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Vegetable Oil Processing AP42 Section: 9.1 1.I Title: Vegetable Oil Processing Comments and letters from industry 1995 MIDWEST RESEARCH INSTITUTE Suite 350 401 Harrison Oak Boulevard Cery. North Carolina 27513-2412 Telephone (919) 6774249 FAX (919) 6774065 Date: May 20, 1996 Subject: Site Visit -- Cargill Emission Factor Documentation for AP-42, Section 9.11.1 EPA Contract No. 68-D2-0159;MRI Project No. 4602-03 From: Tom Lapp To: AP-42 Section 9.11.1 Project File I. Purpose The purpose of the visit was to briefly review comments from the National Oilseed Processors Association (NOPA) and to conduct a walking tour of the soybean crush plant. This information will be incorporated into the revision of the background report and AP-42 Section 9.11.1, Vegetable Oil Processing. 11. Place and Date Cargill, Incorporated River Road, Box 2309 Fayetteville, North Carolina 28302 August 2, 1995 111. Attendees NationaPOilseed Processors Association David C. Ailor Director of Regulatory Affairs Washington, DC Carsill, Inc. Ron Moeller Assistant General Superintendent Operations and Engineering Minneapolis, MN Tom Richardson Plant Superintendent Fayetteville, NC U. S. Environmental Protection Asency Dallas Safriet, EFIG Ron Ryan, EFIG Roy Huntley, EFIG Midwest Research Institute (MRII Tom Lapp IV. Discussion The visit as held primarily to conduct a walking tour of the facility in order to observe the actual processing steps in operation. Prior to the tour, a brief meeting was held to discuss general information on the soybean processing industry and to review suggested NOPA process diagrams for incorporation into the final report. This discussion presents information on the soybean processing industry and a description of the refining of edible soybean oil. The review of NOPA diagrams consisted of a discussion of process flow diagrams previously submitted to EPA by NOPA. Copies of the annotated diagrams are attached to this memorandum. A. General Information Generally, the soybean industry annually processes 1.1. to 1.3 billion bushels of soybeans. For 1995, most plants are operating at about 70 percent of capacity. The Cargill plant at Fayetteville is one of the larger plants in the U.S. and is in the top 20 percent in terms of production capacity. For most plants, there have not been a lot changes over the past 15 years and those changes that have occurred were the result of EPA regulations or the increase in energy costs. During this 15 year period, there has been a move from the use of deep bed extractors towards shallow bed extractors. Also, changes have occurred in the desolventizing/toaster (DT) systems. Generally, plants do not change control devices without an increase in capacity. In conventional soybean processing plants, there is no production of soybean meal for human consumption (white flake production). Only about 8 plants in the U.S. have flasher systems for white flake production. These flasher systems use superheated hexane in the flake desolventizing step and do not use meal dryers. B. Soybean Oil Refining Crude soybean oil contains free fatty acids, phosphorus compounds, protein fines, and triglycerides. The crude oil can be either treated directly with caustic or undergo an optional step to degum the oil, which removes the lecithin. After treatment with caustic, the oil is centrifuged to separate the aqueous refining by-product lipid from the oil. This lipid solution contains protein fines, phosphorus compounds, some saponified triglycerides, and sodium salts of the fatty acids. Following separation of the lipid, the oil is washed with water and centrifuged to remove some of the remaining saponified triglycerides. The refined oil is then bleached and deodorized. In the bleaching step, the refined oil is treated with bleach clay and then transferred to a vacuum bleaching tank. Following the bleaching step, the spent clay is filtered from the oil and the refined, bleached oil is ready for the deodorizing step. Prior to the deodorizing step, the bleached oil may be hydrogenated using a nickel catalyst and the resultant liquid supercooled to filter out the saturated oil. The refined, bleached oil is deodorized by stripping in a still with steam ejectors. In the stripping process, any triglycerides and fatty acids remaining in the refined, bleached oil are removed and the refined-bleached- deodorized (RBD) oil is ready for processing into commercial products. A process flow diagram for the edible oil processing operation is attached to this memorandum. ', Crude or Refining Degummed Oil I Refi,ning Refining Caustic .I 1 By-product (Centrifuge) Lipid I I I .I. I I I I Water Water Washin'g Soapy Water (Centrifuge) I--+ Spent Bleach Clay + (EnclosedBleaching Plate Filter) Bleach Clay (Oil) Contact Stripping Deodorizer and Vacuum w (Still with Cooling Water with Triglycerides Ejector Steam Steam Ejectors) .I. Refined-Bleac hed-Deodorized (RBD) Oil Edible Oil Processing 97/28/95 18:47 S202 833 3638 EAUCK & ASSOC. @010/013 ,,+ Sampling Q.." Raw Soybean Weigh and Dump 3 Particulate Emissions (SCC 3-02-007-81) cStorage i! Soybeans To Preparation (Figure 9.11.1-2) Figure 9.1 1.1-1. Flow diagram of typical soybean handling/elevator operations. (Source Classification Codes in parentheses.) ?7/28/05 18:47 B202 833 3836 BAUCK El ASSOC. a011/013 ATTACHMENT 2 Soybeans from Handling/Elevator Operations (Figure 9.11.1.1) - ---> I- - I I J Cracking 1 .:_ . ~. ~. .. ' .. ' !I j; .:a, 4 I I . I.. - .' ,. -Particulate::. 1 .. Flaking i. .. .!!. .. ... !q . :i .d o.g.lo...I -b, vz ..Emissions ; 1 (SCC .I.,. +-j&"JWJJ. I !.- - 3.02407-88) flakes to Solvent Extractjon (Figure 9.11.1-3) Figure 9.1 1.1-2. Flow diagram of the typical process for preparing soybeans for solvent extraction. (Source Classification Codes in parentheses.) .. 9 U7/28/95 16:47 B202 833 3836 UUCR & ASSOC. ~012/013 ATTACHMENT 3 Hexane and Sream Vapors I I Figure 9.1 1.1-3. Flow diagram of the "conventiod"soybean solvent exmaion process. (Source Classification Codes in parentheses.) -- :07/28/B5 10:47 E202 833 3830 UUCK & ASSOC. @013/013 ATTACHMENT 4 Cool Dried Meal from Hulls from Solvent Extraction Preparatlon (Fgurs 9.11.1-3) (Figure 9.11.1-2) 1 1 Particulate Meal Grinding Hull Grinding Particulate Emissions and Sizing and Sizing Emissions - (SCC 342407#tr) (SCC 302-00786) - 1 Hull Toasting 4.- T Meal Toasted Hull ~ l19elo Storage (Millfeed) (High Protein) Storage \ I I I Meal-Millfeed Blending 1 Meal Storage (Low Protein) Particulate ,. (Rail, Truck, Barge) Emissions Figure 9.1 1.1-4. Flow diagram of the "convenuonal" process for dry material sizing, grinding, and loadout. (Source Classification Codes in parenrheses.) Crude or Refining I Refining I Refining Caustic I (Centrifuge) I) By-product Lipid I I Water Water(Centrifuge) Washing I--+ Soapy Water Spent Bleaching Bleach Clay Bleach Clay (Enclosed Plate Filter) + (Oil) Contact Stripping Deodorizer Cooling Water and Vacuum w (Still with with Triglycerides Ejector Steam Steam Ejectors) and Fatty Acid + Refined-Bleached-Deodorized (RBD) Oil Edible Oil Processing !l & .-07/28/85 16:44 B202 833 3656 HAWK ASSOC. a001/013 II NATIONAL OILSEED PROCESSORS ASSOCIATION 1255 TWENTY-THIRD STREET, N.W. WASHINGTON, DC 20037 Phone: (202)452-8040 Fax: (202) 466-4949 -FACSIMILE TRANSMITTAL FORM- # OF PAGES IN THIS FAX (including cover page): If transmittal is incomplete or unclear, please call (202) 452-8040 for assistance. - FROM: David C. Ailor, NOPA Director of Regulatory Affairs July 28, 1995 1255 TWENTY-THIRD U.S. Environmental Protection Agency STREET, Oflice of Air Planning and Standards (MD-15) N.W. Quality WASHINGTON, Research Triangle Park, NC 2771 1 DC 20037-1 174 Attn.: Mr. Dallas W. Safriet, Emission Inventory Branch Emission Standards Division PHONE: (202) 452-8040 Re.: EPAs Revised Draft Emission Factor Documentation for AP- 42 Sectlon 9.1 1.1, Vegetable Oil Processing (June 1995) FAX: (202) 835-0400 Dear Mr. Safriet: On June 9, 1995, Mr. Tom Lapp (Midwest Research Institute), acting on your behalf, sent our organization, the National Oilseed Processors Association (NOPA), the EPAs Revised Draft Emission Factor Documentation for AP-42 Section 9.1 1.1, Vegetable Oil Processing, that the EPA intends to publish in an upcomlng supplement to AP-42, Compilation of Air Pollutant Emission Factors. You asked that we review and provide you with our comments on the revised draft document towards the Agency publishing this sectlon as a new section In AP-42. NOPA is a national trade association comprised of 13 regular and 27 associate member companies wlth plants engaged in the processing of vegetable meals and oils from oilseeds. NOPAs 13 regular member firms process an estimated 1.1 billion bushels of oilseeds annually at 72 plants in 22 states, employing an estimated 4.700 workers. We very much appreciate the invitation to share our views with you on a topic of such relevance to our industry. Generally speaking, the dowment is much improved over the Draft Emission Factor Documentation for AP-42 Section 6.1 1.1 that you provided us for review/comment in August 1993. However, it is still incorrect or lacking in a few areas, and should be revised accordingly. Our detailed commentshecommended revisions are presented in the enclosure to this letter. As you know, on Wednesday, August 2, you and several other representatives of EPA-OAQPS will be joining Ron Moeller (Cargill) and me in Fayetteville, NC. for a tour of Cargill’s Fayetteville Crush PlanVOil Refinery. Ron and I would like to utilize that meeting as an opportunity to briefly review our comments with you and answer any questions you may have. Please advise me should that present a problem. (1929-19B9) - NATIONAL SOYBEAN PROCESSORS ASSOCIAllON .07/28/05 18:45 e202 833 3636 IIAUCK & ASSOC. 't) Dallas W.
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