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Com miss ion o f the European Co mm un i t i es
energy
I ned i b l e render i ng by means
of the w e t pressin g process
Demonstrat ion project
R e p o r t
EUR 10652 EN
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Commission of the European Communities
energy
Inedible rendering by means
of the wet pressing process
Demonstration project
KOFO K dfod fabrikken stjyden
DK-8723 Lsning
Contract No EE/084/82
Final report
Directorate-General
Energy
1986 EUR 10652 EN
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Publ ished by t he
C O M M I S S I O N O F T H E E U R O P E A N C O M M U N I T I E S
D i r e c t o r a t e - G e n e r a l
T e l e c o m m u n i c a t io n s , I n f o r m a t i o n I n d u s t ri e s a n d I n n o v a t i o n
B t im e n t J e a n M o n n e t
L U X E M B O U R G
L E G A L N O T I C E
Neither the Commiss ion of the European Communit ies nor any person act ing on
behal f of the Commiss ion is responsib le for the use which might be made of the
fo l low ing in fo rmat ion
Cataloguing data can be found at the end of th is publ icat ion
Luxembourg: Off ice for Off ic ia l Publ icat ions of the European Communit ies, 1986
ISBN 92-825-6519-X Catalogue nu m be r:
ECSC-EEC-EAEC, Brussels Luxembourg, 1986
Printed in Luxemb ourg
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1. Introduction
T r a d i t i o n a l i n e d i b l e r e n d e r i n g o f o f f a l s a n d w a s t e m a t e r i a l s f r o m s l a u g h t e r i n g a n d
m e a t p r oc es s ing is bas ed on ba t c h w is e d r y r end e r ing ( s te r i l i z a t i o n and d r y in g in a
c o o k e r ) f o l l o w e d b y s e p a r a t i o n o f m e a l a nd f a t b y m e a n s o f h e x a n e e x t r a c t i o n . T h i s
p r oc es s has tw o m a jo r d i s ad v an tage s : 1) The ene r gy c on s um pt ion i s h igh ( app r ox . 75
kg o i l per ton raw m at er ia l ) and the process does not a l l ow f o r seconda ry use o f the
ene r gy i n t he ex haus t s team f r om the c ook e r s - 2 ) Hex a ne ex t r a c t i o n i nv o l v es r i s k s
o f ex p los ion and t he r i s k o f undes i r ab le r es idues i n t he ex t r a c te d f a t and m ea l .
I n o r de r t o ov e r c o m e the h igh ene r gy c os t s i n r end e r ing a new c onc e p t f o r t he
p r oc es s o f r ende r ing has been dev e lope d a t t he Dan is h M e a t Res e a r c h I ns t i t u te i n
Ros k i l de and t es te d i n p i l o t ex p e r im en ts a t a Dan is h ren de r in g p lan t . The new
pr oc es s was t e r m ed w e t p r es s ing .
The p r oc es s i s bas ed on t he d i s c ov e r y t h a t i t i s pos s ib le a t l ow tem pe r a t u r e
( 5 0 - 6 0 C , j u s t ab o v e m e l t i n g p o i n t o f t h e a n i m a l f a t ) t o s e p a r a t e n e a r l y a l l f a t a n d
m o r e t han 6 0% o f t he wa t e r f r o m th e s o l i ds o f t he r aw m a te r ia l s by m eans o f a
p r es s ing p r oc es s . Th i s has m ade pos s ib le t he des ign o f a p r oc es s w i t h o p t im iz e d use
o f t he ene r gy nec es sa r y f o r s t e r i l i z a t i o n and r em ov a l o f wa te r , t hus r edu c ing t h e
ener gy c ons um pt ion f r o m 75 k g o i l pe r t on r aw m a te r ia l s in t he t r a d i t i o na l p r oc es s
to an ex p ec ted f i g u r e o f app r o x . 35 k g o i l pe r t on r aw m a te r ia l s i n t he new p r oc es s .
A s a f u r t h e r adv an tag e no o r ga n ic s o l v en t s a r e needed f o r t he new p r oc es s .
The in i t i a l wo r k i nd i c a te d t ha t t he p r es s ing o f r aw m a te r i a l s was f eas ib le bu t a ls o
th a t a l o t m or e wo r k had t o be done in o r de r t o t u r n t he p r oc es s i n to a f u l l s c a le
o p e r a t i o n .
T h u s , a n e x p e r i m e n t a l p r o ce s s in g l in e w a s c o n s t r u c t e d a t t h e re n d e r i n g p l a n t K O F O
( f o r m e r l y s t j yd e n ) a n d a n e x t e n s iv e R & D w o r k w as i n i t i a t e d .
2 . O b j e c t i v e s o f th e p r o j e c t
T h e p r o j e c t r e l a t e s t o t h e e r e c t i o n o f a f u l l - s c a l e p r o d u c t i o n l i n e f o r c o n v e r t i n g
i n e d i b l e o f f a l a nd t h e l i k e to m e a t - a n d - b o n e m e a l a n d a n i m a l f a t b y m e a n s o f t h e
we t p r es s ing s y s tem .
The p r oduc t i on l i ne was des igned f o r hand l i ng 10 t ons r aw m a te r ia l s pe r hou r a t t he
c o o p e r a t i v e p l a n t o f K O F O i n L s n i n g , D e n m a r k .
The l i ne was c onnec ted t o t he ex i s t i ng 5 t / h ex pe r im en ta l p r oc es s ing l i ne ,
c o n s t r u c t e d an d u se d i n t h e p r e l i m i n a r y R & D w o r k .
The p r o j ec t has been d i v ided i n to tw o phas es , a phase f o r t h e c on s t r u c t i o n and
runn ing in o f the new process ing l ine and a measur ing phase .
The ob je c t i v e o f t he f i r s t phase o f t he p r o jec t was t o des ign and c o ns t r uc t t h e
fu l l - s c a le p r od uc t i o n li ne and t o s how fea s ib i l i t y o f t he p r oc es s i n f u l l - s c a le
ope r a t i on . The ob jec t i v e o f t he s ec ond phas e was t o ob ta in k ey f i gu r es f o r t he
ene r gy f l o w in t he s y s tem and t o ob ta in f i gu r es f o r t he ene r gy s av in g .
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3 . D e s c r i p t i o n o f t h e p r o j e c t
The bas ic new pr inc ip le in the process is the use o f a co nd i t io n in g and pre -pre ss in g
o f t he r a w m a te r ia l s , a p r oc es s wh ic h has nev e r been t r i ed ou t on r ende r ing
m ate r ia l s . The p r es s ing p r oc edu r e d i v ides t he r aw m a te r ia l s i n a s o l i d and a l i qu id
phas e , t hus enab l i ng t he des ign o f a who le ope r a t i o n a im ing a t m in i m iz in g t he
e n e r g y c o n s u m p t i o n o f r e n d e r i n g .
Th is is ac h iev ed by ev apo r a t i ng 8 0 - 9 0% o f t he w a te r i n t he l i qu id phase f r o m the
p r ess in a v ac uu m ev a por a to r us ing was te ene r gy f r o m th e d r y ing o f t he s o l i d phas e
f r o m th e p r es s . The p r inc ip le o f t h e p roc es s i s s hown in d ia g r a m , F igu r e 1 .
The we t p r es s ing p lan t a t K O FO i s s hown in d iag r am in F igu r e 2 . The ex i s t i n g 5 t / h
p la nt used fo r the resea rch and de ve lo pm ent phase is in w h i te whereas the
equ ipm en t i ns ta l l ed i n o r de r t o ex ten d t he p r od uc t i o n l ine t o 15 t / h ( t h i s p r o je c t ) i s
s hown in ha t c h ing . The ene r gy f l ow s y s tem i s s hown in F igu r e 3 .
O f fa l and c ondem ned an im a ls a r e p r eb r ok en ( m ax . s i z e 70 m m ) and t r ans po r ted t o a
we ig h ing b i n . The r aw m a te r ia l s t he n pass a m a gne t and a m e ta l de tec to r wh ic h i n
t u r n s o r t o u t m a g n e t i c m a t e r i a l a nd m a t e r i a l s c o n t a i n i n g n o n - m a g n e t i c m e t a l . T h e
r e j ec ted r aw m a te r ia l s a r e c onv ey ed ou t o f t he s y s tem and f i n a l l y t r e a te d i n a d r y
r ende r ing c ook e r . The r aw m a te r ia l s f r eed o f m e ta l a r e has hed t o a s i z e o f l es s t han
19 m m and ind i r e c t l y hea ted w i t h ho t wa te r t o 60 C in a c oa gu la to r . They pas s a
s t r a ine r s c r ew w i t h ad jus tab le ho le s i z e and a r e t hen p r es s ed in a tw in s c r ew p r es s ,
wh ic h d i v ides t h e r a w m a te r ia l s i n two phas es, a s o l i d phase (p r ess c ak e ) c on ta in in g
4 0 - 5 0 %
wa te r and 4 - 7 % c rude f a t on a d r y m a t te r bas i s , and a l i qu id phas e
c on ta in in g f a t , wa te r and som e s o l i ds . The l i qu id phase is hea ted t o 100 C w i t h l i v e
s team and pass ed t h r ou gh a 3 - phas e dec an te r ( t r i c an te r ) wh ic h s epa r a tes i t i n t o f a t ,
s t i c k w a te r and g r ax . The g r ax is r e tu r ne d t o t he c oagu la to r , t he f a t is s en t f o r
r e f i n i n g a n d s t e r i l i z a t i o n a n d t h e s t i c k w a t e r c o n t a i n i n g 8 % d r y m a t t e r a n d 0 . 6 %
c r ude f a t i s pum ped in to t he 3 s tage was te hea t ev a po r a to r f o r c o nc en t r a t i on . The
c o n c e n t r a t e c o n t a i n i n g 3 5 % d r y m a t t e r ( 8 - 9 % f a t i n D M ) is m i x e d i n t o t h e
p r es s c ak e , wh ic h is d r i ed i n a p la te c o n ta c t d r y e r i nd i r e c t l y h ea ted by l i v e s te am .
The m ea l l eav es t he d r y e r a t no l es s t han 110 C a t wh ic h t e m pe r a tu r e s te r i l i z a t i o n
i s ac c o m p l i s hed . The m e a l has a m o is tu r e c on ten t o f 5 - 7 % and a f a t c on te n t o f
7 - 8 % . I t i s t r a n s p o r t e d t o m i l l i n g b y m e a n s o f a p n e u m a t i c t r a n s p o r t s y s t e m . T h e
d r y e r gas ses pas s a s c r ubbe r whe r e t he pa r t i c u la tes a r e r em ov e d f r o m th e v apour s
and a s m a l l p r op o r t i o n o f t he v apour s is c ondens ed . The s c r ubbe r l i q u id d e l i v e r s ho t
w a te r (90 C ) t o t he c oa gu la to r v ia a hea t ex c han ger .
The gasses the n pass a hea t exchang er w her e par t o f the i r ene rgy is t ra ns fe r re d to
the d i s t r i c t h ea t i n g s y s tem . The gass es f i n a l l y s e r v e as hea t ing m e d ium f o r s tage I in
t he was te hea t ev apo r a to r .
The p r inc ipa l equ ipm en t us ed in t he 15 t / h we t p r es s ing s y s tem i s t he f o l l ow ing :
2 hashe rs : S IMO 40 0/1 90 .0 , 2F 2500 - 90 kW
1 c o a g u l a t o r : A t l a s O C 2 - 6 0 0 - 1 1 k W
1 s t r a in e r s c r e w : A t l as O C45 0 - 5 k W
2 tw in sc rew presses : A t la s - S to rd BS 35 F - 45 kW
3 dry ers : A t la s PC D 1854 - 110 kW
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2 t r i c a n t e r s :
1 wa s te h e a t e v a p o r a to r :
F l o t t w e g Z - 4 2 - 3 / 4 4 - 1 8 . 5 / 2 5 k W
A t l a s WHE 3 0 8 4 .
In o r d e r t o e n a b l e m e a s u r e m e n ts o f e n e r g y c o n s u m p t i o n i n t h e s y s te m th e f o l l o w i n g
measur ing po in ts were es tab l i shed ( the f i gu res re fe r to F igu re 3 ) :
O
D
S
S
m
IH
E U
E U
E D
04
m
1 2 J
E U
manua l read ing
a u t o m a t i c r e c o r d i n g
Te m p e r a tu r e o f s te a m fo r d r y e r s
Te m p e r a tu r e o f c o n d e n s a te f r o m d r y e r s
Pressu re o f s team fo r d rye rs
Te m p e r a tu r e o f g as b e fo r e s c r u b b e r
Te m p e r a tu r e o f g a s a f t e r s c r u b b e r
T e m p e r a t u r e i n o v e r f l o w f r o m s c r u bb e r
Te m p e r a tu r e o f ga s a f t e r h e a t e x c h a n g e r
Te m p e r a tu r e o f ga s a f t e r e v a p o r a to r , s ta g e 1
Te m p e r a tu r e o f g as a f t e r c o n d e n s e r f o r e v a p o r a to r
Te mp era tu re o f gasses be fo re f i n a l condenser
Te m pe ra tu re o f non -c onde ns ib le gasses a f te r condenser
Te m p e r a tu r e i n c o n d e n s a te
Te m p e r a tu r e in c o n d e n s a te f r o m e v a p o r a to r
P o we r c o n s u m p t i o n ( k Wh ) : Ha s h e rs e t c .
Drye r No . 3 and 4 e tc .
Screw presses e tc .
Dr y e r No . 5 e t c .
Co o l i n g t o we r s
P n e u m a t i c t r a n s p o r t s y s t e m
H a m m e r m i l l s e t c .
P u m p fo r n o n - c o n d e n s i b l e s
To ta l o f p l a n t .
S te a m c o n s u m p t i o n f o r d r y e r s
L i v e s te a m a n d f l a s h s te a m c o n s u m p t i o n ( t r i c a n te r )
A m o u n ts o f c o n d e n s a te f r o m e v a p o r a to r
A m o u n ts o f c o n d e n s a te f r o m s c r u b b e r
A m o u n ts o f c o n d e n s a te f r o m v a r i o u s s o u r c e s
E f f i c i e n c y o f h e a t e x c h a n g e r
M e a s u r e m e n ts a n d r e c o r d i n g s we r e p e r fo r m e d a t 6 0 m i n u te s i n te r v a l s , e x c e p t f o r
t h e r e c o r d i n g o f t o ta l p o we r c o n s u m p t i o n , wh i c h wa s d o n e e v e r y 2 4 h o u r s .
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4 . I m p l e m e n t a t i o n o f t h e p r o j e c t
A s t h e c o n s t r u c t i o n o f t h e p l a n t w a s e x p e c t e d t o b e a n i m p o r t a n t a n d d i f f i c u l t t a s k ,
a p r o jec t m a nag em en t g r oup was m ade by m a k ing t he c h ie f en g inee r r es pons ib le f o r
t he t ec hn ic a l as pec t s on a f u l l t im e basi s du r ing t he c ons t r uc t i on pe r iod . The
m ea s ur ing and r ep o r t i n g as pec t s we r e t he r es p ons ib i l i t y o f an eng inee r f r o m the
Dan is h M ea t Res e a r c h I n s t i t u te be ing f am i l i a r w i t h t he p r o jec t as he had been
i n v o l v e d i n t h e p i l o t e x p e r i m e n t s f r o m t h e v e r y b e g i n n i n g . T h e e c o n o m i c a l a s p e c ts
wer e t ak en c a r e o f by t he m anag ing d i r ec to r o f K O FO . Thes e t h r e e peop le f o r m ed
t h e p r o j e c t m a n a g e m e n t g r o u p -
A s t he p r o jec t r equ i r ed t he s upp ly o f a l o t o f d i f f e r e n t equ ipm en t , and as t he
p r oc es s was new and c ons equ en t l y p r oc ess gua r an tees c ou ld be d i f f i c u l t t o ob ta in i t
was dec ided no t t o c a l l f o r t ende r s f o r a f u l l p r oc es s l i ne . I ns tead t he p r oc es s was
d iv ided i n s ev e r a l pa r t s and f r o m a l i s t o f po t en t i a l s upp l i e r s i n v i t a t i o n f o r t ende r s
we r e i nv i t ed f o r eac h pa r t p r oc es s . Th i s p r oc ed u r e was c hos en f o r t he f o l l o w i ng
reasons :
1 ) t o ob ta in t he h ighes t pos s ib le ex p e r t i s e r ega r d ing eac h s ing le pa r t o f t he p r oc es s
2) to ob ta i n the bes t poss ib le gua rante es as to the ind iv id ua l pa r ts o f the process
3 ) t o a c h i e v e c o m p e t i t i v e p r i c e s
In c e r t a in cas es i t was nec es s a ry t o t es t equ ipm en t f r o m a l t e r na t i v e m an u fac tu r e r s
b e f o r e d e c i d i n g w h i c h e q u i p m e n t t o b u y .
The r es u l t was t h a t 21 c om p an ies m ade tende r s f o r t he m os t im p or t an t pa r t s o f t he
p r o je c t , and ou t o f t hes e 12 we r e c hosen t o s upp ly t he equ ipm en t .
The s upp l i e r s ( and s ub - c on t r ac to r s ) c hos en wer e as f o l l ows :
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E q u i p m e n t
E q u i p m e n t f o r r a w
m a t e r i a l h a n d l i n g
1 hasher
1 c o a g u l a t o r
1 sc rew press
2 P C D - d r y e r s
1 t r i c a n t e r
1 e v a p o r a t i n g s y s t e m
P n e u m a t i c m e a l t r a n s p o r t
V e n t i l a t i o n o f p r o c e s s
a i r
S t e a m t r a n s f e r
I n s t a l l a t i o n o f d r y e r s
and ev apo r a to r
E l e c t r i c i n s t a l l a t i o n s
Sta in less s tee l tubes
Suppl ie r
S v r t e k , S t r i b ,
D K - 9 5 0 0 M i d d e l f a r t
Z i a s - T r a d i n g
D K - 4 2 2 0 K o r s r
s t j y d e n ,
D K - 8 7 2 3 L s n i n g
A t l a s , D K - 2 7 5 0 B a l l e ru p
A t l a s , D K - 2 7 5 0 B a l l e ru p
C r n i c a s , L o n d o n
A t l a s ,
D K - 2 7 5 0 B a l le r u p
F j o r d v e j e n s M a s k i n f a b r i k ,
D K - 7 8 0 0 S k i v e
S t r m & P e t e r s e n ,
D K - 7 1 0 0 V e j l e
S v r tek , S t r i b
D K - 9 5 0 0 M i d d e l f a r t
C e n t r u m I s o l e r i n g ,
D K - 7 1 0 0 V e j l e
H o r s e n s E l e k t r o ,
D K - 8 7 0 0 H o r s e n s
D a m s t a h l ,
D K - 8 6 6 0 S k a n d e r b o r g
S u b - c o n t r a c t o r
S i m o t e k ,
DK - 4200 S lage ls e
F l o t t w e g W e r k ,
D 8313 V i l s b i b u r g
The c oo r d in a t i o n and p lann ing o f t he de l i v e r ie s and t he r es po ns ib i l i t y f o r as s em b l ing
a l o t o f d i f f e r e n t equ ipm e n t i n to a p r oc es s l i ne was t ak en c a r e o f by t he c h ie f
e n g i n e e r .
The c ons t r uc t i on phas e was c onc luded ac c o r d ing t o p lan and no r ea l d i f f i c u l t i es wer e
e n c o u n t e r e d d u r i n g c o n s t r u c t i o n .
5 . C o m m i s s i o n i n g a n d o p e r a t i o n
D u r i n g c o m m i s s i o n i n g a n u m b e r o f p r o b l e m s w e r e e n c o u n t e r e d a n d so l u t i o n s s o u g h t .
S om e m a jo r p r ob lem s a r e l i s t ed be low :
M e c h a n i c a l d r i v e f o r t h e c o a g u l a t o r o f t e n b r o k e d o w n d u e t o o v e r l o a d i n g . H a s
b e e n r e p l a c e d by a m o r e r i g i d c o n s t r u c t i o n .
B e a r i n g s i n t r i c a n t e r w e r e l e a k i n g a t h i g h t e m p e r a t u r e s . R e p l a c e d .
T r an s fe r o f g r ax f r o m th e t r i c an te r i n to t he d r y e r had t o be abandoned due t o an
oc c as io na l l y r a th e r h igh f a t c o n te n t i n t he g r ax . G r ax i s now r e tu r ne d t o t h e
c o a g u l a t o r .
- V e n t i l a t o r f o r d r y e r b r o k e d o w n f r e q u e n t l y . W as p l a c e d i m m e d i a t e l y a f t e r
s c r ubbe r . M o v ed t o a pos i t i on a f t e r t he c ondens e r f o r the ev a po r a to r .
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- C i r c u la t i o n pum p fo r t he ev a por a to r was unab le t o pu l l ou t v i s cous c o nc en t r a te .
A c o n c e n t r a t e p u m p w a s i n s t a l l e d .
The hea t ing o f t he l i qu id be fo r e t he t r i c a n t e r and t he p r ope r s ep a r a t i on o f t he t h r e e
phases i n t he t r i c an te r i s one o f t he m or e t r i c k y pa r t s o f t he w e t p r es s ing s y s tem . I n
fa c t , t he am oun t o f ene r gy us ed f o r hea t ing was f a r h ighe r t han ex pec te d f r o m
t h e o r e t i c a l c a l c u l a t i o n s ( s e e b e l o w ) .
De v e lo pm en t w or k i s s t i l l go ing on i n o r de r t o des ign a s y s tem wh ic h
1 ) m in im iz e s t he ene r gy c ons um pt ion
2 ) r es u l t s i n a good s epa r a t i on o f t he t h r ee phases i n t he t r i c a n t e r
3 ) i s eas i l y c on t r o la b le
C e r t a i n o t h e r o p e r a t i o n a l p r o b l e m s h a v e b e e n e x p e r i e n c e d d u r i n g t h e l o n g t e r m
tes t i ng o f t he s y s tem :
- Te m pe r a tu r e c o n t r o l o f m ea l a t d i s c ha r ge f r om d r y e r s has been inac c u r a te and
u n r e l i a b l e . V a r i o u s e l e c t r o n i c c o m p o n e n t s h a v e b e e n r e p l a c e d w i t h m o r e r e l i a b l e
e l e c t r o n i c h a r d w a r e .
Excess we ar o f p la te s in dry er has been d isco ver ed . The wea r on ly takes p lace in
c e r ta in pos i t i ons . Th is m ay m ea n a s e r ious r ed uc t i on i n l i f e ex pec ta nc y o f d r y e r s .
S o lu t i ons a r e be ing s ough t i n c o l l ab o r a t i on w i t h t he s upp l i e r .
Ho we v er , i t s hou ld be s ta te d t ha t no m a jo r p r ob lem s hav e s hown up du r ing t h e
op er a t i o n o f t he p la n t , t hus p r ov in g t he f ea s ib i l i t y o f t he p r oces s on an i ndus t r i a l
s c a le .
6 . M e a s u r e m e n t s
M e as ur em en ts o f ene r gy c ons um pt ion t ook p lac e i n t he s p r ing o f 1984 , t he f i n a l
c a l c u la t i o ns be ing bas ed on 20 p r o du c t i on da y s , o r a t o ta l o f 460 p r o du c t i on hou r s .
K O F O r u n s v a r i o u s p r o d u c t i o n s : P r o d u c t i o n o f m e a t - a n d - b o n e m e a l a n d a n i m a l f a t
by m eans o f w e t p r es s ing and by m eans o f a ba t c h c ook ing s y s tem fo l l ow ed by
s o lv en t ex t r a c t i o n , p r oc es s ing o f hogs ' ha i r i n to a hy d r o l i z e d m ea l and a p r o du c t i on
o f a pu lp f r om c h ic k en o f f a l . E ner gy w is e t hes e p r oduc t i ons a r e m ix ed up and c anno t
be s ep a r a te d . Cons e quen t l y t he c a l c u la t i on o f ene r gy c ons um pt ion i n t he w e t
p r es s ing s y s tem in pa r t s had t o be c a r r i ed ou t i n an i nd i r ec t m anner .
T h e f o l l o w i n g p r o c e d u r e w a s a p p l i e d :
E v a por a ted wa t e r l eav es t he s y s tem as c ondens a te f r o m the s c r ubber and f r o m
var io us condensers and dra in s (Pos . , O and R in F igu re 3 ) . The a mo unts h ave a l l
been m eas ur ed .
F u r t h e r m o r e , s o m e w a t e r ( M t / h ) le a v e s t h e s y s t e m w i t h t h e n o n - c o n d e n s i b l e s . T h e
avera ge te m pe ra tu re o f these gases was 42 C (Tab le V I ) , = 100 , p~ = 8365 Pa,
R~ ( gas c ons ta n t ) = 461 .52 N m /k g and t he f l o w ( m ea s ur ed ) = 1866 m 7 h :
M - 8365 1866
n n
.,.
M
x - 4 6 1 .5 2 ( 27 3
+
42) 1000
=
t / h
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T h e w a t e r l e a v i n g t h e s y s t e m co n s i s ts o f w a t e r f r o m r a w m a t e r i a l s an d f r o m a d d e d
w a t e r , i . e . l iv e s t e a m a n d f l a s h s t e a m i n j e c t e d i n t o t h e p re s s l i q u i d b e f o r e t h e
t r i c a n t e r . Thes e am oun ts a r e m eas u r ed (pos . M and N , F igu r e 3 ) and s u b t r ac ted .
Tab le I s hows the r ec o r d in gs and c a l c u la t i on s o f f i gu r es f o r ev apo r a ted wa te r i n
eac h m eas u r ing pe r iod ( no r m a l l y 24 hou r s ) .
D u r i n g m e a s u r i n g a t o t a l o f 3 3 0 2 t w a t e r h a s b e e n e v a p o r a t e d . T h e d r y m a t t e r y i e l d
( m e a t and bone m ea l p lus an im a l f a t ) i n t he c o r r es pond ing pe r io d was 44 . 7% . Thus ,
t h e a m o u n t o f r a w m a t e r i a l s t r e a t e d i n t h e w e t p r e s si n g s y s t e m d u r i n g m e a s u r i n g ,
X, is
x
=
_2g2
= 5jmi
or 13 t r aw m a te r ia l s pe r hou r ( t o ta l : 460 h ) as c om par e d t o t he ex pe c ted 15 t / h .
L i v e s team i s us ed as hea t ing m ed iu m f o r t he d r y e r s and is a l so i n je c te d i n to t he
p r es s l i qu id be fo r e t he t r i c a n t e r i n o r de r t o i nc r eas e t he t em pe r a t u r e o f t he l i qu id t o
app r ox . 1 00 C . The am ou n ts o f s t eam us ed hav e been m ea s u r ed (pos . I , K , L and N in
F igu r e 3 ) , and c o nv e r ted t o k g o i l , us ing t he f i gu r es f o r t he K O FO bo i l e r s , i . e . 14 .87
k g s team pe r k g f ue l o i l .
The day t o day and ov e r a l l f i gu r es f o r s t eam and f ue l o i l c on s um pt ion i n t he
m eas ur ing pe r iod a r e s hown in Tab le I I .
h 6 3 8 . 6 t s t e a m
9 3 3 . 3 - -
102 0 .3 - -
h 259 2 .2 t s t eam ( o r 5 . 6 t s t ea m /h )
174 ,324 k g f ue l o i l (o r 380 k g o i l / h )
L i k e w i s e , t h e f u e l o i l c o n s u m p t i o n f o r t h e d r y e rs c a n b e r e l a t e d t o e v a p o r a t e d w a t e r
o r r a w m a t e r i a l s t r e a t e d :
52 .8 k g f ue l o i l pe r t wa te r ev apo r a ted o r
29 .2 k g f ue l o i l pe r t r aw m a te r ia l s .
S i m i l a r f i g u r e s c a n b e c a l c u l a t e d f o r t h t r i c a n t e r :
S team c ons um pt ion ov e r 460 h : 328 .7 t ( 0 . 7 t / h ) c o r r es pond ing t o
fue l o i l c ons um pt ion ov e r 460 h : 22 ,105 k g ( 48 k g /h )
A l t e r n a t i v e l y t h e t r i c a n t e r u se d
6 .7 k g f ue l o i l pe r t wa te r ev apo r a ted o r
3 .7 k g f ue l o i l pe r t r aw m a te r ia l s .
I t s ho u l d b e n o t e d t h a t t h e t r i c a n t e r f u r t h e r m o r e u se d
125 .1 t f l as h s team du r ing t he m eas u r ing pe r io d , o r
350 kg f las h s team pe r ho ur .
- 7 -
PCD 3 used in
4 -
5 -
3 PCD'sused in
corresponding to
460
460
460
460
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It should be noted that the dryers are by far the most power consuming part of the
mac hinery, using nearly 40 kWh/t raw mat erials or more than 55 of the tot al .
The kWh's used on each measuring day per ton water evaporated are calculated and
tabulated (Table III).
Temperatures in various parts of the system were automatically recorded by a data
logger every hour in the measuring period (pos. 00-05, 09-18, Figure 3). Ranges and
average figures for temperatures are shown in Table VI.
7 .
Technical and economical results
Energy savings in the 10 t/h wet pressing production line may be calculated by
comparing the energy consumption in the measuring period with the energy
consumption at KOFO in one year immediately preceeding the installation of wet
pressing.
The savings will be related to the expected production of 50,000 t/year although the
cap acity of the produc tion line (the combined 5 t/h R & D- pla nt and the pr oject) lies
10-15 below that.
Fuel oil consumption 1-7-81 to 30-6-82: 8 693 t
Raw materia ls 1-7-81to 30- 6-8 2: 124,857 t
Own production of electricity 1-7-81to 30- 6-8 2: 5,57 6,24 0 kWh
Fue l oil used for el ec tr ic ity produ ction : o fVi gofT 568,593 kg
Average dry m att er yield (1-7 -81 to 30-6- 82): 43
Average electrical power consumption (1-7-81 to 30-6-82):77.8 kWh/t raw materials
or 136.5 kWh/t wa ter evapo rated
Energy savings for 50,000 t/year:
r- . , (65.1 - 33.2) 50,000 ,
.
Fuel oil -* 0 00
=
^595 to e
El ec tric ity (77.8 - 69.1) 50,000 8.6 IO
5
= 37 toe
To tal saving: 1,632 toe
The costs of the plant are as follows (less VAT):
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C o n s t r u c t i o n a n d e r e c t i o n D . K r .
E q u i p m e n t f o r r a w m a t e r i a l h a n d l i n g 3 4 9 , 9 3 7
^ - ^ - 2 5 3 ,8 5 0
8 4 0 , 0 0 0
Hasher
Co agu la to r and s t r a ine r s c r ew
S c r ew p r es s , d r y e r s , ev ap or a t i ng s y s tem
OHU UUU
11,777,612
T r i c a n t e r 6 1 2 , 8 5 6
P n e u m a t i c m e a l t r a n s p o r t 4 3 0 , 3 8 6
V e n t i l a t i o n o f p r oc es s a i r 193 ,9 52
S t e a m t r a n s f e r 2 5 6 , 6 0 6
Ins u la t i on 180 ,357
C o o l i n g t o w e r s 7 3 5 , 5 7 9
E l e c t r i c i n s t a l l a t i o n s 1 007 786
S ta in les s s tee l t ubes 116 ,05 9
T o t a l ,
c o n s t r u c t i o n a n d e r e c t i o n 1 6 , 7 5 4 , 9 8 0
M e a s u r e m e n t s a n d r e p o r t s
A p p a r a t u s a n d i n s t a l l a t i o n 7 2 , 5 8 6
D a t a c o l l e c t i o n 3 7 , 4 0 0
R e p o r t i n g 3 4 , 7 1 0
T o t a l ,
m e a s u r e m e n t s 1 4 4 , 6 9 6
T o t a l c o s t s o f t h e p r o j e c t 1 6 , 8 9 9 , 6 7 6
The c a p i t a l c os ts a r e ac c o r d ing l y (bas ed on D .K r . 16 ,754 ,980 , an es t im a te d l i f e o f
equ ipm en t o f 7 y ea r s and an i n te r es t r a t e o f 14 p .a . ):
D e p r e c i a t i o n 2 , 3 9 3 , 5 6 9 D . k r .
I n t e r e s t 1 172 849 -
T o t a l 3 , 5 6 6 , 4 1 8 D . k r .
or 71D.kr . / t r a w m a t e r i a l s
The ope r a t i ng c os t s m ay be c a l c u l a te d as f o l l o ws ( bas ed on 1984 - p r i c e s , 3 m en pe r
sh i f t in 3 sh i f t s and a supe rv isory s ta f f o f 3 persons) :
Fu e l o i l 33 .2 50,000 2 ,038 3 , 38 3, 08 0 D.k r .
E l ec t r i c i t y 69 .1 50 ,000 0.30 1 036 500 -
Lab our cos ts 3 3 180,000 + 3 300,000 2 ,5 20 ,0 00 -
Main tenance 0 .03 50,000 1 ,000 1 500 000 -
T o t a l 8 , 4 3 9 , 5 8 0 D . k r .
Co s t pe r t r aw m a te r ia l s t r ea ted 169 D .k r .
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The ov e r a l l c os t s ( O per a t i ng and c ap i t a l c os t s ) a r e t hus 240
D.Kr./ t
r a w m a t e r i a l s .
A c a l c u l a t i o n o f th e e c o n o m i c a l v i a b i l i t y o f t h e n e w s y s t e m c o m p a r e d w i t h
c on v en t iona l rend e r ing m ay lead t o t he f o l l ow ing f i g u r es ( a l l c os t s bas ed on 1984
f igu r es ) :
Sav ings in energy consumpt ion (p .a . ) :
He av y f u e l o i l s av ed 1 ,595 2 ,038 = 3 ,2 50 ,61 0 D .k r .
kWh save d: (77.8 - 69 .1) 50,000 0 .30 = 130 ,500 -
Sav ings in the cos t o f mater ia ls consumed (p .a . ) :
Hexane saved: 450,000 2 .75 =
1 237 500
D.kr .
Sav ings in o ther cos ts
La bou r cos ts ( less one man) 18 0,00 0 D.k r .
M a i n t e n a n c e c o s ts 5 0 0 , 0 0 0 -
To ta l annua l s av ings = 5 ,2 98 ,61 0 D .k r .
Pay back pe r iod 5 298 610 = 3 .2 years
8 . Conc lus ions and ou t l o ok
The we t p r es s ing p r oc es s has now been s uc c es s fu l l y t es ted under r ea l p r oduc t i on
c on d i t i ons and t he t es t s have p r ov en t ha t d i f f e r e n t t y pes o f o f f a l c an be p r oc es s ed
by t he p r oc edu r e . A num ber o f m ino r m od i f i c a t i on s o f t he s y s tem has been m ade as
a r es u l t o f t he p r o j ec t .
A n ene r gy c ons u m p t ion o f 33 .2 k g o i l and 69 .1 k W h pe r un i t o f o f f a l hand led , o r 60 .1
k g f u e l and 125 k W h pe r t on wa te r ev a por a ted hav e been foun d . A n a nnua l s av ing o f
1 ,632 t oe was r ec o r de d f o r t he we t p r es s ing s y s tem c om par ed t o t he c o nv e n t io na l
s y s tem a t K O F O ( bas ed on a t h r ou ghp u t o f 50 ,000 t o f f a l pe r y ea r ) .
The r e a r e no r ea l t ec hn ic a l p r ob lem s ou ts tand ing i n t he dev e lopm en t o f t he we t
p r es s ing p r oc es s a l t houg h the p r ob le m d i s c ov e r ed ab ou t ex c ess wear o f c e r t a in
p la tes i n t he d r y e r o ugh t t o be s o l v ed in o r de r t o av o id a s ho r t l i f e - t im e o f t he
d r y e r s . I m p r o v e m e n t s o u g h t t o b e m a d e i n th e h e a t i n g s y s t e m f o r t r i c a n t e r f l u i d s
a n d i n t h e c o n t r o l l i n g o f t h e f l u i d t e m p e r a t u r e .
A n o p t i m i z a t i o n o f t h e w h o l e s e p a r a t i o n p r o c e s s i n t h e t r i c a n t e r s e e m s i n d i c a t e d .
A l l leads t o t he as s um pt ion t ha t t he c o m m er c ia l po te n t i a l i s h igh and t h a t t he r e a r e
no r ea l obs tac les t o a s uc c es s fu l i nd us t r i a l dev e lopm en t o f t he s y s te m . I n f ac t , t he
w e t p r es s ing s y s tem , as m ar k e te d by A t l as Da nm ar k , i s i ns ta l l ed i n t h r e e Dan is h
p lan t s w i t h a r a te d t h r ou ghp u t o f 50 t r aw m a te r ia l s pe r hou r i n t o t a l . To our best
knowledge the sys tem is a lso in use in one German and one I r ish p lant , and a 14 t /h
p lan t is be ing i ns ta l l ed i n t he US A . E qu ipm en t f o r t h e we t p r es sing s y s tem i s
d e l i v e r e d f r o m a n u m b e r o f E E C m a n u f a c t u r e r s , e . g . t h e e v a p o r a t i n g s y s t e m ,
c oagu la to r s and d r y e r s a r e p r oduc ed in Denm ar k , t he t r i c an te r i n G er m any , and in
fu tu r e t he p res ses i n I t a l y , thus c r ea t i ng new jobs in a num ber o f E E C c ou n t r i e s .
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Table
I:
Evaporated water during measuring
V J
Measur-
ing
period
1
2
3
4
5
6
7
8
9
10
11
12
1 3
14
15
16
17
18
19
20
Total
Averag
Temper
Density
Hours
24
24
22
20
24
24
24
24
26
24
24
24
18
25
24
24
24
19
24
18
460
per h
ature
Pos
.
Scrubber)
3
m
9 .2
12.2
8 .6
6 .2
12.7
4 . 5
4 . 9
3 .4
6 .1
11.3
10.8
8 .9
5 .9
8 .1
10.3
11.7
15.2
12.0
5 .5
5 .2
ton
8 .9
11.8
8 .3
6 .0
12.3
4 . 4
4 . 8
3 . 3
5 .9
11.0
10.5
8 .6
5 .7
7 . 9
10.0
11.3
14.7
11.6
5 .3
5 .0
167.3
0.36
90
Pos
. R
Miscellaneous)
3
m
85 .1
80.5
77 .9
57 .0
73.4
92.8
92.8
74.0
74.3
81.8
94 .3
106.6
78.2
91.3
94.7
92.6
87 .2
79.5
86.4
7 0 .1
0.97
ton
84.2
79.7
7 7 .1
56.4
72.7
91.9
91.9
73.3
73.6
81.0
93.4
105.5
77 .4
90.4
93.8
91.7
86.3
78.7
85.5
69.4
1653.9
3.60
55
Pos
. 0
Evaporator)
3
m
70.0
77 .6
58.7
81.0
70.1
75.9
117.7
70.4
55.2
69.1
59.0
140.6
84.1
58.2
62.2
65.9
66.6
49 .3
47 .7
65.0
0.99
ton
69.3
76.8
58 .1
80.2
69.4
7 5 .1
116.5
70.0
54.6
68.4
58.4
139.2
83.3
57 .6
61.6
65.2
65.9
48.8
47 .2
64.4
1430.0
3.11
35
Non
condens-
ables
(ton)
2 . 6
2 .6
2 . 5
2 .4
2 .6
2 .6
2 .6
2 .6
2 . 7
2 .6
2 .6
2 .6
2 .2
2 . 7
2 .6
2 .6
2 .6
2 . 3
2 .6
2 . 3
50.9
0.11
0.99
Flash
steam
(ton)
( 6 .3 )
( 6 .3 )
4 . 9
4 . 9
4 . 3
6 .0
5 .3
4 . 1
6 . 3
7 . 3
9 .4
7 . 2
7 . 2
7 . 6
5 .4
8 .4
8 .5
6 .9
4 . 6
4 . 2
125.1
0.27
Live
steam
(ton)
18.3
18.4
16.3
16.4
18.2
18.8
18.7
14.0
16.1
17 .5
18.1
17.9
13.7
16.0
16.3)
15.7
15.4
11.8
17 .5
13.6
328.7
0.71
Total
evapo-
rated
(ton)
189.6
195.6
167.2
166.3
179.5
198.8
239.8
167.3
159.2
187.8
192.4
281.0
189.5
182.2
189.7
194.9
193.1
160.4
162.7
158.9
Total
evapo-
rated from
r aw
materials
165.0
170.9
146.0
145.0
157.0
174.0
215.8
149.2
136.8
163.0
164.9
255.9
168.6
158.6
168.0
170.8
169.2
141.7
140.6
141.1
3302.1
7.18
( )Estima ted average) values
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Table H: Fu el o il consu mption per period during measuring
M e a s u r
ing
per iod
1
2
3
4
5
6
7
8
9
10
1 1
12
13
14
15
16
17
18
19
20
T o t a l
Average
H o u r s
24
24
22
20
24
24
24
24
26
24
24
24
18
25
24
24
24
19
24
18
460
per h
PC D 3
pos I)
ton)
27.5
2 6 . 2
4 8 . 9
1 9 . 9
1 8 . 4
3 2 . 6
1 6 . 7
5 1 . 7
2 5 . 1
2 8 . 6
3 0 . 8
3 1 . 0
4 7 . 0
3 2 . 0
2 9 . 8
3 3 . 5
3 2 . 3
5 1 . 0
2 9 . 2
2 6 . 4
6 3 8 . 6
1 .39
L
PC D 4
pos K)
ton)
5 1 . 9
4 9 . 2
4 6 . 2
3 5 . 6
4 7 . 1
5 0 . 3
4 6 . 0
1 2 . 7
6 9 . 1
5 0 . 2
5 1 . 4
5 5 . 3
4 3 . 4
4 8 . 2
5 2 . 1
4 9 . 8
4 7 . 9
4 5 . 3
4 4 . 4
3 7 . 2
9 3 3 . 3
2 . 0 3
i v e s t e a m
P C D 5 T r i c a n t e r
pos L)
ton)
5 5 . 5
5 4 . 3
5 8 . 3
4 0 . 6
5 0 . 3
5 2 . 4
5 2 . 9
5 5 . 7
4 5 . 3
5 0 . 5
5 2 . 7
6 9 . 2
4 1 . 6
5 0 . 9
5 2 . 7
5 2 . 5
4 9 . 9
5 2 . 1
4 7 . 2
3 5 . 7
1 0 2 0 . 3
2 . 2 2
pos N)
ton)
1 8 . 3
1 8 . 4
1 6 . 3
1 6 . 4
1 8 . 2
1 8 . 8
1 8 . 7
1 4 . 0
1 6 . 1
1 7 . 5
1 8 . 1
1 7 . 9
1 3 . 7
1 6 . 0
1 6 . 3 )
1 5 . 7
1 5 . 4
1 1 . 8
1 7 . 5
1 3 . 6
3 2 8 . 7
0 . 7 1
Tota l
ton)
1 5 3 . 2
1 4 8 . 1
1 6 9 . 7
1 1 2 . 5
1 3 4 . 0
1 5 4 . 1
1 3 4 . 3
1 3 4 . 1
1 5 5 . 6
1 4 6 . 8
1 5 3 . 0
1 7 3 . 4
1 4 5 . 7
1 4 7 . 1
1 5 0 . 9
1 5 1 . 5
1 4 5 . 5
1 6 0 . 2
1 3 8 . 3
1 1 2 . 9
2 9 2 0 . 9
6 . 3 5
C o n v e r t
ed to kg.
f u e l o i l
r ;
10303
9960
11412
7566
9011
10363
9032
9018
10464
9872
10289
11661
9798
9892
10148
10188
9785
10773
9301
7592
196429
427
D i s t r i c t h e a t i n g
C o n v e r t -
Gca l
2 0 . 0
1 8 . 4
1 5 . 3
7 . 9
1 4 . 0
1 8 . 9
1 1 . 3
1 5 . 5
1 3 . 7
1 7 . 9
2 2 . 0
1 0 . 3
9 . 0
2 2 . 8
2 3 . 4
1 9 . 1
1 9 . 5
1 5 . 6
1 0 . 5
5 . 5
3 1 0 . 6
0 . 6 8
ed to kg
oil
2279
2097
1743
900
1595
2154
1288
1766
1561
2040
2507
1174
1026
2598
2667
2177
2222
1778
1197
627
35396
7 6 . 9
1) Conversion factor:
1 ,000
1 4 . 8 7
2) Conversion factor:
1,000
9.75x0.9
( )
Estimated (average) values
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Table III: Specific power consumption oil and electricity) during measuring
Measuring
period
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Total
P e r t
Hours
24
24
22
20
24
24
24
24
26
24
24
24
18
25
24
24
24
19
24
18
460
aw materie
Oil
consumption
(kg)
10303
9960
11412
7566
9011
10363
9032
9018
10464
9872
10289
11661
9798
9892
10148
10188
9785
10773
9301
7592
196429
us:
Evaporated
from raw
materials
t)
1 6 5 . 0
1 7 0 . 9
1 4 6 . 0
1 4 5 . 0
1 5 7 . 0
1 7 4 . 0
2 1 5 . 8
1 4 9 . 2
1 3 6 . 8
1 6 3 . 0
1 6 4 . 9
255 9
1 6 8 . 6
1 5 8 . 6
168 .0
1 7 0 . 8
1 6 9 . 2
1 4 1 . 7
1 4 0 . 6
1 4 1 . 1
3302.1
Kg fuel oil
p e r t
evaporated
water
6 2 . 4
5 8 . 3
7 8 . 2
5 2 . 2
5 7 . 4
5 9 . 6
4 1 . 9
6 0 . 4
7 6 . 5
6 0 . 6
6 2 . 4
4 5 . 6
5 8 . 1
6 2 . 4
6 0 . 4
5 9 . 6
5 7 . 8
7 6 . 0
6 6 . 2
5 3 . 8
59.48
3 2 . 9
kW hper t
evaporated
water
133
121
138
117
122
127
89
140
137
129
135
85
121
133
128
131
137
145
149
126
125
6 9 . 1
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Table
IV :
lectr ic power consumption
( p o s . A - )
during measuring
Measur-
ing
period
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Total
Hours
24
24
22
20
24
24
24
24
26
24
24
24
18
25
24
24
24
19
24
18
460
Pos.
A
kWh
3 68
3 4
2952
2588
2872
32
29 4
3176
2888
2948
3168
3 8
3012
3172
3112
3148
3176
3 48
3100
2336
59916
Pos.
kWh
7896
7120
6824
5288
6148
8192
5724
7 6
634
7412
8 68
776
7 68
7632
7628
84 8
8544
7744
7576
6664
145 96
Pos.
C
kWh
1620
1540
1280
1280
1360
1440
1320
1300
1400
1460
1540
1400
1200
1460
1440
1500
1560
1240
1340
1060
2774
Pos.
D
kWh
4798
4636
44 2
3532
432
4846
4272
4212
3952
4634
5 48
4682
4324
4566
4674
4782
4958
4172
44 2
3612
88824
Pos.
E
kWh
1168
1135
1154
994
1077
1125
1353
1193
1074
1275
1293
1568
1463
1412
1522
1684
1745
1511
1576
1462
26784
Pos.
F
kWh
1158
1014
1131
1002
1092
1170
1067
1155
1071
1126
999
1120
1089
948
1149
1028
1179
1027
1116
838
21479
50
of
Pos.G
kWh
1965
1903
2275
1933
2123
2 3
23 5
2485
1873
2013
2 38
2128
2115
1660
1813
1685
1915
1573
1673
1560
39 38
Pos.
H
kWh
208
206
195
179
151
207
175
210
193
190
186
168
179
196
199
197
170
181
208
154
3752
Total
kWh
21881
2 594
2 213
16796
19143
22183
19120
2 791
18791
21 58
2234
21834
2 45
21 46
21537
22432
23247
2 496
2 991
17686
412629
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Table V: Ele ctric power consumption in wet pressing
H a s h e r s , e v a p o r a t o r , t r i c a n t e r s ,
r aw m a te r ia l s t o p r oc es s e t c . ( P os . A )
Presses , conveyors (Pos . C)
Dryers (Pos . B + D)
Coo l i ng t ower s ( P os . E )
P n e u m a t i c m e a l t r a n s p o r t (P o s . F )
M i l l i n g ( i P o s . G )
V e n t i l a t o r f o r nonc ondens ib les ( P os . H )
T o t a l
T o t a l f o r
p e r i o d
(kWh)
59916
27740
233920
26784
21479
39038
3752
412629
kW
130
60
509
58
47
85
8
897
k W h / t
e v a p o r a t e d
w a t e r
18
8 . 4
7 1
8 . 1
6 . 5
1 1 . 9
1 . 1
125
k W h / t
r aw
m a t e r i a l s
10
4 . 6
39
4 . 5
3 . 6
6 6
0 . 6
6 9 . 1
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Table VI: Tem perature measu rements
T e m p e r a t u r e o f s t e a m f o r d r y e r s
C o n d e n s a t e f r o m d r y e r s
D r y e r gas be fo r e s c r ubbe r
D r y e r gas a f t e r s c r ubbe r
O v e r f l o w f r o m s c r u b b e r
D r y e r gas a f t e r hea t ex c han ger
G as f r o m ev a por a to r 1 . s t age
G as f r o m ev apo r a to r a f t e r c ondens e r
G as be fo r e f i n a l c ondens e r
Nonc ondens ib les
Condens a te f r om f i na l c ondens e r
Condens a te f r om ev apor a to r c ondens e r
Pos .
00
0 1
02
03
04
05
09
10
1 1
12
13
14
15
16
17
18
Lowes t - h ighes t
r e c o r d e d
158- 65
129- 39
8 7 - 1 0 1
7 8 - 9 4
6 5 - 9 4
72- 93
5 4 - 8 4
2 0 - 4 2
5 0 - 8 4
3 0 - 6 4
4 0 - 7 5
3 1 - 4 6
A v e r a g e
162
133
98
85
88
83
67
32
66
42
62
38
All figures: Degree Centigrade
18
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w r fl
^o
6 .
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O C F A l .
OP FM.
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project
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Readings every 60 minutes (_)
Recording by data logger [ ^
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ro
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European Communi t ies Commiss ion
EUR 10652 Inedible render ing by m ean s of the we t pressing proc ess
D e m o n s t r a ti o n p r o j e c t
KO O Kdfodfabrikken stjyden
Luxem bourg : Off ice for O ff ic ia l Publ icat ions of the European Com mun it ies
1986 III, 21 pp., 6 tab ., 3 fi g. 21.0 29.7 cm
Energy series
EN
ISBN 92-825-6519-X
Catalogue numb er :1
Pr ice (excluding VAT) in Luxembourg
ECU 4.50 BFR 200 IRL 3.20 UK L 2.80 USD 4.50
The render ing of offa l and waste mater ia ls from s laughter ing and meat
processing is based tradi t ional ly on batchwise dry render ing fo l lowed by separa-
t ion of meat and fat by means of solvent extract ion.
The energy consumption in such a process is high , i.e. of the order of 75 kg fuel
oi l per tonne raw m ater ia ls having an average wat er co nten t of near ly 60 /o. A
new energy-saving process has been developed based on a condit ioning and
prepressin g of the raw m ater ia ls at tem pera tures of the order of 60 C. The
pressing procedure div ides the mater ia ls into a sol id phase with low fat content
and a f lu i d phase con taining more tha n 60 /o of the total wa ter a nd near ly al l the
fat. The sol id phase is dr ied in an indirect ly heated dr ier . The fat from the f lu id
phase is remo ved in a tr icanter . 80-90 of the water in the resul t ing l iq uid
phase is removed in a three-stage vacuum evaporator us ing waste heat from the
dr iers as heating medium. Pi lot exper iments have indicated that such a process
is feasible and that the energy consumption in the process would be of the order
of 35 kg fuel o i l per tonne.
The object ive of the present project was to design and construct a fu l l -scale
production l ine us ing the wet pressing system, to demonstrate the feasibi l i ty of
the process in fu l l -scale operat ion and to obtain key f igures for the energy
consumption. The project was carr ied out at the Danish cooperat ive render ing
plant KOFO in Lsning.
I t was proven that the process with minor modif icat ions is highly feasible
in large-scale operat ion. The measur ing of energy consumption showed the
fo l low ing f igures :
( i) 33.2 kg fuel o i l per tonn e offa l or 60.1 kg per tonn e wa ter e vapo rated , and
( i i ) 69.1 kWh per tonne offa l or 125 kWh per tonne water evaporated.
An a nnual energy saving of 1 632 toe w as reco rded fo r the we t pressing system
compared to the conventional process former ly used at KOFO and based on a
throug hput of 50 000 t of fal per ye ar.
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