CCP-3: Ethanol Recovery & Spray Drying
Process Objective
Extract and purify flaxseed gum (mucilage) from the hull fraction using aqueous extraction and ethanol precipitation.
Equipment Configuration
Hull → Extraction Tank → Decanter Centrifuge → Vacuum Concentrator → Ethanol Precipitation → Centrifuge → Spray Dryer → Gum Powder
→ Ethanol Recovery → Recycled Ethanol
Equipment Specifications
| Unit |
Type |
Capacity |
Material |
Notes |
| Extraction tank |
Jacketed, agitated |
2000 L |
SS 316L |
pH control, 50–90°C |
| Decanter centrifuge |
Horizontal bowl |
1000 L/hr |
SS 316L |
Solids 15–25% |
| Vacuum concentrator |
Falling film |
500 L/hr |
SS 316L |
60°C, –0.8 bar |
| Precipitation tank |
Double cone |
2000 L |
SS 304 |
Ethanol 70–90% v/v |
| Basket centrifuge |
Vertical |
300 kg/hr |
SS 316L |
Cake solids 30–40% |
| Spray dryer |
Co-current |
200 kg/hr |
SS 316L |
Inlet 180°C, outlet 80°C |
| Ethanol recovery column |
Packed |
50 L/hr |
SS 304 |
Rectification to 96% |
Process Parameters
| Parameter |
Set Point |
Tolerance |
| Extraction temperature |
75°C |
± 5°C |
| Extraction time |
60 min |
± 10 min |
| Water-to-hull ratio |
15:1 |
± 2:1 |
| Ethanol precipitation concentration |
80% v/v |
± 2% |
| Spray dryer inlet temperature |
180°C |
± 5°C |
| Spray dryer outlet temperature |
80°C |
± 3°C |
| Parameter |
Target |
Verification |
| Gum yield (from hull) |
18–25% |
Weight balance |
| Polysaccharide purity |
≥ 80% |
Phenol-sulfuric |
| Protein in gum |
≤ 6% |
Kjeldahl |
| Residual ethanol |
< 100 ppm |
GC headspace |
| Moisture (powder) |
≤ 5% |
Halogen balance |
CCP-3 Monitoring
| Check |
Frequency |
Critical Limit |
Action |
| Solvent recovery efficiency |
Continuous |
< 100 ppm residual |
Stop, recalibrate column |
| Spray dryer outlet temp |
Continuous |
80°C ± 3°C |
Adjust feed rate |
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