宜春市年产15000吨茶油生产线工厂设计
摘要
油茶是我国主要的木本食用油料树种,全国油茶总面积约5500万亩,占我国木本食用油料面积的80%。全国年茶油产量约15-20万吨,占木本食用油产量的80%。油茶是世界上稀缺资源,茶油的品质与价值与橄榄油相近。研究表明：茶油能有效防治心脑血管疾病、降低胆固醇和空腹血糖、抑制甘油三脂的升高,帮助“三高”患者改善健康。茶油耐贮藏,不易酸败,不受致癌的黄曲霉素B1的污染。同时油茶还是食品、制药、化工以及化妆品工业的重要优质原料。
目前油茶籽制毛油的方法主要有压榨法和浸出法：热榨法高温蒸炒、高温高压压榨技术,设备多,工艺操作复杂,毛油色泽深,油中的天然维生素等营养物质被破坏；浸出法制油多采用平转浸出、常温蒸发法,使6#溶剂油消耗过多,生产存在安全隐患,释放的溶剂气体对环境也不友好；较高的温度分离毛油,破坏了油中的天然维生素等营养物质,且精炼成本升高。茶油精炼大多以间歇式精炼方式为主,导热油炉加热对茶油的的维生素E等营养物质破坏严重。且导热油炉采用的矿物油,对人体有较大的致癌作用。在脱臭工艺中高温时间长,真空度高,产生较高的反式脂肪酸,影响茶油的品质。总之,目前油茶籽加工生产规模小、技术水平低、工序繁多、操作麻烦；生产成本高,对环境污染大。浸出工艺落后,生产出来的毛油质量差,精炼成本高。对有益物质破坏严重,产生较高的反式脂肪酸,影响产品整体品质,因此,急需高新技术注入,使油茶产业得到快速发展。
本文拟设想在重要油茶产区宜春市新建一个年产15000吨精制茶油加工厂在加工厂工艺路线的选择上,对目前茶油的加工技术进行了分析和比较,采取国内外先进技术工艺路线进行新建项目的建设。主要为低温冷榨技术,入榨温度在50℃以下,机榨饼残油率低,毛油质量好,可直接达到GB11765-2003-级压榨油标准；箱链式浸出、负压蒸发技术,浸出效果好,饼粕残油率低,毛油质量好,溶剂消耗少,环境影响小；符合欧盟技术标准的物理精炼技术,软塔脱臭工艺,自动化程度高,批间差异小,安全性高,85%以上的维生素E能保存在油脂中,产生反式脂肪酸小于1%,符合欧盟质量标准,能耗低,精炼成本低；将这些技术做为新建茶油加工厂建设的主要技术路线。
对项目建设涉及到的选址、产品方案、工艺流程、设备选型、水电气平衡、车间总平面布置、建筑要求、环境要求等进行的阐述。建立一个规模化、现代化、集国内外先进技术的加工企业,以期为茶油加工行业提供技术示范,提高茶油加工行业的整体水平,为茶油产业的快速发展提供技术支撑。
Camellia oleifera Abel is the main woody edible oil tree in China. Total area of national Camellia oleifera Abel is about 55 million mu, which accounts for 80% of our woody edible oil area. National annual output of camellia oil is about 150-200 thousand ton, which accounts for 80% of our woody edible oil output. Camellia oleifera Abel is the scarce resource in the world. The quality and value of camellia oil were the same as olive oil. And the clinical outcome shows that camellia oil can effectively prevent and treat cardiovascular and cerebrovascular diseases, decrease cholesterol and fasting plasma glucose, inhibit the increase of triacylglycerol and help patients with hypertension, hyperproteinemia and hyperglycemia to improve their health. Camellia oil is storagable, not rancid easily and against pollution of carcinogenic Aflatoxin B1. At the same time, camellia oil is also an important high-quality raw material in food, pharmaceutical, chemical and cosmetic industries.
At present, the method of camellia oil-making is mainly squeezing and extracting. The method of squeezing and frying in high temperature has many negative effects such as equipment too much; technological operation too complex; crude oil dark color and too much solvent of 6# consumption, which produce many safety problems and destroy our environment. Moreover, during the process of separating crude oil, high temperature destroys the natural vitamin and other nutrients. Also the cost is high. The way of fining about camellia oil is intermittent, which can result in the breakage of Vitamin due to heater of stove. What's more, mineral oil used in process of heating stove will produce carcinogen. Then during the technique of deodorization, trans fatty acids will be engendered because of high vacuum, which affects the quality of camellia oil. In conclusion, predicaments existed in current camellia oil processing industry, which are many enterprises with small scale, low level of technique, much operation, high cost and polluting environment. Trans fatty acids in the whole process depress the quality of product. So there is pressing need of new technique that can promote development of camellia oil business.
In this paper, a new camellia oil processing factory with an annual capacity of 15000t refined camellia oil was planned to establish in Yichun city which is the important Camellia oleifera Abel region from this paper. On the selection of technological line, this study analyzed and compared current processing technology of camellia oil, and used advanced technological line at home and abroad for the construction of new project. The new camellia oil processing factory used advanced cold pressing technology about below 50 degree in which remnant oil are low and the quality of crude oil can achieve the standard of GB11765-2003. Moreover, there are other techniques such as box chain leaching, negative pressure evaporation technology whose effect is good including low remnant oil, fair crude oil, small quantity of consumption about solvent, less effect on environment. Soft column deodorization technology conformed to EU technical standards whose degree of automatization is high. Its batch variance is little and the degree of safety is high. Vitamin E is kept in the oil about more than 85% and trans fatty acids are lower than 1% up to EU technical standards. The consumption of energy and cost are low. These are their main technical route.
Location Selection, product scheme, technological process, equipment selection, balance of water, electric and gas, workshop horizontal design, architectural requirement and environmental requirement were studied for the project construction. Establishing a processing enterprise with scalization, modernization and a dvanced technology at home and abroad is to provide technical demonstration for camellia oil processing industry. Raising the whole level of camellia oil processing industry is to provide a technology support for rapid development of camellia oil industry.
目前油茶籽制毛油的方法主要有压榨法和浸出法：热榨法高温蒸炒、高温高压压榨技术,设备多,工艺操作复杂,毛油色泽深,油中的天然维生素等营养物质被破坏；浸出法制油多采用平转浸出、常温蒸发法,使6#溶剂油消耗过多,生产存在安全隐患,释放的溶剂气体对环境也不友好；较高的温度分离毛油,破坏了油中的天然维生素等营养物质,且精炼成本升高。茶油精炼大多以间歇式精炼方式为主,导热油炉加热对茶油的的维生素E等营养物质破坏严重。且导热油炉采用的矿物油,对人体有较大的致癌作用。在脱臭工艺中高温时间长,真空度高,产生较高的反式脂肪酸,影响茶油的品质。总之,目前油茶籽加工生产规模小、技术水平低、工序繁多、操作麻烦；生产成本高,对环境污染大。浸出工艺落后,生产出来的毛油质量差,精炼成本高。对有益物质破坏严重,产生较高的反式脂肪酸,影响产品整体品质,因此,急需高新技术注入,使油茶产业得到快速发展。
本文拟设想在重要油茶产区宜春市新建一个年产15000吨精制茶油加工厂在加工厂工艺路线的选择上,对目前茶油的加工技术进行了分析和比较,采取国内外先进技术工艺路线进行新建项目的建设。主要为低温冷榨技术,入榨温度在50℃以下,机榨饼残油率低,毛油质量好,可直接达到GB11765-2003-级压榨油标准；箱链式浸出、负压蒸发技术,浸出效果好,饼粕残油率低,毛油质量好,溶剂消耗少,环境影响小；符合欧盟技术标准的物理精炼技术,软塔脱臭工艺,自动化程度高,批间差异小,安全性高,85%以上的维生素E能保存在油脂中,产生反式脂肪酸小于1%,符合欧盟质量标准,能耗低,精炼成本低；将这些技术做为新建茶油加工厂建设的主要技术路线。
对项目建设涉及到的选址、产品方案、工艺流程、设备选型、水电气平衡、车间总平面布置、建筑要求、环境要求等进行的阐述。建立一个规模化、现代化、集国内外先进技术的加工企业,以期为茶油加工行业提供技术示范,提高茶油加工行业的整体水平,为茶油产业的快速发展提供技术支撑。
Camellia oleifera Abel is the main woody edible oil tree in China. Total area of national Camellia oleifera Abel is about 55 million mu, which accounts for 80% of our woody edible oil area. National annual output of camellia oil is about 150-200 thousand ton, which accounts for 80% of our woody edible oil output. Camellia oleifera Abel is the scarce resource in the world. The quality and value of camellia oil were the same as olive oil. And the clinical outcome shows that camellia oil can effectively prevent and treat cardiovascular and cerebrovascular diseases, decrease cholesterol and fasting plasma glucose, inhibit the increase of triacylglycerol and help patients with hypertension, hyperproteinemia and hyperglycemia to improve their health. Camellia oil is storagable, not rancid easily and against pollution of carcinogenic Aflatoxin B1. At the same time, camellia oil is also an important high-quality raw material in food, pharmaceutical, chemical and cosmetic industries.
At present, the method of camellia oil-making is mainly squeezing and extracting. The method of squeezing and frying in high temperature has many negative effects such as equipment too much; technological operation too complex; crude oil dark color and too much solvent of 6# consumption, which produce many safety problems and destroy our environment. Moreover, during the process of separating crude oil, high temperature destroys the natural vitamin and other nutrients. Also the cost is high. The way of fining about camellia oil is intermittent, which can result in the breakage of Vitamin due to heater of stove. What's more, mineral oil used in process of heating stove will produce carcinogen. Then during the technique of deodorization, trans fatty acids will be engendered because of high vacuum, which affects the quality of camellia oil. In conclusion, predicaments existed in current camellia oil processing industry, which are many enterprises with small scale, low level of technique, much operation, high cost and polluting environment. Trans fatty acids in the whole process depress the quality of product. So there is pressing need of new technique that can promote development of camellia oil business.
In this paper, a new camellia oil processing factory with an annual capacity of 15000t refined camellia oil was planned to establish in Yichun city which is the important Camellia oleifera Abel region from this paper. On the selection of technological line, this study analyzed and compared current processing technology of camellia oil, and used advanced technological line at home and abroad for the construction of new project. The new camellia oil processing factory used advanced cold pressing technology about below 50 degree in which remnant oil are low and the quality of crude oil can achieve the standard of GB11765-2003. Moreover, there are other techniques such as box chain leaching, negative pressure evaporation technology whose effect is good including low remnant oil, fair crude oil, small quantity of consumption about solvent, less effect on environment. Soft column deodorization technology conformed to EU technical standards whose degree of automatization is high. Its batch variance is little and the degree of safety is high. Vitamin E is kept in the oil about more than 85% and trans fatty acids are lower than 1% up to EU technical standards. The consumption of energy and cost are low. These are their main technical route.
Location Selection, product scheme, technological process, equipment selection, balance of water, electric and gas, workshop horizontal design, architectural requirement and environmental requirement were studied for the project construction. Establishing a processing enterprise with scalization, modernization and a dvanced technology at home and abroad is to provide technical demonstration for camellia oil processing industry. Raising the whole level of camellia oil processing industry is to provide a technology support for rapid development of camellia oil industry.
引文
[1]廖书娟,吉当玲,童华荣.茶油脂肪酸组成及其营养保健功能[J].粮食与油脂,2005(06)：07-09
[2]马力,周建平,刘红梅.油茶的性质及其精炼工艺.农产品加工学刊,2006(09)：18-20
[3]2009-2012年中国茶油产业市场调查及投资前景预测报告
[4]邓桂兰,彭超英,卢峰.油茶饼粕的综合利用研究[J].四川食品与发酵,2005(03)：41-44
[5]蔡肖群,陆顺忠.红山茶新品种及茶油精加工技术引进简报.广西林业科学,2001(03)：134-135
[6]郭应安.茶油生产的研究与实践[J].中国油脂,24(6)：25-26
[7]2009年国产食用油品牌前十名竞争力研究及2012年产业发展前景预测报告
[8]《江西省统计年鉴》(2006)
[9]邓小莲,谢光盛,黄树根.保健茶油的研制及其调节血脂的作用.2002(05)：96-98
[10]《宜春市统计年鉴》(2006)
[11]王湘南,陈永忠.油料冷榨及在油茶加工中的应用前景.湖南林业科技,2006(03)：93-94
[12]钟海雁,王承南,谢碧霞.超临界CO2萃取茶油的初步研究.科研开发,1999：13-14
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[14]姜建国,吴群,山长柱,等.油茶籽低温冷榨制油工艺实践[J].粮食与食品工业,2008(04)：17-18
[15]GB11765-2003油茶籽油国家标准
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[17]夏伏建,黄凤洪,钮琰星,等.油茶籽脱壳制油工艺的研究与实践[J].中国油脂,2004(01)：34-35
[18]郑竞成.浸出茶油加工工艺研究[J].粮食与油脂,1999(04)：11
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[20]罗晓岚.油脂在脱臭后反式脂肪酸的生产及维生素E的损失问题的探讨[J].中国油脂,2000(01)：26-29
[21]武丽荣.反式脂肪酸的产生及降低措施[J].中国油脂,2005(03)：42-44
[22]国家发改委《投资项目可行性研究指南》(2006)
[23]《当前国家重点鼓励发展的产业、产品和技术目录》(2006)
[24]2008年科技部重大科技专项《油茶产业关键技术研究与示范》
[25]江西省人民政府2010年重大科技专项《江西省油茶产业关键技术研究与示范》
[26]柏云爱,宋大海,张富强,等.茶油籽油与橄榄油营养价值的比较[J].中国油脂,2008(03)：39-41
[27]张余权.化妆品用茶油精炼工艺的研究.中南林学院,2003,35
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[2]马力,周建平,刘红梅.油茶的性质及其精炼工艺.农产品加工学刊,2006(09)：18-20
[3]2009-2012年中国茶油产业市场调查及投资前景预测报告
[4]邓桂兰,彭超英,卢峰.油茶饼粕的综合利用研究[J].四川食品与发酵,2005(03)：41-44
[5]蔡肖群,陆顺忠.红山茶新品种及茶油精加工技术引进简报.广西林业科学,2001(03)：134-135
[6]郭应安.茶油生产的研究与实践[J].中国油脂,24(6)：25-26
[7]2009年国产食用油品牌前十名竞争力研究及2012年产业发展前景预测报告
[8]《江西省统计年鉴》(2006)
[9]邓小莲,谢光盛,黄树根.保健茶油的研制及其调节血脂的作用.2002(05)：96-98
[10]《宜春市统计年鉴》(2006)
[11]王湘南,陈永忠.油料冷榨及在油茶加工中的应用前景.湖南林业科技,2006(03)：93-94
[12]钟海雁,王承南,谢碧霞.超临界CO2萃取茶油的初步研究.科研开发,1999：13-14
[13]H.J拉泽洪,H.D戴克,忻耀年.菜籽脱皮冷榨的理论和实践[J].中国油脂,2000,25(6).
[14]姜建国,吴群,山长柱,等.油茶籽低温冷榨制油工艺实践[J].粮食与食品工业,2008(04)：17-18
[15]GB11765-2003油茶籽油国家标准
[16]忻耀年.油料冷榨的概念和应用范围[J].中国油脂,2005,30(2)
[17]夏伏建,黄凤洪,钮琰星,等.油茶籽脱壳制油工艺的研究与实践[J].中国油脂,2004(01)：34-35
[18]郑竞成.浸出茶油加工工艺研究[J].粮食与油脂,1999(04)：11
[19]沈建福,张志英.反式脂肪酸的安全问题及最新研究进展.中国粮油学报,2005.8(04)
[20]罗晓岚.油脂在脱臭后反式脂肪酸的生产及维生素E的损失问题的探讨[J].中国油脂,2000(01)：26-29
[21]武丽荣.反式脂肪酸的产生及降低措施[J].中国油脂,2005(03)：42-44
[22]国家发改委《投资项目可行性研究指南》(2006)
[23]《当前国家重点鼓励发展的产业、产品和技术目录》(2006)
[24]2008年科技部重大科技专项《油茶产业关键技术研究与示范》
[25]江西省人民政府2010年重大科技专项《江西省油茶产业关键技术研究与示范》
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