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De Smet Presentation 1
NewNew
CompactCompact
TechnologyTechnology
Sunflower Seed ProcessingLarge Capacities
Sunflower Seed ProcessingLarge Capacities
OFI 2014
Etienne Le ClefDavid de Schaetzen
De Smet Presentation 2
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Mio TPY
Sunflower production 2013
Seed prices : the Lowest
De Smet Presentation 3
400
450
500
550
600
650
700
Jan Feb Mar Apr May Jun Jul Aug Sept Okt Nov Dec Jan Feb *Mar April May
US
$/T
Month
Seed Prices
Soybean Sunseed Rapeseed
USDA Markets & Trade
Sun oil : Highest price
De Smet Presentation 4
800
900
1000
1100
1200
1300
1400
Jan Feb Mar Apr May Jun Jul Aug Sept Okt Nov Dec Jan Feb *Mar April May
US
$/T
Month
Comparative Oil Prices
Soy oil Sun Oil Rape Oil
USDA Markets & Trade
Sunmeal : Lowest Value
De Smet Presentation 5
200
250
300
350
400
450
500
550
600
Jan Feb Mar Apr May Jun Jul Aug Sept Okt Nov Dec Jan Feb *Mar April May
US
$/T
Month
Comparative Meal Prices
Soybean Sunseed Rapeseed
USDA Markets & Trade
Simplified Mass BalanceUn-dehulled
De Smet Presentation 6
1) Sunflower inlet INLET 2) After dehulling 3) After cooking
Mass Flow t/h 41.67 1000TPD Mass Flow t/h 41.67 1000TPD Mass Flow t/h 40.36 969TPD
Water Content 7.5% 75TPD Water Content 8% 75TPD Water Content 4.5% 44TPD
Oil Content 42% 420TPD Oil Content 42% 420TPD Oil Content 43% 420TPD
Protein Content 14% 140TPD Protein Content 14% 140TPD Protein Content 14% 140TPD
hull content 25% 250TPD hull content 25% 250TPD hull content 26% 250TPD
Rest 11.5% 115TPD Rest 12% 115TPD Rest 12% 115TPD
4) after prepressing 5) after Extraction 6) After DTDC
Mass Flow t/h 28.57 686TPD Mass Flow t/h 23.09 554TPD Mass Flow t/h 23.90 574TPD
Water Content 6% 44TPD Water Content 6.4% 44TPD Water Content 11.0% 63TPD
Oil Content 20% 137TPD Oil Content 1% 6TPD Oil Content 1% 6TPD
Protein Content 20.4% 140TPD Protein Content 25.3% 140TPD Protein Content 24% 140TPD
hull content 36% 250TPD hull content 45% 250TPD hull content 44% 250TPD
Rest 17% 115TPD Rest 21% 115TPD Rest 20% 115TPD
Simplified Mass BalanceDehulled From 14%
De Smet Presentation 7
1) Sunflower inlet INLET 2) After dehulling 3) After cooking
Mass Flow t/h 41.67 1000TPD Mass Flow t/h 34.72 833TPD Mass Flow t/h 33.09 794TPD
Water Content 7.5% 75TPD Water Content 9% 75TPD Water Content 4.5% 36TPD
Oil Content 42% 420TPD Oil Content 50% 420TPD Oil Content 53% 420TPD
Protein Content 14% 140TPD Protein Content 17% 140TPD Protein Content 18% 140TPD
hull content 25% 250TPD hull content 10% 83TPD hull content 10% 83TPD
Rest 11.5% 115TPD Rest 14% 115TPD Rest 14% 115TPD
4) after prepressing 5) after Extraction 6) After DTDC
Mass Flow t/h 19.48 468TPD Mass Flow t/h 15.74 378TPD Mass Flow t/h 16.02 384TPD
Water Content 8% 36TPD Water Content 7.6% 36TPD Water Content 11.0% 42TPD
Oil Content 20% 94TPD Oil Content 1% 4TPD Oil Content 1% 4TPD
Protein Content 29.9% 140TPD Protein Content 37.1% 140TPD Protein Content 36% 140TPD
hull content 18% 83TPD hull content 22% 83TPD hull content 22% 83TPD
Rest 25% 115TPD Rest 30% 115TPD Rest 30% 115TPD
De Smet Presentation 8
Simplified Mass Balance
Dehulled From 15%
1) Sunflower inlet INLET 2) After dehulling 3) After cooking
Mass Flow t/h 41.67 1000TPD Mass Flow t/h 34.72 833TPD Mass Flow t/h 33.09 794TPD
Water Content 7.5% 75TPD Water Content 9% 75TPD Water Content 4.5% 36TPD
Oil Content 42% 420TPD Oil Content 50% 420TPD Oil Content 53% 420TPD
Protein Content 15% 150TPD Protein Content 18% 150TPD Protein Content 19% 150TPD
hull content 25% 250TPD hull content 10% 83TPD hull content 10% 83TPD
Rest 10.5% 105TPD Rest 13% 105TPD Rest 13% 105TPD
4) after prepressing 5) after Extraction 6) After DTDC
Mass Flow t/h 19.48 468TPD Mass Flow t/h 15.74 378TPD Mass Flow t/h 16.02 384TPD
Water Content 8% 36TPD Water Content 7.6% 36TPD Water Content 11.0% 42TPD
Oil Content 20% 94TPD Oil Content 1% 4TPD Oil Content 1% 4TPD
Protein Content 32.1% 150TPD Protein Content 39.7% 150TPD Protein Content 39% 150TPD
hull content 18% 83TPD hull content 22% 83TPD hull content 22% 83TPD
Rest 22% 105TPD Rest 28% 105TPD Rest 27% 105TPD
Protein Value
De Smet Presentation 9
24
36
44
48
20
25
30
35
40
45
50
250 300 350 400 450 500 550 600 650
Axis
Title
Prices US$ / Ton
LP Sun 24%HP Sun 36%
LP Soya 44%HP Soya 48%
20
25
30
35
40
45
50
250 300 350 400 450 500 550 600 650
Protein
De Smet Presentation 10
ImpactorsBigger Capacity : 200 TPD
De Smet Presentation 11
Impactors sizing
TPD TPD Main
Recycling No Recycling kW
DGBA-1580 135 150 11
DGBA-2280 175 200 18
Process improvementsTo avoid oil loss
De Smet Presentation 12
• Separate seed according to sizes
• Avoid recycling the unbroken seed to same impactors
• Adjust aspiration to sizes
SEED Selection
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
0 1 2 3 4 5 6
Particules size (> 2 / 3 / 4 / 5 mm)
Size Distribution
Small Seed33 %
Big Seed67 %
Seed SelectionSmall and Bigger seed
De Smet Presentation 14
Seeds from Storage / 730
Daily bin
716D
708/16D
736D
to Atm
Fe
701
785A
786
785B
Trash
DUST CONTROL
740
Small Seeds to Dehulling
Large Seeds to Dehulling
Trash
• Overflow from big to small
• Overflow from small to big
• Reduce the grey zone
Big seed / Small seed
De Smet Presentation 15
5736/14/1 5736/14/2
TP571
5
5714/15714/2
5780/1 5780/2 5780/3 5780/4
5783A1 5783A2
5708/80/1 5708/80/2 5708/80/3 5708/80/4
5708/83A1 5708/83A2
5715A1-25715A1-1 5715A2-25715A2-1
571508/A2-1571508/A1-2571508/A1-1
5783B1
5708/83B1
5715B1-25715B1-1
571508/B1-2571508/B1-1
5780/5 5780/6
5783A3
5708/80/5 5708/80/6
5708/83A3
5715A3-25715A3-1
571508/A3-2571508/A3-1571508/A2-2
5736/14/3
5714/3
TP703/1
701
730/01®
785A
785B
740
708/85B
M701
M708/85B
M740
oversDus
t
to Atm
716/40
M736/40
736/40
708/16M708/16
786
Stones
708/40M708/40
Ø 500
717/1
717/2
Stones
Small Seed
(33%)
Big Seed
(67%)
UNBROKEN SEEDSmaller than Average seed
0%
10%
20%
30%
40%
50%
60%
70%
0 1 2 3 4 5 6
Particules size (> 2 / 3 / 4 / 5 mm)
Size Distribution
Unbroken seed Separate impacting Avoid recycling !
De Smet Presentation 17 Ital Green Oil, Italy
5783P5 5783P6
5780P11&12
5783R1
One Section of 3 each processing 800 TPD for total plant capacity of 2400 TPD
One Section for 800
TPD
One Section for 800
TPD
Hulls to
Storage
DEHULLING SECTION
OVERS TREATMENT
HULLS TREATMENT
5783S3
Meats to PreparationOvers for
Re-work
Mid Fraction
Meats
Hulls
5780P9&10 5780R1&2
5717H1
5717H45717H3
5717H2
5714H6
5714H5
5715P9&10 5715P11&12
5715S5&6
5715R1&2
5714R2
5714R1
Minority flow small
seed
Majority flow large
seed
NST 2222Double Deck
De Smet Presentation 18
OversMidsFinesDeck 1
Deck 2 Capacity 400 TPD !
De Smet Presentation 19
Mass Balance (1 step)
100 kg (25 kg Hulls) 11 kg (Hulls)
10 kg
(Over = recirculation)
29 kg
(Bottom
fraction)
60 kg
(Mid
Fraction)
SEED
< 14 kg
Hulls
residual
Mass Balance (2 steps)
De Smet Presentation 20
100 kg (25 kg Hulls) 11 kg (Hulls)
10 kg
(Over =
recirculation) 29 kg
(Bottom
fraction)
60 kg
(Mid
Fraction)
SEED
< 14 kg
Hulls
residual
4 kg (Hulls)
12 kg
(Bottom)
22 kg
(Mid)
< 10 kg
Hulls
residual
22 kg
(Top)
De Smet Presentation 21
NST 2222
De Smet Presentation 22
Mechanics
Stolz
De Smet Presentation 23
Multiple level body
Stolz
Compact Plant LayoutFootprint 20 m X 10 m
De Smet Presentation 25
Recovering entrained Oil and Protein
• New Beaters
Stolz
De Smet Presentation 26
TURBO SIFTER
Hulls (2% oil)
Hulls (1% oil)Meats (Hulls)
Oil in Hulls (above botanic) reduced by 1%
TURBO SIFTER
De Smet Presentation 27
Screen = « Stator » - 5 rpm
Beater = Rotor – 240 rpm
De Smet Presentation 28
Surface Turbosifters (m2)
Type Diam(mm) Length (mm)
Surf (m2)
BMCT 750 1300 3
BMCT 1250 1150 4.5
BMCT 1250 + 1800 7
Tail end DehullingTo increase protein level
HP meal LP meal
De Smet Presentation 29
HP LP
36% 70% 30% 32.7%
38% 60% 40% 30.5%
40% 50% 50% 30.0%
Starting from 35%
New D-Series Rotating tube Dryers
Conditioning
• Heating seed to 95 – 100 °C
• Drying from 8% to below 4%
De Smet Presentation 31
20
002
,50
0
Rotary Tube Dryer
� M
ea
l in
let
from
DT
We
t A
ir o
utle
t �
Finished in the workshop
De Smet Presentation 32
De Smet Presentation 33
Ready to ship
Sizes D-Series Rotary Dryers-Conditioners
Model Diam x Lengthm
MotorkW
HE Area Capacity
m2 TPD
RTD -180 1.8 x 8 15 180 300
RTD -235 2.35 x 18 30 500 550
RTD -260 2.6 x 18 75 720 1000
RTD -300 3.0 x 24 110 1130 2000
RTD -340 3.4 x 24 132 1550 3000
RTD -380 3.8 x 24 160 2010 4000
Advantages of RTD
De Smet Presentation 35
- Controlled filling rate- Generous Heat Exchange area- Better Drying up to 3 - 4%- Less Power- Less Air Emissions !
Strong, Rigid Frame with Access
Feed End Drive
One Piece Cast Cage, Opens to 90 °
Maximum Separation of Drive and Pressing Sections
Discharge End Bearing
• Press Options
• Barring Motor
• Cake Breaker
• Press Handing
• Shaft Cooling
• Feeder Layout
• Goldstar or HF
Parts
Multiple Stage Low Compression Worm Assembly
Vertical & Horizontal Feeder Unit
Design FeaturesRosedowns
2 Main Recent Innovations:
•Increased Stages of Compression - Improved Residual Oil
• - Improved Milling Defect
– 800 Series 3 -> 5 Stage
•Longer Choke:
– Longer Time to Form a Cake
– Greater Frictional Back Pressure
•Successful at:
– Saipol Bordeaux (800 Series)
– Saipol Le Meriot (800 Series)
– ADM Europoort (800 Series)
– Aarhus Karlsham (600 Series)
Design Features
1 2 3 4 5
Rosedowns
The Sterling Series• Technical Data & Capacities
Series With Flaker No Flaker
100 Series SterlingBore Diameter
Working Length
Nominal Power rating
100 TPD200mm
5 fields
75 kW
75 TPD200mm
5 fields
75 kW
200 Series SterlingBore Diameter
Working Length
Nominal Power rating
200 TPD250mm
6 fields
150 kW
150 TPD250mm
6 fields
150 kW
400 Series SterlingBore Diameter
Working Length
Nominal Power rating
325 TPD300mm
7 fields
250 kW
250 TPD300mm
7 fields
250 kW
600 Series SterlingBore Diameter
Working Length
Nominal Power rating
550 TPD350mm
8 fields
400 kW
450 TPD350mm
8 fields
400 kW
800 Series SterlingBore Diameter
Working Length
Nominal Power rating
750 TPD400mm
11 fields
600 kW
600 TPD400mm
11 fields
600 kW
Pre-pressing without flaking
800 Series SterlingBore Diameter
Working Length
Nominal Power rating
750 TPD400mm
11 fields
600 kW
20 kWh/T
600 TPD400mm
11 fields
600 kW
24 kWh/T
De Smet Presentation 39
Flaker Roll Diameter
Working Length
Nominal Power rating
400 TPD800 mm
2100 mm
132 kW
8 kWh/T
-
0 kWh/T
Total 750 TPD
28 kWh/T
600 TPD
24 kWh/T
Cake Crisping
De Smet Presentation 40
2709/25/2
2730/25/2
Air Inlet �
95 °C
20 °C
105 °C
65 °C
De Smet Presentation 41
With / Without FlakersTo obtain good milling defect
Let’s consider 1300 TPD SF Seed :(= ~1000 TPD after dehulling)
- With Flakers : - 3 x flakers (350–400 TPD) / Abs power : ~7 kWh/T
- Cooking : drying to 3 - 4 %- 2 x Sterling 600 / Abs power : ~ 17 kWh/t- Milling Defect (after press) : 0.4 - 0.5%
- Wihout Flakers :- NO flakers
- Cooking : drying to 3 - 4 %- 2 x Sterling 800 / Abs power : ~ 19,5 kWh/t- Milling Defect (after press) : 0.4 - 0,5%
De Smet Presentation 42
Let’s consider 1300 TPD SF Seed :(= ~1000 TPD after dehulling)
- With Flakers : CAPEX- 3 x flakers (350 TPD) = 3 x ~275.000 Euros
- Building ~880m³ (&… ) for flakers = ~100.000 Euros- 2 x Sterling 600 = 2 x ~300.000 Euros
Total = ~1.525.000 Euros
- Wihout Flakers : CAPEX- NO flakers = 0 Euros
- 2 x Sterling 800 = 2 x ~370.000 Euros
Total = ~ 720.000 Euros
CAPEX
De Smet Presentation 43
OPEX
Let’s consider 1300 TPD SF Seed :(= ~1000 TPD after dehulling)
- With Flakers : OPEX- Extra Elec. consumption : ~7 + 17 = 24 kWh/T
Based on ~ 0,10 Euros / kWh� 1000TPD x 24 kWhT x 0,10 Euros x 300 days/year
- = ~720.000 EurosWithout Flakers : OPEX
- Elec. consumption : ~19.5kWh/T
Based on ~ 0,10 Euros / kWh� 1000TPD x 19,5 kWhT x 0,10 Euros x 300 days/year
= ~585.000 Euros
De Smet Presentation 44
TotalLet’s consider 1300 TPD SF Seed :
(= ~1000 TPD after dehulling)
- With Flakers : CAPEX & OPEX- CAPEX (Flakers + Press) ~1.525.000 Euros- OPEX (Elec) ~720.000 Euros/Year
- Without Flakers : CAPEX & OPEX- CAPEX (Press only) ~720.000 Euros- OPEX ( Elec) ~585.000 Euros/Year
Conclusion
• Capex: 1.525.000- 720.000 = 805.000 €
• Opex : 720.000 – 585.000 = 135.000 €/Y
• Maintenance: ….
De Smet Presentation 46
Desmet Ballestra Group
The End !
