Seed Oil Extraction Startup Time Reduction
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Solution Overview
Problem
Current oil extraction methods from seed flakes are inefficient, particularly in the initial startup phase due to the need for heating the entire system, which can delay operation by hours and require hazardous solvents like hexane, and face issues with solvent recovery and fines accumulation leading to clogging.
Innovation Solution
A method involving a counter-current extraction process using a multi-chamber sliding cell extractor with steeply angled hoppers for improved drainage, a DTDC column for solvent recycling, and a distillation system for efficient solvent recovery, along with electronic level control and sub-atmospheric pressure to enhance startup efficiency and reduce solvent content, and a three-stage fines removal system to prevent clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the entire system is heated for startup, then oil extraction can proceed, but startup time is delayed by hours
Solution Approach 1:
The hopper is pre-heated to a temperature sufficient to vaporize hexane before seed flakes are introduced. This preliminary heating action eliminates the need to heat the entire system during startup, reducing startup time from hours to minutes while ensuring safe vaporization of solvent.
Solution Approach 2:
The invention skips the lengthy process of heating the entire extraction system by directly introducing pre-heated seed flakes or pre-heating only the critical hopper area. This rushes through the heating phase by focusing energy only where needed, dramatically reducing the time required to reach operational temperature.
2Productivity
If hexane is used as solvent, then oil extraction efficiency is improved, but safety hazards increase
Solution Approach 1:
The system operates under controlled atmospheric conditions where hexane vapor is immediately vaporized and removed in a controlled manner. The hopper heating creates a controlled environment that prevents hazardous accumulation of hexane vapor, maintaining safety while preserving extraction efficiency.
Solution Approach 2:
The invention replaces extensive thermal heating of large system volumes with targeted localized heating of the hopper area. This substitution reduces the total amount of hexane vapor generated and improves control over vaporization, thereby reducing safety hazards while maintaining extraction performance.
3Ease of manufacture
If conventional extraction methods are used, then process simplicity is maintained, but solvent recovery efficiency decreases
Solution Approach 1:
The hopper serves dual functions: it is both the feed chamber for seed flakes and the heating zone for solvent vaporization. By merging these functions, the system achieves efficient solvent recovery without adding separate heating equipment, maintaining process simplicity while improving solvent recovery efficiency.
4Reliability
If the system is heated extensively, then solvent vaporization is complete, but energy consumption increases
Solution Approach 1:
Heating is applied locally to the hopper area where seed flakes are introduced, rather than heating the entire extraction system. This localized heating achieves complete solvent vaporization at the critical point while minimizing energy consumption by avoiding unnecessary heating of other system components.
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
This method significantly reduces startup time, enhances solvent recovery efficiency, and minimizes clogging issues, improving overall oil extraction efficiency and operational safety by using a counter-current extraction process with a multi-chamber sliding cell extractor and a DTDC column.
Implementation Method 1
introducing seed flakes into an extractor, thereby producing an extracted seed flake stream and a miscella stream
Implementation Method 2
introducing the extracted seed flake stream into a DTDC column, thereby producing a first solvent recycle stream and a seed meal stream
Implementation Method 3
introducing the miscella stream into a distillation system, thereby producing a second solvent recycle stream and a seed oil stream
Data Source
AI summary
A method for removing oil from seed flakes, including introducing seed flakes into an extractor, thereby producing an extracted seed flake stream and a miscella stream, introducing the extracted seed flake stream into a DTDC column, thereby producing a first solvent recycle stream and a seed meal stream, and introducing the miscella stream into a distillation system, thereby producing a second solvent recycle stream and a seed oil stream.