Copra Expeller
| Infobox on Copra Expeller | |
|---|---|
| Example of Copra Expeller |  |
| Facts | |
| Origin | This table shows only a selection of the most important countries of origin and should not be thought of as exhaustive.
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| Stowage factor (in m3/t) | 1.70 - 2.00 m3/t In order to ensure better utilization of transport volume, copra expeller should be compressed. Storage in silo cells is risk-free. |
| Angle of repose | approx. 42° |
| Humidity / moisture | Copra expeller requires particular temperature, humidity/moisture and ventilation conditions
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| Oil content | 1.5 - 7.0% |
| Ventilation | Copra expeller requires particular temperature, humidity/moisture and ventilation conditions. Recommended ventilation conditions: surface ventilation. See text for further details. |
| Risk factors | Self-heating / Spontaneous combustion Oil content: 1.5 - 7.0% Copra expeller is liable to the risk of self-heating/spontaneous combustion. |
Copra Expeller
Description
Coconut oil is obtained by extracting the oil contained in copra. The residue is generally called copra cake, sometimes it is called copra meal. Coconut oil is used for food and for industrial purposes. Edible oil, by international standards should have less than 0.1% free fatty acid content. The oil obtained from good quality copra, with a free fatty acid content of < 0.1%, is used as cooking oil without any further processing. Even if the free fatty acid content is 3-5%, the international standard of < 0.1% can be obtained by refining and deodorizing. Edible oils are either used as cooking oil (frying oil) or processed further into filled milk, table margarine and baker's margarine.
In industry, coconut oil is used for manufacturing toilet and laundry soap. In its original or modified form, it is used as a vehicle in the paint and varnish industry. Coconut oil is also processed into methyl esters, fatty acids and fatty alcohols. These intermediate products are raw materials for manufacturing detergents, surfactants, emulsifiers, plasticizers and various other organic products which are bio-degradable. Copra cake is used in blending animal feed.
Extraction Technology, Dry Processing:
Oil extraction from copra is carried out by two methods: mechanically by pressing; or by use of solvents. Mechanical and solvent extraction uses standard technology that has been developed in the vegetable oil industry. For oil seeds such as copra which have a high oil content, mechanical extraction is efficient and economical. For oil seeds with low oil content or for further oil extraction from copra cake, the solvent extraction method is more suitable. The residual material from solvent extraction is called copra meal. Oil extraction involves five basic steps: copra storage; preparation of copra; oil extraction - full press, prepress - solvent, and full solvent methods; processing of extracted oil; processing of cake or meal and storage of products.
Full press method:
In the full press method of oil extraction, maximum pressure is applied to the material and sufficient time is allowed for the oil to escape. The temperature of the material should not be allowed to rise to a level where the oil darkens due to overheating. The pressure is applied to the material between the screws and the cage of slitted steel bars. Pressing may be done in a single or in double stages. By adjusting the clearance in the choking device, the thickness of the cake can be controlled. When the clearance is reduced to decrease the thickness of the cake, the pressure applied is increased. To prevent overheating the oil, the shaft is usually hollow for water cooling, and the oil is sprinkled over the cage bars.
Prepress-solvent method:
In the prepress-solvent process, the oil is partially extracted by preliminary low pressure mechanical extraction, and then subjected to solvent extraction to remove most of the residual oil. The oil content of the initial copra material is around 70%; after the mechanical prepress extraction, the residual oil content in the prepressed cake is 16 - 20% for optimum operation. After full press extraction, the oil content in the residual copra cake is 6 - 10%, depending upon efficiency. The equipment used for prepressing is similar to expellers used for full pressing, but adjusted for less pressure and therefore it has a higher throughput.
Full solvent method:
In solvent extraction, oil in the material is leached with a solvent (where the oil dissolves in the solvent) whereas the insoluble meal is retained unaffected. The extent of extraction depends upon the kind of solvent, the temperature of solvent, the ratio of solvent to meal, the number of extraction stages, the shape of particles, the porosity of the material, and the contact duration. The most common solvent used is Template:Hexane because of its price, low toxicity, suitable boiling point for recovery and handling, and its availability. Solubility of oil in hexane increases with temperature.
The resulting streams from solvent extraction are: the micella or oil, solvent solution, and the extracted meal which comprises the meal, some solvent and a little residual oil. The solvent in the meal is removed by heating to boil off the volatile solvent, and the solvent is recovered by condensation. The solvent from the micella is removed and recovered by evaporation and condensation. Traces of solvent left in the meal and the oil are removed by steam-stripping under reduced pressure.
The equipment for solvent extraction consists of two general types; the roto-cell type with cells revolving around a vertical axis, and the basket type with baskets travelling horizontally while the solvent is sprayed over the material in counter-current flow. In the full solvent process, the prepared copra is first subjected to a first extraction (percolation), using the weak micella from the second extractor as starting solvent, and producing the strong micella for oil recovery. The extracted meal is then flaked and subjected to a second extraction (immersion) which uses fresh solvent as starting solvent and produces the weak micella solvent for the first extractor. The solvent with the extracted oil is removed in a Desolventizer-Toaster (DT) which is either of the multi-decked vertical design with steam heated pans and paddle scrapers, or the horizontal barrel type with rotating conveying paddles attached to a horizontal shaft, and steam jacketed walls. These are equipped with condensers for solvent recovery and scrubbers to remove dust entrained in the vapours. In some designs, the heat with the vapours leaving the DT is used to pre-concentrate the micella prior to evaporation of the micella.
The solvent with the micella is recovered, first by an evaporator, usually of the falling film type, where hexane is distilled off by indirect steam heating, and subsequently by a stripping column where traces of hexane in the oil are stripped by steam under vacuum. The water-hexane vapours from the stripper are condensed and collected in a water-hexane separator where hexane is separated by gravity from the water. It is decanted and reused in the extraction. Vent vapours of hexane from the extractors and condensers are recovered in a vent recovery system where hexane is absorbed by mineral oil. Hexane is recovered from the mineral oil by stripping, and recycled to the extractor.
Processing extracted oil:
Processing the extracted oil is the next basic step in the oil extraction technology. Oil from the expellers contain substantial quantities of solids (foots) that should be removed before the oil is pumped into the storage tanks. The oil is cleaned first by settling and screening and subsequently by filtration. The screening equipment is a rectangular steel tank equipped with a continuous drag chain conveyor with scraper blades, which scoop the settled solids and lift them over a fine screen for drainage at one end of the screening tank, after which they are conveyed back to the expellers to be mixed with the copra. The filtering equipment generally consists of a plate and frame filter press with canvass filtering media. Some factories use leaf filters with perforated steel filtering leaves. The foots or filter cake from the filters are recycled to the expellers for oil extraction. The oil from solvent extraction is free of solids. It leaves the stripping column at 120°C and is cooled and pumped into the storage tanks through an oil meter.
Processing cake or meal:
Copra cake leaving the expellers has a temperature of about 110 °C and is cooled in a cake cooler. The cake cascades down the cooler baffles and is cooled by a cross-flow of cooled air from blowers. After cooling, it is ground to fine particles by hammer mills or disc mills. The ground cake is bagged for local use or pelletized for export. Pelletizing requires additional equipment which small plants cannot afford. However, cake or meal for export has to be pelletized for safer and easier handling and conveying. Prior to pelletizing, the cake has to be moistened to about 12% moisture and then fed to the pellet mill. Moistening in this manner improves pelleting property, and is required for export. The oil content of copra cake should be around 6 to 10% and moisture not higher than 12%. For copra meal, the oil content is 0.5 - 2% depending on the efficiency of solvent extraction. Due to absorption, the moisture level rises during storage.
Storage of products:
The unpelletized copra cake should be bagged in woven sacks and stacked about 10 high on wooden pallets. It is hazardous to store unpelletized cake in bulk for long periods. The piles of unbagged meal should be kept small and turned over as frequently as necessary to prevent spontaneous combustion.
The (hot) finished expellers leave the production plant with a variable moisture content. After pressing, the expellers are cooled and, since they are in large pieces, they are ground and adjusted to a water content suitable for storage and transport. The ground products are then held in intermediate storage in silo cells or sent for transport.
Applications
Copra cake/expeller/meal is used as an ingredient in blending animal feed, due to the presence of oil, protein and carbohydrates. Copra cake from poor quality copra has a limited market due to its degraded condition and the presence of aflatoxin.
Shipment/storage
Upon shipment, the copra produce should be accompanied by certificates stating the moisture, residual oil content and the maturing time of the product. It should also be stated that the product really is expeller and not extraction meal (extracting agent/solvent content). Oil contents of < 1.5% are indicative of extraction meal. Copra expeller concern light gray to yellowish pieces (flakes) of variable size with a smooth, somewhat curved cut surface.
Overheating during the production process, or subjecting the product to pro longed storage, may be manifested by brown or reddish to black discolouration. Expeller is mainly transported as bulk cargo.
Favorable travel temperature: 5 - 25°C.
At elevated external temperatures, the product temperature must be no more than 10% higher than the external temperature.
In tropical ports, temperatures of 25 - 55°C may occur in the products to be loaded.
If the cargo temperature during the voyage rises to >55°C and any further increase is observed, countermeasures must be taken, e.g. tight closing of all hatch openings and injection of CO2 or inert gas may have to be considered. The product is best stowed in the coolest possible locations. Do not stow close to the engine room or over heated double bottom tanks.
Risk factors
- Humidity/Moisture
- Self-heating / Spontaneous combustion
The subsequent phases of self-heating possibly culminating in a cargo fire and the action to be taken are described in the article as outlined under Feedstuffs (self-heating process).
It is possible to conclude from characteristics observable in the ship's hold, such as temperatures, appearance and odor of the cargo, whether the product was loaded at too high a temperature and whether it has undergone self-heating with microbial spoilage and subsequent autoxidation.
The following features must be observed and recorded for this purpose:
- the flow behavior of the cargo in the heap (caked, free-flowing)
- the color of the product (normal, brown to black) and the distribution of color differences in the product in the hold
- the odor of the product (normal, healthy, fresh, musty, burnt)
- the temperature and appearance of the cargo at various depths in the bulk load
- the appearance of the cargo surface when the hatches are opened
- the appearance of escaping smoke/fumes (steam is white, smoke from overheated product with a temperature of above 90°C is black)
On the basis of this information, it is possible to conclude on the spot whether:
- the product was loaded too moist
- the product was loaded at too high a temperature after a drying process (toasting)
- the product was shipped shortly after production without complying with the maturing time
- biogenic self-heating has occurred during the voyage as a result of metabolic processes in microorganisms
- self-heating has occurred without a preceding biological self-heating process by chemical autoxidation of unsaturated fatty acids
- the product was loaded in a discolored state (brown to black) as a result of drying processes (toasting) performed during manufacture
Odor
Active behavior: Copra expeller has a slight, pleasant odor, but should not be stored together with odor-sensitive products as odor tainting may otherwise occur.
Passive behavior: Copra expeller is sensitive to unpleasant and/or pungent odors. Odor-tainted expeller is rejected by livestock (especially horses and cattle).
Contamination
Active behavior: Copra expeller causes severe dusting during cargo handling, such that there is a risk of dust explosion at dust/air ratios of 20 - 2000 g/m3.
Passive behavior: Copra expeller is sensitive to contamination by dust, dirt, fats and oils. The holds or containers should thus contain no residues of previous cargoes, such as ores, minerals, chemicals, salts, fertilizers.
Mechanical influences
No risk.
Toxicity / Hazards to health
An increase in CO2 and CO content in the hold air indicates that a cargo fire has begun. Danger: Risk of asphyxiation and poisoning on inhalation. No access is permitted to the hold until it has been adequately ventilated and the atmosphere tested with a gas detector. The CO content may rise from 0.002 - 0.005 vol.% to 1 vol.%. The lethal (fatal) dose is approx. 0.1 vol.%.
Foreign admixtures (e.g. toxic castor seeds) and poisonous protein breakdown products are harmful to animals. Levels of infestation with the mold Aspergillus flavus of 3% are very harmful, in particular to turkeys, chicks and ducks, due to the aflatoxin complex.
Shrinkage/Shortage
Slight losses (trickle losses) may occur during cargo handling.
Insect infestation / Diseases
Insect infestation, especially by various species of beetles (e.g. khapra beetle), is widespread. On extended storage, there is a risk of mite infestation, which is promoted by heat and moisture.
If required by the consignor or import regulations, fumigation (e.g. with Methyl Bromide) must be performed.
Reference is made to the relevant IMO regulations on hazardous cargo.
Note:(Source including Transport Information Service of the GDV)