Capacities: Plants are designed, installed and commissioned on a turnkey basis for the following capacities:
Each AS26 Super Centrifuge, Feed = 1.0 Ton / hour.
Each AS16 Super Centrifuge, Feed = 0.55 Ton / hour.
Continuous Bleaching Process: The neutral, washed and dried Vegetable Oil still contains some color bodies and small traces of soap (<50 parts per million) which have to be removed. The Continuous Bleaching Plant equipped with hermetic leaf filters, operates under vacuum to prevent oil oxidation. The oil is cold mixed with metered quantities of bleaching earth and / or other bleaching agents and thereafter heated to the correct temperature and pumped to the Continuous Bleacher operating under vacuum where an adequate retention time is provided to ensure effective bleaching. The oil earth slurry is further pumped to two hermetic leaf filters operating sequentially resulting in continuous bleached oil (filtrate) discharge.
Advantages: Continuous Bleaching Process cuts costs on labor, maintenance, spares and bleaching earth. Continuous Bleaching Process proportions bleaching earth to oil or fat, continuously and accurately. Optimum conditions of vacuum, temperature and dryness of both components, facilitate efficient deaeration and degassification of the oil-earth mixture. Continuous Bleaching Process minimizes operator attendance by fully automating the process.
Capacity: Continuous Bleaching plants are available for plant capacities of 50 TPD and above. For capacities below 50 TPD, batch bleaching process is recommended.
Deodorization: The deodorization process is highly specialized type of steam distillation under high vacuum based upon the principle of falling film to remove objectionable volatile components such a ketones, aldehydes and alcohols. The bleached oil is pumped by the feed pump to the deaerator, where the pretreated oil is degassed. This deaerated oil is passed through a heat exchanger, where the oil is heated by exchanging the heat of the deodorized oil. The oil is further heated to the stripping temperature in the preheater, wherein thermic fluid is circulated. The above mentioned oil is fed to a flash chamber and flows thereafter to an oil distributor inside falling film deodorizer. The oil descends counter current to the stripping steam in the form of very thin film and gets completely deodorized. The fatty acids distilled are condensed, cooled and stored.
The oil from the bottom, flows to an intermediate vessel having an arrangement for dosing citric acid. This deodorized oil is then pumped through a heat exchanger to the polishing filter. The filtered oil is thereafter passed through a cooler and discharged for collection.
Advantages of Falling Film Technology: Falling Film has a short hold up time during deodorization, compared to any conventional deodorizing plant. The hold up time is approximately 30 seconds, compared to 90 to 130 minutes. Deodorization takes place inside the tubes from a thin film of less than 0.3 mm thick. Thus there is a good heat as well as mass transfer, without any significant pressure drop. This plant can process heat sensitive oils without interchange effects of ester. Due to short hold up time at high temperature and under high vacuum, there is no color fixation of oils. Due to low pressure drop, the stripping steam consumption, is approximately 110 kilograms / ton of oil, which is much lower than that of conventional plants giving approximately saving on steam of 30 to 40%.
The energy consumption of the vacuum plant is essentially reduced, because a lower amount of stripping vapor has to be sucked off. The counter flow configuration of the falling film deodorizer results in lower entraining loss of oil. There is a lower water demand in the vacuum equipment due to size reduction. Fuel oil consumption is less as compared to conventional Continuous Deodorizer.
Fat Splitting: In fat splitting or hydrolysis, vegetable oils or animal fats are split into fatty acid and glycerine, merely by addition of water. The one tower fat splitting process, employs highly innovative and advanced technology for continuous fat splitting without a catalyst. The splitting takes place at a high (55 Bar) pressure in presence of water. The fat and water flow in opposite directions, resulting in high glycerin to water concentration and low steam consumption. The one tower splitting plant is totally continuous, and designed in such a way that the fat is pumped in and the fatty acid and water with glycerine is pumped out continuously. The plant is totally automated and its operation is as simple as switch button. All control instrumentation is connected to the switch board, making fat splitting possible for just one operator to supervise the splitting plant.
Advantages: Fat splitting has a minimum steam consumption (approx. 200 kilograms / ton of fat) achieved by the heat exchange in the splitting tower.
High glycerine to water concentration (with a free fatty acid content of 5% in the crude fat, the glycerine to water concentration is approximately 20%) is made possible by the specially designed water distribution system inside the top of the tower. Discharge temperature of fatty acids from the plant is at approx. 80^oC.
Distillation Process of Fatty Acids: Distillation of heat sensitive fatty acids is a highly complex and difficult operation, requiring specialized process and equipment. Fatty acid distillation process is the most efficient, state-of-the-art process available in the world today, for the distillation of fatty acids obtained from high pressure splitting. Distillation is specially designed to obtain premium quality fatty acids, free from odors and low molecular weight components and minimum color contaminants, with the help of a pre-run column. The process involves stripping the maximum amount of unwanted volatiles from the fatty acids.
Equipment: The Plant consists of a de-gassing and de-watering stage, complete with a condenser /gas cooler and a condensate receiver, two pumps, a pre-run column with falling film evaporator, a product preheater, one reflux condenser, two other condensers, the main distillation column with a falling film evaporator and a residue stage falling film evaporator, a condenser serving as a product preheater for the de-gassing and de-watering stage, a final condenser, a gas cooler, a residue cooler, a distillate receiver and three pumps.
Process Description: The carriers of color and odor of split crude fatty acids (secondary components, mainly created by oxidation and decomposition with a much lower boiling point), are drawn off together with the fatty acids in the de-gassing / de-watering stage, mainly with the stripping steam added at the bottom. The fatty acids are then continuously fed to the pre-run column, where most of the remaining secondary components, the odor and color, are removed by steam distillation. The deodorization of fatty acids, and the separation of odor and color components is effected by the addition of steam to the bottom.
The fatty acids from the bottom, are pumped back partially to the column through a falling film evaporator, where the temperature is raised above 200^oC by heating oil, using thermic fluid heating. The reflux is brought about by the reflux condenser. The control is effected via circulation of water. The material with odor and color, moves to the next condenser due to initial cooling by the reflux condenser. The vapors entering the next two condensers help obtain maximum recovery from the first running, separated in the liquid phase separation tank.
The fatty acids from the pre-run column, are fed into the distiller column. The acids from the bottom of this column are then pushed back partially through the column via the falling film evaporator, where the appropriate temperature to achieve the maximum rate of evaporation inside the distiller column is maintained. The distilled fatty acid vapors leaving the column transfer heat partially to the crude fatty acid in a condenser and then enter the next condenser, where the maximum recovery of the distilled fatty acids is effected. These are then collected in the distillate receiver. The necessary reduction in the temperature of the distilled fatty acids is achieved with the help of the distillate cooler.
As the level inside the distiller column increases, the fatty acids from the bottom of the column are pumped into the residue falling film evaporator, which are then fed back to the distiller column. With an increase in the level of falling film evaporator, the accumulated residue is then discharged, is conveyed to residue storage, after proper cooling in the residue cooler,.
Advantages of Falling Film Technology for Pre-run and Distillation of Fatty Acids: The pre-run improves the quality of the distilled fatty acids by getting rid of low molecular weight fatty acids, odorous materials and coloring compounds. The evaporation takes place inside the tubes from a thin liquid film, usually less than 1 mm in thickness, resulting in good mass transfer with minimum pressure drop. The device requires only small effective volumes, as the tube wall is heated immediately. The formation of the film takes place under the influence of gravitational force. Heating is achieved by a falling film evaporator, where highly effective heat transfer is obtained with very short liquid hold-up times in the tube. Falling film evaporators need minimum maintenance and are best for heat sensitive fatty acids. The unique design of the plant makes the process totally reliable.

Process Description: For refining the oil, there are three basic processes in the refinery. First process is neutralizing the oil in the neutralizer, to remove the Free Fatty Acids (FFA) by adding caustic soda. Oil is heated up to about 60^oC, by thermic fluid coils and oil is stirred by stirrer. Soap stock formed due to chemical reaction is allowed to settle at the bottom of the neutralizer, from where Soap stock is taken out into soap pan.
Neutralized oil is drawn into the second vessel called bleacher, where color of oil is removed by bleaching process with the aid of chemicals such as carbon black and bleaching earth. Oil is generally heated up to 110^oC by thermic fluid coils. Stirring is also continued. Bleaching process is done under vacuum.
Bleached oil then goes to the filter press where bleaching earth and chemicals are separated and clean bleached oil is then drawn to deodorizer where oil is heated above 110^oC through thermic fluid coils and then live steam is purged into the oil from the bottom steam nozzles and temperature of oil is raised up to 200^oC to 220^oC through thermic fluid coils. Thus smell is removed from the oil in the deodorizer. Oil then goes to cooler, where water circulating in coils, take away heat and oil is cooled. Oil then goes to second filter press, where completely refined and transparent colorless oil is obtained.
Thermic Fluid Boiler, Vacuum Pump, Barometric Condenser, Catchalls, Steam Generator etc. play their role in the refining process. So these equipments are part of the refinery and connected with the vessels through pipelines.
Additional Process for palm oil refinery: Specially for palm oil refinery, fractionation process is required, in which palm olene and palm sterene are separated by scientifically cooling the refined palm oil, by chilling plant and then filtering the oil. For this purpose crystallizing vessel is used, in which chilling pipe coils cool the oil for fractionation. Palm sterene crystals are formed, due to chilling, which are separated in the filter press and pure liquid of palm olene is obtained and palm sterene cake is retained in the filter press.
UN Number for Coconut Oil : 1363
UN Number for Seed Cake: 1386
Hazard Class: 4.2

Specifications of Refinery: Capacity 5 tons per day, 4 batches of 1,250 kilograms each.
(1) All the main vessels, two neutralizers, one bleacher and one deodorizer are properly arranged on the first floor of the steel structure. All these vessels hang on the steel structure. Just below the two neutralizers, two soap pans rest on the ground floor in which soap stock is collected. There is a steam pipe arrangement in the soap pans.
(2) Steel structure has size of 14 feet x 14 feet (4.25 meters x 4.25 meters). First floor is 9 feet above the ground level. There are 8 columns of double channel, which supports the entire steel structure. It has a staircase and railing on all the sides of steel structure, at the first floor and also on staircase. Two filter presses are also accommodated on the first floor of the steel structure.
(3) Two oil tanks, raw oil tank and bleached oil tank are accommodated under the structure on the ground floor. The cooler, thermic fluid boiler, two steam generators, vacuum pump, water pumps, oil pumps and refined oil tank are arranged on the ground floor around the steel structure, outside the 14 feet x 14 feet steel structure. So total space occupied is about 30 feet × 30 feet (9 meters x 9meters).
(4) 40 feet tower is erected just near the deodorizer and its complete structure is supported from the ground floor. It is attached with the refinery structure. Barometric condenser is arranged at 40 feet height to create proper vacuum.
(5) All types of pipelines are interconnected as per the requirement of the refinery i.e. oil (yellow), vacuum (blue), steam (black), water (white), thermic fluid (red). At all appropriate places, proper valves are provided in the pipelines.
(6) Neutralizer is provided with thermic fluid coil for heating the oil.
(7) Bleacher is provided with double pipe coil coolers. One is for thermic fluid and another is for cooling water.
(8) Deodorizer is provided with a pipe coil. In the coil, thermic fluid is circulated. Steam is ejected from the stainless steel nozzles provided on the steam pipe, cross supported at the bottom.
(9) Cooler is provided with pipe coil, which circulates cooling water.
(10) In every vessel, temperature gauge is provided. Vacuum gauge is provided on deodorizer, bleacher and cooler.
(11) Neutralizer is open on the top having conical bottom.
(12) Bleacher has dished ends on both the sides. Similarly deodorizer has dished ends on both the sides. Cooler has also dished ends on both the sides.
Specification of Refinery with fractionation Process:
(13) There will be chilling plant for fractionation process, which will include shell and tube chiller, compressor, motor, pump, condenser, control panel box etc.
(14) Crystallizing unit, which is similar to neutralizer complete with chilling coil.
(15) Filter press for separation of palm olein and palm sterene.