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生活垃圾煤成型挤出机的设计含11张CAD图,生活,垃圾,成型,挤出机,设计,11,CAD

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一、毕业设计（论文）的内容根据桂林某企业生活垃圾煤生产线中成型挤出机的成型要求，设计出一种可行的挤出机结构。分析动力要求，选择原动机。进行挤出机结构的方案论证。绘制挤出机部件机构的装配图，进行有关理论分析和计算。绘制主要零件的零件图。编制关键零件的加工工艺卡。完成部件的三维结构设计。二、毕业设计（论文）的要求与数据1. 根据垃圾煤的产品尺寸要求，针对某型号生产线中挤出机的设计参数为依据，作为挤出机的原始设计参数要求。计算原动机的功率参数。2. 分析挤出机的工作原理，进行结构设计。3. 挤出机绘制部件的装配图，进行有关理论分析和计算。4. 编制关键零件的零件图。5. 建议用三维软件完成部件的结构设计。6. 编写设计说明书，详细说明设计思路和计算分析过程。7. 完成4万字符的英文资料翻译。三、毕业设计（论文）应完成的工作1、完成二万字左右的毕业设计说明书（论文）；在毕业设计说明书（论文）中必须包括详细的300-500个单词的英文摘要；2、独立完成与课题相关，不少于四万字符的指定英文资料翻译（附英文原文）；3、绘制出破碎机部件的装配图和零件图，折算A0图纸3张以上。编制主要零件的加工工艺卡，进行必要的理论计算，给出计算结果。四、应收集的资料及主要参考文献1. 孙桓, 陈作模. 机械原理M. 北京：高等教育出版社, 2001.2. 徐灏. 机械设计手册. 机械工业出版社, 1991.3. 濮良贵, 纪名刚. 机械设计M. 北京：高等教育出版社, 20054. 杨叔子. 机械加工工艺师手册M. 北京：机械工业出版社, 2002.5. 吴宗泽. 机械设计实用手册M. 北京：机械工业出版社, 2002.6. 罗学科，谢富春主编. 数控原理与数控机床M. 化学工业出版社, 20047. 刘江; 唐传军; 张旦旦. 数控铣床立柱结构动态分析与优化J. 机械设计, 2010年09期,63-668. SolidWorks公司著. SolidWorks装配体建模M. 北京：机械工业出版社, 2005.9. 胡仁喜等. SolidWorks 2005机械设计及实例解析M. 北京：机械工业出版社, 2005.10. Lee, J.H.; Wang, W.; Kweon, S.H.; Kim, Y.S.; Lee, Y.M.; Yang, S.H. Structural design and optimization of a 3-axis miniaturized machine tool with high precision positioning stages J. Key Engineering Materials, v 339, p 321-326, 2007. 五、试验、测试、试制加工所需主要仪器设备及条件计算机一台CAD设计软件（AutoCAD，CAXA，UG，Pro/E，Solidworks）等任务下达时间：2012年1月09日毕业设计开始与完成时间：2012年1月9日至 2012年 6 月03日组织实施单位：教研室主任意见：签字： 2011年12月30日院领导小组意见：签字： 2012 年 1月 05日 1毕业设计的主要内容、重点和难点等主要内容：1. 根据垃圾煤产品选择合适的原动机； 2. 确定挤出机的结构方案，进行方案的论证；3. 绘制装配图，设计关键零件的零件图；4. 利用三维CAD软件设计出挤出机装配结构部件的三维装配结构；5. 撰写设计说明书，进行有关计算和说明；6. 完成4万字符的外文资料翻译。 重点：1. 确定挤出机机构的方案； 2. 绘制机构的装配图，给出相关的理论分析和计算说明。 难点：1. 根据工作要求，剔除挤出机机构的合理方案，对方案进行优化和选择； 2. 绘制挤出机机构的装配图和主要零件零件图，用三维软件完成部件的结构设计； 3. 机构的相关参数的选择和计算； 2准备情况（查阅过的文献资料及调研情况、现有设备、实验条件等）文献资料：1. 孙桓, 陈作模. 机械原理M. 北京：高等教育出版社, 2001.2. 徐灏. 机械设计手册. 机械工业出版社, 1991.3. 濮良贵, 纪名刚. 机械设计M. 北京：高等教育出版社, 20054. 杨叔子. 机械加工工艺师手册M. 北京：机械工业出版社, 2002.5. 吴宗泽. 机械设计实用手册M. 北京：机械工业出版社, 2002.6. 李波编著. 挤出机设计理论和计算M. 北京：中国建材工业出版社, 2010.107. 郭英. 螺杆挤压机M. 纺织工业出版社, 19868. SolidWorks公司著. SolidWorks装配体建模M. 北京：机械工业出版社, 2005.9. 胡仁喜等. SolidWorks 2005机械设计及实例解析M. 北京：机械工业出版社, 2005.10. Lee, J.H.; Wang, W.; Kweon, S.H.; Kim, Y.S.; Lee, Y.M.; Yang, S.H. Structural design and optimization of a 3-axis miniaturized machine tool with high precision positioning stages J. Key Engineering Materials, v现有设备：计算机一台，UG，SolidWorks和CAXA等软件。3、实施方案、进度实施计划及预期提交的毕业设计资料实施方案：1. 根据任务书，阅读有关资料，进行调研，明确任务和设计思路；2. 确定总体方案，根据原始设计参数，选择原动机，分解总体方案，确定各个部分结构并选择机构方案；2. 绘制总体装配图和有关部件的装配图，利用三维软件绘制三维装配图；3. 进行相关计算，理论分析，撰写说明书。进度实施计划：2012.3.12012.3.15 查阅资料，进行调研，完成开题报告；2012.3.17 2012.3.25 翻译英文资料；2012.3.262012.4.1 确定总体方案，进行有关分析计算；2012.4.22012.4.10 绘制挤出机的三维装配图和主要零件的零件图；2012.4.112012.4.26绘制二维的装配图和主要零件的零件图；2012.4.272012.5.10 运动参数及零件参数的相关计算2012.5.122012.5.20修改完善，撰写说明书，打印图纸。预期提交的毕业设计资料：1 机构装配图及零件图；2. 完整的设计说明书及英文资料翻译。指导教师意见李文华同学根据毕业设计任务书给出的设计任务和要求，阅读了相关文献，进行了认真思考，做了相关准备，开题报告完整可行，同意开题。指导教师（签字）： 2012年2月 日开题小组意见开题小组组长（签字）：2012年 月 日 院（系、部）意见 主管院长（系、部主任）签字： 2012年3月 日 生活垃圾煤成型挤出机的设计 摘 要 垃圾再生煤是一种新型绿色能源，它具有容易燃烧，火力猛，燃烧完全和排污少的特点。是一种很好的燃料。中国现在能源利用中，煤占有很大一部分比例。垃圾再生煤可以运用到居民日常生活，工业领域，运用前景广泛。本文根据垃圾煤生产线上对垃圾煤成型挤出机的工作要求，设计出一种可行的挤出机结构，主要工作包括：进行挤出机的结构方案论证，设计可行挤出结构方案。绘制挤出机部件的机构装配图，主要零件的零件图。进行有关理论分析和计算，以满足强度和使用要求。分析工作动力要求，选择合适的原动机及减速机。编制关键零件的加工工艺卡。对挤出机机中关键部位的零件编制加工工艺卡，可以了解其加工工艺过程，方便加工制造。用三围软件UG完成部件的结构设计。本次挤出机采用了叶轮挤压式原理，包含有减速箱的设计，挤出机头的设计，箱体和机筒的设计。挤压部采用螺旋结构，挤压部螺旋轴采用悬臂式设计结构，机筒的结构采用组合式结构并内装衬套减少物料对机筒摩擦。并在结构设计的基础上进行重要零件的校核，确保其的可行性。关键词：挤出机；叶轮；机头；三维建模ABSTRACT Regeneration of waste coal is a new type of green energy, it has easy burning, fire, and combustion characteristics of full and less emissions. Is a good fuel. Energy use in China now, coal accounts for a large proportion. Waste recycling coal use to the residents daily life, industrial areas, use Outlook extensively. According to this article on waste coal briquetting waste coal production line extruders working requirements, design a feasible structure of extruder, major work includes:Structural plan of the extruder, design feasible extrusion structure. Draw out the body assembly drawings of machine parts, parts of the main part. Theoretical analysis and calculation to meet strength and usage requirements. Analysis of power requirements, select the right prime mover and gearbox. Processing technology of preparation of key parts of the card. On key parts in extruder machine parts processing technology of preparation of cards, you can understand the process, facilitate the processing and manufacturing. Measurements software UG structure design of the finished part. Impeller in the extruder adopts the principle of pressure-, containing the gearbox design, design of the extrusion die, tank and barrel design. Extrusion using spiral structure, extrusion screw design of axis-cantilever structure, structure using the modular structure and the contents of the cylinder lining reduces friction material on the barrel. And important parts on the basis of structural design of checking to ensure its feasibilityKeywords: extrusion machin；impelle；the nose；Three-dimensional modeling 目 录第1章 绪论11.1垃圾再生煤的发展现状11.2垃圾再生煤发展中存在的问题11.3垃圾煤成型挤出机的发展前景11.4 毕业设计任务和要求1第2章垃圾煤成型挤出机的方案设计22.1 工作原理22.2 垃圾成型挤出机的方案选择22.3 方案确定4第3章 主要零部件的设计53.1 螺旋叶轮的设计53.1.1 工作特性分析与结构设计53.1.2 参数设计63.2 垃圾煤成型挤出机机头的设计83.3 机头卡环的设计103.4 支撑部分的设计113.5各部分箱体的设计123.5.1 支撑端箱体材料的选择123.5.2 轴承的润滑和密封143.5.3 叶轮轴筒的设计153.5.4 叶轮轴筒体内衬套的设计16第4章 挤出机的动力系统选择174.1挤出机的电机选择174.2减速器的选择184.3联轴器的选择18第5章 挤出机的受力分析及校核185.1 挤出机的受力分析195.1.1 螺旋叶轮的受力分析195.1.2 挤压成型力的分析计算195.1.3 主轴的力分析205.2 强度校核215.2.1 轴承强度校核215.2.2 机头卡环连接螺栓的强度校核235.2.3 挤出机地脚螺栓的强度校核245.2.4叶轮强度的校核25第6章 主轴加工工艺文件的制定266.1 零件的工艺分析266.2 毛坯的选择266.3 工艺卡的制定27结论27致 谢29参考文献30附录 材料清单31 Industrial Crops and ProductsVolume 22, Issue 3, November 2005, Pages 207222Oil extraction of oleic sunflower seeds by twin screw extruder: influence of screw configuration and operating conditions I. Amalia Kartika, P.Y. Pontalier, L. Rigal Laboratoire de Chimie Agro-Industrielle, UMR 1010 INRA/INP-ENSIACET, 118 Route de Narbonne, 31077 Toulouse Cedex 4, France Received 8 October 2004. Accepted 6 January 2005. Available online 14 March 2005. /10.1016/j.indcrop.2005.01.001, How to Cite or Link Using DOI Permissions & ReprintsAbstractThe objective of this study was to investigate the effects of screw configuration, position of screw elements and spacing between them allowing to realize oil extraction of oleic sunflower seeds on a twin-screw extruder. Experiments were conducted using a co-rotating twin-screw extruder (Model Clextral BC 45, France). Twelve screw profiles were examined to define the best performance (oil extraction yield, oil quality, mean residence time, and thermo-mechanical energy input) by studying the influence of operating conditions temperature pressing, screw rotation speed and seed input flow rate.Generally, the position and spacing between two screw elements affected oil extraction yield. An increase of oil extraction yield was observed when the reversed screw elements were configured with increased spacing between elements or/and with smaller pitch screw. In addition, more oil extraction yield was produced as the temperature pressing, screw rotation speed and seed input flow rate were decreased. The higher oil extraction yield was obtained under operating conditions 80C, 60rpm and 24kg/h. Furthermore, the operating parameters influenced energy input and mean residence time of matter. Both energy input and mean residence time increased when the temperature pressing increased. However, increase of screw rotation speed and seed input flow rate decreased mean residence time. Effect of the operating parameters on oil quality was unimportant. In all experiments tested, the oil quality was very good. The acid value was below 2mgKOH/g of oil and total phosphorus content was very poor, below 40mg/kg.KeywordsTwin-screw extruder; Oleic sunflower; Oil and extraction1. IntroductionIndustrial oil extraction from oleaginous seeds is commonly realized through mechanic pressing with a hydraulic or single expeller press, followed by solvent extraction. The hydraulic press is most effective but this process is discontinuous. Recently, the application of continuous oil extraction process using extrusion technology gets some attentions from few researchers ( Vadke and Sosulski, 1988, Isobe et al., 1992, Clifford, 2000, Wang and Johnson, 2001, Crowe et al., 2001, Singh et al., 2002andZheng et al., 2003). Extensive studies on extrusion processing of oilseeds using twin-screw extruder to generate oil ( Guyomard, 1994, Bouvier and Guyomard, 1997, Dufaure et al., 1999aandDufaure et al., 1999b) and fatty acid ester (Lacaze et al., 1996) have been successfully carried out too.The continuous oil extraction of oilseeds is widely carried out in a single-screw press. This type of machine consists of a single-screw of variable pitch and channel depth, slowly rotating in a cage type barrel (Isobe et al., 1992). Transport of material in a single-screw press depends mainly on friction between the material and the barrels inner surface and screw surface during screw rotation. Thus, a solid core component is often necessary to produce the friction. This causes excess frictional heat, large energy consumption and oil deterioration. Furthermore, single-screw presses provide inadequate crushing and mixing if they are not configured with breaker bars or other special equipment. A twin-screw oil press can be expected to solve these problems because of the higher transportation force, similar to a gear pump, and better mixing and crushing at the twin-screw interface. In addition, energy consumption of the twin-screw press is more efficient ( Isobe et al., 1992andBouvier and Guyomard, 1997).The preparation of the raw material, such as size reduction, flaking, cooking and moisture preconditioning of the seeds are necessary to improve single-screw press performance, as well as the mechanical design of the worm and barrel assembly. Maximum pressure increased, and press throughput and residual oil (RO) in presscake decreased, with a reduction in choke opening and with lowering shaft speed of the single-screw press (Vadke and Sosulski, 1988). In addition, when whole seeds or flakes were preheated in the range 40100C, the pressure and press throughput increased and RO decreased. Press throughput and oil output both achieved maximal at canola seed moisture content of 5%, while the RO showed a continuous increase with increasing seed moisture content. Oil recovery of crambe seed extraction on a single-screw press and sediment content increased, and residual oil and pressing rate decreased as seed moisture content decreased (Singh et al., 2002). In the case of flaxseed, oil recovery increased as whole seed moisture content increased (Zheng et al., 2003).Twin-screw extruder played an important role in the food industry to transformer the material physically and chemically in a single step. The main application of twin-screw extruder is widely found in the production of various products such as snacks, cereals and pet food. In the present day, several studies have expanded the utility of twin-screw extruder as a reactor to conduct a thermo-mechano-chemical action plus a liquid/solid extraction, as in hemicellulose extraction ( NDiaye et al., 1996andNDiaye and Rigal, 2000), in a continuous mode.The great capability of twin-screw extruder to conduct diverse functions and processes has a good correlation with advantages of their characteristics. According to Dziezak (1989), those advantages include (i) ability to provide better process control and versatility, especially in pumping efficiency, controlling residence time distribution and uniformity of processing, (ii) ability to process specialty formulation, in which the single-screw extruder can not handle it and (iii) flexibility to design machine, which permits self-cleaning mechanisms and rapid changeover of crew configuration without disassembling the extruder.Twin-screw extruder is mainly built by elements, namely screw, including (i) forward pitch screw, principally conducts a conveying action, (ii) monolobe paddle (DM), primarily exerts a radial compression and shearing action, (iii) bilobe paddle (BB), exerts a significant mixing and shearing actions, a conveying and axial compression actions in combination with forward pitch screw, and (iv) reversed pitch screw, carries out intensive shearing and considerable mixing, and exerts a strong axial compression in combination with forward pitch screw (Rigal, 1996). The arrangement of different characteristics of screw elements (pitch, stagger angle, length) in different positions and spacing determine screw profile/configuration that is main factor influencing performance (product transformation, residence time distribution, mechanical energy input) during extrusion processing ( Gogoi et al., 1996a, Choudhury et al., 1998, Gautam and Choudhury, 1999aandGautam and Choudhury, 1999b). Furthermore, by modularity of its configuration and screw profile, the twin-screw extruder enables a large number of basic operations, such as material transport, grinding/crushing, mixing, chemical reaction, liquidsolid extraction, liquidsolid separation and drying, to be carried out in a single step (Rigal, 1996) in which the conventional presses can not handle it.The great amounts of researches concerning on study of screw configuration are found in the agro-industry field, particularly, for starch transformation. Screw configuration by placing longer reversed screw element (Barres et al., 1990) or nearer from the die (Colonna et al., 1983) increased starch breakdown. Furthermore, the systematic increases in starch breakdown ( Gautam and Choudhury, 1999aandGautam and Choudhury, 1999b) and in mechanical energy input and water solubility index (Choudhury and Gautam, 1998) were observed as the mixing elements were moved farther away from the die, with longer elements, and with increased spacing between elements. The incorporations of reversed screw element (Gogoi et al., 1996b), kneading element (Choudhury et al., 1998) and mixing elements combination (Gogoi et al., 1996a) increased specific mechanical energy, expansion ratio and water solubility index.In oil extraction case, a significant increase in oleic sunflower oil yield was observed as the length and the pitch of reversed screw elements were increased and reduced, respectively (Dufaure et al., 1999a). In addition, oil yield could be improved with adding the monolobe paddle screws (DM) in module 5 just above the filtration module and with increasing the stagger angle of bilobe paddle screws (BB). Furthermore, a investigation of continuous oil extraction method using extruder divided into two zones, (i) twin-screw zone, which was built from two co-rotating and co-penetrating screws and (ii) double single-screw zone, which was constructed from two co-rotating single-screw, increased oil extraction yield of whole sunflower seeds up to 90% with residual oil content in cake meal lower than 15% (Bouvier and Guyomard, 1997).As well as screw configuration, the preparation of the raw material is also important to enhance oil extraction. The oil extraction yield from whole sunflower seeds in a contra-rotating twin-screw press was low (75%), but could be increased to 93.6% if raw materials was dehulled (Isobe et al., 1992). In the case of colza seeds, the oil extraction yield from dehulled seeds was always lower than whole seeds (Bouvier and Guyomard, 1997). The oil yield increased up to 80% with a high temperature pressing and natural moisture content of oleic sunflower seeds (Dufaure et al., 1999a).In relation to these results, the studies more systematic should be realized to improve oil extraction yield and to reduce residual oil content in cake meal. Moreover, it has to optimize operating conditions and characterize oil extraction quality, residence time distribution and mechanical energy input.This study purposed to evaluate the effects of screw configuration and operating parameters such as temperature pressing, screw rotation speed and seed input flow rate on oil extraction of oleic sunflower seeds using twin-screw extruder. The characterization of extraction performance was observed by the determinations of extraction yield, oil quality, mean residence time and thermo-mechanical energy input.2. Materials and methods2.1. MaterialsAll trials were carried out with whole and uncleaned sunflower seeds (36% of impurities content), which were supplied by La Toulousaine de Cereales (France). These seeds were from oleic type with the average acidity of 0.95%. All solvent and chemicals were analytical grades that were obtained from SigmaAldrich, Fluka, Prolabo and ICS, France.The oil content of seed used in the first set of tests (screw configuration study), expressed in relation to the dry matter content of uncleaned seed, was 44.74% (NF V03-908). The seed moisture content at storage was 8.27% (NF V03-903).In the second set of tests (operating conditions study), the oil content of uncleaned oleic sunflower seed was 42.49% in relation to the dry matter. The seed moisture content at storage was 7.13%.The seeds were neither dehulled nor flaked prior to entering twin-screw extruder. Dehulling of oilseeds is adapted to the quality of the hulls and how easily they can be removed. Generally, European factories do not hull sunflower seeds. The hull by itself constitutes nearly 25% of the seed ( Isobe et al., 1992andKarleskind, 1996). Flaking of seeds is extremely important as a solid-liquid extraction by solvent is conceived after mechanic pressing. In this study, the oil extraction was only carried out with mechanic pressing, without solvent extraction.2.2. Twin-screw extruderExperiments were conducted with a co-rotating twin-screw extruder (Model Clextral BC 45, France). The extruder was built with seven modular barrels, each 200mm in length, and different twin-screws which had segmental screw element each 50 and 100mm in length. Four modules were heated by thermal induction and cooled by water circulation. Material was fed into the extruder inlet port by a volumic screw feeder (type 40, Clextral, France). A filter section consisting of six hemispherical dishes with perforation of 1mm in diameter was outfitted on module 5 to separate extracted oil. Furthermore, screw rotation speed, seed input flow rate and barrel temperatures were monitored from a control panel. Fig. 1 shows the schematic modular barrel of twin-screw extruder.Fig. 1.Schematic modular barrel and global screw configuration of twin-screw extruder BC 45.View thumbnail images2.3. Experimental2.3.1. Screw configuration studyThirteen screw configurations were evaluated in this experiment (Fig. 2). First configuration was the best configuration obtained in previous work (Dufaure et al., 1999a). Seven screw configurations (profiles 17) were built by placing monolobe paddles (DM) and bilobe paddles (BB) elements at different position. Bilobe paddles (BB) were located at 50 and 150mm from the right side module 5 (filter module). Monolobe paddles (DM) were positioned by spacing 50 or 100mm from BB. Furthermore, position and interval effects of two reversed screw (CF) elements were studied by placing a CF element at 50 and 100mm from the left side module 5 and by spacing second CF element at 0, 50, 100 or 150mm from first CF element. Another five configurations (profiles 812) were developed from profile 5 by modifying the position of DM elements and/or by reducing the pitch of reversed screw elements. DM elements were positioned at module 2 before BB elements and the pitch of CF elements were decreased from 25 to 15.Fig. 2.Screw configurations for oil extraction of oleic sunflower seeds.View thumbnail imagesFor all profiles, barrel temperature, screw rotation speed and seed input flow rate were fixed at 80C, 60rpm and 24kg/h, respectively. In the case of profiles 8, 11 and 12, screw rotation speed was fixed at 100 and 70rpm. To ensure a stable flow rate and temperature, the extruder was operated for approximately 2025min before processing the actual samples. Upon achieving steady operation, filtrate (oil containing the foot) and cake meal samples were immediately collected over a period of 20min. Sample collection time was determined with a stopwatch. The filtrate and cake meal were weighed. The filtrate was further centrifuged to separate the foot from the oil. The moisture and residual oil contents of the cake meal were measured according to standards NF V03-903 and NF V03-908. For each tests, sample collection was carried out just the once. The calculation of oil extraction yield was determined by relationships following: (1)(2)where Qs is the inlet flow rate of seed (kg/h), QF and Qc are respectively the outlet flow rate of the filtrate (kg/h) and the cake meal (kg/h). Ts, TF and Tc are the oil content of the seed (%), the filtrate (%) and the cake meal (%), respectively. In some cases, a dead stop procedure allowed us to collect material at different locations (mainly on modules 14) in screw channel for particle size distribution analysis. A number of materials (50g) taken from screw channel were successively filtered on 3, 2, 1 and 0.5mm opening sieves to separate all particles. All fractions were weighed for measurement of the particle size distribution.2.3.2. Operating conditions studyExperiments were done in three steps and conducted with screw profile 5. First, experiment was conducted at various temperatures (80120C) with a fixed screw rotation speed of 60rpm and a seed input flow rate of 24kg/h. The choice of these temperature limits were based on information reported in the literature (Dufaure et al., 1999a). Furthermore, a number of feed input flow rates (1749kg/h) and screw rotation speeds (60200rpm) were tested to determine the optimal operating condition. In this case, the temperature along the barrel was fixed at 80C. Sample collections and analysis were determined according to procedure in previous study.2.4. Oil quality analysisThe quality parameters of a crude oil included (i) the acid value, expressed in mg of KOH/g of oil (standard NF T 60-204), indicates the free fatty acid content of the oil; (ii) the iodine value, expressed in terms of the number of centigrams of iodine absorbed per gram of oil (standard AOCS-Cd 1d-92), is a measure of the unsaturation of oils. The higher the iodine value the greater the unsaturation of oils; (iii) the saponification value, expressed in mg of KOH/g of oil (standard ISO 3657), is the amount of alkali necessary to saponify a definite quantity of the oil; (iv) the phosphorus content, expressed in mg of phosphorus per kg of oil (standard AOCS Ca 12-55), determines phosphorus or the equivalent phosphatide content by ashing the oil in the presence of zinc oxide followed by the spectrophotometric measurement of phosphorus as a blue phosphomolybdic acid complex. Total phospholipids content was determined by multiplying phosphorus content by 30. Moreover, the fatty acids and tocopherols compositions of crude oil were determined with gas chromatography (FAME method) and HPLC (IUPAC 2, 432 COFRAC CM 40), respectively.2.5. Specific mechanical energyThe specific mechanical energy (SME) was calculated by the following equation: (3)(4)where P is the motor power, I and Ss are correspondingly electrical intensity and screw rotation speed. 2.6. Residence time distributionThe residence time distribution (RTD) was determined by introducing directly a certain amount of seeds (5g) colored with erythrosine into the entrance of the extruder. Samples (filtrate and cake meal) were collected every 10s. The cake meal samples were dried (105C, 24h) and ground in a micro-grinder. Furthermore, the quantity of colorant in samples was determined by CIE L*a*b* method using a spectrocolorimeter (Minolta Seri CM-500i, Japan). The color values measured are presented as L*, a* and corresponding to lightness, the green-red and the blue-yellow components, respectively. Those results are the average of five consecutive measurements.3. Results and discussion3.1. Effect of screw configuration3.1.1. Oil extraction yieldThe position of BB, DM and CF elements and the spacing between two elements affected generally the oil extraction yield R and Ro (Fig. 3). High oil extraction yield based on residual oil content of cake meal (R) was observed when first reversed screw element was moved farther from second reversed screw, as observed on profiles 3, 5, 8 and 11, compared to profiles 0, 7 and 9 where no spacing between reversed screw elements. For certain interval of two CF elements, oil extraction yield increased with decreasing interval between BB and DM elements, as observed on profiles 2 and 5. In another cases, the reduction of the interval of BB and DM elements decreased the oil yield (profiles 1 and 4, 3 and 6). The modifications of the configuration of BB and DM elements or/and the pitch of screw elements did not influence the oil yield (profiles 8 and 11), in contrary the oil extraction yield decreased (profiles 5 and 10).Fig. 3.Variation of oil extraction yield on different screw configurations.View thumbnail imagesIn the case of Ro, high oil yield separated from filtrate by centrifugation was mainly observed when interval between BB and DM elements was reduced, as observed on profiles 46. The modifications of the configuration of BB and DM elements or/and the pitch of screw elements decreased the oil yield (profiles 811). These results have a significant correlation with the foot content of filtrate, the higher foot content of filtrate the lower oil extraction yield Ro.The modification of the monolobe paddle (DM) and bilobe paddle (BB) screw configuration from profile 0 and the placing interval between two reversed screw (CF) elements produced a stronger compression action of CF elements and increased shearing action of BB and DM elements. The analysis of the particle size distribution of sunflower seed on modules 14 (Table 1) showed that the particle size of sunflower seed changed progressively from initial dimension since module 3 (profiles 16). The addition of BB elements in module 2 did not have important effect on the size reduction of seed. This phenomenon indicated that DM elements had a stronger effect on matter breakdown than BB elements, so the screw configuration with placing DM elements followed by BB elements was better design to rupture the matter by shearing action. In addition, the incorporation of the DM elements with longer BB elements produced a stronger matter breakdown, as observed on profiles 9 and 10 (Table 1). Furthermore, the incorporation of reversed screw (CF) elements in module 6 caused an expanded structure, which broke easily when shear force was applied. This facilitated diffusion of the lipid droplets released through the fibrous matrix toward the surface of the matter.Table 1. Effect of the position of BB and DM elements on particle size distribution of oleic sunflower seed on modules 14 under different positions of CF1CProfilePosition of BB and DMInterval between first BB and DM (mm)Position of CF1CInterval between two CF1C (mm)Particle size (mm)Particle size distribution (%) on module 12341BB: 50, 450; DM: 200150CF1C: 50, 15050389814313231118202012124480.51101738883463231216262812119450.517223858743423151321281224470.519203878527223131521141229410.51164239181331323917221512227370.5116333918428423915201612132360.51174238762143231216168121614110.5112357438663186231018197121614110.5141134620.521514Full-size table3.1.2. Specific mechanical energy (SME)The location of monolobe and bilobe paddles elements and the spacing of reversed screw elements influenced SME and intensity (Table 2). The general trends were higher SME and intensity values, as reversed screw elements were not spaced (profile 7) or/and monolobe paddle elements were located earlier than bilobe paddle elements (profile 9). Besides, SME input and intensity increased progressively when conveying or/and reversed screws elements had a smaller pitch screw (profiles 8, 11 and 12). In another cases (profiles 16, and 10), the modification of the configuration of BB, DM and CF elements influences fairly SME and intensity. The maximum specific mechanical energy of 189Wh/kg was obtained under profile with spacing two reversed screw elements of 100mm and screw pitch of 15mm (profile 11).Table 2. Performance of extraction parameters on different screw configurationsProfileFiltrate Cake meal Intensity (A)aSME (Wh/kg)Flow rate (kg/h)Foot content (%)Acid valueFlow rate (kg/h)Residual oil content (%)Moisture content (%)05.66111.4917.1023.797.5516.03131.3417.7920.448.4051/5596.6726.2671.6417.4920.848.1450/5597.8836.1561.6617.2219.538.4150/5593.3746.1571.7417.3620.627.4351/56103.4556.6081.3117.2219.657.9257/60108.3266.2171.6917.4621.077.9450/55101.2476.43221.4917.5721.138.1960/64122.9087.29361.5216.6620.748.7455/57164.5896.91311.3617.5524.058.2467/71122.22106.73251.3917.6523.058.3058/62102.99117.63391.5216.6620.418.6660/66188.89126.01221.4817.9222.228.7067/72168.70aElectric current (A) required by the motor to ensure turning of the screws and matter conveying.Full-size tableEffect of screw configuration on SME input has a good correlation with degree of fill. Reversed screw, monolobe and bilobe paddles elements are flow-restricting/power consuming elements that vary in their ability to increase the degree of fill, and generate back pressure when placed in a screw profile. Reversed screw element is a stronger flow-restricting element compared to DM and BB elements. The strongest flow restricting, as observed by Choudhury and Gautam (1998), is conducted with combining BB, DM and CF elements. The more severe the screw configuration, the greater was the degree of fill. This is because a longer filled length is required to build up pressure for flow of material across the screw element with higher flow restricting ability. The spacing between the two restricting elements increased the filled length and therefore the SME input to material. This is due to high material viscosity in region where material encountered the first flow-restricting element giving rise to higher filled volume (Gautam and Choudhury, 1999b).3.1.3. Extraction performance and qualityThe results showed that the modification of screw configuration affected the performance of extraction parameters, in particular the foot content of filtrate (Table 2). Lesser foot content was obtained under profiles 06 compared to profiles 712. The foot content of filtrate as well as the intensity increased when the reversed screw elements were not spaced (profiles 7 and 9) or had a smaller pitch screw (profiles 8, 11 and 12) or/and the DM elements were located prior to BB elements (profile 10). Another extraction parameters, such as the flow rate of filtrate and cake meal, were not a function of screw configuration. These parameters were not relatively developed with screw configuration, except for profiles with smaller pitch screw (profiles 8 and 11).For all profiles, the extracted oil had a good quality because the acid value remained stable at less than 2mgKOH/g of oil. The modification of screw configuration did not influence generally the oil quality, as observed on profiles 0 and 5 (Table 3). The crude oil quality of both these profiles was apparently acceptable. The iodine and saponification values, as well as acid value, were tolerable. Furthermore, the extracted oil was rich -tocopherol and oleic acid. Besides, it had very poor phosphorus content. These conditions were favorable to improve the oil stability and to facilitate the refining process.Table 3. Crude oil quality of the profiles 0 and 5Parameter qualityProfile 0Profile 5Acid value (mgKOH/g of oil)1.491.31Iodine value (giodine/100g of oil)82.8482.44Saponification value (mgKOH/g of oil)202.3214.8Phosphorus content (mg/kg)20.100.8216.910.89Phospholipids content (mg/kg)603.0124.64507.2526.72Tocopherol content (g/g)-Tocopherol721.35956.52-Tocopherol20.0726.20-Tocopherol3.415.10Fatty acid content (%)Myristic acid (C14:0)0.040.00Palmitic acid (C16:0)3.073.53Stearic acid (C18:0)3.743.61Oleic acid (C18:1)85.4284.99Linoleic acid (C18:2)5.425.68Linolenic acid (C18:3)0.020.00Arachidic acid (C20:0)0.290.30Eicosenoic acid (C20:1)0.110.17Behenic acid (C22:0)1.501.29Lignoceric acid (C24:0)0.390.42Full-size tableThe cake meal for all configurations tested was not good quality. The moisture and residual oil contents were high, above 7% and 19% in relation to dry matter, respectively. Higher residual oil content was obtained particularly when the reversed screw elements were located without an interval, as observed on profiles 0 and 9. However, the modification of screw configuration did not improve the cake meal quality.Finally, based on oil extraction yield R and Ro, energy mechanic specific and oil quality, high oil extraction performance was obtained when the operation was conducted with profile 5. In this study, the profile 5 was thus better screw configuration to realize the oil extraction of oleic sunflower seeds by twin screw extruder type clextral BC 45.3.2. Effect of operating conditions on extraction performance3.2.1. Temperature effectThe result showed that the oil extraction yield based on residual oil content of cake meal (R) decreased when the barrel temperature increased, although there was a slight increase in the mean residence time of cake meal (Fig. 4) and the energy input, particularly the thermal energy (SEE) (Table 4). In addition, the application of high temperature in the oil extraction enhanced the residual oil content of cake meal (Table 4). This condition facilitated to decrease the oil extraction yield. Based on oil content of filtrate, the oil extraction yield (Ro) increased when the barrel temperature increased, followed by a slight decrease in the mean residence time of filtrate and the foot content of filtrate.Fig. 4.Effect of the temperature on oil extraction yield and mean residence time (Ss=60rpm; Qs=24kg/h).View thumbnail imagesTable 4. Performance of extraction parameters on different operating conditionsOperating condition Filtrate Cake meal Intensity (A)SEE (Wh/kg)SME (Wh/kg)Ss (rpm)Qs (kg/h)T (C)Flow rate (kg/h)Foot content (%)Flow rate (kg/h)Residual oil content (%)Moisture content (%)6017803.841411.2422.239.0737/3935.9799.526024806.081717.5021.349.2553/5510.4991.72602980o.p.o.p.o.p.o.p.o.p.o.p.o.p.o.p.60241005.991317.4821.507.9950/5699.4492.2860241205.961017.1223.473.6558/63102.26107.6010024805.261418.9025.748.2733/3512.7295.6110029806.562323.5326.457.9940/4132.34101.4810048809.463336.8129.478.0353/5510.1381.2515024805.221418.7625.668.4933/3415.66139.801504880n.f.n.f.n.f.n.f.n.f.n.f.n.f.n.f.20024803.541718.8827.507.2030/318.51188.94Ss, screw rotation speed; Qs, seed input flow rate; T, barrel temperature; o.p., no operation permitted; n.f., no filtration permitted.Full-size tableThe influence of temperature on residence time and energy input has a significant correlation with material viscosity and degree of fill (Gautam and Choudhury, 1999b). Higher degree of fill is obtained when the flow of material across restricting elements is more viscous, and consequently the residence time and the energy input will increase when the temperature decreases. However, the contrary phenomenon was observed in this study.The oil expression using high temperature has few favorable effects on increase in oil fluidity, breaking of the walls of additional fatty cell and coagulation of the protein fraction of seed (Karleskind, 1996), hence the lipid droplets release easily through the fibrous matrix toward the surface of the matter. On the other hand, this operation increased the residual oil content of cake meal due to reduced plasticity of the seed (Wiesenborn et al., 2001). In this study, the residual oil content of cake meal remained stable for an increase in the barrel temperature to 100C, but further increase enhanced the residual oil content to above 23% in relation to dry matter. Besides, the moisture content of cake meal decreased when the barrel temperature increased, and therefore this decreased the plasticity of the material.3.2.2. Screw rotation speed and seed input flow rate effectsThe reduction in the screw rotation speed increased the mean residence time of the matter through twin-screw extruder, and then increased the oil extraction yield R and Ro (Fig. 5). Under this condition, the energy input decreased progressively due to a grand reduction in the mechanical energy input (Table 4). Several papers reported that an increase in feed flow rate at constant screw rotation speed caused a decrease in residence time ( Barres et al., 1990andNDiaye and Rigal, 2000), which decreased the level of material transformation. Fig. 6 shows the evolutions of the mean residence time and the oil extraction yield with seed input flow rate that were in good agreement. The oil extraction yield (R and Ro) and the mean residence time of the matter increased when the seed input flow rate decreased (in case of screw rotation speed of 100rpm). However, further decrease did not increase the oil extraction yield, although there was an increase in the mean residence time of the matter (in case of screw rotation speed of 60rpm). For both these cases, the specific mechanical energy (SME) decreased with increasing the seed input flow rate (Table 4).Fig. 5.Effect of the screw rotation speed on oil extraction yield and mean residence time (T=80C; Qs=24kg/h).View thumbnail imagesFig. 6.Effect of the seed input flow rate on oil extraction yield and mean residence time (T=80C).View thumbnail imagesThe plotting of the oil extraction yield (R) as a function of specific mechanical energy showed two operating zones permitting oil expression of sunflower seed using twin-screw extruder (Fig. 7). High oil extraction yield was obtained under SME zone from 100 to 140Wh/kg. That condition was obtained under 80C, 24kg/h and 100150rpm. Below 100Wh/kg, the oil extraction yield could be increased if the screw rotation speed was decreased and the seed input flow rate was remained constant. Further increase in seed input flow rate did not improve the oil yield, in contrary the oil yield decreased.Fig. 7.Oil extraction yield (R) as function of the specific mechanical energy (T=80C).View thumbnail imagesThe flow rate of filtrate and cake meal increased when the seed input flow rate increased, followed by an increase in foot content of filtrate and residual oil content of cake meal (Table 4). The expansion in flow rate and residual oil content of cake meal was observed too when the screw rotation speed was increased. However, the expansion in screw rotation speed decreased the flow rate of filtrate. Both feed rate and screw rotation speed did not have grand effect on moisture content of cake meal. This parameter was remained stable with increasing the feed rate, however it decreased moderately when the screw rotation speed increased.The decreasing of the screw rotation speed and the increasing of the seed input flow rate induced a higher degree of filling of the screw where this caused a grand expansion in the intensity. When these operating factors were modified further, the torque exceeded the intensity limit. The extruder clogged before reaching steady state condition and no sample was collected, as observed when it was operated under 80C, 60rpm and 29kg/h. The operation with low feed flow rate was thus recommended for low screw rotation speed.3.3. Effect of operating conditions on oil qualityFor all conditions tested, the quality of extracted oil was satisfied (Table 5). The acid value remained stable at less than 2mgKOH/g of oil. The iodine and saponification values were tolerable. The phosphorus content was very poor, below 40mg/kg. Furthermore, the extracted oil was rich -tocopherol and oleic acid, and observed that the higher temperature and screw rotation speed the richer -tocopherol (Table 6). The operating conditions did not relatively affect the oleic acid content.Table 5. Effect of operating conditions on crude oil qualityOperating condition Acid value (mgKOH/g of oil)Iodine value (giodine/100g of oil)Saponification value (mgKOH/g of oil)Phosphorus content (mg/kg)Ss (rpm)Qs (kg/h)T (C)6017801.4982.8525.180.426024801.4984.19168.315.810.83602980o.p.o.p.o.p.o.p.60241001.5782.15166.724.270.2660241201.5482.97164.538.560.0910024801.6984.13188.824.750.9910029801.5884.93160.834.010.4110048801.4484.49161.016.220.5115024801.6982.11178.824.441.711504880n.f.n.f.n.f.n.f.20024801.7483.02137.923.811.97Full-size tableTable 6. Effect of operating conditions on fatty acids composition and tocopherol content of crude oilOperating condition Fatty acid (%) Tocopherol content (g/g) Ss (rpm)Qs (kg/h)T (C)C14:0C16:0C18:0C18:1C18:2C20:0C20:1C22:0C24:06017806024800.003.813.6685.585.140.230.201.090.29710.819.33.5602980o.p.o.p.o.p.o.p.o.p.o.p.o.p.o.p.o.p.o.p.o.p.o.p.60241000.003.873.6285.385.080.320.211.190.34760.920.53.760241200.003.803.6585.305.210.230.311.100.39818.623.04.210024800.053.633.6885.685.130.240.101.180.30793.121.54.110029800.003.303.7086.365.090.220.001.320.0010048800.003.653.5786.834.860.260.000.830.0015024800.003.433.6285.583.150.310.191.350.361504880n.f.n.f.n.f.n.f.n.f.n.f.n.f.n.f.n.f.n.f.n.f.n.f.20024800.053.703.7185.545.130.230.091.290.26Full-size tableThe variation in acid, iodine and saponification values with operating conditions were evidently less important compared to phosphorus content, mainly the variation with temperature. The phosphorus content increased when the barrel temperature increased. The increase of barrel temperature facilitated more effective drying the seed in which it motivated more efficient crushing of the seed due to its reduced elasticity. This intense crushing breaks the cell walls and leads to more efficient co-extraction of the membrane phospholipids, as reported by Dufaure et al. (1999a). High phosphorus content was observed too under high screw rotation speed and feed rate.4. ConclusionThe screw configuration and the operating conditions played an important role to influence the oil extraction yield, the energy input and the residence time of matter during twin-screw oil expression of sunflower seeds. The oil extraction yield and the specific mechanical energy were highest as the reversed screw elements were moved with increased spacing between elements or/and with smaller pitch screw. A systematic increase in oil extraction yield was observed as the barrel temperature, the screw rotation speed and the seed input flow rate were decreased. The energy input increased when the barrel temperature and the screw rotation speed increased while the residence time of matter through extruder increased when the screw rotation speed and the feed input rate decreased. Moreover, the twin-screw process in different screw configurations and operating conditions leads to produce a good oil quality.ReferencesBarres et al., 1990C. Barres, B. Vergnes, J. Tayeb, D. ValleTransformation of wheat flour by extrusion cooking: influence of screw configuration and operating conditionsJ. Cereal Chem., 67 (1990), pp. 427433Bouvier and Guyomard, 1997Bouvier, J.M., Guyomard, P., 1997. Method and installation for continuous extraction of a liquid contained in a raw material. PCT/FR97/00696.Choudhury and Gautam, 1998G.S. Choudhury, A. 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All rights reserved.Supplementary content1 2 3 4 5I am the captionRelated articlesTwin-screw extruder for oil processing of su.Industrial Crops and Products Twin-screw extruder for oil processing of sunflower seeds: Thermo-mechanical pressing and solvent extraction in a single step Original Research ArticleIndustrial Crops and Products, Volume 32, Issue 3, November 2010, Pages 297-304I. Amalia Kartika, P.Y. Pontalier, L. RigalAbstractA new application of twin-screw extruder as a machine to conduct a thermo-mechanical pressing and a solvent extraction of sunflower oil in a single step and in a continuous mode was studied. Experiments were conducted using a CLEXTRAL BC 45 co-rotating twin-screw extruder and whole sunflower seeds with fatty acid methyl esters as a solvent. The influences of screw rotation speed (SS), feed rate (QS) and solvent-to-solid (S/S) ratio were examined to define the best performance of the oil extraction yield, the oil quality and the specific mechanical energy. Generally, the screw rotation speed, feed rate and solvent-to-solid ratio affected oil extraction yield. An increase of oil extraction yield was observed as screw rotation speed and feed rate were decreased, and solvent-to-solid ratio was increased. In addition, oil extraction yield increased as screw rotation speed and feed rate were simultaneously increased to QS/SS ratio of 0.2. Highest oil extraction yield (98%) with best cake meal quality (residual oil content lower than 3%) was obtained under screw rotation speed of 185rpm, feed rate of 30kg/h, and solvent-to-solid ratio of 0.55. Furthermore, the operating parameters and solvent-to-solid ratio influenced energy input. A decrease of screw rotation speed and feed rate followed by an increase of solvent-to-solid ratio increased energy input, particularly specific mechanical energy input.PDF (730 K) Extraction of sunflower oil by twin screw ex.Bioresource Technology Extraction of sunflower oil by twin screw extruder: Screw configuration and operating condition effects Original Research ArticleBioresource Technology, Volume 97, Issue 18, December 2006, Pages 2302-2310I. Amalia Kartika, P.Y. Pontalier, L. RigalAbstractA new application of twin-screw extruder as a machine to conduct a thermo-mechanical pressing and a solvent extraction of sunflower oil in a single step and in a continuous mode was studied. Experiments were conducted using a CLEXTRAL BC 45 co-rotating twin-screw extruder and whole sunflower seeds with fatty acid methyl esters as a solvent. The influences of screw rotation speed (SS), feed rate (QS) and solvent-to-solid (S/S) ratio were examined to define the best performance of the oil extraction yield, the oil quality and the specific mechanical energy. Generally, the screw rotation speed, feed rate and solvent-to-solid ratio affected oil extraction yield. An increase of oil extraction yield was observed as screw rotation speed and feed rate were decreased, and solvent-to-solid ratio was increased. In addition, oil extraction yield increased as screw rotation speed and feed rate were simultaneously increased to QS/SS ratio of 0.2. Highest oil extraction yield (98%) with best cake meal quality (residual oil content lower than 3%) was obtained under screw rotation speed of 185rpm, feed rate of 30kg/h, and solvent-to-solid ratio of 0.55. Furthermore, the operating parameters and solvent-to-solid ratio influenced energy input. A decrease of screw rotation speed and feed rate followed by an increase of solvent-to-solid ratio increased energy input, particularly specific mechanical energy input.PDF (486 K) Direct extraction of oil from sunflower seed.Industrial Crops and Products Direct extraction of oil from sunflo