Fat Extraction from Animal By-Products Using Three-Phase Separation
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Solution Overview
Problem
Existing methods for extracting fat from animal by-products suffer from low fat yields, high free fatty acid (FFA) content, and inefficiencies in energy and water consumption, making them unsuitable for high-quality biodiesel production.
Innovation Solution
A method involving crushing the feed stock to 50 mm or less, followed by heat treatment to at least 95°C, then comminuting to 10 mm or less, and separating a three-phase system comprising a fat, aqueous protein, and solid phase, allowing for high fat yield and low FFA content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional dry rendering is used to extract fat from animal by-products, then the process is simple to operate, but the fat yield is low (less than 85%) and FFA content is high
Solution Approach 1:
The invention applies preliminary action by crushing the animal by-products before sterilization and fat extraction. This pre-crushing step increases the surface area and facilitates more efficient fat release during subsequent processing, thereby improving fat yield without significantly complicating the overall process
Solution Approach 2:
The invention changes key process parameters by using sterilization temperatures of 95°C or higher (above conventional rendering temperatures) and controlling the water content at 45-70%. These parameter changes enable more complete fat extraction while maintaining operational simplicity
2Ease of operation
If conventional dry rendering is used to extract fat from animal by-products, then the process is simple to operate, but the FFA content in the extracted fat is high
Solution Approach 1:
The invention changes the temperature parameter by using sterilization temperatures of 95°C or higher, which promotes more complete hydrolysis and extraction of triglycerides while minimizing the formation of free fatty acids. This parameter change improves fat quality without complicating the process
3Manufacturing precision
If wet rendering is used to extract fat from animal by-products, then the FFA content is reduced compared to dry rendering, but the process requires more water and energy
Solution Approach 1:
The invention applies self-service by utilizing the water already present in the animal by-products (45-70% water content) for the extraction process. This eliminates or reduces the need for additional water input and the energy required to heat and evaporate excess water, thereby reducing energy consumption while maintaining low FFA content
4Device complexity
If the feed stock is not crushed before sterilization, then the process is simpler, but the fat yield is low due to incomplete fat release
Solution Approach 1:
The invention applies preliminary action by crushing the feed stock before sterilization to increase surface area and facilitate fat release. This simple mechanical preparation step significantly improves fat yield without adding substantial complexity to the overall process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Achieves a fat yield of at least 95% with low FFA content, enabling efficient separation and purification of fat for biodiesel production.
Implementation Method 1
heat treatment to at least 95°C
Implementation Method 2
separating a three-phase system comprising a fat phase, an aqueous protein phase and a solid phase
Data Source
Figure 1
AI summary
A method for the separation of fat from animal by-products, comprising a supply step a) of providing a feed stock of animal by-products, a treatment step b) of heating the feed stock, a comminution step c) of comminuting the heated feed stock, wherein the feed stock is reduced in size to obtain fragments with a size of 10 mm or less, and wherein a three-phase system, comprising a fat phase, an aqueous protein phase and a solid phase, is obtained, and a separation step d) of separating the fat phase from the three-phase system obtained in comminution step c).