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EXTRACTION
Fellows ch. 6
Extraction?
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Introduction
• Separation process which involves two phases,
e.g solid-liquid or solid-gas (liquid-liquid?)
• Separation is achieved when the compound to
be separated dissolves in the solvent while the
rest of the components remain where they
were originally.
• Application : separation of oil, e.g from
soybean, corn, rice bran.
1\ Expression
• Main applications : the extraction of components
plant materials,
• These are located within the cell structure of the
plants disrupt the cells release them.
Operation:
• single-stage both ruptures the cells &
expresses the liquid,
• two stages size reduction to produce a pulp or
flour, followed by separation in a press.
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In general, single-stage operation:
• more economical,
• higher throughputs
• lower capital and operating costs
a two-stage expression:
• for some products that are especially hard (ex. oil
bearing nuts).
• Better extraction by heating oilseeds or flours
to reduce the oil viscosity, release oil from intact
cells and remove moisture.
• There is an optimum moisture content for each
type of oil seed to obtain a maximum yield of oil.
In fruit processing,
• the press should remove the maximum quantity
of juice, without substantial quantities of solids,
or phenolic compounds from the skins which
cause bitterness and browning.
using lower pressures and fewer pressings.
• Increase the pressure slowly to avoid the
formation (solid material is easily deformed) of a
dense impenetrable press cake
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Equipment
A. Batch presses
1] The tank press
• for fruit juice production
• high yields of good-quality juice.
a horizontal
cylinder, divided
internally by a
membrane
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During an automatically
controlled pressing cycle of 1.5 h,
fruit pulp is fed into one side of
the membrane
During an automatically
controlled pressing cycle of 1.5 h,
fruit pulp is fed into one side of
the membrane
compressed air
is applied to
the opposite
side
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Juice flows out through channels
and, when pressing is completed,
the tank is rotated to loosen and
discharge the press residue.
2] Cage press,
• up to 2 t of fruit pulp or oilseed flour is placed
into a vertical perforated or slatted cage,
either loose or in cloth bags.
• The pressure is gradually increased on the top
plate and liquid is collected at the base of the
press.
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B. Continuous presses
1] Belt presses (for fruit processing)
• a continuous belt passes under tension over two
hollow cylinders, one of which is perforated.
• Pulped fruit is fed onto the inside of the belt and
is pressed between the belt and the perforated
cylinder.
• Produce high yields of good-quality juice but high
capital costs and difficulty in maintenance and
cleaning.
2] The screw expeller (for both fruit processing and oil
extraction)
• consists of a robust horizontal barrel containing a
helical screw (Fig. 6.8).
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The pitch of the screw flights gradually
decreases towards the discharge end,
to increase the pressure on the
material as it is carried through the
barrel.
The final section of the barrel is
perforated to allow expressed liquid to
escape.
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Press cake is discharged through the
barrel outlet and the pressure in the
barrel is regulated by adjusting the
diameter of the discharge port.
A modified screw press, in which high
shearing forces act on the seeds as
they are forced through a series of
throttle rings located in the barrel.
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3] The roller press (for
sugar cane
processing),
• pulp or sugar cane is
fed between heavy
fluted metal rollers
and liquid flows
along the grooves to
a collection pan.
2\ Extraction using solvents
separation of specific components of foods, incl.
production of:
• cooking oils or speciality oils from nuts and seeds
• flavours and essential oils (e.g. black pepper,
cardamom, clove, ginger, hops, parsley, vanilla,
etc.)
• coffee
• sugar
• removal of caffeine from coffee & tea.
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Principle
• Different sollubility between components
• Many extraction operate close to ambient
temperature, but even when elevated
temperatures are used to increase the rate of
extraction, there is little damage
• The main types of solvents used for extraction are
water, organic solvents or supercritical carbon
dioxide.
• The extracted foods may be used directly (for
example cooking oils) or they may be further
processed by concentration and/or dehydration
Solubility
• The highest possible solute concentration in
the final extract leaving an extraction system
is the saturation concentration.
• Thus, solvent/solids ratio must be high enough
so that when fresh solvent contacts fresh
solid, the resulting solution on equilibrium is
below the saturation concentration
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• Solid-liquid extraction involves the removal of
a desired component (the solute) from a food
using a liquid (the solvent) which is able to
dissolve the solute.
• This involves mixing the food and solvent
together (single stage or multiple stages),
holding for a pre-determined time,
separating the solvent.
• During the holding period mass transfer of
solutes from the food material to the solvent,
in three stages:
1. the solute dissolves in the solvent
2. the solution moves through the particle of
food to its surface
3. the solution becomes dispersed in the bulk of
the solvent.
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During extraction, the holding time should be
sufficient for:
• the solvent to dissolve sufficient solute &
• the changes in composition to approach an
equilibrium.
• The time required depends on the solubility of a
given solute in the solvent selected and on:
1\The temperature of extraction.
• Higher temperatures increase the rate of solutes
to dissolve & the rate of diffusion into the bulk of
the solvent.
• Most operations is limited < 100ºC
economic considerations, extraction of
undesirable components or heat damage to food
components.
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2\The surface area of solids exposed to the
solvent.
• The rate of mass transfer is directly
proportional to the surface area
reductions in particle size increase the rate
of extraction up to certain limits.
3\The viscosity of the solvent.
• should be sufficiently low to enable the
solvent to penetrate easily the bed of solid
particles.
4\The flowrate of the solvent.
• Higher flowrates reduce the boundary layer of
concentrated solute at the surface of particles
and thus increase the rate of extraction.
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Type of Extraction Process
• Single-Stage Batch Processing
Solid is contacted with solute-free solvent
until equilibrium is reached. After equilibrium,
the solvent phase is drained out of the solids.
Example : water decaffeination of coffee
• Multistage cross-flow extraction
Solid is contacted repeatedly each time with
solute-free solvent, for example : Soxhlet
Solvents
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Solvent:
• water (leaching)
low cost & safety;
to extract sugar, coffee & tea.
• Organic solvent
for oils and fats
highly flammable great care in operating
procedures and to ensure that equipment is gas-
tight and electrical apparatus is spark-proof.
Solvent:
• Supercritical carbon dioxide
for removing caffeine from coffee or tea
for producing hop extracts for brewing.
to extract and concentrate flavour compounds
from fruits and spices, and speciality oils from
citrus and a variety of nuts and seeds.
The combination of supercritical CO2 and
extrusion to produce a new range of breakfast
cereals, pasta products and confectionery.
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Supercritical CO2
• “supercritical” arises from
the critical temperature and
critical pressure lines on a
pressure–temperature
diagram (Fig.).
• The supercritical region for
CO2 is when it is above the
critical pressure line and to
the right of the critical
temperature line (31ºC).
• As a solvent it acts as a liquid but has a low viscosity
and diffuses easily like a gas.
Supercritical CO2
• being highly volatile easily separated from
solute without leaving any residues in the food.
• non-flammable, non-toxic, bacteriostatic and low
cost.
• For more complete extraction or for applications
that involve less soluble solutes, it is used at
higher temperatures and pressures.
• The upper limit for the operating temperature is
the heat sensitivity of the food components and
the upper limit for pressure (about 40 MPa) is the
cost of pressurised equipment.
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Equipment
• Extractors :
single-stage |
multi-stage static
| continuous
extractors.
• The components
of a typical
extraction unit
that uses near-
critical CO2
solvent:
Equipment
• The
components of
a typical
extraction unit
that uses near-
critical CO2
solvent:
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Equipment
• The
components of
a typical
extraction unit
that uses near-
critical CO2
solvent:
Equipment
• The
components of
a typical
extraction unit
that uses near-
critical CO2
solvent:
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In supercritical CO2
extraction, CO2 is
stored as a near-
critical liquid in the
condenser
and then pumped to
the extraction vessel
through a heat
exchanger by a high
pressure pump.
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The material to be
extracted is purged
with gaseous CO2 to
remove air and then
liquid CO2 is pumped
in at a rate that
permits a sufficient
residence time for
equilibrium
conditions to be
established.
The solution is then
passed to the
separation vessel in
which conditions are
adjusted to minimise
the solubility of the
extracted
components (often
by decompression).
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The CO2 is then
returned to the
cooled condenser for
re-use and the
extract is removed
from the separation
vessel.
1] Single-stage extractors
• Heated solvent percolates down through the
particles and is collected below the mesh base,
with or without recirculation.
• To extract oils or to produce coffee or tea
extracts.
• Low capital and operating costs, but produce
relatively dilute solutions which may require
expensive solvent recovery systems for organic
solvents or pollution control measures when
water is used as the solvent.
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2] Multi-stage extractors
• A series of up to 15 tanks, each similar to
single extractors, linked together so that
solvent emerging from the base of one
extractor is pumped counter-currently to the
next in the series.
• To produce oils, tea and coffee extracts and to
extract sugar from beet.
3] Continuous extractors
• For ex., an enclosed tank containing two vertical bucket
elevators made from perforated buckets and linked.
• Fresh material is loaded into the descending buckets of
one elevator and solvent is pumped in at the top to
extract solutes co-currently.
• As the buckets then move upwards, fresh solvent is
introduced at the top of the second elevator to extract
solutes counter-currently.
• The solution collects at the base and is pumped to the
top of the first elevator to extract more solute, or it is
separated for further processing.
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Schemes of various extractors, (a) Perforated-tray extractor, (b) rotating-
diskextractor, (c) mixersettler extractor, (d) spray extractor, and (e) packe
d-tower extractor, (LP) light phase, and (HP) heavy phase
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