APTD-1361
RESEARCH CORPORATION
BACKGROUND INFORMATION FOR ESTABLISHMENT OF
NATIONAL STANDARDS OF PERFORMANCE
FOR NEW SOURCES
' CASTOR BEAN PROCESSING
Contract No. CPA 70-165
Task Order No. 7
Walden Research Corporation
Cambridge, Massachusetts
Prepared for
; Division of Applied Technology
Office of Air Programs
Environmental Protection Agency
Research triangle Park, North Carolina
July 1972
_359 Allston Street OdDO Cambridge DDDD Massachusetts DDDD02139 DDDD617/868/39-JO
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Section
1
. 2
3'
4
5
TABLE OF CONTENTS
Title
INTRODUCTION
.. ............. ................ ...... .....
1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 . 2 To x i c; ty ............................... ~ . . . . . . . . .
1 . 3 Pro due t ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Availability of Information Sources "',.'..........
ECONOMIC AND stATISTICAL BACKGROUND ...................
2.1. General...................................'........
2.2 Production Facilities ............................
2.2.1 Seed Crushing and Oil Extraction Plants ...
2.2.2 Oil Refining Facilities ...................
. .2.2.3 Other Castor Product Facilities ...........
PRODUCTION METHODS AND PROCESSES .....................~
3.1 General..........................................
3.2 Seed Handling ....................................
3.2.1 Hydraulic Pressing ...................~....
3.2.2 Screw Pressing ............................
3.2.3 Solvent Extraction ........................
3.3 Castor Pomace Processing .........................
3.4 0;1 Refining ...............'......................
3.4. 1 Gene ra 1 ............."......................
3.4.2 Dehydrated Castor Oi1 .....................
3.4.3 Sulfated Castor Oil........:..............
3.4.4 Hydrogenated Castor Oil ...................
'3.4.5 Blown Castor Oil..........................
USES OF CASTOR PRODUCTS ...............................
4. 1 0; 1 ......................... ". . . . . . . . . . . . . . . . . . . . .
4.2 Castor Pomace
................................... .
INDUSTRY ENISSIONS ....................................
5.1 Particulates ........................".............
5.2 Emissions from Oil Refining ......................
. .
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Section
6
BEST CONTROL
TABLE OF CONTENTS (continued)
Title
................................ ..........
6.1 Technology.......................................
6.1.1
6.1.2
6.1.3
6.1.4
Dry Particulate Collector .................
~let Scrubbers...................-..........
Ads orpt; on .................... ~ . . . . . . . . . . .
Incinetation ..............................
. .
6.2 Typical Controlled Installations.........:........
REFERENCES
. . . . . . . . . . . . . eo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Page
26
26
26
26
27
27
30
31
.
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111
WALDEN RESEARCH CORPORATION
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1.
INTRODUCTION
1.1 GENERAL
,.
Castor oil is one of the more important vegetable oils being
used i ndustri ally, even though, in terms of volume,. it ranks low among
other oils (Table 1-1) [1]. The castor oil has many uni"que properties,
and is capable of undergoing several kinds ~f chemical transformations,
,
resulting in desirable derivative substances (dehydrated, sulfonated,
sulfated, hydrogenated, and blown castor oil). ' The following excerpt
. .
from a Baker Castor Oil Bull~tin [2] describes the special nature of
the oil. I .
Castor oil is obtained from the seeds of Ricinus Com-
munis, a plant that grows readily in most tropical and
sub~tropical areas. As the result of an extensive
agronomic research program undertaken by this company
in cooperation with the U.S. Department of Agriculture;'
the castor plant is now grown commercially in the
United States. Castor oil is a versatile chemical and
is used as the starting. material for a wide variety of
technical and commercial products. Its unusual chemi-
cal composition facilitates the conversion of castor
oil into numerous derivatives. '
/ I
Castor oil is a triglyceride (ester) of fatty acids.
Approximately 90% of this fatty acid content is
ricinoleic acid, an 18':-carbon acid having a double
bond in the 9-10 position and a hydroxyl group on
the 12th carbon. This combination of hydroxyl group
and unsaturation exists only in castor oil. The com-
position of castGr oil fatty acids, which is remark-
ably constant, is shown below:
Ricinoleic Acid (12-hydroxy oleic)
Dihydroxystearic Acid
Palmitic Acid
Stearic Acid
Oleic Acid
Linoleic Acid
Lino1enic,Acid
. Eicosanoic Acid
89.5%
0~7
1.0
1.0
3.0
4.2
0.3
0.3
The hydroxyl groups in castor oil account for a unique
combination of physical properties: relatively high
,viscosity and specific gravity; solubility in alcohols
. '
1
WALDEN RESEARCH CORPORATION
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TABLE 1-1
OILS, OILSEEDS AND FATS: ESTIMATED WORLD PRODUCTION ON OIL
EQUIVALENT BASIS, AVERAGES 1935-54, ANNUAL 1954~65 !I
COIIIIIOC!i ~ y
Edible Vegetable 0118 ~
. Corn \."11
Cotton80eG
Peanu t
Suybe..n
Suntlower Seed
RApe.eed
Se" ","e Seed
Sarnower.eed
Olive 011
t\>t.u.
~lm 0110 21
Coconut
P&lm Kernel
Pal..
Babac.u K.ernej,
t\>ti1l
N
Inductrlft1 011. ~
LI "",ed
Cfi5tor Dean
Olticica
Tung
Perilla
t\>tlLl
",&1 at.
Butter tat conteDt) II
w'd 6
Tallow and Orea.e.
Tct.u.
Kilrl 11. OU
WlIta.l
~
»
r-
o
f'1
Z
:::0
f'1
VI
f'1
»
::0
('")
:r
('")
o
::0
"U
o
::0
»
-i
o
:z
.
r.tlDVlted WorJd Total
Aver~#lI!.
: 1q3~-J9 :19'.,-49
: ?/ . V
I MH. KIlo
. Ib:" lb."""
.-
.
1
2.710
1 3,130
1 2.160
1 1,~50
1 2.660
1 1,430
1 -r-
I 1,950
1 15,190
I
.1
I
1
1
I
1
1
I'
1 2 2
1
1
1
,
I
1
I
1
1
1
1
1
I
1
I
I
I
1
. 44.560
4.'270
800
2.180
50
7.300
20
300
130
3.140
8.300
5.380
3.060
16.~0
1.090
60
960
2.UO
2.440
3;/60
3,060
1.660
2,330
, 1,410
1,834
16.464
3.240
6'/0
2.000
'(0
5.980
2200
',0
2
236
10
2.89<>
Y6,900
6.200
4.036
11.136
560
Uo
550
1.190
43,(,60
: 1950-)4
?j
MH.
lb.
3.660
3.550
4,110
1.930
2.090
1.490
2.160
18.9')0
4.170
840
2,5'/0
16
I
I 1958 I 1959 : 1960
Mil.
lb.
340
3,940
5,140
6.400
2.740
2.470
1,000
182
2.500
24.712
4.340
920
2,810
11.4
8.U14
2.200
30
300
10
3.036
8.260
1,640
6,500
22.400
8'/0
210
168
1.908
60.;:>110
1'.11.
lb.
380
4.400
5.200
7.330
3.780
2.530
1,210
208
2.410
27.428
4.070
910
2.8SO
106
7.936
2.250
2
282
12
3.026
8.180
8.160
6.930
23.270
834
260
950
2.044
63;104
Mil.
lb.
390
4.560
4,I;SO
7,030
3,150
2.560
1,170
258
2.600
26.9'.>8
4,480
880
2.910
132
8.402
2 150
272.
12'
3.068
8.500
8.000
6,dBo
23.380
836
:>44
1.022
2.102
63 , 92u
I
: 1961 1 1962
1'.11.
lb.
Mil.
lb.
Kil.
lb.
450
",860
5,040
8,040
4.370
2.590
1,170
312
2,950
29.782
8,750
8.170
7,290
24.210
11963
I
I
I 1964 :
1
!(i1.
lb.
480 "90
5.000 5.160
5,~:0 5.610
8.3')0 8,540
5.050 4,5SO
2.400 2.500
1,180 1,170
1;42 "56
2,070 3.730
30,432 32,206
4.650
810
2,730
150
8.340
".840
820
2, ,90
151<
8.594
1..870
830
2.800
160
8,660
910
160
1.0I10
2,110
54,OJO
840
200
892
1.932
54. '22
420
4.610
4,190
'7.320
3.980
2,640
1 ,05Q
2.~
28,064
4.790
880
2 820
'140
8,630
2 ;'10
o
3D
240
10
3.046
8.590
8.090
7.280
23,960
856
240
1.338
2.434
66.131.
2160
56
216
12
3.021.
12
200
10
3.182
s:.
246
8
),488
6.150 8.630
8,130 1.690
8.080 8,780
~4,9GO 25,300
1'.11-
~.
1~S
1/
1'.11.
~.
S30
5.350
6.100
9.OCoQ
5.140
3.150
1,160
390
2.150
33.510
4.650
820
2.610
170
8.650
2 '10
50
256
..
3.310
6,610
7.800
6,4SO
25,120
780
260
1.484
2.524
590 - -1.96- -- 1.10
298):'?0 290
1.364 1.578 1,690
2.252 2.396 2.390
67,830 1';9.4'20 12.C~
!/ Converted trOD data publi.hed by Forei"n Agricu1.tural Service in tbouaand Bhort ton..
Y rvr tbe everage. 1935- 39 and 1945-49. production re-ters to the yel\Z'. 1n vhich the .eed va. produced and not lIecessu11,y when the 011 va. extracted.
Betlnnins w1th 1950-54 average, production rerers to the yeare in which the predominGnt .hare oC the g~ven 011 or Cat. vas produced trom it. related
raw InAterlo1. .
J/ l'rellmlntLT)'.
~ E8timale. or U. S. oil production include actual. 011 produced plus the oil equival.ent or exported oil.eed.; e.t1mate8 for other countries are ba.ed
u~on the product10n ot var10u. 011.eed. time. the e.timated normal proportion cru.hed tor 011.
5/ E.U_ted on the bad. ot exports and information available on producUon and con.Ul:QUon 1n the varioU8 producing are...
~ nend~red lard only in mo.t countrie.. . .
'1/ 19311-)8 average. "
W 1~",,-49 average.
1'.040
-------
in any proportion; limited solubility in aliphatic'
petroleum solvents. The uniformity and reliability of
its physical properties are demonstrated by the long-
time use of castor oil as an absolute standard for vis-
cosity tests. Because of its highly polar'hydroxyl
groups, castor oil is compatible with, and will plas-
ticize, a wide variety of natural and synthetic resins,
polymers; elasto~ers and waxes. It has excellent emol-
lient and lubricating properties and a marked ability
to wet and disperse dyes, pigments and fillers. In
the form of its chemical derivatives, castor 011IS ap-
plication versatility is further enhanced.
The hydroxyl groups, double bonds and ester linkages
in castor oil provide reaction s1tes for the prepara-
tion of many useful derivatives. Chemical reactions
commercially used to create important castor oil
derivatives are as follows:
\
Acetylation
Alkoxylation.
Amination
Caustic Fusion
Chemical Dehydration
Epoxidation
Esteri fi cati on
Hydrogenation
Isocyanat~ Reactions
Oxidative Polymerization
Pyrolysis
Saponification
Sulfation
.r
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. .
Figure 1-1 [2] diagrams the molecular structure 'of'the castor oil and
.1ists some' of the chemical processes to which it may be subjected.
Castor pomace (~~al and flour) is a by-product of the oil ex-
, traction process. A pound of castor seed has an approximate yield of a
, .
half a pound of pomace and a half a pound of oil. !he pomace is gen-
erally used as a fertilizer, although its use as an animal feed has been
attempted with some degree of success.
1.2 TOXICITY
The castor pomace contains a toxic protein called ricin, a
~lightly toxic alkaloid called ricinine,and an allergen. Ricin can be
lethal but is easily detoxifi~d.
All commercially-available imported pomace must be
. [3]. The oil does not contain any toxic ingredients, which
mafn in the press cake~ '
detoxified
instead re-
3
WALDEN RESEARCH CORPORATION
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CASTOR OIL CHEMICAL REACTIONS OF CASTOR OIL
M.W. 928.5 I NArUR£" Jf REACTION ADDED REACTANTS TYPE Of PRODUCTS
I I I (II Hydr::>I,~i~ Acid. enzyme. or Twitchell Farty acids
-C-C-C- reagenT coToly~T Glycerol
----f-:--I---\---- (2) E s~ef'..'co!ion Monohydric olcohol~ E s Ter~
0 0 0 ESTER
/ I \ (31 AICChOlysis Glycerol, glycol~. ~~ono- ond diglycerides.
O=C C=O C=O LINKAGE penToery!hritol. eTO:. monoglycols. e'c.
--+----1-----+-- (41 5cPO.,ificat1on Alkalies Soluole soap.
-c- -c- -C- Alkolies plus metallic salts Insoluble soo~s
" I I - -
1 51 R~::Jction Na reducTion A Icohafs
-C- -C- -C- ----
I I I (6) A~;":]tlon Alkyl amines. Amine SOITS
-C- -C- -C- olkanolom.nes. etc. Amides
I r r (n ~c'':':Je''\;.'Ij'1 SOCLz Fa"y ocid hClo:;e.,s
-C- -C- -C-
I I r
-C- -C- -C- ~~I~.e ~llmerllOT1~n Hear. olr. o,y~en POlymerized OilS
I r I ~~Hyd'"03!:~~~ Hydroge~ (moCeroTe pressure) Hydro.ysteorctes
-C- -c- -C- (10) E~c:..dotion Hydrogen pero,ide Epolidized' Oils
I I !
-C- -C-. -c- 1111 Ha:c ~enr;:ion Clz.Erz.Iz Hologenoted oilS
'---+--.;....-1-----+-- (12) 'Ada;rion reOCTions S. mo!eic ocid POlymerize~. Oll~
HC HC HC DOUBLE 113) Sultor-otion Hz SO. SulfonoTed oils
II II II
HC HC HC BOND
--+----1----+-- 114) Oe"ydrCTion CaTalyst Iplu~ heat) Dehydrated ces.ar oil
-C- -C- -C- -
---:+----I-----t-- (tSI CausTic fUSion NaOH SeOacic acid
HYOPQXYL Co pry I alCohol
HC-OH HC-OH HC-OH GROUP
....--4--':'" -1- --- -+ - - 1161 Pyrclysis High hear Undecylenic Qcid
-c- -C- -C- Heplol~eh1ce
I ' I \171 Hafc!;terlQtion PCls. POCl3 HOloge.noted CCST"r oil
-c- -c- -C- (181 Alkc.ylotion E thy/ene and lor A:~o.yloted COSIO' o'is
I I I
-.C- -C- -C- pro~ylene o.ide~
I I I (19) ESTe,ification Acetic -. rooleic -. AI~yl COSTor 01/5
-C- -c- -C- phthalic onnydrides
I 1 I 120J Arr.i"otion C.'dalion pl~s NH, 12 ...::mino cleaTe
-c- -c- -c- .'--
I I I (2t I Su'~ct;on Hz SO'. S""c:ed castor 0;'
-C -. -C- -C--= .... $hqrf ',,",f s ~! .rke) reO oil I
, I ,- f~prl!S~nt H (221 l"t"e-"c"\e reC':..O~5 .ol'(ene cl;sOc~onoTe Fa .""e"'~
Fi gure 1-1.
Castor Oil
Structure and Derivatives.
4
WALDEN RESEARCH CORPORATION
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1. 3 PRODUCT ION
The castor oil extraction procedure is similar to that' used, for
most oj1seeds but the presence of harmful materials require that greater
care be taken in handling the seeds and in suppressing the dust [4J.
Domestic cultivation of the castor plant has ceased for the time being
at least. A combination of market prices, the end of the govern~~nt
support program, and the development of competitive products, virtually
elim~nated castor as. a domestic farm crop [5J; the 1971 planting was
about 4,000 acres -- with a yield about 2,000 tons of seed or perhaps a
20 day supply for an oil mill, which is completely uneconomical. In ad-
dition, major foreign growers, for reasons of balance of trade, have con-
verted their facilities so that they can also extract and, sell the oil,
in some cases prohibiting export of seed.
Figure 1-2 [6] illustrates the trend away from importing castor
seeds. The result of these two facts (no domestic crop and no seed im-'
ports) is the total absence of domestic seed crushing and oil extractio~~
In the summer of 1971 the last crushing operation stopped (the Plains
Coop Oil Mill, Plainview, Texas). This operation utilized the seeds
, from local farms (which was the last domestic crop).
Thus', the United States castor industry is now almost entirely
concerned with refining the imported oil into its derivative products,
and with distribution of the oil. In addition, there is a large research
effort designed to discover new markets for castor ~roducts because of
continuing inroads both by other natural oils and by synthetic materials.
1.4 AVAILABILITY OF INFOR~~TION SOURCES
Available information in the castor industry has been limited
to dated texts discussing the oil extraction processes, sketchy statis-
tical data frc~ the Bureau of the Census and the Department of Agricul-
ture, and private communication with industry sources.
, 5
WALDEN RESEARCH CORPORATION
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I
I'
I
';'
,u.s. IA1PORTS OF CASTORBEANS
AND CASTOR OIL
MIl. lB.
150
, 100
50
o
1948
'52
'60
'56
'64
U $ DEPARTMENT or AGRICUlTURE
'68
'72
N(G. ERS 18]] 67 1121 ECONOIolIC R£SURCH SERVICE
Figure 1-2
--'---..
6
WALDEN RESEARCH CORPORATION
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2.
ECONOMIC AND STATISTICAL BACKGROUND
2.1 GENERAL
~s indicated in the previous section, the domestic castor prod-
ucts industry is now almost exclusively concerned with distributing oil
and with o~taining oil derivatives. There is also a trade in castor
pomace which is of secondary importance. Brazil supplies the bulk of
our.castor oil imports with Japan supplying virtually, the remainder.
(In 1967 78% of our imp~rts were Brazilian and 21% Japanese [6].)
The domestic consumption of castor products by use is shown in
Figure 2-1. The industry breakdown shown in this figure is not precise
and the only reliable number if the total consumption figure, although
the industry breakdown does give some indication of the relative impor-
tanceof the various users. The reasons for the lack of accuracy are
. due in part'to the relatively small ,consumption of castor products, and
in part to the Census Bureau's attempt to avoid disclosing figures of
. ,
individual companies. The large number of end products and usesshown'~
in Table 4-2 help explain the size of the "OTHER" category as the third
largest consumption.
The oil and fat products market situation has required the cas-
tor products industry to invest extensively in research endeavors in an
attempt to find new uses for castor derivatives. The competition has
been such that a great many of the castor product~ customers of twenty
,years ago have nO\'I found suitable substitute products. The research ef-
fort has, therefore, been of.vital importance in maintaining a constant
level of sales [7]. '
The United States Government has had a castor seed
port policy at various times in the past. Future prospects
tive price support programs iri the industry appear dim.
price-sup-
for effec-
. 7
WALDEN RESEARCH CORPORATION
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2.2 PRODUCTION FACILITIES
2.2.1
, I
Seed Crushing and Oil Extraction Plants
, I
W~th the crushing of the final domestic castor seed crop
at the Plains Coop facility, the last of these operations has corne to an
end. Interestingly, Mr. D. L. Van Horn, former agriculture consultant to
the Plains Coop, states that the 4000-acre 1970 castor crop was purchased
by the McNair Feed Company, which is arranging for its resale and export.
,Apparently, even the availability of this,seed quantity is not sufficient
to justify continued domestic crushing [8].
The only other operation known to be of recent vintage is
that of the Pacific Vegetable Oil Co., located in Richmond, California.
, It is understood that'this has not been in operation for some four to
,five years [9]. '
J
2.2.2 Oil Refining Facilities
-
Using the 1970 Paint Red Book [10] 'and the Chemical Mate-
rials Index [11], a list of companies handling castor products was made.
These, companies were contacted to determine the nature of the castor
products they deal with. Table 2-1 is a list of companies contacted.
Baker Chemical Company is the largest castor oil refiner
in the country, with Spencer-Kellogg second. Over half of the domestic
castor products are supplied by these two firms.
2.2.3 Other Castor Product Facilities
All domestic castor oil and pomace originates from
'foreign sources (excluding Government stocks and material still remain-
ing from very recent American crops). The distribution of the castor
imports is accomplished by brokers or by large processors. ror example,
Brett Corporation (Table 2-1) is an import broker representing one
Brazilian grower. Brett is concerned only with resale of the product.
. ,
.On the other hand, Baker Castor Oil Company is concerned principally
8
, WALDEN RESEARCH CORPORATION
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Figure 2-1. United States Consumption of Castor Oil.
170
Source:
Fats and Oils Situation, U.S.
Dept. of Agriculture; FOS-241,
January 1968; FOS-250, November
1969. .
. 180
Total
160
150
140
. 130-
OTHER
120
...J
-
e 110
0::
e
t-
V)
«5 100
LL
e
Fatty Acids
V) 90-
a
z
::J
e
D-
.80
LL
e
V)
:z:
8 70 .
...J
...J .
.....
:!:: 60-
ILubri cants and
rnar Oil~
50
40
30
Paint and Varnish
10
!
20
o.
1947
Other Drying Oils
50
52
54
56
58
60
YEAR
62
.64
66
68
70
72
.9
-------
TABLE 2-1
CONTACT LIST
Company
Address
Telephone
Contact
Type of Castor Products
Operation
Ashland Chemical Co.
Baker Castbr Oil Co.
Brazl1ian. Industrial
Oi 1 s .
Bret~ Corporation
(Div. Hollingshurst)
Cadwell and Jones
-
I 0
Capita 1 City
Products
Cu1bro Tobacco Co.
~
,.
r-
o
f1"I
2
;0
f1"I
(f)
f1"I
,.
;0
(")
::r
(")
o
;0
"
o
;0
,.
-1
o
Z
Degen Oil & Chern.
Co.
Drew Chemical Corp.
(Div. Pj]cific
Vegetab 1 e Oil)
Emery Industries,
Inc.
.GAF Corporation
Harchem (see Union
Camp Corporation)
Hercu1 es, .Inc.
Englewood Cliffs,
N.J.
Bayonne, N.J.
Ne\'I . York, N.-V.
New York, 'N.V.
E. Hartford~
Conn.
Columbus, Ohio
E. Hartford,
Conn.
. Jersey City, N.J.
Boonton, N.J.
Li nden, N. J .
Kalamazoo, Mich.
201-568-3023
201-436-8800
. NA
212-867-1035
Mr. J. Paraskevas
Mr. Squi res
203-289-9555. Mr. Gordon
.614-299-3131
203-243-2561
201-432-1192
201-887-9300
212-582-7600
616-343-6161
Mr. R...Milliken
Fa rm Manager
Mr.. Pollock
Mr. Retkua
Bu1 k Oil r~gr.
Mr. F. Krupin
Product Mgr.
Mr. J. B. Moniz
r1anager
Distributor. only
Largest cast~r oil refiner
Out of business, was broker only.
Import and distribute only
Mix castor pomace in fertilizer
No longer handle castor products
Use castor fertilizer
Esterification (~ 400 F)
Import only
No longer handle castor products
Sulfation; epoxidation (~ 80-90 C)
Produce sulfonated oil
-------
Company
Humko Products,
Chemi ca 1 Di v.
Kerr rlcGee
Meyer & Mendelsohn
....
....
Old Fox Agricultural
Sales
Pacific Vegetable
Oil Corp.
Plains Coop Oil Mill
Polyester Corp.
Sherwin W~lliams
Chem., Di v. Sherwi n
Will i ams" Co.
Spencer Kellogg Div.
"Tex"tron Inc.
~
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Union Camp Corp.
Woburn Chemical
Corp.
Address
Clifton, N.J.
W. Springfield,
Mass.
Windsor, Conn.
Hazardvi11e,
Conn.
Los Angeles~
Ca 1 if.
P1ainv1ew, Texas
Southampton, N.Y~
Buffalo, N.Y.
(Hdqtrs)
Edgewater, N.J.
(Plant)
Dover, Ohio
Kearney, N.J.
TABLE 2-1 (continued)
Telephone
901-682-9111
413-739-4737
203-688-2734
203-749-8339
213-264-3904
806-293-2604
516-283-4400
716-852-5850
216-343-77.01
201-991-3300
Contact
Mr. A. Cereghino
Vice President
Mr. Cook
Mr. Thomas
Farm ~1anager
Mr. W. Wi 11 i ams
Sales Manager
r~r. S. Ros s
Mr. D. Van Horn
(with McNair Feed)
Mr. J. Craker
r~r. R. Hussong
Prod. Super.
Mr. V. Bedrosian
Plant Manager
Mr. D. Fritz
General Manager
Type of Castor Products
Operation
Produce fatty acids
Mix castor pomace in fertilizer
Use castor fertilizer
Mix casto'r pomace in fertilizer
Produce small amounts of blown 011
and distribute crude oil
World's only modern castor bean
mill, now phased out.
Distribute only
No longer handle castor products
Second largest castor oil refiner
"
Large~t U.S. user of castor
products
Blend only, stopped making de-
hydrated oil in July 1971.
-------
with refining a large portion of the imported oil which'is sold as in-
dustrial products or various intermediates.
",
J
-
. ,12
WALDEN RESEARCH CORPORATION
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3.
PRODUCTION METHODS AND PROCESSES
-----~- -
3.1
GENERAL
/ '
Most of the 'world's castor crop is hand-picked, although machine
picking has be~n used domestically for a nUffiJer of years. A large capi-
tal investment in equipment, plus the need for'using a hybrid castor
plant, have hindered the mechanization process abroad. Screw pressing
is the most conmon oil extraction method in use. The continuous nature
of its operation gives ~t a sizable advant~ge over hydraulic ~ressing.
Solvent extraction is commonly used in conjunction with mechanical press-
ing to complete the oil remDva1 process. The extracted oil is then proc-
I
essed to suit the product requirements, while the castor pomace, a by-
product of the oil extraction procedure, is also prepared for marketing.
Figures 3-1 and 3-2 are flow diagrams showing typical pre-pressing and
solvent extraction.
.r
The following sections describe the basic production procedures;
Much of this information was obtained from data of the Plains Coop Oil"
Mill in Plainview, Texas [~], which is apparently the only modern castor
processing mill in the, world. This mill is in the process of shutting
'down its castor operation for lack of seed as indicated above.
I '
~
\
3.2 SEED HANDLING
The historical trend in the castor industry has been to locate
, the crushing mills in th~ castor growing areas which explains the siting
of the P1ainview mill. The s~eds are transported directly to the mill
from the local farms while seed producers in other areas utilize re-
, , ,
ceiving stations set up to facilitate rail or truck deliveries to the
mill. \'
At the mill, the seeds are deposited into the seed house by a
bucket, conveyor from the truck life or boxcar. Screw conveyors are not
recommended for storage to avoid cracking or squeezing the seeds. The
conveying systems throughout the plant require weekly cleaning to re-
move oil buildup. The seeds begin the extraction process by flowing
13 .
WALDEN RESEARCH CORPORATION
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I.~.~ ~
IUD
---.
-...
..
,/
.. I
t
..
14.
.r
t
L IUD CLtANU
. "'tATS r.UVATOR
&. I'Rt.I'RtSSU
I. FOOTS UTTLINO TANK
10 SETTLED OIL I'VIoAP
IL 'ILTER PRtU .
tl. 'ILURtD OIL TANKS
11 'ILUlltD OIL P\l1oA1'
... CAK[ [LtVATOR
I
~t~tO_o.L'
Figure
\
3-1. .
Pre-Pressing.
I
I
14
. 'WAlDEN RESEARCH CORPORATION
-------
I
, .
,
....
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M-
t,~eal H~r.~nn9
M- r louvered Meal
Coo!cr
M-2 Meal Grinder
M.3 tAceJf Screen
~-_.
~" ..~-
. ~
~.
Eo: I Raw Flake Elevator
E-2 Extractor Feed Conveyor
E-3 Stationary Basket Extractor
E-4 Spent Flake Elevator
E-5 Dcsolvcntizer- Toaster
E-6 Vapor Scrubber
E-7 I st Stage Evaporator
E-8 I st St~ge Condenser
E-9 2nd Stage Evaporator
E-IO 2nd Stage Cond~nser
E-li Final Oil Stripper
E-l2 Vacuum Condenser
Figure 3-2.
Solvent Extraction.
-------
over a shaker cleaner and through a conditioner, raising the temperature
to 210°F, at which point they enter the screw press [12].
. .
3.2.1
Hydraulic Pressing
The hydraulic press, although considered obsolete,' does
produce a very pure, clear castor oil. The United States produced and
used most of the hydraulic presses, and those in use abroad today are
generally second-hard U.S. machines. Because it is a. batch process,
hydraulic pressing entails.a higher labor cost than do the alternative
.methods of oil extraction. . In addition, this method is less efficient
.
in terms of oil recovery. The purer product is possib1e~ however, with
the hydraulic press because the seed undergoes less severe conditions of
. temperature and pressure [4].
Typically, the \"Ihole, cleaned seed is heated to 60-70°C
. and. then pressed. The press cake (pomace) is then removed fro.m the press.
'About two-thirds of the oil is removed in this operation. The remaining
oil is usually removed by solvent extraction (which will be discussed be-
low). The oil removed in this first step is called IINo. 1 oil II and is a
very clear, pure oil suitable for medicinal as well as industrial uses,
whereas the oil removed in subsequent steps, IINo. 3 oil, II is a less pure,
. cloudy extraction suitable for industrial use only.
3.2.2
Screw Pressina
~
The majority of castor seeds (as well as most other oi1-
,seeds) are crushed in screw presses. The screw press allows for con-
tinuous operation and minimum labor requirements, however, the seeds
undergo more severe conditions during the pressing opE;!ration, resulting
in an oil containing more impurities than result from hydraulic press-
i ng [4,13].
The extraction may be accomplished in a .sing1e pressing
(removing up to 92 percent of the oil), or a portion of the oil may be
extracted in a first pressing, with the remainder being obtained by
either a second pressing Qr solvent extraction [4].
16
WALDEN RESEARCH CORPORATION
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At the Plains Coop Oil Mill, the seeds are pressed to
lower the oil content to 12 to 15 percent, after which a solvent e~~
tractor is employed. The oil obtained contains many protein foots'
which-are removed by 'settling and centrifuging before bleaching. The
bleaching earth and foots from the settling and centrifuging are dis-
charged into the pre-press cake, all of which goes to the solvent
plant [12].
3.2.3 Solvent Extraction'
, Solvent extraction is employed to remove the oil that
remains in the pre-press cake. By bringing crushed or ground castor
, .
seeds into intimate contact with a hot petroleum solvent, (such as
hexane or heptane), virtually all of the oil remaining in the seed can
be removed. ' For example, a pre-press cake containing 15 percent oil
will' contain only 1 percent after several hours of exposure to ~he hot.
solvent [4,13].
The Plains Coop uses a stationary basket extractor
(French Oil Mill Machinery Co.), with hexane solvent. It is claimed by
the mill that, using good undamaged seeds, the extracted oil from both
, ,
,the pre-press and the solvent extractor meet No.1 castor oil standards
[12].
3.3 CASTOR POr~CE PROCESSING
A'by-product of the 0;1 extraction procedures is castor pomace,
also called ca~tor meal, equal in weight to about half that of the beans
fed to the process. This is ground, dried', and stored in paper bags be-
fore shipment.
All of the harmful components of the castor seed 'are contained
in this pomace. However, detoxification of the poisonous ricin is quite
sJmple. Following extraction, moisture is added to the level of 15% by
weight and the material held at about 200 F for three to four hours. In
, addition, the a11ergen'potency may be simultaneously decreased as much
'17
WALDEN RESEARCH CORPORATION
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as a hundred-fold, but this may be no aid to sensitive individuals [7].
I
The allergen is similar to that contained in many common grains and seeds.
I
\
,3.4 OIL REFINING
3.4.1
General
Because all castor oil is now imported, it would be very
difficult to determine the production methods employed for U.S. ra~1 mate-
rial. An educated guess, is that 10-15% is obtained by hydraulic pressing.
, ,
, Of the balance, most is screw-press oil and the balance from solvent ex-
, traction.
The extracted oil can be used as is or altered to meet
the differing'requirements of a variety of industries. Some of the unique
'and complex castor compounds that have been developed over the years are
shown in Figure 1,-1. Only those most commonly used are discussed here.
3.4.2 Dehydrated Castor Oil [14,15]
....
Dehydration is accomplished by heating castor oil in the
presence oT a suitable catalyst. The hydroxyl group combines with a hy-
I
, drogen atom from an adjacent group to form water, thereby reducing a
, ,
second ~ouble bond. Upon heating the castor' oil to l80-230°C, anyone
, of the following catalysts may be used: sulfuric acid, sodium sulfate,
phosphoric acid, specially prepared tungstic acid, and phthalic anhydride.
The result is an oil having marked drying powers, making it one of the
few suitable substitutes for tung oil. The chemical reaction is given
below.
CH3(CIl2)~CI! (OU )CH2GI:CH iCII~);COOI! -
, L.;lIOleic .0.1
"20 + OI3(CH2)4CH:CHCHzCH:CH(CHzJrCOOH
9.12.1,;001.", ..,iJ. ~~o
+ CH3(CH~)~CH:CHCH:CH(CII2hCOOH
9.1l.Linul.ic .'-;11. li-2o'1.
18
WALDEN RESEARCH CORPORATION
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Some of the trade names for dehydrated castor oil include:
. I
castung, collanole, isoline, P.G.D.. oil ~ synthenol, and synouryn.
3.4.3 Sulfated Castor Oil [13,14]'
\
\
This product, also termed turkey red oil, requires both
skill and experience to produce. Simply stated, reaction with sulfuric
acid produces sulfation of the hydroxyl group, as well as secondary re-
.actions. The .actual reactions are very complex.
3.4.4 Hydrogenated Castor Oil [~3]
By mixing castor 0;1 with hydrogen under moderate p~es-
sure it becomes hydrogenated, resulting in a very hard fat with a melt-
. ing po'int of 86°C. "Opalwax";~ the trade name .for'a commercial brand
. of hydrogenated castor oil.
,r
3.4.5 Blown Castor Oil [13,15J
The terms "bodied," "blown," poJym~rized," and "oxi-
dized" are used .interchangeably to describe castor oil that has been
. brought into intimate contact with air or oxygen at a temperature
I .
ranging from 80 to 130°C. The blown oil .has a higher viscosity, spe- .
cific .gravity, and saponification value. The oil may be blm'/n in open
. vats or in closed vats' with vents. At elevated temperature this proc-
e~s produces a dense white smoke or fume. This emission is extremely
irritating to the lungs and easily causes choking and coughing [16].
19
WALDEN RESEARCH CORPORATION
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4.
USES OF CASTOR PRODUCTS
---
4.1 OIL
/ "
The wide variety of castor oil uses can best be illustrated by
the list of applications given in Table 4-1 [2]. Table 4-2 shows the
applications of the more common oil derivatives~
Hydraulically-pressed oil is used principally for medicinal and
cosmetic products (usually after de-odorization). Some is also employed
for special hydraulic and lubricant purposes.
",
4.2 CASTOR POI-1ACE
The major worldwide use for castor pomace is as fertilizer. The
" Florida citrus growers and Connecticut Valley tobacco farmers are the
major domestic users. In the tase of tobacco farmers, use appears at
" least partly to be based upon tradition [17]. The high cost of' castor
pomace plus the need to import future supplies, may cause a rapid decline
..,..
in its use as a fertilizer. I I
I "
An alternative. us~ of castor pomace ~s as a cattle feed. The
~el1-known toxic character~stic~;of the castor seed has inhibited ranchers"
I" .
from using the pomace even tho~gh research has shown it to be safe and ef-
fective if it has been detoxif{ed [12]. Casto~ pomace is never us~d as a
,
waste fuel domestically. The table below sho"\oJs approximate end-use values
. of pomace [18]. \ .
,
Market Value $/Ton
Use
Feed
Fertilizer
Waste Fuel
50
\ 12-25
3-4
20
WALDEN RESEARCH CORPORATION
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TABLE 4-1.
Acid Neutralizer (Scavenging)
Adhesives. .. ..
Alcoholysis Catalyst .....'.' '.':::
Alkyds.............~- -
Aluminum
Foil Contings .. """""'"
Paint Vehicles. . ..........
. Siding finish. . ...,.
Amino Resin Modification
. Anti. ...
Blocking ..,... """""""""'"
Bronzing ..., .. .. ''''''''''''''''
Corrosion lubricants .. ....,....
Curtaining .......... ........,.......
Feathering. .,...... """"""""
Floating .......... """"'" ...........
Flooding. ,"""""""'"''''''''''
Foam .. .......... ..."..........:.....
Friction, Polypropylene.
Misting ..... .. ................
Rusting lubricants ...................
Static .... ..................................
Sticking, Resin Emulsions ..........
Streaking .... ...... ...... .............,.......
Syneresis .""'''' ...................
Tack, Butyl Rubber ......................
Trailing.. .. .............................
Wear lubricants
Applian~e Finishes ':"":::::..::::::::::::.
Architectural House Paints ...............
Asphalt Compounds.... ......
Athlete's Foot, powder/ointment... ..
Automotive Polish/Cleaner, emulsion
'Bactericide ..:. ................................
Belt Dressing. . ....... .....................
Binders
Aggregate. . ...... .............
t!relhane . ..... ....................
Brake Fluids... .... ...............
Calendering Aids.......... ..... ..
Calks. ... ...
..............,.............
Can Coatings......................
Candles .............................
Capacitors, Impregnants for
Carbon Paper .......... ....
Catalyst: alkyds, polyesters
Ceramic Slurries. .. ..
Chemical' Intermediates ...
Cleaning Compounds
Clothing Interliner, Foam ...
Co~ti~~~ ..
Color Chip Dispersions ..
Color Dispersions
Consistency MOdification
Copolymers
Corrosion Inhibitors
Cosmetics
Coupling Agents
Crayons. ....
Cutting Oils. .. ......
Defoamers . ........
Dielectric 'Compounds
Dispersants:
Dye, Color, Pigment
Dry Cleaning Compounds
.' Duplicating Stencils' .
Dye 'Carrier.
Elastomers, urethane
Emollient
... "'''' """""
Emulsifiers ..
Emulsion Additives
Enamels.
. Encapsulants
.. " .
APPLICATIO~S LisT FOR CASTOR PRODUCTS
Epoxy Esters. .
Epoxy Modifiers ....". .........
Exempt Solvents
Exterior latex Pai~ts :. ... ....
Extrusion Aids ............ .. ........
Factice
.Filter Foam'~' :........... . ............
/ Flavor Intermediates'::'" ........:...
Flexible lacquers. ... ...... ......
Flexible Foams
Floccin.;: Adhesive' ....... ..... ........
Flooding, Flo'ating and Bronzi~g"
Floor Coverings. .
Flushing Vehicle, Inks.
Foams (rubber; urethane)
Food .
Color, solvent. ...
. ::'a~~~i;i~~ lUb.ri.c~~t.(~~~~"'::::1
Functional Fluids .........
Fungicide.. .. ...':'..""''''''''''''''
Furni.ure Polish/Clea~~'~, E~~i~i~~'
Gasket Compounds I
Germicides '."""""''''
Glazes ........' .................
............ .
Grease ........ ....
Greaseproofing ::::::.
Hair Preparations.
Hot Melts. ""
Hydraulic Fluids :...::.....
Impregnants, Urethane
Injection Molding Aids
Inks
Insecticide.. .....:......
Internal lubricants:
Plastic: ruhber
In\.~~tment Cilsting ..:....
Isocyanate Reactants...
lacquers ..'.......................
laminants. .'. ..... . ..........
latex Paint Additives.
leathcr Coatings. .' .
lc\'cling and Brushability
lipsticks; .. ...... .....
lithium (Calcium) Greases
low Temperature Plasticizers
lubricants .
Mastics
Meat Packagi~g j:il~""""""
Mold Release Agents
Motor Fuel, additive for.
"Nerve" Reducer, Rubber
Oiliness Agents ...............
Ointments ............ .......
Packings, mechanical...
Paints .'
Paper C03ti~g~":."::"""
Penetration Control....
Perfume 1.,termeGiates
Pesticides.
Pharmaceutic~I~'"'''''' .
Phenol Coefficient Syn~rgizer
Phenolic Resins.
Pigment Dispersion .":'.'.. .
Pigmcnt Suspension.
'Plasticization
Plastics, 'Reinforced.
Plastlsols .
P~ug Valve Grease ...
Polishes ... . .. .
21
PolyamIde Plastics ................
Polyesters. . ...... ..............
Post Additive, flow control..... . ......
Potting Compounds. .. .. .. . . .
Primer: Ethylene/Propylene Rubber
Processing Aids
Putties
PVC (Rigid) Proce~~i'~'g"':::::
Resins ........... ..
Rubber ........' .:""""""""
Rubber Accelerator"":::::":::::'
Rubber Cement and Solutions'.
Rubber Compounding ... ......
Rubber Preservatives
Rust-Proof Ag~nt .....:'::.:::'"
Sag and Slump Control.. ..
Sealant.. .. ...
...,.. ......
Shampoos. . .....................
. Sl10ck Absorber Fluid
S~ock Absorbing Elast~m~~~,"F'o~~~'
Slip Agent (Varnishes, lacquers) ...
Soaps .. .
Solubilizers
Sonar Fluid
Stabilizers
Stains.
Strippable Coating~' :::::::::::.: ::::.:
Sulfonation.. .: .... ... ............
Tack Rags ...... ...........................:
Tackifiers
Textiles ..:":" ..: ..............~.~.......
Thixotropes (Rheol~gic~i Ag~'~'t~)'
Traffic Paints..
Troweling Compositio~~":" . .. ..
Transducer Fluid .........:...::.::.:::
Universal Colorants
Urethane Adhesives'" ...............
Urethane Binders ::.':"'"'''.'''
Urethane Cast and Molded G~~'
Urethane Coatinas .
Urethane Elasto~ers'" .................
Urethane Floccing Adhesi~~s' ....
Urethane Foams .. ...
Urethane Impregna~t~ ...... .......
Urethane Potting Compounds. .
Urethane Sealants ... "'"
Varnishes.
Vehicle Ink.
Vinyl Compounding""':'.' .
Vinyl Resins, Stabilizers.
Vinyl-Urethane Coating ..
Viscosity Control... ....
Water-Proofing... .......
Wax Blends.
Wax Polishes -. ... """"'"
Wax Substitutes .
Wetting Agent :.. . :". :
Wire Drawing Compounds
WIre Enamels
Wood Fillers
Yarn Dre6Slngs
,.....................
.. ..,.,............,.
. ...... ".,........,.
. . .. ...., .,.,.".,..
"""'"''''
WALDEN RESEARCH CORPORATioN
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TABLE 4-2
---- -
APPLICATIONS OF SPECIAL'CASTOR OIL DERIVATIVES
".
Type of Product
I Applications
Blown Castor Oil (polymerized oils)
/
Adhesives'
F1 oor coveri ngs
lacquers
lubricants
I .
"Nerve" reducer, rubber
Pigment dispersion
Plasticization
~esins .
yiscosity Control
. A1 kyds
Adhesives
Cosmetics
Hydraulic Fluids
Inks, .
Isocyanate reactants,
laminants
lubricants
Mold release agents
Rubber preservatives
Refined Castor Oil
Dehydrated Castor Oil
"/
(drying oils)
/1
{
\
\
I
Alkyds
Calks
Copolymers
Enamels
, Oil-based paints
Putties
Resins
Varnishes
Traffic paints
Ink vehicles
Wi, re ename 1 s
Aluminum siding finish
Aluminum paint vehicles
Pnenolic resins
,
Fatty Acids
Bacteri ci de
Copolymers
Corrosion innibitors
Cosmetics
Cutting oils
Epoxy esters
Flavor intermediates
Foam rubber
22
. '
WALDEN RESEARCH CORPORATION
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"
Type of Product
Fatty Acids (continued)
TABLE 4-2 (continued)
Hydrogenated Oil (hydroxy waxes)
. .
I
,\ Applications
F .\ .d
unglcl es
Germicides
Grease
Inks
Perfume intermediates
Pharmaceuticals
Polishes
Polyamide plastics
Resins '
Soaps .
Wax blends
Candles
Cosmetics
Crayons
Food packaging
Grease
Hot melts
Impregnants
Inks
Investment casting
Mold. release agents
Paper coatings.
Pharmaceuticals
Polishes
Potting compounds
Sealants
Slip agent
\,Iax blends
23
WALDEN RESEARCH CORPORATION
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5.
INDUSTRY EMISSIONS
5.1
PARTICULATES
The emission of particulates may occur during the handling of
the seed befor~ processing, ar.d in the handling and use of the c~stor
pomace after processing. Particulate emission rates have never been
quantified and the lack of domestic cultivation and crushing makes such
future testing unlikely. As an alternative, a study of emissions from
'. '
similar oilseed~ may yield a valid approximation.
The particulates emitted contain some of the toxi'c components
of the castor seed, especially the emissions that occur before process-
, ,
in9, since, at this stage, the ricin cannot yet be detoxified. Also, as
has been well documented [19], h~ndling the castor seed can result in
'allergenic reactions due to the dust; this can occur during harvesting,
'transportation, conveying, etc. .r
It has been related to us that wh~n the Plainview Coop was be-.
ing established, it was deliberately located downwind and somewhat remote
from the nearby town. During their period of operations, the only com-
plaints due to allergenic dust came (occasionally) from the single home
nearest to the plant.
5.2 EMISSIONS FROM OIL REFINING
In most respects, the emissions from castor oil refining proc-
esses are similar tq those encountered in the processing of other veg-
etable oils. Unlike the particulate emissions, the oil emissions are
non-toxic, increasing the s'imilarity with other vegetable oi'ls.
Baker, Pacific and Spencer Kellogg all "blowll ca~tor oil and in-
cinerate the off-gases, the first two in afterburners, the last in their
boiler. Spencer Kellogg also carries out dehydration (at approximately
500 F), scrubbing the exhaust gases. Degen makes alkyd resins by ester-
ification but by employing reflux operations with a solvent, claims to
. ,
have no atmospheric emissions.
. .
24
WALDEN RESEARCH CORPORATION
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Table 2-1 indicates that the above discussion i~cludes most of
the high-temperature processing of the castor oil itself.
/
. .
.r
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'25
WALDEN RESEARCH CORPORATION
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6.
BEST CONTROL
---- -
6.1
TECHNOLOGY
,.
6.1.1
Dry Particulate Collector
.
The collection of particulate emissions can be accom-
plished through the use of a fabric filter (or baghouse)'. This would be
feasible wherever the emission source was suffi~iently localized to per-
mit hooding. For exampl~, hooding \'JOuld be ,necessary at the s~ed unload- .
ing areas, and at the shaker cleaner locations. The castor pomace bagging
facilities would also need trooding. All such sources could be ducted to
I
a central .processing plant where a fan would provide motive power. Shut-
off devices (butterfly valves) would allow selective application of the
air cleaning equipment. Design should provide for velocities of approxi-
mately 150 fpm through the hood opening to be effective in preventing es-
cape of dust. Fabric selection can be tailored over a broad range ac-
cording to process requirements and collection efficiency of 99.9% or
greater can be achieved. /
/ .
6.1.2 Wet Scrubbers
-
I .
,I .
A major drawbatk with the em~loyment of wet scrubbers on
dust col1ection'is the introdu4tion of a water pollution problem. .
,
I
For treatment of hydrocarbon and odors, research findings
. [20] stated "performance ..'. li~ited to removal of fumes condensed by or
dissolved in the wash water ..~ operating with water as. the washing agent
does not and cannot remove those gases \'/hi ch are 'major odor producers."
, .
Nothing in more recent work, in this or any other field of odorous gases
\
indicated a different conclusio~ -~ whether on low pressure scrubber de-
vices, packed towers or high pressure venturi scrubbers..
Supplementing the performance of the wet scrubbers by
means of additives is a very distinct possibility and has been employed
successfully in some fields -- rendering plants, for example. The addi-
tive is any of several possible oxidizing agents such as potassium per-
manganate, or calcium or sodium hypochlorite, or others.
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WALDEN RESEARCH CORPORATION
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One of the potential problems here is th~t this scheme
has been known to be effective in overcoming known emissions odors but at
the same time has been responsible for the generation of new and equally
potent malodors. It.is a.system that must be piloted carefully before
applying to a full-scale commercial operation.
6.1.3 Adsorption
Installation of equipment for adsorption of odors on ac~
tivated carbon is a process that is successfully employed on solvent
vapors (such as dry cleaning plants) and similar operations. Although a
possible control method for organic emissions from oil processing, it is
very unlikely that it is being applied commercially.
6. 1..4
Incineration
Incineration of organic gases has generally been accepted
as the one certain method for elimination of organic compounds and their
as~ociated odors. During prop~r'incineration all carbon and'hydrogen .-
oxides become harmless, non-regulated carbon dioxide and water vapor.
Thus, organics and/or hydrocarbons are, by definition, non-existent and
odor is no longer possible. Resulting water vapor, even if visible, is
specifically.exempt under even the most stringent regulations. Three
schemes for incineration are possible and are outlined below.
6.1.4.1 Catalytic oxidation. The.offending gases and
vapors are collected and blown to the equipment wherein they are heated,
by combustion of fuel, to the. range of 600-800°F. They are then passed
through a catalyst bed which {s usually an. inexpensive base material
coated with a precious metal. The catalyst causes a f~rther temperature
rise due to oxidation of the hydrocarbons. The disadvantages of cataly-
tic units are: (1) they are more expensive from a capital investment
standpoint than other incineration equipment, (2) it is possible that
contaminants in the gases can "poison" the c;atalyst, rendering it inef-
fective and requiring its replacement, and (3) it has occasionally been
. observed that catalytic uni.ts, while destroying most of the contaminants,
generate new' compounds which have their own obnoxious odor characteristics.
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WALDEN RESEARCH CORPORATION
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--j
OXIDIZED GAS OUTLET
\ ,?""'PREHEA T:
BURNER
BLOWE:\ /),
i .~ >',0'.'
'"
/
. CATALYST
ELEMENTS
.f
Catalytic afterburner. (Courtesy
Catalytic Combustion Corporation)
-
6.1.4.2 Thermal incineration requires that'the same oxi-
dation process as above proceeds in the presence of higher temperature
generated by fuels or the combustible cont~nt of gas itself. The general
requirements are that the temperature be in the range of l200-1400°F and
the residence time petween 1/4 and 1/2 second [211. Also stressed by some
are such factors as turbulence and mixing. The temperature may be raised
to this level by introduction of combustion gases, by heat exchange or
other means. (Some report the necessity of going as h,igh as l500°F.)
6.1.4.3 Flame, or fume, incineration is very closely al-
lied to the above method. The difference is that the contaminated gases
pass through the flame by forcing mixing or, better, are,employed as part
or all of the source of combustion air. The same parameters of time and
temperature are indicated by some, but others feel that flame incinera-
tion, with its temperatures of 2000-2500°F, implies virtually instant
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WALDEN RESEARCH CORPORATION
. .~ . . - ". ,.
"'.' ~\ ..~~....
.. _. - ,.... ---
-------
'----7 ~ -
oxidation -- as indeed it is for the hydrocarbons of the fossil fuel which,
I .
under proper combustion conditions, are completely o~idized to C02 and H20.
Because of the higher temperatures involved, flame or thermal incineration
have greater fuel requirements and, therefore, higher operating costs than
a catalytic unit. -However, they do not incur the risk of catalyst poiso;1-
ing nor the cost of catalyst replacement after a period of time.
..
. .r
I .
IIflACtOlY ""'10 ,nIL 'HILL
IlflACtOlY liNG lAm.
c;.u "Nfl ",....0
7
."'lIt,OI cON,..........nD All SIII"-'"
Vertical ga,.lIr.d ~flerburn.' with tangential enl,i., for bath the fuel and conlamlnaled 01,.
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WALDEN RESEARCH CORPORATION
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6.2 TYPICAL CONTROLLED INSTALLATIONS
According to a source at the Spencer Kellogg Company (the,sec-
ond largest oil refiner), the only pollution problem they have is an odor
problem, for which they use masking chemicals [22J. When beans were proc-
essed at their plant, in the past, cyclones and fabric filters were used
to control dust.
The largest castor oil refiner is the Baker,C~stor Oil Company,
\-/hose Bayonne, tiew Jers~y plant \'/as visited by Walden Research and EPA
personnel. Their blown oil operation emissions are controlled by an in-
cinerator manufactured by Hirt Cowbustion Engineers, Model HIH-4600X.
. The unit has a design capacity' of 4,600 scfm of Idi1ute~" off-gases from
eight castor oil cooling kettles. Hirt has test data on the unit indi-
cating hydrocarbon discharge of less than 100 ppm when the unit is oper-
ated at 1400°F and with maximum inlet hydrocarbon loading. The unit is
, .r
a high induced draft fume incineratrir [22,23J.
The Plains Coop Oil Mill uses fabric filters to control dust
generated in the storage area. The fertilizer companies also report the
use of bag filters in thei.' mixing areas to control the castor pomace
, dust [24J.
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WALDEN RESEARCH CORPORATION
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REFERENCES
, ,
~United States Fats and Oils Statistics 1909-1965," Statistical Bul-
letin No. 376, Economic Research Service, USDA, Washington, D.C.
(August 1966).
2. Baker Castor Oil Company, "Castor Oils and Chemical Derivatives,"
Technical Bulletin 123, Bayonne, N.J. (1970).
1.
, 3. ' Personal communi cati on wi th U. S. Coast Guard; Titl e 46, Code of
Federal Regulstions, Parts 146-149.
4. Altschul, Aaron M., ed., Processed Plant Protein Foodstuffs, ,Chapt. 4,
Chapt. 31, Academic Press Inc., New York (1958).
, 16.
5. ' Personal communication with Mr~ R.- P. Hutchins of the French Oil 'Mill
, Machi nery Co. '
6.
Kromer,' George H., liThe U.S. Castor Oil Situation," Reprinted from
"Fats and Oils Situation," FOS-241, USDA, Hashington, D.C. (Jan.
'1968). .r
7.
8.
Personal communi cati on \'Ii ~h Baker Castor Oil Company.
Personal communication \'/ith Hr. D. L. Van Horn, NcNair Feed Co.
Personal communication with Dr. George O. Kohler, ~!estern r.1arketing
& Nutrition Research Division, Agricultural Research Service,
, Berkeley, California.
9.
10.
11.
, ,
Paint Red Book, Palmerton Publishing Co. Inc., N.Y., N.Y. (1970).
Chemical Materials Catalog, Reinhold Publishing Co., N.Y., N.Y.
(1971) . '
1.2. Ridlehuler, J., "011 Seed Crops - Castor Processing, II Oil Mill
Gazetteer,'pp. 62-64 (Ju~e 1968).
13. Eckey, E. ~1., ~table Fats and Oils,' pp. 587-597? Reinhold Pub1ish-
ing'Corp., New York (1954).
14. Jamieson, George S., Veqetable Fats and Oi1s - Their Chemistry, Pro-
duction, and Utilization for Edible, ~!edicinal, and Technical Pur-
poses, pp. 47-53, Reinhold Publishing Corp., N.Y., N.Y. ~1943).
15,.
Bailey, Alton E., Industrial Oil and Fat Production, 2nd ed., pp. 187,
431-435,913-916, Interscience Publishers, Inc., New York (1951).
Personal communication with Mr. J. J. Sab1eski, Environmental Protec-
tion Agency.
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WALDEN RESEARCH CORPORATION
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REFERENCES (continued)
--'- -
17.
Personal communi caffon with tobacco gro\'/ers (~1eyer & Nendel sohn,
Windsor, Conn., Culbro Tobacco Co., E. Hartford, Conn.).
Personal communication \':ith Dr. George' Kohler, I-Iestern r-1anufacturing
& Nutrition, Research Division, Agricultural Research Service, USDA.
19. Apen, Ed\./i n M., et a 1., IIHea lth Aspects of Cas tor Sean dust, II U. s.
Dept. nf HEW, PuElic Health Service Publication No. 999-AP-36.
18.
, 20.
: I .
Selheimer, C. H., et al., "Fume Control in the Paint and Varnish In-
dustry," Parts 1-11, Of1:icial Digest of the Federation of Paint and
Varnish Production Clubs, Vol. 27, No. 355" p. 706 (August 1954).
21.
,.
Danielson, J. A. (Ed.), Air Pollution Engineering Manual, U.S. Dept.
of HEW, National Center for Air Pollution Control, Publ. 999-AP-40,
Cincinnati, Ohio, p. 693-4 (1967).
22.
Personal conmunication with Mr. Robert C. H~ssong of the Spencer
Ke,.logg Company. . .r
23. 'Personal communication with Mr. Harold Feldstein, Sales Manager, Hirt
Combustion Engineers, MonteQell~, California. -
I
, 24. Personal communication with fertilizer manufacturers (Old Fox Agri-
cultural Sales, Hazard~ille, Conn., Kerr McGee, W. Springfield, Mass.,
Cadwell & Jones, E. Hartford, Conn.).
II
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WALDEN RESEARCH CORPORATION
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