University Institute of Chemical Technology

Kavayitri Bahinabai Chaudhari North Maharashtra University ,Jalgaon

Presentation on Inplant Training at

SHALIMAR NUTRIENTS PRIVATE LIMITED SONKHAMB,NAGPUR

By,

Mr. Pranay R. Kathwate

Final Year B. Tech, Oil Technology

University Institute of Chemical Technology, KBC-NMU, Jalgaon

 Chapter 1
Introduction

Overview of Shalimar Nutrients Private Limited

Shalimar group is primarily involved in business of poultry since over a period of 48 years,
Shalimar Nutrients Private limited is incorporated on 21 December 2010.is Paid up capital is a Rs.300
cr involving production, processing and preservation of meat fish, fruit vegetables, oil and fats With its
poultry feed names like sona, total eco, matrix and food and packaged products including
chicken drumsticks, chiken keema, chicken breast boneless, chicken lollipop, chicken precut.
Dairy products possessing adya fresh milk. Soya industry outputted most important brand of
soyabean oil is total gold.
 Chapter 2
General Information
Soyabean Oil
• Soyabean oil is a vegetable oil extracted from the seeds of the soyabean (Glycine Max).
• The U.S. is the largest soyabean producing country around the world.
• Soyabean oil are the most important source of fat in the human diet.
• It is one of the most widely consumed cooking oil. As a drying oil processed soyabean oil
is also used as a base for printing inks and oil paints
• Production of high quality meal and crude oil is the main objective in soyabean
processing.
Constituents of Soyabean
Constituents Percentage :
1. Oil : 18-20
2. Proteins : 35-40
3. Carbohydrate : ~ 35
4. Vitamins : B
5. Minerals : ~5
• Constituents fatty acids in Soyabean Oil:
A) saturated fatty Acid : 16%

B) mono Unsaturated fatty Acid : 23%

C). poly-unsaturated fatty Acid : 58%

1. Poly-unsaturated α-linolenic acid (C-18:3) : 7-10%

2. Linoleic acid (C-18:2) : 51%

3. Mono- unsaturated oleic acid (C-18:1) : 23%.

 Chapter 3
Unloading Point
3.1 Process Description
The various processes done at the plant are –
1) Seed Unloading Section

2) Preparatory Section

3) Solvent Extraction Section

4) Refining Section
3.2 Seed unloading Section
• The unloading section is the important section of the plant. As the main product means soya
meal and the soya oil are produced from the soya seed.
• The important is unloading the seed from the lorries and pre cleaning of the seed before
providing it to the storage.
• The soya seed is bean purchased from various Agricultural Product Market Committees
(Mandis), Dealers and Farmers. This seed is transported at plant by Lorries.
• Every bag sample of Lorries are analysed at unloading point.
• At unloading point, there are total 4 unloading points and 1 unloading point for farmers.
• . At every point, there is separate pulse jet system bag filter.
• Then seed transfer to precleaning

The processing of the unloading to the storage is done in the proper manner,
which is shown in following flowsheet.
 Seed Unloading

Seed pre cleaner -1A Destoner Seed pre cleaner -1B

mitti churi
Air Aspirator Air Aspirator

Silo 1 Silo 2 Silo 3 Silo 4

Pre Cleaner No.2A

Pre Cleaner No.2B
(Mesh 6,8 &1mm
(Mesh 6,8 &1mm

Day Silo
(500 MT)
3.3. Pre-Cleaning Section:
• The pre-cleaner is the machine which is used to clean the seed from the foreign matters.
Mechanical separations are applicable to heterogeneous mixture.
• These techniques are based on physical difference between the particle size, shape and
density.
• This pre-cleaner is operated by horizontal gyration with 5 HP motor.

• The seed pre-cleaner having two compartments, The seed is provided to each compartment
by pocket feeders. Each division has two meshes of 12mm upper and 1.8mm lower mesh.
• The seed transferred from upper mesh is coming at lower 1.8 mm mesh where the foreign
material like small size stones soil, particles, soya meat and sand is separated and only the
required clean seed is removed from topside of these meshes to the bottom of pre-cleaner.
• This clean seeds travels to belt conveyor by this belt conveyor, the seed is transferred at silos
for storage.
.
3.5 Storage system

• Soyabean seed is received from precleaning section through chain conveyor to bucket elevator which
drop it at silos.

• There are four silos having storage capacity of 10000 MT each. Silos are made up of the alloy of the
galvanised steel.

• The three major factors affecting the storability of soyabean seed are moisture content, temperature
and duration of storage.

• Soyabeans with moisture above 12% should be dried to reduce the risk of deterioration from seed.

• For safe storage, a combination of the three factors providing unfavourable conditions for mold
development, sucas low product moisture, low temperature and short storage period, is desirable .
 Chapter 4
Preparatory Section
• The function of the preparation process is to properly prepare the seeds for extraction of the oil, either by
solvent or mechanical methods and, if applicable, remove the hulls and other materials from the
soyabean seed or meat.
• Soya seed may contain from 18 to 20% oil
The operations typically involve in preparation are-
 Post cleaner
 Destoners
 Seed grading
 Cracker
 Hull Remover
 Conditioning(cooking)
 Flaking
 Extrusion
4.1 Preparatory Operations:
• The seed are taken from the silos by chain conveyors and bucket elevators which feeds the seed
into the day silo (daybin) adjacent to the preparation building.
• Day silo (daybin) is the cylindrical storage having conical shape at bottom side and it has the
capacity of 500 MT.
• There are two advantages of day silo. First is to provide the continuous soyabean seed to the
section which helps to operate machines continuously.
• While the second advantage is to register the quantity processed, a scale is installed underneath
the day silo (daybin).
• Day silo bottom has the rotary valve which is used to continuous sealing and feeding the
soyabean seed.
4.2 Post Cleaner :
• Post cleaning operations consist of eliminating impurities from the soyabean seed.

• The cleaning of the oil seeds serves two purposes. The first one is the removal of impurities
and second one the regulation of the bulk density.
• At the post cleaner, seed is cleaned by the linear vibrating separator.

• There is a cyclone separator at the inlet of post cleaner which is operated with the air
volumetric flow rate of 1500m3/hr.
• At post cleaner, large size foreign material is removed over 12mm mesh size and the seed is
coming on the 2.5 mm mesh. Over the 2.5 mm mesh seed is drop to the inlet of the seed grader
which is exactly the below of post cleaner.
4.3 Seed Grader:
• Seed grader has the same construction as post cleaner except it has only one deck of different
mesh sizes one after another.
• Seed grader is mainly used for separating the seed according to its size to make the cracking
which is necessary for next operations.
• size of The meshes is 4mm and 5mm.

4.4 Destoners:
• The important purpose of destoners is to remove the foreign matter such as soil, stones and
metal traces by using the specific gravity difference made by the vibration.
• . At the destoners, there is cyclone separator is also fitted to make the separation easier. By
these cyclone separators vacuum is generated which help to remove the fine particles as
well as make the specific gravity difference.
• There is one destoner. Each destoner has the two inclined deck
4.5. Cracker:-
• Crackers are mainly used to size reduction
• Due to size reduction, mainly two purposes are done which are first is to break the cell wall and
remove the hulls of seed.
• Cracking is done by cracking rolls of sizes 1250 x 350mm One cracker has two pair of rolls.
• There are four crackers with the same quantity except the difference in their rolls distance.
• Crushed seed from out from cracker in screw conveyor which transfer it to dehuller.

4.6. Dehulling (Decorticating):-

• If the hulls are present in expanded cake, protein content of soya meal decreases. Hence, when
high protein soya meal is required then dehulling operation plays an important role.
• . In this operation, seed hulls present in crushed seed are primarily removed by aspiration.

• At dehulling, aspiration is done by vacuum that is generated by cyclone separator. By using the
4.7 Cooker:-
• Cooking the seed is a most important process in the preparation of soya extrudate.
• In this process, the seed is heated and increase moisture content of the seed. Due to increasing
the moisture content, the cell wall of the seed is softened, which helps to easy removal of the
oil from the seed.
• In addition, it helps to increase the protein content of the soya meal, which is the most
important necessity.
• Cooking process is also help to make the flakes.
• Cooking of seed is done in the cylindrical vessel of mild steel in which there are six
compartments are arranged. Out of six compartments, three compartments have jacketed
steam to heat the seed while other three compartments have sparge steam.
• The height of 6000mm and diameter of 4500mm.
• The temperature of cooker is maintained between the 70-80ºC.
4.9 Flaker / Flaking Mill :
• Flaking break the cellular structure of the seed material and reduces the distance that solvent needs to
penetrate to reach the oil in the seed material cells.

• The flaker has two large diameter rolls in parallel, turning in opposing direction at approximately 250 to 300
rpm.

• Typical flakes are in the range of 0.3 to 0.4 mm thick and 8 to 18 mm in diameter.

• There are total four flakers in Shalimar Nutrients Pvt. Ltd, Good solvent extraction performance is highly
dependent on good Flaking performance.
4.10. Extruder / Expander :
• These flakes can be directly used for the solvent extraction, but the oil recoverability is
increased if these flakes are extruded.
• Additionally, the wet extruder in a soyabean plant increases temperature sufficiently to stop the
phospholipase enzyme from converting additional hydratable phosphatides into nonhydratable
phosphatides. This reduces acid, caustic, and silica consumption in the downstream refinery.
• There is a steam pressure maintained in the range of 3-5Kg/cm2.
• The flakes are heated in the range of 90–1100C temperature.
• The pressure developed prior to the restricted orifice discharge increases the product density.
The result is a hot, fragile, pellet-like product, with greater bulk density than the incoming
flakes, greater porosity than the incoming flakes, and significant cell rupture.
4.10 Dryer and Cooler:-
• For drying and cooling the extrudate cake, there is special equipment, which is dryer and
cooler.
• The extrudate cake temperature coming from the expander is about 90 0C, at which
extraction cannot work properly. So it should be cooled for proper extraction.
• Also these extrudate cake has high amount of moisture content. At the dryer and cooler, the
moisture content is maintained and then this cake is cooled to about 35-45 0C.
• It is the horizontal equipment having eight compartments made by the plates.

• These extrudate cake driven on the belt drops in the screw conveyor at the last of the dryer
and cooler and it transfer to solvent extraction plant (SEP) section.
 Chapter 5
Solvent Extraction Plant
Solvent Extraction Plant
• The solvent extraction process has the benefit of significantly higher oil yields than mechanical
extraction, along with lower unit operating costs.
• Extraction of oil from oil-bearing material is usually done by pressing, solvent and pressing and
solvent combined depending on their oil content.
• Soyabean seed is required solvent extraction. Soyabean seed is low oil bearing material with oil
content 18-20%.
• The major drawback of solvent extraction is the high initial capital cost to construct a facility.
• The solvent used in the majority of oilseed solvent extraction plants around the world is
commercial n-hexane, a mixture of hydrocarbons generally boiling in the temperature range of
Principle of Solvent Extraction:-
Diffusion is that irreversible process by which matter spontaneously
moves from a region of higher concentration to one of lower concentration. The
laws of diffusion correlate the rate of flow of the diffusing substance with the
concentration gradient responsible for the flow.

Process Description:
After leaving the preparation process, soyabean cake are delivered to the
solvent extraction operation. As this process typically uses solvent (Hexane).

Figure illustrates the typical unit operations

5.1. Perforated Belt Type Extractor:-
• The extractor used for extraction of oil is designed by Desmet Ballestra.

• This is the horizontal percolation type extractor uses a moving perforated belt underneath an
extended bed of material. The Desmet extractor has one moving part i.e. the belt

• The belt is set on a slight incline and carries the solids up the incline, throughout the extractor.
• . There are several miscella stages and a final hexane wash.
• The total length and width of extractor is about 18m and 2.05m respectively. Bed requires time
about 45min to each circulation.
• Extractor holding capacity of soyabean cake over a belt at time is 22MT. The extraction capacity
of plant is 800 MT/Day.
• The temperature of cake is about 52*C.

• In most cases, the quantity of oil in the final miscella is about 5-10 per cent by weight higher
than the oil content of the original material.
5.2. Recovery of Solvent from Miscella
• The first step of the miscella distillation is economising or evaporation of the solvent from
the miscella. This evaporation is done in the Economiser
• Economiser is the vessel composed of two parts. Lower part is shell and tube cylinder while
upper part has more diameter than lower with closed cylindrical vessel.
• As heating medium, hot vapours from the DT-DC are used, which vapours flows around the
tubes and flow further to the condensers.
• Miscella enters at upper part connected at the top of the tubes. The miscella is flashed there and
the vapours are going to the hexane condenser.
• The heated miscella goes to the second distillation step which is flashing and stripping. Before
entering miscella into the flasher, it is heated in Oil / miscella exchanger and heater.there are 3
heater and three flasher.
• The heated miscella leaves from exchanger at temperature of 118 0C at the top and enters the
• In flasher the hexane vapours are separated from it and sucked by vacuum and forwarded to
the solvent condenser.
• In stripper the remaining solvent is evaporated under combined effect of vacuum and
steam. The temperature inside the stripper is approximately 120-1250C maintained by
sparge steam and vacuum of 210mm of Hg.
• After the stripping, oil is enters into oil-dryer for removal of the moisture and any residual
solvent content.
• Outlet temperature of oil from dryer is approximately 102-1060C while the vacuums
generated from the evictor is about 600mm Hg.
• The dried oil is pumped to the heat recovery at the oil / miscella heat exchanger and then to
the cooling plate heat exchanger by means of the cooling water.
5.4. Recovery of Solvent from the Meal:
Recovery of the solvent from the soya meal is the important process for reducing the solvent
losses as well as to make the meal for the use feed material. This recovery of the solvent is
mainly done in the desolventiser toaster .
Desolventiser -Toaster -Dryer-Cooler (DT-DC):-

The extracted meal leaving from extractor is scaled with solvent of approximately 24-25%. The
purpose of the desolventiser is as the name indicates to desolventise the meal. The de-oiled
meal from the extractor is fed by the solvent tight conveyor into the DT-DC unit.

The following advantages of DTDC given below:-

1. Improved solvent recovery.

2. Finished meal discharged is guaranteed to contain no solvent.

3. Maintain the urease activity for easy digestion.

4. Proper humidification of meal during desolventization.

 Chapterr 6
Refinary Plant
REFINING SECTION
Triacylglycerols (acyl easters of glycerols) constitute nearly 99% of crude vegetable oils.
The remaining components include phospholipids, free fatty acids, pigments, sterols,
carbohydrates, proteins, and their degradation products .
Two processes have been developed for the refining of edible oils and fats, i.e. physical
and chemical refining. The names physical and chemical refining come from the process
technology used to remove the free fatty acids (FFA) that are responsible for the oil acidity
Physical refining is a process making use of the lower boiling point of the FFA
compared to the boiling point of the triglyceride oil. In chemical or alkaline refining, an alkali
is used to neutralise the FFA.
At Shalimar Nutrients we use Chemical Refining for refining of soyabean oil.
The convectional Soyabean oil refining process consist of four step, which are as
follow,
1. Degumming
2. Neutralization
3. Bleaching
4. Deodorization
Flow diagram of conventional soyabean oil refining is given below
6.1. Degumming
• Degumming is a process for removal of phosphatides from crude soyabean and other
vegetable oils to improve physical stability and facilitate further processing.
• Degumming primarily removes phospholipids, metal ions and other impurties from the
crude oil.
• Phospholipids are of two types

a) Hydratable Phospholipids (HP)

b) Non Hydratable Phospholipids (NHP)
• The Hydratable phospholipids have greater affinity for a water phase, can be by addition of
water, mixing and separating to remove them(water degumming)
• Whereas non hydratable phospholipids have greater affinity for oil phase. All treatment with
phosphoric acid with proper temperature, time and agitation conditions can easily remove
these non hydratable phospholipids (acid degumming)
• Flow sheet for degumming and Nutralization process is given belowf

Receiving of crude oil PHE (oil temp. 60-70*C) Hydration Tank Separator 1 Degumm oil

Gums
Softener water
addition 90-90*C
To lecithin

RT 2 RT 1
Disc Mixture 2 Knife Mixture 1 PHE
8 – 12 min 25 -30 min

Caustic 16 – 20 Be Phosphoric Acid

PHE (95 – Knife Mixture

P D Pump Separator 2 Separator 3
100*C) 2

NOT (Under
Vacume Dryer
Vcume)
6.1.1. Water Degumming
The water degumming process involves adding water to the crude oil, hydrating the water soluble components, and then
removing the majority of them via centrifugal separation.

Process
• At Shalimar, the crude oil is first taken from the crude oil storage tank
• Heat oil to 62 -68 * C in PHE.
• Water adding about 1.5 – 3 % and mixing for 30-35 in hydration tank.
• Centrifugual separation of hydrated gums .

• Operating Parameters:
•  Crude Oil Temperature : 62 – 68 0C
•  Hot Water Temperature : 95 0C
•  Flow Rate of Crude oil : 5000 - 5500 kg/hr.
•  Flow Rate of Water : 55-60 kg/hr.
•  Steam Pressure : 2 kg/cm2
•  Back Pressure of (CS) : max. 2 – 2.5 kg/cm2
6.1.2. Acid Degumming
Acid degumming is the process use for removing non hydratable phosphatide . Acid degumming leads to a
lower residual phosphorus content than water degumming.

Process :
• Water degummed oil is send to knife mixer where it is chemically treated with 85% phosphoric acid about 0.1%
(w/w).
• From the knife mixer, oil is goes to the retension tank 1 where it is attain retension time of 25 - 30 min.
• After this the oil is send to the retension tank 2 by overflow system for neutralisation.

Operating Parameters:
 Degummed Oil Temperature : 60 -65 0C

 Flow Rate of Crude oil : 5000 kg/hr.

 Phosphoric Acid dosing : 0.1% – 0.15 %
 Steam Pressure : 8 kg/cm2
 Back Pressure of (CS) : 2 – 2.5 kg/cm2
6.2. Neutralization
Neutralization is a method of refining that involves the use of alkalis to react with free fatty
acids in the oil. This process of refining is also known as Alkali refining. or deacidification. Here oil
is treated with an alkali, which converts the free fatty acids into oil insoluble soap.
Apart from removing the free fatty acids in soap-stock formation, refining step also reduces
colour of the oil considerably and enhance the bleach ability.
Process
• After this the oil from retension tank 1 is send to retension tank 2 where it is oil chemically
treated with caustic or NaOH of 16 – 20 boume in in line mixture then send to retension tank 2
the oil got only 10-12 min .
• oil from RT 2 is fed to PHE where oil gain the temperature upto 85*C by steam-oil PHE.
• . Now the oil soap solution is fed to separator where oil and soap seperates.
• Soap send to acid oil plant and oil is heated to 95*C by PHE and fed to knife mixer where oil and
water mix and water washing is done.
• Now the oil and water fed to separator where water is separated and soap free oil is send to
vaccum dryer to evaporate the water
Alkali requirement
%NaOH = % FFA x 0.142 + % excess NaOH
Operating parameters:
 Neutral Oil Temperature : 900C
 Flow Rate of Neutral oil : 5000 kg/hr.
 Flow Rate of Caustic soda : 45 - 50 lit/hr.
 Steam Pressure : 8 kg/cm2
 Back Pressure of (CS) for Neutralization : 1,8 - 2 kg/cm2
 Back Pressure of (CS) for Washing : 0.5- 0.8kg/cm2
 Knife Mixer : 900 rpm
 Vacuum Dryer Vacuum : 650 mmHg
 Hot Water Temperature : 920C – 95 oC
 Long mix Process Retention Time : approx. 8 – 12 min
6.3. Bleaching Process
Originally described as a process of mixing oil and clay adsorbent to remove colour,
the bleaching operation effectively removes some of the colour, reduces the contents of
chlorophyll, residual soap and gums, trace metals, oxidation products, and indirectly impacts
on deodorized oil colour. flow sheet of bleaching and deodorization process is given below
Nutral oil Tank Salary Mix Tank Bleacher Polish bag filter A
PLF Filter
(NOT) (SMT) ( 30 min ) (10 micron)

Spent
earth

Spiraflow Dearator Polish Bag Filter BOT (Under

VHE 210 _220*C 160 _ 180*C 12*c ( 5 micron) Vacume)

VHF 240 - Cooling PHE Polish Bag Filter(5 PHE (35

Deodorizer 40*C)
250*C (40 – 60 )* C micron)

R.O.T.
Process :
• Oil is enter to PHE for got the temperature upto 108*C.
• Now the oil enters into the salary mixing tank (SMT) where it chemically treated with bleaching earth
about 1-1.5%.
• oil is send to bleacher where oil and water spends time of about 30min with no agitation. Here the oil
and bleaching earth is mixes by using open steam .
• After this the oil reached to PLF( pressure leaf filter) where bleaching earth is removed by filters in PLF
and neutal bleached oil is obtain.
• the oil is moves through polish filters of 5 micron then the oil is stored in BOT .
Operating parameters:
 Neutral Oil Temperature : 85 87 0C
 Flow Rate of Bleach oil : 5000 kg/hr.
 Vacuum : 650 - 700 mmHg
 Steam Pressure : 0.8 - 1 kg/cm 2
 Bleaching Earth Dosing (%) : 0.8 - 1%
 Bleach oil Temperature : 110 *C
6.4 Deodorization:-
Deodorization is basically a vacuum steam stripping at elevated temperature during which free fatty acids and
volatile odoriferous components are removed to obtain bland and odourless oil. Although the process is commonly
named “deodorization”, it is a combination of three different operations: distillation (stripping of volatile components),
actual deodorization (removal of odoriferous components), and heat bleaching (thermal destruction of pigments).
Process of Deodorisation

• the oil from the BOT is moves through the steam-oil PHE (110*C) Then the oil is passes through the polish filter of 10
micron .

• The oil enter into the deareator chamber through nozzles.

• Next to this, the oil is moves through the expira flow which is actually a shell and tubes heat exchanger where
temperature achieve 152*C.

• then the bleached oil moves through the economiser where got tem upto 210*c. then the oil is fed to vaccum heat
exchanger where oil is heat up by themi fluid. The temperature gained here is about 240-250*C which is ready to feed
into the deodorizer.
• Now the oil from the VHE is fed to the first compartment of deodoriser where strong vaccum and high temperature
forces out all fatty acids and odoriferous compounds .
• In compartment 1 the retension time is maximum than 2 ad 3 therefore maximum fatty acid is recovered .
• There is steel pipe provided through which oil paased to the second compartment. Here also oil receive the
retension time and helps to minimise the FFA and odour.
• In similar fashion the oil reached to the 3rd compartment and then to the fourth compartment i,e
economiser where it is cooled by using bleached oil and got the temperature of 182*C and through the
expira flow and some PHE, cooler and from last PHE it is cooled by water upto 33*C and then to
ROT( Refined oil tank)

Operating parameters
 Final oil Temperature : 34 – 35 *C
 Flow Rate of Deodorized oil : 4800 kg/hr.
 Vacuum : 760 mmhg or 1 tor
 Steam Pressure : 8 kg/cm2
 Thermic Fluid Temperature : 260 – 270 *C
 Deodorizer Temperature : 245 – 250 *C
 Cooling Water Temperature : 32*C
retention time for deodorization – 2 – 2.15 hr
 FFA Final Temperature : 50 – 57 *C
 Total Deodorizer Capacity : 100 MT
6.5. Lecithin Recovery
Soyabean oil containing 1.5-3.0% Phospholipids. in general usage, lecithin refers to a complex,
naturally occurring mixture of polar lipids obtained by water-degumming crude vegetable oils and
separating and drying the hydrated gums.

Process:-
• In the water degumming process, the hydratable gums are separated from the disc bowl centrifuge
separator.
• These gums are dropped in cylindrical vessel conical bottom shape storage tank.

• These gums are fed to the gums retention tank in which low-pressure jacketed steam is used to
heat the gums to reduce moisture content
• gums are fed to heater for heating it with high-pressure steam and continuous agitation.
Temperature at heater is maintained about 90-1100C.
• After this the gums are fed to vapour separator where water vapours are separated by using vaccum
provided upto 620 mm hg then the gums are fed to next vapour separator to removes the remaining
• Operating Parameters
• 1. Hydratable Gums Temperature : 600C
• 2. Final Lecithin Temperature : 35 40 *C
• 3. Temperature at heater : 95-110oC
• 4. Vaccum at 1 st. vapour separator : 600 mm hg
• 5. Vaccum at 2 nd. vapour separator ; 650 mmhg
• 5. Steam pressure : 3 Kg/cm2

• Quality Control Parameters

 AIS(Acetone Insoluble) : 63% – 64%
 AI(Acetone Soluble) : 36%-37%
 HIS(Hexane Insoluble) : < 0.1%.
 Colour : Light honey to brown.
 Viscosity at 25^oc : 77 -80 poise
Acid Oil Plant
During alkali refining of oil, soap-stock is produced. This soap-stock is made up of the
saponification of free fatty acids and the non hydratable phosphatides, which are acid conditioned
during acid degumming. This soap-stocks used for making the acid oil .

Process :
• required amount of soap-stock is filled in the tank, the sparge steaming about 4Kg/cm2 is
operated, which works for heating and agitating the mixture.
• After h boiling it240-250Kg of conc. H2SO4 (98%) is added to it.

• The mixture is settled about 4hours. Then three layers of acid oil, sludge and water are
formed . Water is drained out from the bottom valve to water-oil separation tanks through
which it is send to the ETP for softening. , next means sludge is drained out to the sludge tank.
• . At last, acid oil is drained out to the acid oil storage tank. It is recovered about 2-2.5MT from
each batch
Losses in refinery :
Difference between weight of crude oil and refinery oil is refining loss.
In Shalimar Nutrients Pvt. Ltd Refining oil recovery is about 94.5 % so total refining loss is about 5.5% from
that only about 0.35 % dead loss and Faty acid recovery is about 0.9% and Lecithin recovery is about 3.5 -
3.8 %
1)Losses in degummimg
During degumming, due to emulsifying nature of phospholipids, degumming posses some losses. Due to
degumming 3.5 to 3.8% of oil losses occurs

Crude oil phosphorous ppm = 930ppm

= 930 *31.7/10000 = 2.94 %

Formula = {P(csbo) – P(dsbo)} * 31.7 * 1.6

10000

= (950 – 255) * 31.7 *1.6

2) Losses in Neutralisation
Soap is a byproduct of neutralisation which is also emulsifying in nature hence during elimination of soap, soap
carry neural oil along with hence the losses in the oil are given below.

Formula = FFA(dsbo) * 1.5

= 0.9* 1.5 = 1.35 %

3) losses in bleaching
During bleaching process the bleached earth takes 18% of oil of his weight hence the losses can be calculated by
using following formula

Formula = % of earth * oil % in bleaching earth

Pure Earth % in bleaching earth

= 0.8 * 18 = 0.17%

82

if flow of oil is 5000 kg/hr then

4) deodorization losses
During deodorizasion process the losses ensue are given below.

= {FFA in – FFA out} * 100

{FFD in – FFA out}

= (0.11 – 0.03) *

( 55 – 0.03 )

=0.14 %
 Packaging of Oil
• Refined Oil Packaging
From the refinery section, the refined oil is stored in the storage tanks. At these tanks, refined oil
can be stored for many days. At “Shalimar nutriants Pvt. Ltd.”,complete packaging of the refined
oil is not done due to it’s less marketing strategy.Therefore, the refined oil is not completely
packed in the packaging materials like pouches, bottles, jars and tins.
• Mainly the materials used for the packaging are as follows:

1 Tinplates containers.

2. Semi-rigid containers.

3. PET (Polyethylene Terephthalate) bottles.

4. HDPE (High Density Polyethylene) containers
 Quality Control Laboratory
All the tests and techniques are performed at Shalimar Nutrients are taken from Bureau of Indian
Standards (BIS) and American Oil Chemist's Society (AOCS).
The tests performed in the laboratory are as follows
• 1. Moisture Content 9. Rancidity (Peroxide Value )

• 2. Specific Gravity 10. Tocopherol Content Present in Fatty Acids

• 3 .Flash point 11. TBHQ Test of Refined oil

• 4. Colour of Oil) 12 .Color in Soya Lecithin

• 5. Saponification Value 13.Soap Content in Vegetable Oil

• 6. Acid Value 14. Crude fibre content in soya meal

• 7. Iodine Value 15. Urease Activity

8. Phosphorous content
• Some adulteration test like 1) 1Cottonseed Oil (Halphen's Test) 2. Mineral Oil , 3) Argemone oil.
 Conclusion
• These six months of industrial in-plant training period is very valuable in four years degree
course of Oil Technology. In this month's, we have got the knowledge about Oil Industry, how
theoretical concept employs practically and what is actual work of engineer in industry

• In this training period we have studied all unit operations and processes like extraction,
distillation, absorption, evaporation, drying, and filtration. We have also go through equipment's
like heat exchanger, pumps, valves, compressors and the most important system we have
studied is Oil Extraction and Oil Refining processes.

• The plant of "Shalimar nutrients Private Limited" is very economical due to the high amount of
heat recovery. The main advantage of this plant zero air pollution and water pollution is also
minimum due to recycling of water.