加国头条 i4cc.ca ｜压榨与膨化工艺的组合

股票代码：837819 证券简称：华泰机械

The Combination of Pressing and Extruding

压榨工艺

Oil press process

虽然螺旋榨油机是所有压榨厂的核心设备, 但必须配合适当的料坯的预处理, 以充分发挥其潜能。

Although screw oil presses are the core equipment of all oil mills, proper preform pretreatment shall be carried out to maximize their potential.

油料种籽的预处理对于获取种子细胞结构内的油滴非常重要。然而, 完全破坏的细胞壁导致一个粉状的产品, 缺乏足够的结构强度, 以允许压力保持和油滴分开。通常的轧坯工序是在既能让油滴的通道打开又能允许承受挤压力之间提供折中方案。类似的现象比如油料脱皮过程的控制。在葵花籽或油菜籽 (油菜籽) 中, 一定的皮含量增强了料坯的结构强度, 是一个经济的压榨工厂操作所必需的。

Pretreatment of oilseeds is important to obtain oil droplets within the seed cell structure. However, the completely destroyed cell wall results in a powdery product that lacks sufficient structural strength to allow pressure to remain separate from the oil droplets. The usual flaking process is to provide a compromise between the opening of the oil droplets and the ability to withstand the pressing forces. The control of the oil peeling process is one of the pretreatments. In sunflower seeds or canola, a certain amount of peel enhances the structural strength of the preform and is required for an economical oil mill operation.

因为适当的轧坯对于榨油机的成功运行是一个非常重要的因素,今天的榨螺的几何尺寸,包括一些高压和高剪切力区域轴的长度结合形状各异的衬圈,代替了一部分前段研磨装置,使上游料坯制备的要求可以不那么严格。在任何情况下，当针对一个较差的坯片料(轧坯缺陷)，整个系统必须考虑。良好的轧坯是成功的关键，特别是在预榨/溶剂浸出工艺中。

Since proper flaking is a very important factor for the successful operation of the oil press, the geometry of today~q~s pressing screw, including the length of some high-pressure and high shear-force shafts, combined with differently shaped collars replace some front grinding apparatus, the requirements for the preparation of the upstream preform become less strict. In any case, when treating a preform (flaking defect), the entire system must be considered. Good flaking is the key to success, especially in pre-press and solvent extraction processes.

料坯制备(蒸炒、调质)应调节温度和水分。温度似乎是次要的，但它与蒸炒(调节)工序的干燥效率有关。含水量对料坯与榨油机榨膛内的摩擦有很大的影响，从而影响压力的上升和出油。

The preparation of the preform (cooking, conditioning) should adjust the temperature and moisture. The temperature seems to be secondary, but it is related to the drying efficiency of the cooking (conditioning) process. The moisture content has a great influence on the friction in the preform and the pressing chamber of the oil press, thus affecting the pressure rise and oil output.

尽管我们对含水量和内部压力之间的关系有了了解, 但并不是所有的条件都得到了详细的研究和发现。它不是单独的水份含量导致某种结构具有一定的流变行为。干燥过程本身似乎是一个决定性因素。这是一个已知的事实, 蛋白质变性发生在油料调质设备内特定的条件下高温, 潮湿的空气和停留的时间。由于不同的油料调质装置的工作方式有所不同-例如, 立式蒸炒锅的特点是相当长的停留时间和相对潮湿的环境，而滚筒式或管束炒锅立即释放水分和料坯停留的时间较短，料坯理想的入榨水分必须与蒸炒设备类型结合在一起看。此外, 最佳条件也取决于油料种子的类型。

Although we have an understanding of the relationship between water content and internal pressure, not all conditions have been studied and discovered in detail. It is not a separate moisture content that causes a structure to have a certain rheological behavior. The drying process itself seems to be a decisive factor. Protein denaturation occurs under specific high temperature conditions in the oil conditioning equipment. The humid air and residence time will vary depending on the mode of operation of the different oil conditioning equipment. For example, vertical cooker is characterized by relatively long residence times and relatively humid environments, while drum-type or tube-bundle cooker requires shorter moisture release and preform residence time. The ideal moisture content of the preform must be combined with the type of steaming equipment. In addition, the optimal conditions also depend on the type of oilseeds.

压榨工艺可与溶剂浸出结合使用时称为预榨，或作为真正的机械制取油过程–全榨工艺。

The press process, when used in combination with solvent extraction, is called pre-pressing, or as a true mechanical process for oil extraction – the full press process.

预榨

Pre-pressing

预榨的特点是油料处理量大，从油料中预先挤压出适度的油。预榨的典型油料种子是油菜籽和葵花籽，它们是世界上最重要的“软种子”。溶剂浸出工艺可以适度容忍高含油率油料的压榨饼前期处理的问题。然而，溶剂浸出法比机械压榨更经济，因为脱除溶剂和蒸馏分离溶剂和溶剂再循环是一个能量(蒸汽)消耗过程。这对于提取大约66%到75%的油料中的油是合适的。当试图仅靠机械压榨法出更多的油，电耗、内部部件的磨损将大幅上升,螺旋榨油机超负荷运转,榨机的产量降低和预榨饼结构松散使溶剂渗透更加困难。另一方面，如果预榨饼中留下过多的油，则预榨饼结构较软，预榨饼输送到溶剂浸出器时，滤饼会解体，粉末对浸出器中溶剂的浸泡和渗滤效果有不利影响。

The feature of pre-pressing is that the oil is processed in a large amount, and a moderate amount of oil is pre-extruded from the oilseed. The typical oilseeds for pre-pressing are canola and sunflower seeds, which are the most important "soft seeds" in the world. The solvent extraction process can moderately tolerate the problem of pre-treatment of pressed cakes with high oil content. However, the solvent extraction process is more economical than mechanical pressing because the solvent removal and distillation separation solvent and solvent recycle is an energy (steam) consumption process. This is suitable for extracting approximately 66% to 75% of the oil in the oilseed. When trying to obtain more oil by mechanical pressing alone, the power consumption, wear of internal components will rise sharply, the screw oil press is overloaded, the output of the press is reduced, and the structure of the pre-pressed cake is loose, making solvent penetration more difficult. On the other hand, if there is too much residual oil in the pre-pressed cake, the structure of the pre-squeezed cake is soft, and when the pre-pressed cake is transferred to the solvent extraction device, the filter cake will be disintegrated. The powder adversely affects the soaking and percolating effects of the solvent in the extractor.

65 - 75%的出油率相当于预榨饼中残油率约为18 - 20%。今天的预榨工艺可能具有每天3000吨以上的油料处理能力。

A 65 - 75% oil output means that the residual oil in the pre-pressed cake is about 18 - 20%. Today~q~s pre-pressing process may have an oil handling capacity of more than 3,000 tons per day.

全压榨

Full press

完全压榨工艺是在没有溶剂浸出的情况下，仅依靠机械方法从油料种籽中提取油脂。由于油料的性质，油料压榨在物理上受到分子间和毛细管力的限制。然而，当一个典型的预榨系统显示油脂得率约70%时，全压可以达到90%以上。这就意味着全压饼中常见的残余油含量5 - 8%。

The full press process relies on mechanical methods to extract oil from oilseeds without solvent extraction. Due to the nature of the oil, the oil press is physically limited by intermolecular and capillary forces. However, when a typical pre-press system shows an oil rate is about 70%, the full press can reach more than 90%. This means that the residual oil content in full pressed cakes is 5 - 8%.

为了达到额外的得油率，油料种籽必须在螺旋榨油机中长时间保持在较高的压力。较高的压力主要是由于料坯水份低，导致榨油机中的摩擦较大。由于机械强度的原因，较高的压力限制了榨油机的产量，因为它决定了榨油机榨笼的最大直径。此外，所需的更长的保留时间要求轴转速比较低，这将进一步限制处理量。因此，全压榨榨机的特点是其处理能力有限，大约只有现代预榨机能力的1/10。

In order to achieve an additional oil output, the oilseed must be maintained at a higher pressure for a long time in the screw press. The higher pressure is mainly due to the lower moisture content of the preform, resulting in greater friction in the oil press. Due to the mechanical strength, the higher pressure limits the output of the oil press because it determines the maximum diameter of the press bar cage. In addition, the required longer retention time requires a lower shaft speed, which further limits the output. Therefore, the full press is characterized by limited processing capacity, which is only about 1/10 of the capacity of modern pre-pressers.

Harburg-Freudenberger建立了两步全榨工艺，仅用少量预榨机在相当温和的预压条件下压出大部分的油，并通过减少最终榨油机数量来提高最终产油率。在预榨和终榨操作之前，油料热处理准备步骤调整水分和温度以达到最佳的加工条件。由于该产品经过两次压制，现代榨螺具有良好的挤压能力，由于有几个部分具有高剪切力，这一过程运行之前油料不需要机械处理 (破碎，轧坯)。

Harburg-Freudenberger has established a two-step full-press process that uses a small number of pre-presses to obtain most of the oil under fairly mild pre-press conditions and increases the final oil output by reducing the number of final presses. Prior to the pre-press and final press operations, the oil heat treatment preparation step adjusts the moisture and temperature to achieve optimum processing conditions. Due to the two-press forming of the product, the modern pressing screw has a good pressing capacity. As there are several parts with high shear forces, the oilseeds do not require mechanical treatment (cracking, flaking) before this process runs.

两步全榨系统

Two-step full press system

改进的两步全榨系统使用冷预压，在常温下油料进行首次压榨。在第二次压榨之前，适当调整预榨饼的水份和温度。预压冷榨油可采用单独的过滤系统进行处理。

The improved two-step full press system uses a cold prepressing and the oilseed is first pressed at normal temperature. The moisture and temperature of the pre-pressed cake are adjusted appropriately before the second press. The pre-pressing cold pressed oil can be treated with a separate filtration system.

对于每一个项目来说，与预榨和溶剂浸出相比较，全榨和预榨的经济性都需要单独考虑，考虑到这些过程的当地许可、环境影响、当地能源价格、当地饼粕市场、安全方面以及许多其他因素。

For each project, the economics of both full press and pre-press need to be considered separately compared to pre-press and solvent extraction, taking into account local permits, environmental impacts, local energy prices, local cake and meal market, safety aspects and other factors.

其他应用工艺

Other application processes

螺旋榨油机是一种连续固液分离的优良设备，其应用前景十分广阔。这个过程的一个一般的先决条件是物料的结构强度，它必须允许压力的积累，进入液相和支持低粘度的流体。因此，该系统不适用于浆料。其他产品，尤其是脱水产品，通常需要双螺旋榨油机，两根螺旋轴相互旋转，用于强制进料和输送。这些单元和过程的典型特征是机械简单的结构和低系统压力。

The screw oil press is an excellent equipment for continuous solid-liquid separation, and its application prospect is very broad. A prerequisite for this process is the structural strength of the material, which must allow for the accumulation of pressure, which can enter the liquid phase and support fluids of low viscosity. Therefore, this system is not suitable for slurry. Other products, especially dewatering products, usually require a twin-screw oil press with two screw shafts rotating relative to each other for forced feeding and conveying. Typical features of these units and processes are mechanically simple construction and low system pressure.

高压重型单轴螺旋压榨机在油脂加工工业中应用于从动物肉类中分离脂肪的熬制工业中。其他领域的应用是木屑的脱水，陈化、变质粮用于酿造工业或合成橡胶。

High-pressure heavy-duty single-shaft screw presses are used in the oil processing industry in the tanning industry to separate fat from animal meat. Other applications are the dewatering of wood chips, aged and degraded grains used in the brewing industry or in synthetic rubber.

给合：膨化与压榨

Combination: extruding and pressing

这两个单元操作不仅使用机械上非常相似的机器。创新尝试着一系列操作组合。膨化是一个热处理过程，而蒸炒/调质是有效榨油的先决条件。因此，将这两项单元操作结合起来的想法是不言而喻的。它始于“全脂”油料产品(主要是大豆和棉籽粉)上安装了一个小型装置，作为动物饲料，使用膨化机进行湿热处理，以减少抗营养因子。由于该产品的含油量较高，动物无法充分利用，而且是市场上的一种有价值的商品，用螺旋压力机去油似乎是一个合理的步骤。

These two units are very similar processed used in mechanical operation, and they are combined in a series of operations. Extruding is a heat treatment process, while cooking and conditioning are prerequisites for effective oil extraction. Therefore, the idea of combining these two units’ operations is self-evident. It began with a small device installed on "full fat" oil products (mainly soybean and cottonseed meal) as an animal feed, using a puffing machine for wet heat treatment to reduce anti-nutritional factors. Because the product has a high oil content and is a valuable commodity on the market, and animals cannot be fully utilized, it seems to be a reasonable step to use a screw press to remove oil.

不幸的是，正如前面解释的，膨化高含油量油料不是很有效或需要特殊几何形状的螺旋轴和大量电能。然而，一旦这些初始问题得到解决，该系统的特点是非常简单的设置，良好的出油效率，榨油机高产量、低能耗。膨化机排料时物料水分的闪蒸要求有良好的抽风系统，以避免在下游输送机或螺杆榨油机中过度凝结。

Unfortunately, as explained earlier, extruding high oil content oilseeds is not very efficient or requires special geometry of the helical shaft and a large amount of electrical energy. However, once these initial problems are solved, the features of the system such as simple setup, good oil production efficiency, high output of the oil press, low energy consumption will become an advantage. The flashing of the moisture of the material during the discharge of the extruder requires a good air extraction system to avoid excessive condensation in the downstream conveyor or the screw press.

组合：压榨膨化

Combination: pressing and extruding

膨化与螺旋压榨相结合的优点和好处是很明显的，但相反的顺序已经被应用并且仍然可以在一些地方看到。该工艺方案的主要动机在于膨化机能够产生具有一定结构和稳定性的颗粒状物料。在螺杆压榨(预压榨)性能差的情况下，油脂含量高的饼进入溶剂浸出系统后，过量的粉末导致溶剂渗透率差，饼的残留油含量高。用于压榨后的压榨饼的膨化机旨在改进压榨饼结构强度。早期的压榨－膨化在多油料工厂中测试，在那里膨化机已经可以用于大豆加工。这种组合的整体成功的过程机器有限，因为(i)需要安装额外的电能, (ii)膨化机产生的额外的热量必须被饼干燥、冷却器与去除,和(3)冷却空气量必须处理以减少灰尘和气味排放。如果没有膨化机，就有必要投资上游设备，用于料坯制备和压榨，以生产出适宜的预榨饼，使它在溶剂浸出之前不需要任何额外的处理。

The advantages and benefits of combining extruding with screw press are obvious, but the reverse order has been applied and can still be seen in some places. The main motivation of this process scheme is that the extruder can produce granular materials with a certain structure and stability. In the case of poor performance of the screw press (pre-press), after the cake having a high oil content enters the solvent extraction system, the excess powder causes poor solvent permeability and the residual oil content of the cake is high. The extruder for the press cake after pressing is intended to improve the structural strength of the pressed cake. Early press-extrusion was tested in a multi-oil plant where the extruder was already available for soybean processing. Machines that successfully implement this combination are limited because of the extra power that needs to be installed. The extra heat generated by the extruder must be dried by the cake, cooled and removed, and the amount of cooling air must be treated to reduce dust and odor emissions. Without a extruder, it would be necessary to invest in upstream equipment for preform preparation and pressing to produce a suitable pre-pressed cake that does not require any additional treatment prior to solvent extraction.

未来展望

Future prospects

膨化机/挤压机和榨油机/螺旋榨油机是一种机器，在今天和在可预见的将来，它们将在油料压榨工业中占有指定和合理的位置。螺旋榨油机的单机能力将继续提高，仅受机械限制。预榨浸出和全榨将并存。工程师将继续努力缩小全榨和溶剂浸出之间的出油率的差距，使全榨成为更经济的选择。与膨化机的组合作为热和机械制备的两用机可能会变得更加普遍。但是，对其他工艺变化的持续研究，例如在压榨过程中注入超临界二氧化碳，可能有一天会导致一个新的标准制油工艺过程，不仅是油脂得率，而且是油脂和蛋白质质量的重点。

Extruders and extruding machines, as well as oil presses and screw oil presses, are the same machine, and they will occupy a designated and reasonable position in the oil press industry today and in the foreseeable future. The stand-alone capacity of the screw press will continue to increase and is only limited by machinery. Pre-press, extraction and full press will coexist. Engineers will continue to work to reduce the gap between oil extraction and solvent extraction, making full press a more economical option. The combination with an extruder as a dual machine for thermal and mechanical preparation may become more common. However, ongoing research on other process changes, such as injecting supercritical carbon dioxide into the press process, may lead to a new standard oil production process that is not only important for oil extraction rate but also for the quality of oils and proteins.

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