SOY OIL

PROCESSING
INDUSTRY
A Case study
Green Productivity for
Presented by-
Indian Group
Team
Production manager To lead the team and assign
responsibilities
Health and Safety officer advising on health/safety
QA/QC representatives Advice on quality production
Production Engineer Feasibility of processes,
optimisation and financial aspects
R&D rep. technological issues, ways to
improve productivity
Environmental Engineers For the assessment of
environmental impacts


Seed unloading and cleaning section:
Soybean seed supply
Lab
Testing
Discarded
seed
Transfer
(Bucket elevator
& Redler
conveyor)
Unloading
Dust
Spilled
seed
Dust
Storage in
storage silos
Transfer
(Bucket elevator
& Redler
conveyor)
Spilled
seed
Dust
Storage in day silos
PROCESS FLOW DIAGRAM
Preparatory section:
Seeds from day silos
Secondary
Screening
De-stoning
Spilled
seed
Stones&
mud balls
Conditioning in
cookers
Dryer
To Solvent Extraction Plant
Spilled
seed
Dust
Transfer
(Bucket elevator
& Redler
conveyor)
Spilled
seed
Dust
Cracking of
seed
Spilled seed
& leftovers
Dust
Steam
Spilling
Condensate
Flaking in
Flaker
Spilling
Moisture
Heat/
Dry air
SEP
Rotary Type
Extractor
Dried Flakes Hexane
Miscella DOC
Desolventisation
Toasting
Drying
Cooling
Steam
Hot Air
Hexane+
Steam
Cyclone
Economizer
Screens
Accepted Size
Packing
Oversized lumps
Lump Crusher
Evaporator
Hexane/Wate
r Seperator
Water Hexane
Drained out
Hexane
condenses
Stripper/drier
Oil
Storage
Jet/ Chiller Condenser
Hexane
Vapours
Major Waste Streams or Area of Losses
1. Dust, husk, traces, mudball and stones due to
removal from received seed
2. Leakage of Hexane vapours due to
drying of DOC
dissolving in steam and water
leakage in different compartment
incomplete retrieval from mineral oil
evaporation losses and vent losses

3. Mineral oil wastages due to
inadequate recycling process
4. Crude oil losses due to
Retention in DOC
Leakages during transportation and storage
Insufficient cooking and flaking

5. Energy losses due to
Inefficiency in conversion and transportation of
steam
Poor quality of coal
Obsolete technologies
Poor maintenance

Fishbone Diagram for Hexane Loss
Fish bone diagram:
Green Productivity Option
1. Dust, Husk, traces, mud balls and stones
Personal Protective Equipments
Procurements of better quality seeds
Proper ventilation and disposal arrangements
2. Leakages of Hexane
Proper housekeeping and maintenance of equipments
Procurements of high quality hexane
Change in technology - using mechanical extraction
- Methanol+ NaOH
Recovery from mineral oil
3. Energy losses
Good quality coal
Adoption of more efficient technologies
Proper thermal insulation
Good maintenance of equipments
Efficient heat recovery systems
4. Oil losses
Proper house keeping and maintenance of
equipments
Sealing of leakages
sufficient cooking flaks
Use of high quality seeds & hexane
Appropriate temp. control and monitoring
5. High inventory costs
Proper estimation of requirements
Proper and adequate storage arrangements
for seeds
6. Waste water generation and water losses
Adequate capacity & efficient ETP
7. Health hazards
Proper handling tools and equipments
Personal protective equipments
Spreading health and safety awareness
programmes
Utilisation and disposal of ash
GP Objectives & Targets
Objectives Targets
1. Reduction of Hexane
loss by 20% in 2 yrs
a) Maintenance of
equipments (5%)
b) Sealing of leakages
(7%)
c) Use of high quality
hexane (4-5%)
d) Efficient recovery
from mineral oil (3-2 %)
Objectives Targets
2. Reduce oil losses by 25% in 2 yrs a) Maintenance of equipments (5%)
b) Sealing of leakages (5%)
c) Increase cooking time to 60 min.
(10%)
d) Optimise & Control thickness of
Flaks (5%)
3. Curtail energy losses by 10% in 2
yrs
a) Procure good quality coal (3%)
b) Proper thermal insulation (3%)
c) Efficient heat recovery systems
(4%)
GP Policy For The Plant
We at Rama Phosphates Ltd will strive as an organization
to reduce the level of hexane wastage as it will lead to
better productivity and work towards our aim of
sustainable development by conserving natural resources.

In order to achieve this, we aim to practice:
To meet relevant environmental legislation
To prevent pollution, reduce waste and resource
consumption, encourage recovery & recycling as opposed
to disposal, where feasible
To introduce state of the technology to enhance plant
efficiency and reduce losses
To ensure proper health & safety working environment for
all employees