Professional Documents
Culture Documents
John Taulo
Deputy Director (Research and Development)
Malawi Industrial Research and Technology Development Centre
P.O.Box 357, Blantyre
E-mail: mirtdc@malawi.net
Website: mirtdcmalawi.com
April 2005
ABSTRACT
This paper contains a technical report on a project to be carried out on
design and development of screw press. The project focuses on
qualitative analysis of existing screw presses and modifying them for
production in local workshops. The analysis will be based on both
technical and financial appraisals. Limitations therefore will include
complexity of the turbine, ease of fabrication and production costs among
others.
The first screw press model was consuming relatively more energy and
needed high power source for its operation.
unsmooth operation, oiling up, heavy foots, high oil content in cake fibre,
and comparatively high cost of maintenance.
The model
was found
inefficient for hard oil seeds such as sunflower, soybean and cotton seed.
The
above
enlisted
shortfalls
necessitated
further
research
and
development.
In
order
to
overcome
the
above
stated
problems,
the
technical
development work was geared towards further increasing the oil recovery
rate at a competitively low energy consumption, increasing the operation
efficiency and life of the expeller. Also achieving smooth operation both
on soft as well as hard oil seeds on expeller.
Depending on the defined limitations, the screw press is to process 100 to
120 kg oilseed per hour. This compares favourably well with TinyTech,
Lahore and Sundhara expellers . This report includes briefs on the designs
considered, engineering drawings and calculations of the final design
selected.
DESIGN BRIEF
The shortage of both edible as well as non-edible oils and fats for
industrial use has been continuing in Malawi for the past three decades.
As the local production of the vegetable oils is meagre compared to their
demand, so the shortage is met through imports from various sources.
Undoubtedly, the agriculture sector should endeavour to minimise our
dependance on imports but scientific and technological improvements also
have a major role to play.
One of the primary objectives of the present government is to provide
more job opportunities in the rural areas and to ameliorate the condition
of the rural population by raising their per capita income. The research
and development work on small scale oil expelling system is a significant
step taken by the Centre in this direction. This technology will not only
bring about uplift of the socioeconomic condition of the rural population,
but also reduce the gap between supply and demand of edible oils in
Malawi.
TABLE OF CONTENTS
Abstract
Design Brief
Introduction
Scope
Objective
Methodology
CHAPTER 1:
1.1
INTRODUCTION
Screw Pressing
The material to be
pressed is fed between the screw and barrel and propelled by the rotating
screw in a direction parallel to the axis. The configuration of the screw
and its shaft is such that the material is progressively compressed as it
moves on, towards the discharge end of the cylinder. The compression
effect can be achieved, for example by decreasing the clearance between
the screw shaft and the cage (progressive or step-wise increase of the
shaft diameter) or by reducing the length of the screw flight in the
direction of the axial movement.
releases the oil which flows out of the press through the slots provided on
the periphery of the barrel, while the press cake continues to move in the
direction of the shaft, towards a discharge gate installed at the other
extremity of the machine.
1.2
The main problems of the old screw design were unsmooth operation,
oiling up, heavy oil in cake fairly high maintenance, heavy power
consumption and its unsuitability for hard oils seeds.
Removal or
1.3
Objectives
The main objective of the project will be to improve the village level oil
seed processing system. Specifically:
a) To continue technical developments in optimising the screw design
for screw press model (2)
b) To evaluate the performance of the newly developed screw press
during field trials
c) To conduct socioeconomic studies on the improved oil seed
processing technology.
CHAPTER 2:
2.1
REVIEW OF LITERATURE
The seed crushing industry is one of the oldest industries in the world.
The Chinese were the first people to express oil seeds. As far as the year
3000BC, the Egyptians knew how to obtain oil using a press composed of
a sausage-shaped rush bag slug between vertical posts of a strong
wooden frame.
79AD were excavated. A large pestle and mortar was found, a long pole
acted as a grinding pestle and hollowed trunk of a tree held the seeds.
An ass or an ox walked around the press, dragging the top end of the pole
and thus grinding the seeds in the hollowed tree trunk. Centuries later
other seeds such as linseed, rapeseed, cottonseed, groundnut, soy bean
and palm kernel which required greater pressure for oil expressing, were
available.
The
manufacturers have come a long way since then with improved material
of construction, manufacturing methods, research and development and
have increased the efficiency of the screw press.
As a result, various
Operating principles
The screw press is designed to continuously remove oil from oil bearing
seeds. As such , it is fed continuously, and discharges oil and low oil
bearing solids continuously. This continuous separation of oil and solids is
effected by a pressure established by a screw turning within a confining
slotted cylinder or barrel. The screw pick up and force incoming oil
bearing material toward and through an adjustable opening at the
discharge end of the press.
This force creates a pressure on the material which causes the oil therein
to be released and pass from the expeller through the slots in the barrel.
Varying the size of the opening, or choke, for a given feed rate, within
limits, for a given choke setting, changes the amount of pressure on the
confined material and thus determines, to a great extent, the amount of
oil which will be removed or conversely, the residual oil content of the
discharge solids.
2.3
CHAPTER 3:
METHODOLOGY
The frame should be from welded steel and provide maximum strength
and allow for simple installation of the press. The motor is to be mounted
on the press, either on the base plate behind the gear box or on the side
of the gear box.
4.1.2
Gear Box
The gear box should be of the worm box type, for high efficiency, it should
be fitted, as standard, with large bearings that will withstand the loads
generated by the pressing operation. It must run 24 hours/day, 7 days a
week for extended periods.
environment and should be separated as far as possible for the hot dirty
environment of the pressing sections.
4.1.3
Cage Assembly
The cage should be split on the centre line with the two halves bolted
together. This design should allow for quick and easy access to the press
internals for cleaning or inspection.
When closed the cage lock firmly to the frame, to prevent it from
moving relative to the frame
The cage should form the drained barrel of the press. To form the
drained barrel the cage should be lined with lining bars separated
by spacers.
4.1.4
Worm Assembly
The worm assembly should feature two compression zones to
maximise the efficiency of oil extraction without generating the high
pressures that absorb power and cause excessive wear of parts.
4.1.5
The thrust bearing carries the thrust loads generated by the press. These
are quite high , especially when full pressing a fibrous feed material. The
design should ensure that the bearings are located at the feed end of the
press and external to the main frame body to give the best working
Choke
The Choke is the discharge point of the solid residual from the press. The
cake at this point is under the highest pressure and it is the driest. This is
therefore potentially a high wear zone of the press. The design should
provide for a simple and effective choke system that needs a minimum
of adjustment. It should be long enough to form a good cake; have cake
cutters that can be easily be changed; and stand up to the high pressures
and the hot, dirty and steamy environment.
4.2
4.2.1
The design offered must be field proven and manufactured using locally
available materials.
4.2.2
Capability
Requirements
Specification
under
conditions
Availability
Environmental Conditions
and
with
Temperature :
25C
Humidity
20 80 % without condensation
Dust
to IP 65 specification
Noise
85 dB(A)
4.2.2.3
Performance
Exact performance will depend on the type and quality of feed material
and the pretreatment used in the system . However, the press is expected
to achieve the following:
Throughput:
Oil in Cake:
Power requirements :
Energy:
4.2.3
The worm shaft with the bearings supported on the frame, is subjected
high torsional stresses. The design should allow the press to be used for
over 10 years.
4.2.4
Maintainability
Size
1500 mm
Frame width:
500 mm
: 200 kg
Cage dimensions:
bore- 100 mm
No of fields 3
Lining type-hard faced, landed bars
4.2.6
Product Cost
The final product has been projected to cost between K150,000 and
K400,000.
4.2.7
Quantity
Manufacture
Barrel bars, worm parts will be produced by sand casting method, or any
other cheap but suitable method. These will then be assembled. Shafts
will be produced by turning on the lathes.
4.2.9
Materials
Standards
Safety
Testing
The prototype will be tested for fatigue ,and torsional shear stresses.
Thereafter ,testing will be done for performance only.
CHAPTER 5:
CONCEPTUAL DESIGNS
Concept 1:
China Expeller
Concept 2:
Dong- Kwang
Concept 3:
Keller- P0015
Concept 4:
Sundhara- Presses
Concept 5:
Taeby-Press
Concept 6:
Tiny Tec-Expeller
TABLE 1:
CONCEPT
CRITERIA
EASE OF
OPERATION
EASE OF
MAINTENANCE
OVERALL
COST
SAFETY
PERFORMANCE
EASE OF
MANUFACTURE
NUMBER OF
PARTS
TOTAL NUMBER
OF `` +``
TOTAL NUMBER
OF`` S``
TOTAL NUMBER
OF ``-``
13
14
16
10
13
14
11
17
14
10
10
S = same as ,
E
9
+ = Better than,
= worse than
The following factors will influence the choice of expeller design type:
1.
Cost
The target user group of the press will be rural Malawians, most of these
live below the poverty line (i.e. earning less than USD 40 per annum).
The cost of the end product will therefore be kept as low as possible. The
design chosen will be one whose maintenance and operating cost are
relatively lower.
2.
Technical Aspects
Ergonomics
4.
Legal Aspects
CHAPTER 5:
DESIGN CALCULATIONS
NOMENCLATURE
Pitch (m)
R1
R2
Volume displacement
Production capacity
pg
r
r
Vs
Power
Worm efficiency
Torque
F
F
RB
BM
Diameter of shaft
SP
P
P
m
s
Motor power
Shaft power
5.2.1
= area x pitch
Vs
(d2 d2 s)
4
= 2.344 x 10-4 m3
m =V
i.e. P(
m ,V
, L,
,f
i,
fi
Drive Power =
Power
= 4.56 k W
x Lx
0.9
0 .9
5.2.4.1
Determination of efficiency
Adopting JIS on data for maximum and minimum efficiency as shown in appendix ---,
the minimum efficiency of 79 % is chosen.
5.2.4.2
Ps =
4.56
= 0.79 =
= 5.77 k W
The worm shaft will transmit 5.77 kW of power.
5.2.4.3
Motor Power
P P
m
(1+
5.2.4.4
n =
N (1
s)
The actual motor speed is given by where s is the slip factor. Using table 10.4 on
appendix., is determined as s = 6%. since we have
5.3.1
Screw Configuration
The screw will consist of 7 worm sections including reverse worm in the sixth position.
Table 2:
2
10.16
10.16
6.8
3
7.62
7.62
6.8
4
5.08
5.08
6.8
5
4.46
3.81
6.8
6
3.81
3.2
6.8
7
3.81
3.2
6.8
Configuration option 2
4
6.35
6.35
6.8
5
5.71
5.71
6.8
6
5.08
5.08
6.8
7
4.44
4.44
6.8
Table 3:
Number
Configuration - option 3
of
worm 1
sections
length of worm(cm)
Pitch of worm(cm)
Screw hub diameter(cm)
5.1
5.1.1
15.54
15.54
6.8
6.35
6.35
6.8
6.35
6.35
6.8
6.35
6.35
6.8
6.35
6.35
6.8
11.43
11.43
6.8
6.35
6.35
12.7
12.7
6.8
70
640 m3
m3 /min
640 x 60
Each worm displaces
70
m3 /min
640 x 60 x 40
= 4.56 x 10
m3/min
2L (R1 R2)
1.1
640 x 40
3.3
Apparent Density
Apparent density = weight of material passing across a worm
volumetric displacement of that worm
=
3.5
Angular velocity rv = n2
n1
= 40
1/6
240 rpm
n2
d2/2 = m N2
2
=
x 2
60
and vp = r2w2
40r
6 x 96
2
x 2 rad x 1 min
= 4.2 rad/s
min
1r
60s
= 288 x 4.2
= 1209.6 mm/s
w2
rv
and vp
4.2
288 mm
48 mm
= 25.2 rad/s
1/6
r1w1 =
48 x 25.2
= 1209.6 mm/s
PINION GEAR
PULLEY
PINION SHAFT
= 5
= 620N/mm2
= 0.4 x 620
= 248 N/mm2
= 148 N/mm2
( )2
2
(41.33)2 +
=
19.732
2
=
Speed of pinion = 240 rpm
Power transmitted
28.57 N/mm2
25.2 rad/s
= 5 KW
Therefore torque T = P/
= 198.4 Nm
5000
198400 Nmm
25.2
Pitch circle diameter of pinion
Therefore pitch circle radius
= 16 x 6 = 96 mm
=
48 mm
= 198400
r
4133.3 N
48
4133.3 tan 20
= ( 4133.32+ 1504.42)
1504.4 N
4398.6 N
198.4
Pulley radius
0.14
0.14
661.3 N
0.3
0.09
4398.6N
661.3N
RA
RB
For equilibrium , Fv
= 0, M =
RA + RB = 5059.9 N
Taking moments about A ,(positive clockwise)
(4398.6 x 0.14) + ( 661.3 x 0.37) 0.28 RB = 0
therefore RB = 3073.2 N
0.14
RA = 1986.7 N.
0.14
0.09
4398.6N
661.3N
1986.7
RA
3073.2
RB
1986.7
661.3
SHEAR FORCE
DIAGRAM
2411.9
59.5
0
BENDING MOMENT
DIAGRAM
- 59.5 Nm
Equivalent torque =
=
=
Te
J
( 278100)2 + (198400) 2
341617 N mm
= q
r
341617
d4/32
d
28.57
d/2
1/2 x 341617 x 32
28.57
39.34 mm
Y = 0.154 0.912
N
= 0.154 0.912
0.097
16
x module
=
Allowable stress
=
=
where
6 x 3.142 = 18.85
SF
= safety factor
SP
= speed factor
Kt
= 1/18.85
0.053
Kt
1.6
1.28
3300
allowable stress
620
5 x 1.28 x 1.6
60.55 N/mm2
Ft
YxCx
=
4133.3
0.097x18.85x60.55
37.34 mm
=
40 mm
2
=
=
3.7
x 6/2
=9.42 mm
10 mm
Drive design
= 6:1
= 1.2
9.6 KW
80.
at
100mm
+ diameter
of pulley
small pulley
Correction factor
700mm
0.95
Basic power per belt from power rating table 140 mm and 1440
rpm gave 5.73 KW
Speed ratio power increment
Corrected power per belt
Number of belts
= 1.21
Dsign power
6.59 KW
9.6/6.59 =
1.46
100 mm x 2 SPB
APPENDIX
(kW)
0.4
0.75
0.4
1.5
2.2
3.7
5.5
0.4
~ 0.25
7.5
11
15
0.25 ~ 0.15
18.5
22
30
37
45
Table __:
0.15
~ 0.10
Table ____: Data for percent slip of different types of electric motors
s (%)
2P
kW
4P
E
6P
E
0.2
9.5
10.0
10.0
10.5
0.4
8.0
8.5
8.5
9.0
9.5
10.0
0.75
7.0
7.5
7.5
8.0
8.0
8.5
1.5
6.5
7.0
7.0
7.5
7.5
8.0
2.2
6.0
6.5
6.5
7.0
6.5
7.0
3.7
5.5
6.0
6.0
6.5
6.0
6.5
5.5
5.5
6.0
5.5
6.0
5.5
6.0
7.5
5.5
6.0
5.5
6.0
5.5
6.0
11
5.0
5.5
5.5
6.0
5.5
6.0
15
5.0
5.5
5.0
5.5
5.5
(19)
5.0
5.0
5.0
22
4.5
5.0
5.0
30
4.5
5.0
5.0
37
4.5
5.0
5.0