Solid Fat from Liquid Oil via Alkali Neutralization
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Solution Overview
Problem
Current methods for processing oily liquid Air Flotation sludge fat and vegetable soap stock into a non-oily solid form are inefficient, requiring reheating and are costly due to high energy consumption, and do not easily convert these low-value products into a dry, free-flowing form suitable for handling and application without combining with protein ingredients.
Innovation Solution
A process involving heating the oily liquid fat or soap stock to above 85°C, removing moisture, and adding an alkali such as calcium hydroxide or sodium hydroxide to form fatty acid salts, which are then cooled to create a non-oily, free-flowing solid product with a bypass function for ruminant animals, eliminating the need for additional heat processing and equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If oily liquid AF sludge fat or vegetable soap stock is processed into hot liquid oil form through heat and vacuum processes, then the fat can be extracted and used, but the product becomes viscous after cooling and requires additional heating and energy consumption for handling
Solution Approach 1:
The patent changes the physical and chemical parameters of the fat by converting it from liquid oil form to solid fat form through controlled cooling and crystallization processes. This parameter change allows the fat to maintain a stable solid state at room temperature without requiring continuous heating, thereby reducing energy consumption while improving handling ease through free-flowing particle characteristics
Solution Approach 2:
The patent utilizes phase transition by cooling the hot liquid oil to below its melting point, causing it to transform from liquid to solid state. This phase transition creates a free-flowing solid fat product that does not require reheating for handling, eliminating the energy cost associated with maintaining liquid state while preserving the fat's functional properties
2Ease of operation
If oily liquid AF sludge fat or vegetable soap stock is processed into non-oily solid product, then handling and delivery become easier, but the conversion process is complex and requires multiple processing steps
Solution Approach 1:
The patent segments the processing into distinct stages: heating to separate free fatty acids, neutralization with alkali to form soap stock, filtration to remove impurities, and cooling to crystallize the solid fat. This segmentation simplifies each individual step while achieving the overall goal of converting liquid oil to free-flowing solid fat, making the complex process more manageable and easier to operate
Solution Approach 2:
The patent extracts free fatty acids from the oily liquid through heating and separation, then removes impurities through filtration. This extraction process isolates the valuable fat components while eliminating unwanted substances, enabling the production of pure solid fat that is easy to handle and deliver without requiring complex additional processing equipment
3Quantity of substance
If AF sludge fat is processed through normal dry process, then moisture is removed, but the oily sludge cannot be converted into dry non-oily product due to its composition
Solution Approach 1:
The patent changes the chemical composition parameters by neutralizing free fatty acids with alkali to form soap stock, then filtering and cooling to crystallize the fat. This parameter change transforms the oily sludge into a dry solid fat product with controlled moisture content, making it convertible to a handleable dry form that normal drying processes cannot achieve alone
Solution Approach 2:
The patent creates a composite processing approach by combining thermal processing (heating to separate FFA), chemical processing (alkali neutralization), mechanical processing (filtration), and thermal processing (cooling to crystallize). This composite method overcomes the limitations of normal dry processes and successfully converts oily sludge into dry non-oily solid fat product
4Quantity of substance
If low-value AF sludge fat is processed into solid fat product, then the product value increases, but the processing cost increases due to energy consumption for heating and cooling
Solution Approach 1:
The patent utilizes phase transition by cooling the processed fat below its melting point to crystallize it into solid form. This phase transition occurs naturally through controlled cooling, and the resulting solid fat maintains its free-flowing properties without requiring additional energy input for maintenance, thereby increasing product value while minimizing energy loss
Solution Approach 2:
The patent converts the harmful effect of high energy consumption into a benefit by using the cooling process not just as a necessary step but as a value-adding crystallization process. The controlled cooling transforms the liquid fat into solid crystals with desirable handling properties, turning what could be seen as an energy loss into a beneficial product enhancement that justifies the energy investment
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
The process converts oily liquid fat or soap stock into a non-oily, free-flowing solid product that is easier to handle, deliver, and apply, with a bypass function for ruminant animals, reducing energy costs and eliminating the need for reheating, while ensuring product safety through inactivation of microorganisms and improved solubility characteristics.
Implementation Method 1
adding an alkali such as calcium hydroxide or sodium hydroxide to form fatty acid salts
Implementation Method 2
heating the oily liquid fat or soap stock to above 85°C, removing moisture
Implementation Method 3
which are then cooled to create a non-oily, free-flowing solid product
Data Source
AI summary
A novel processing method of producing a solid fat products from air flotation sludge fat, vegetable soap stock and an oily liquid oil ingredient with more than 15% free fatty acid level on a fat basis is provided. The liquid fat or oil ingredient is heated to above 85 degree C., mixed with an alkali, dried to less than 18% moisture, and cooled to below 45 degree C. to convert the oily liquid fat or oil ingredient into the solid fat product in dry form. The product has the bypass fat function. The product is free-flowing and easy to be handled, delivered and applied.