DELINTING OF COTTONSEED BY USMAN GHANI KHATRI Delinting of Cottonseed In developed countries, cottonseed subjected to various processes to get maximum utilities of seeds. Whereas in Pakistan 90% of cottonseed directly crushed (with linter on seed) to obtain oil and meal. Where 7 to 8% oil is extracted by oil expellers and rest of khalli or meal is used as animal feed. Continue… Those ginners who have oil expellers can use more economical process by installing delinting units. The demand of delinted cotton is growing as raw material for Viscose especially pulp, where in Pakistan it being wasted as mixed during crushing process with Khalli – till decade and half before India was using this process of crushing, since then India is applying Modern Technology to achieve maximum benefit of cottonseed. Continue… The meal from expellers may further process through solvent process, where Hexane is used as solvent which is recovered at the end of process of recycle by desolventisation. Some traces of solvent still remains in meal or khalli, that can be removed by toasting processing of meal, there are many big feed manufacture who are willing to buy this material for further processing meal to remove any trace of solvent or Toxin like Gossypol and afflotoxin. Solvent process gives additional 7 to 8% of oil then conventional expellers, this process is more economical, viable and profitable. Continue… Since one decade China and India are working continuously on cottonseed processing to get maximum benefit of cottonseed. Following diagram shows various stages of process:- COTTONSEED PROCESSING The Cottonseed consists mainly of inner kernel, usually called 'meats'. This meaty portion contains all the oil as well as proteins. The meat is enclosed in a tough fibered shell called Hull. Over the hull stick out the cotton fibred which escape the ginning and left on seed These cotton fibers are called 'Lint'. About Cottonseed And Its Products: Cotton, or Kapas as it is called, obtained from the field contains about 65 to 70% cottonseed. The seed is separated from the cotton in ginneries. An average analysis of cottonseed obtained from long staple variety of cotton is as follows: a) Oil content: 19% b) Protein content: 19% c) Lint content: 11 % d) Hull content: 36% Continue… When the seed is delinted, it yields lint as a by- product. The delinted seed is usually de-hulled yielding meats and hulls. The hull is another byproduct. When the meats are crushed in expellers one gets crude cottonseed oil and oilcan. The oilcan, when subjected to solvent extraction, yields further crude cottonseed oil, and deoiled cotton meal rich in proteins. Use of Cotton Products: Cottonseed oil when refined is edible. The deoiled cottonseed is rich in protein content and extensively used as a cattle feed. In Europe, it is used specially and can be fed to the cattle in place of hay. The lint obtained from cottonseed is used as raw material in papermaking, artificial silk manufacture, ammunition making (nitro cellulose) and upholstery. Plant, Process and Machinery: Cottonseed is first cleaned free from the foreign matter such as stones, shale, sticks, iron, earth etc. The foreign matter in the seed can be anywhere between 2 -5% depending upon the way Kapas is handled at the fields. It is essential to remove the foreign matter so as to protect the further processing machinery from damage and excessive wear and tear. Seed cleaning is carried out over reciprocating type sieves to separate sticks, shales, belhes, earth etc. The seed is then pneumatically lifted to separate the heavy matter such as stones, iron, etc. The cleaned seeds are then fed into a battery of delinting machines in which tight rolls of seed are pressed over high-speed circular saws. The saws scrape off the lint form the seed and the lint is sucked pneumatically into lint beating and cleaning devices. Continue… The lint beating and cleaning is done to increase the cellulose content of the lint and the product is bagged. Delinting is generally done in two stages, in the first stage a light cut is taken and in the 2nd stage more severe cut is allowed. The fiber length of the first lint is much longer than the second cut lint. Long fiber is preferred for the use in paper and artificial silk industry, The recovery of lint varies from seed to seed depending on its original lint content, But generally the recovery is about 1.9% to 2.2% first cut and 3.8% to 4.5% second cut. Continue… The delinted seed is then fed into hullers wherein the outer hull of the seed is cracked by knife-edge mounted on high-speed rotors. The mixture of hulls and meats so produced is passed over reciprocating sieves to separate the meats from hulls. The hulls are passed through a series of separators and beaters to ensure that they are free of entrained oil and protein bearing meats and then bagged, The meats containing about 35% oil and 35% protein are conveyed to the expelling section (Oil Mill) for crushing. Some portion of hulls is allowed to go with meats for adjusting the protein content of the final meal to the desired level. Continue… In the Oil Mill the meats are cooked in a tempering apparatus and fed into a series of expellers consisting of heavy screws working in strong cages, The meats arc squeezed with pressure as high as 5 to 10 tonnes per Sq. Inch. At this pressure the oil is squeezed out through the slits in the cage and the meats, pressed into oil cakes, containing about 7% to 8% oil, are discharged through the cage, Continue… The Crude oil obtained from the expellers is filtered through plate and frame type filter presses and then sent to refinery, In the refinery the oil is first neutralized with caustic soda, which reacts with free fatty acid content of the oil and forms soap, The soap is separated from the oil by means of centrifuges or by settling and is called soap stock. The treatment with caustic soda also removes the gums, dark coloring matter and pigments from the crude oil. The oil is then washed with hot water to free it from soap and caustic soda, The washed oil is dried in a flash drier and is sold as washed cottonseed oil. To convert into cooking edible oil, the washed oil is first bleached with activated earth and carbon and then deodorized under high vacuum and temperature with open steam. Continue… The oil cake received from the Oil Mill is conveyed to the preparatory section of the solvent extraction plant. To get best extraction results the oilcake is broken into 3 to 4 mm pieces with minimum 'fines', in cake sizing and cracking machines, The cake so prepared is fed into extractor where it is treated with low boiling petroleum solvent called normal hexane. The hexane dissolves the oil from the cake forming a solution and the oil content of cake is reduced to below 0.7%, The solution of oil in hexane is distilled in specially designed distillation equipment under vacuum, to evaporate the solvent from the oil. The oil thus separated is sent to the refinery and handled the same way as the expeller oil. The deoiled cake from the extractor containing absorbed solvent is heated to about 100 Degree Celsius in tubular jacketed driers with steam to evaporate the solvent or in specially designed desolventiser toaster. Continue… The desolventised material is cooled, humidified in a humidifier and bagged. The solvent vapors issuing from the desolventiser as well as from the distillation are condensed in series of condensers and recovered. The solvent thus recovered is used for further extraction. The process flow with the material balance is shown in Appendix attached herewith. As seen from the flow chart and above description of the process, the machinery required for processing cottonseed can be classified as follows: Continue… a) Cottonseed pre-processing plant consisting of seed cleaning, delinting, and decorticating machinery to produce cottonseed meats, lint and hulls. b) Oil Mill for crushing cottonseed meats to produce cottonseed oil and oilcake. c) Solvent Extraction Plant to extract oil from cottonseed oilcake to produce crude extracted cottonseed oil and deoiled cottonseed meal. d) Refining plant to refine both expeller and extracted crude cottonseed oil and produce washed cottonseed oil and/or edible cooking oil. e) The auxiliary equipment to provide utilities to the project such a steam, power, water etc. THANKING YOU
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