Inert-Powder Separation of Solid Fat From Polyunsaturated Grease
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Solution Overview
Problem
Existing winterization processes for polyunsaturated fatty acid grease face challenges in crystallization efficiency, separation efficiency, and solid fat recovery, particularly for raw materials with low saturated fatty acid content, leading to incomplete precipitation, long operation times, and reduced product yield.
Innovation Solution
A method involving the addition of inert solid powders as crystal seeds and filtration aids during winterization, followed by melting solid fat with hot air or steam, allowing for efficient crystallization, separation, and recycling of solid fat without long-term filtration issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional winterization process is used for polyunsaturated fatty acid grease with low saturated fatty acid content, then the crystallization is slow and incomplete, but the operation time becomes long and product yield is reduced
Solution Approach 1:
The patent applies preliminary action by adding inert solid powders (such as activated carbon, diatomite, or perlite) to the polyunsaturated fatty acid grease before cooling crystallization. These inert powders serve as crystal seeds and filtration aids that prepare the system in advance, enabling rapid and complete crystallization of solid fat components without requiring extended operation times. The inert powders are added at a controlled amount (0.1-6.0% by mass) to optimize the crystallization process.
2Productivity
If conventional filtration method is used to separate solid fat, then the separation is incomplete, but the filtration time becomes long and solid fat recovery is reduced
Solution Approach 1:
The patent uses inert solid powders as intermediaries that facilitate the separation process. These powders act as filtration aids that form a porous structure during crystallization, enabling efficient separation of solid fat from the liquid polyunsaturated fatty acid grease. The inert powders remain in the filter cake after filtration, allowing for rapid and complete separation without requiring prolonged filtration time.
Solution Approach 2:
The patent implements discarding and recovering by retaining the inert solid powders in the filter cake after filtration and then recovering the solid fat through hot air or steam treatment. The inert powders are not discarded but rather reused in subsequent batches, while the solid fat is recovered and can be utilized for various purposes. This approach improves separation efficiency and reduces filtration time.
3Productivity
If solid fat is not recovered from filter cake, then the process is simple, but the product yield is reduced and resource waste increases
Solution Approach 1:
The patent applies discarding and recovering by recovering solid fat from the filter cake through hot air or steam treatment. The filter cake containing inert powders and solid fat is subjected to heating, causing the solid fat to melt and be collected. This recovery process improves product yield and reduces resource waste without significantly increasing process complexity, as the same filtration equipment can be used for both filtration and recovery operations.
Solution Approach 2:
The patent uses parameter changes by applying temperature variation (using hot air or steam at controlled temperatures) to transform the solid fat from a solid state in the filter cake to a liquid state for collection. This parameter change enables efficient recovery of solid fat while maintaining process simplicity, as the temperature control is straightforward and can be implemented using existing heating systems.
4Productivity
If inert material is added to improve crystallization, then the crystallization is rapid and complete, but the filtration process becomes more complex
Solution Approach 1:
The patent uses inert solid powders as intermediaries that simplify the filtration process rather than complicate it. These powders form a porous structure during crystallization that facilitates filtration, and they remain in the filter cake to enable rapid separation. The presence of inert powders actually reduces filtration time and improves separation efficiency, contradicting the assumption that they increase process complexity.
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 method achieves rapid and complete crystallization, high product yield, improved lipid clarity, and efficient solid fat recovery, reducing operational time and environmental impact.
Implementation Method 1
adding a certain amount of inert solid powders to a polyunsaturated fatty acid grease, and stirring slowly, cooling crystallization
Implementation Method 2
introducing hot air or hot steam for melting solid fat absorbed in filter cake
Implementation Method 3
introducing hot air or hot steam for melting solid fat absorbed in filter cake
Implementation Method 4
filtering to obtain a clarified polyunsaturated fatty acid grease
Data Source
Figure 1
AI summary
The present invention provides a method of efficiently separating solid fat from polyunsaturated fatty acid grease. The method comprises adding a certain amount of inert material to the polyunsaturated fatty acid grease, and cooling crystallization, and then filtering through a filter to obtain clarified polyunsaturated fatty acid grease. Afterwards introducing hot gas through the filter to make solid fat adsorbed on a filter cake in the filter dissolved and then recycling it through a filter plate. Inert solid substances can be applied next time. The method of the present invention can be efficiently separated saturated and low-saturated fatty acids from polyunsaturated fatty acid grease. In the process, the winterization crystallization time is short, the crystallization is complete, the crystal separation is easy. It will not cause some solid fat melted and thus re-enter the filtrate due to long separation and blowing dry in conventional process. The yield of final product is high up to 89.8%-97.8%. After winterization, a lipid clarity of the polyunsaturated fatty acid grease is good, and no crystal precipitation would occur at 0°C for 5 hrs.