Glycerine Distillation Plant
Glycerine Distillation Plant is broadly divided into three main sections viz.de-aeration section, distillation section and bleaching section.
The bleached glycerine is filtered and then finally cooled down to storage temperature before discharging to the battery limits.
It is well known that Oil is ester of Glycerol and fatty acids, which can be decomposed in to their original constituent (Fatty acid and glycerol) or synthesized in to Triglycerides by Fatty acids and glycerol.
Estrification reaction is reverse of Hydrolysis process. It is carried out by reacting fatty acids with glycerol. In addition to esters, water is also a product of estrification. The reaction is reversible and proceeds to completion only if water is removed from the medium. The equilibrium between the forward reaction (Estrification) and the reverse reaction (Hydrolysis) is controlled by water content of the reaction mixture. In the presence of excess water, hydrolysis predominates, whereas under water eliminating conditions Estrification is favored.
Fatty Acid Plant
Fatty Acid industry is associated with production of fatty acids and glycerine. Both vegetable oils & animal fats are being used as feedstock for fatty acids / glycerine manufacturing. The fatty acids are manufactured as a distillate mixture or a pure fraction. Pure fractions can be obtained either from fractionation plant or by selectively choosing the feed-stock & carrying out straight distillation.
The bio-diesel system is able to use different cold- and hot pressed fresh vegetable oils as well as pre-treated used vegetable oils.
In all cases, if the operator of the plant follows the required qualities of the input materials and ensures a constant process operation, the product quality will be in correspondence with the requirements of the European bio-diesel standard DIN EN 14214 as well as with all other conventional international norms.
It has to be pointed out, that used vegetable oils and certain fresh oils like palm oil only can be used for the production of so-called “summerbiodiesel” because the winter stability can not be ensured yet. For all different raw materials a transesterification grade of > 98 % and constant product quality will be reached.
The current offered plants are a BASE-LINE offer and further customization / improvement will be done against customer’s specific request.
Mectech's Revolutionary on-line seperation system for fatty acid and glycerine phase
Driving force for Static Separator is gravity flow. The Separator is a static device having highly specialized internals and level controller. The internals are so specially designed that, the disperse phase smaller droplets gets agglomerate on the surface to form bigger globules. This enhances process of separation of the two phases.
The agglomerated bigger globules represents Free Disperse Phase and is padded through an environment where sufficiently quiescent conditions are maintained, so that disperse phase globule rises to the continuous phase surface; forming a layer of disperse phase liquid. The removal of both phases from the separator is through level controller. Both phases are freely discharged under gravity.
Fatty acids sourced from Palm stearin, Rice-Bran Oil, Coconut Oil, Tallow…etc. are typically blended together to form fatty acids blend for soap manufacturing. Today all premium grade soaps are being manufactured from blend of the distilled fatty acid.
Fat Splitting Plant
In Fat Splitting Plant, hydrolysis reaction of oil / fat is carried out. The reaction takes place at high pressure and high temperature. Triglycerides (fat/oil) react with water to convert into fatty acids and glycerol. The Fat Splitting Plant is a high-pressure single tower system. The fatty matter proceeding from battery limits is pre-heated and fed to the de-aerator operating under vacuum.
The de-aerated fat is fed via a high-pressure pump to the bottom of the tower. In bottom of the tower, there is a heat recovery section where de-aerated fat isheated by the exiting sweet water. The process water is fed via a high-pressure pump to the top of the splitting tower.
In top of the tower, there is a heat recovery section where process water is heated by the discharging crude fatty acids. The high pressure splitting tower is provided with temperature controllers.
Fatty Acids Distillation Plant
Fatty Acids Distillation plant is broadly divided into three main section. vis. de-gasification, pre-cut system and main distillation system. These main process section are supported for optimum cooling based on thermostatised water system.
Crude fatty acids from battery limit is filtered, pre-heated and admitted to the de-gasifying unit operating under vacuum, where it is dried and de-gasified. Crude fatty acids, from de-gasifier is heated in thermic fluid exchanger and fed to the pre-cut column.
The pre-cut column operates under vacuum and is composed of various section; starting from bottom, the main sections are vaporization section, Two sections of distillation packing bed, pump-around section and scrubbing section. From bottom of the column, the product is sent to Fatty Acid Distillation column.
The main distillation column operates under vacuum and is composed of various section; starting from bottom the main sections are vaporization section, stripping section, one set of washing section, one pump-around section and one scrubbing section
Hydrogenation is the process to change the physical characteristics of natural fats and oils. Hydrogenation of vegetable oils involves the addition of hydrogen, in the presence of a Nickel catalyst, to the carbon-carbon double bonds present in the fatty acid chains.
Interesterification can be defined as a redistribution of the fatty acid moieties present in a triglyceride oil over its glycerol moieties. Interesterification has become the alternative fat modification technology to partial HYDROGENATION.
Interstification is the process of re-arranging the fatty esters within and between tri-glycerides resulting in the most cases a change in the physical properties of the oil / fats. Interstification is the intra and inter molecular exchange of fatty acids on the glycerol back bone of tri glycerides. In the chemical Interstification process commonly used catalysts are sodium methylate and ethylate followed by sodium methoxide.
In enzymatic Interstification process, the enzyme commonly used is lipozyme TL1M.
The simple procedure of hydrogenation in the presence of Nickel catalyst is carried out with such perfection that MECTECH has become a trend-setter organisation vis-a-vis turnkey projects for Vanaspati Ghee.
Recovery of wet Lecithin is done from hydratable gums of soyabean oils and rice bran oils.
Lecithin is the predominant source of food and pharmaceutical. Food lecithin is usually de-oiled to improve its functionality. The major phospholipids as listed below are the source of the Lecithin
The Phosphatidylcholine enriched fraction is an excellent oil in water emulsifier and the Phosphatidylinositol enriched fraction is good water in emulsifier is often used in the chocolate industry.