protein content of 46 to 48%, and a hydroalcoholic solution with a concentration of 50 to 55% is used as a solvent for producing SPC meal, to remove the carbohydrates present in the Hypro meal. Petition 870260060215, dated 06 / 19 / 2026, pp. 44 / 50 12 / 13

[036] In the present process (Fig. 1), the desolventizer, dryer and cooler are present in a single unit (one of each piece of equipment and not two of each, as in the conventional process) and can serve both the production of final Hypro meal, coming from the Hypro extractor, or serve the production of SPC meal, when the Hypro meal, instead of going directly to the desolventizer, feeds the SPC extractor to subsequently go to the desolventizer, dryer and cooler. Thus, the present process makes it possible to produce both Hypro meal and SPC meal by using the same equipment (desolventizer, dryer and cooler).

[037] When the production option is Hypro bran, the mass coming out of the Hypro extractor feeds directly into the desolventizer, dryer and cooler. The oil and the alcoholic solvent go through a distillation process for separation and reuse in the process.

[038] When the production option is SPC bran, the mass exiting the Hypro extractor will feed the SPC extractor and, subsequently, the desolventizer, dryer, and cooler.

[039] In the current processes (FIG. 2), the Hypro bran mass exiting the Hypro extractor passes through the desolventizer-toaster 1, ensuring 100% removal of the alcoholic solvent present; it then goes to the dryer 1, to reduce its moisture content, and finally, it passes through the cooler 1, reducing its temperature; the Hypro bran is then ready to be marketed or to feed the SPC extractor, to continue processing and thus obtain the SPC bran. Thus, to obtain the SPC bran, the Hypro bran from the SPC extractor passes through the desolventizer-toaster 2, then through the dryer 2, and then through the cooler 2, to then produce the SPC bran to be marketed.

[040] Previously, for the production of SPC bran only, the Hypro bran coming out of the Hypro extractor needed to go through the exclusive desolventizer; however, the proposed process allows direct feeding into the SPC Extractor, promoting energy savings.

[041] Unlike current processes, the proposed process (FIG. 1) has only one desolventizer, dryer and cooler line, which receives the bran mass. Petition 870260060215, dated 06 / 19 / 2026, pp. 45 / 50 13 / 13 Hypro, coming directly from the Hypro extractor, or SPC Bran mass, coming from the SPC extractor.

[042] Eliminating the passage of Hypro bran through the desolventizer, dryer, and cooler before entering the SPC extractor for the production of SPC bran is one of the technical contributions of the present invention, in addition to the real possibility of using anhydrous ethanol (99.5% concentration) as a solvent, given that this elimination has enabled a reduction in the consumption of steam, electricity, and cooling water. Furthermore, the claimed process also requires less physical space for the plant, since it eliminates the need for a desolventizer, dryer, and cooler line.

[043] The optimizations carried out in the process claimed made it possible to use anhydrous ethanol as a solvent, allowing the extraction of lighter-colored oils, better smell, better quality bran proteins and also achieving a 2% increase in soybean oil extraction.

[044] It should be noted that the process described can be applied in plants to obtain bran with a high protein content using oilseeds in general as raw material, such as soybeans, peanuts, cotton, sunflower and canola.

[045] The ethanol used in the solvent composition is a vehicle that facilitates the washing of less rich soybean meal and the removal of oils present in it.

[046] From the above, the contribution to the technical field of the process described is evident. Petition 870260060215, dated 06 / 19 / 2026, pp. 46 / 50

Claims

1 / 2 CLAIMS 1. SYSTEM FOR OBTAINING SOYBEAN MEAL, SOYBEAN OIL AND OILSEED MEAL WITH HIGH PROTEIN CONTENT characterized by comprising a single desolventizing, drying and cooling line, consisting of a single desolventizer, a single dryer and a single cooler, configured to selectively receive the Hypro meal mass coming directly from the Hypro extractor or the SPC meal mass coming directly from the SPC extractor, in which the system uses anhydrous ethanol at 99.5° INPM and a hydroalcoholic solution with a concentration of 50 to 55% by weight as solvents.

2. SYSTEM FOR OBTAINING SOYBEAN MEAL, SOYBEAN OIL AND OILSEED MEAL WITH HIGH PROTEIN CONTENT, according to any one of claim 1, characterized in that, for the production of Hypro meal, the mass from the Hypro extractor directly feeds the desolventizer, dryer and cooler of the single desolventization, drying and cooling line.

3. SYSTEM FOR OBTAINING SOYBEAN MEAL, SOYBEAN OIL AND OILSEED MEAL WITH HIGH PROTEIN CONTENT, according to any one of claims 1 or 2, characterized in that, for the production of SPC meal, the mass from the SPC extractor directly feeds the desolventizer, dryer and cooler of the single desolventization, drying and cooling line.

4. SYSTEM FOR OBTAINING SOYBEAN MEAL, SOYBEAN OIL AND OILSEED MEAL WITH HIGH PROTEIN CONTENT, according to any one of claims 1, 2, or 3, characterized by eliminating the passage of Hypro meal through the desolventizer / toaster 1, dryer 1, cooler 1, before entering the SPC Extractor, for the production of SPC meal.

5. SYSTEM FOR OBTAINING SOYBEAN MEAL, SOYBEAN OIL AND OILSEED MEAL WITH HIGH PROTEIN CONTENT, according to any of the preceding claims, characterized by being applicable in plants to obtain meals with high protein content using oilseeds in general, such as soybeans, peanuts, cottonseed, sunflower and canola, as raw materials.

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