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Taibah University

Mechanical Engineering Department

Summer Training Course (Final Report)

Prepared by Ahmed Yahya Barradah

ID 3001020

Advised by Dr. Naseer Ahmed

Dr. Waseem Orfali

5/8/2013

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Acknowledgement

I would like to express my deepest appreciation to all those who provided me the possibility to

complete this report. A special gratitude I give to Dr. Naseer Ahmed, whose contribution in

stimulating suggestions and encouragement, helped me with my training especially in writing

this report. Also, I would like to thank Dr. Waseem Orfali for his guidance and support.

Furthermore I would also like to acknowledge with much appreciation the crucial role of the

staff of Soybean Crushing Company and Derivatives, who gave the permission to use all

required equipment and the necessary materials to complete my summer training course. A

special thanks goes to the Operation Director, Mr. David Kidd, who gave me suggestions about

the departments and where to begin. Last but not least, many thanks go to the managers of all the

departments who have invested his full effort in guiding me in achieving the goal. I have to

appreciate the guidance given by other supervisors as well as the technicians and operators

especially in all the departments that has improved my skills thanks to their comment and

advices.

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Abstract

The purpose of this report was to summarize the period that I spent in the summer training

course and the skills that I developed through the training. My summer training took place at

Soybean Crushing Company and Derivatives (SOYA) which is an industry located in Yanbu.

This industry, as its name says, is specialized in crushing soybeans and turns them to meal, oil or

hulls to sell them to plenty of other agricultural industries.

The company has about ten different departments. As a mechanical Engineer trainee, I was

trained in almost four departments in the industry which are the departments located in the field.

Three major departments were Terminal, Maintenance and Production, whereas the fourth minor

department was the Safety Department. I used to write a detailed report about everything that I

learnt on daily basis. Moreover, I took pictures of equipments and copied some materials related

to the machinery of the industry. Great focus was required to properly absorb all what came

through me in all the departments in such a short period (two months). I followed the appropriate

planning for covering everything in the field.

I initially organized all the reports that I wrote, pictures that I took and documents that I copied

to put them in one major report. This report would make my two months training more valuable

since it is documented by photos and detailed information.

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Table of Content

Acknowledgement 2

Abstract 3

Introduction 6

Terminal Department 7

Maintenance Department 9

Production Department 12

Health, Safety & Environment Department 17

Conclusion 18

Appendix 19

References 29

Sketches and Diagrams 30

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Table of Figures

Figures 1-6 19

Figures 7-12 20

Figures 13-18 21

Figures 19-24 22

Figures 25-30 23

Figures 31-36 24

Figures 37-42 25

Figures 43-48 26

Figures 49-54 27

Figures 55-57 28

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Introduction

Soybean Crushing Company and Derivatives (SOYA) is an industry that was created in 2005 in King

Fahad Industrial Port, Yanbu. It is the first crushing company of its sort in the Kingdom of Saudi Arabia

with the state of art latest equipment and machinery installed with the best technical and commercial staff

available in the country. It commenced crushing in April 2007, using US soybeans for commissioning of

the plant. Producing crude degummed soybean oil by way of using hexane as the process for extraction,

soybean ground hulls and soybean meal. The soybean meal produced is mainly an ingredient used in the

production of compounded animal and poultry feed. Oil is also used based on the compounded feeds

produced, as resin for paint manufacturing and majority of the oil sold is used for refining purpose. Hulls

being the minimum of quantity produced are the main ingredient used in feeds for ruminants and or

animal feeds.

Many companies buy those three products whether inside Saudi Arabia such as Fakieh, Astra and

FEEDCO or even outside the Kingdom such as Kuwait and Jordan. Soybean imports are mainly procured

from the USA and Brazil depending on the harvest period and availability, special attention is given to

soybean that allow us to produce soybean meal with the base requirements of 47.5 / 48% Protein, keeping

in mind the Saudi Govt. standards and requirements. Out of the 3 products from the crushed soybeans,

only the crude oil is exported to companies that carry out refining for edible oil manufacturing and or for

factories that produce emulsion paints. Pricing are based on international oil seeds markets using the

CME group quotes on daily movements on the futures trades.

SOYA has many different departments. In the administration building, it contains Commercial, IT,

Finance, Procurement and Operation Departments. In addition, the field contains the Terminal,

Maintenance, Production and Safety Departments. Summer training took place in the field so minimum

two weeks were spent at each of the four departments.

1-Terminal Department: generally contains ship unloader, silos, conveyor system to transfer the shipment,

meal storage and crude vegetable oil tanks.

2 - Maintenance: this contains three major parts: utility, electrical and mechanical. Utility includes

boilers, cooling tower, chillers, air compressors and ETP. Electrical and Mechanical deal with the

preventive maintenance and the technical issues.

3-Production: this has three basic areas: Pre-cleaning, Preparation and Extraction. We can also add one

more area which is the lecithin plant.

4-Safety: it deals with any accidents that may causes serious injuries. In addition, this department is

responsible for the environment and reducing the danger of environmental pollution. They also make

different seminars and presentations about health and safety.

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Description of Training

Departments

1. Terminal Department:

1.1) Overview: Terminal is one of the departments here in Soya which takes care of the shipment the time it comes and

the process of that is kind of not easy; it also transfers the shipment within the industry. Most probably

the shipment is seed so for sure we need some huge tanks that can keep them in a good situation. These

huge tanks are called SILOS which have an aeration system to keep the seeds healthy and safe. After

making the productions, Terminal also will handle the production either if it is meal, oil, hulls or lecithin.

Meal will go to a place called Meal Storage and lecithin will be kept at lecithin storage in small barrels till

the time of sale. Oil (VIGITABLE CRUDE OIL) will be stored at three large tanks. Trucks will take the

meal by something called day bin.

1.2) Parts: - SILOS (which has a capacity of 13,000 metric tons of each), Soya contains 13 silos.

- Conveyor system (which takes care of transferring the materials in every area at the industry in the

terminal and in the other departments). Furthermore, conveyor systems have a lot of ways to process and

a lot of types, here in Soya there are three main ones which are:

1-Belt (as the one in the airport that transfers the luggage but here it is used for many things such as:

transferring the shipment from the ship to the silos)

2- Chain conveyor (has some specific jobs to make, and mostly it contains two gear box and electric

motor some of them has hydraulic motor ( 4KW- 500 rpm))

3- Elevator (which is the most common one, to elevate the seeds or any processed material inside the

plant either it goes up or down.)

- Meal Storage (from its name it can store the meal that was already produced in the plant)

- Oil Tanks (there are three of for keeping vegetable crude oil). Oil tanks have minor pumps for loading

and major pumps for shipping; they have some sort of a naming system like C1, C2 and C3. Air

compressor is needed here as well for the process, each tank has a capacity around 6126 metric tons.

- Bins (there are six bins for filling the trucks either with hulls, meal or oil) meal bin capacity is around

(40 metric tons), however, hulls bin capacity is (35 metric tons).

-Lecithin plant (it is a plant for saving the lecithin in small barrels have a capacity around 200 kg).

* Lecithin is a product that has high percentage of viscosity usually in a range around (7.8 – 7.9),

speaking of which, lecithin is a very sensitive material or product that gets affected easily by the quality

of the seeds in the first place as well as the flowing process. Seeds that come from Canada or US have

better quality than the ones that come from Brazil. Lecithin can be made by two different ways according

to this company: chemical treatment or hydro (by water) as we will see in the production department.

Lecithin is a gummy material so it will be hard to make it move smoothly inside the pipe lines till it

reaches the lecithin storage, so increasing the temperature of the gummy material would be a perfect

solution, temperature will be raised to 50 C to make it melt and flow easily.

- The Ship Unloader: one of the major areas in the terminal which transfers the seeds from the hatches in

the vessel till it puts them on the conveyor. The range for the unloader is 32 meters. Most of the time the

Vessels have hatches with 38 meters long so the unloader won’t be able to take all the seeds, because of

that the vessel will turn around so the other side will come close. As a result, the unloader will be able to

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discharge all the seeds. In future, the company might plan to use vacuum process to make this procedure

easier and for sure time will be saved.

1.3) Procedure: (sketch will be attached) First, the ship unloader will discharge the seeds (the shipment) from the hatches in the vessel till it

reaches the conveyor system; all these processes are controlled by SCADA system. There is one

controlling room near to the unloader to check the process every now and then. The first type of conveyor

will be chain conveyor which has the responsibility of transferring the seeds from the unloader to the

silos. In addition, chain conveyor will put the seeds in another conveyor before it reaches the silo which is

belt conveyor to move the seeds easily. After that, the seeds will go through Rotary Magnet (for removing

the unneeded parts). Now the third type of conveyors will show up after getting the seeds from the rotary

magnet it will be transferred by elevator to the Scale (this scale will measure the weight of each batch of

the shipment separately to avoid mistakes afterwards). Hopper will be the next stage which is like a

collector that has a loose inlet and a very narrow outlet. Another elevator now will transfer the seeds to

the silos. Silos have some controlling tools at the tunnel below each one of them, some minors and one

major in the middle. This one has a sensor to know when the silo gets filled. Inside the silos, there is one

of the conveyors named screw conveyor or (AUGER) the purpose of this auger is to bring all the beans to

the center. This auger works by motor to collect the seeds inside the silo till the time it reaches the center

(this procedure will make the seeds in a good manner and situation because it will move the seeds upside

down plus these silos have aeration system).

After the seeds got processed in the production area, the meal goes to the meal storage (this storage has

scraps to move the meal to the specific place in the storage, so from this point it will be transferred till it

reaches the day bins.

The percentage of each product in the industry:

62 % Meal, 21% Oil, 8% Hulls so the total will be 91%!! Yes! The 9% will be a loss for the company

during the processes.

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2. Maintenance Department: Every industry or operating field needs a repair shop or we can call it a workshop to fix and

repair any straggle or problems that might happened during the operations. Basically, this main

department has three important areas, or four areas according to different criteria. Some

industries consider this department as heart of the company, it takes care of the electrical issues,

mechanical and utility. However, utility section is one of the most important sections in the

whole industry so we cannot just say it is a repair shop because it got the boilers, chillers, air

compressors and ETP. Mechanical and electrical are taking care of the work orders from other

departments and other technical issues. To sum up, Maintenance has three areas which is: Utility,

Mechanical and Electrical and they will be explained according to its importance.

2.1) Utility:

Which has four areas, each one has its own responsibility to make the industry works properly.

Boiler, chiller, cooling tower, ETP and the air compressor.

2.1.1) Boiler:

It is a closed vessel in which water is heated. Steam should be generated, superheated or any

combination thereof under pressure or vacuum process by direct application of heat. Generally,

boilers are classified according to its: capacity, design type or their use. For example: low

pressure boilers are designed to stand maximum 15 psi, however, high pressure boilers can stand

above than 15 psi.

According to the design type, boilers can be classified into two main ones:

1- A fire tube boiler: which has fire or gasses combustion in the tubes, and water

surrounding the tubes. It comes in different shapes: vertical, horizontal, fire box or so.

This type is used in SOYA.

2- Water tube boilers: have water running through the tubes and fire or gasses of

combustion surrounding the tubes.

General boiler operations include:

Start up: most furnace explosions occur during start up and when switching fuels.

Operations and general maintenance: requires proper training, equipment familiarity and routine

maintenance procedures.

Shutdown: whether for short time or long time, different procedures exit. If the boiler is placed

out of the service for an extended period of time.

Boilers in SOYA are controlled and monitored by SCADA system as everything else in the

industry. There are two boilers, each works by its own motor and fan. Each has a capacity of 15

tons type of the pumps is centrifugal, there is a small window called sight glass which let you

observe the operation inside the boiler. Firing rate is important and it can be checked easily via

display screen which displays the readings. Water in the boilers has some specifications such as

the PH and some important chemicals just to avoid wearing and rust. Mostly the temperature will

output at 185 degrees centigrade. Boilers are feed from two sources: outside tank and from

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process water tank. Softeners have their job for filling and discharging the water. Diesel is the

fuel which used in the combustion process.

2.1.2) chiller:

Chiller works quite similar to refrigeration cycle from general view. Chiller has main purpose to

decrease the temperature of the water that goes to any process in the production, reduction of

temperature should be high. As if we have an input temperature of 40 degrees, chiller should

decrease it to 24 or so. Best company that provide high quality chiller is YORK. Screw chiller is

the one in SOYA.

Procedure:

Water enters the cycle in low pressure vapor (so it is in a gas phase), then it continues to the

rotary screw compressor, the output from the screw compressor is high pressure vapor, this vapor

will pass through discharge area till it reaches the oil separator (temperature and pressure here

are increased), oil should be separated from the vapor before it reaches the condenser. Now the

material is high pressure vapor without oil. Valve will monitor the quantity. After knowing the

quantity the vapor will go to the condenser, condenser will absorb heat from the heated vapor

causing it to condense. Condensed drains is the output of the condenser, this drains will pass

through liquid return line called (orifice), finally, this condensed liquid will go to the evaporator

and the cycle will start again, all the water in chiller is supplied by the cooling tower. (Sketch is

attached)

2.1.3) cooling tower:

A tower which has main purpose to cool down the temperature of the water before it goes to the

chiller but in a minor range of increment. It has some mechanical equipment such as:

1- Fans: heavy duty, axial flow with aluminum alloy blades to monitor the thermal

performance of the cooling tower.

2- Bearings: ball bearings with moisture proof seals steel.

3- Water outlet: using nozzle system to output the water properly.

4- Water distribution system:

5- Fan drive: fan is driven by taper lock sheaves.

6- Sheaves.

7- Fan motor.

2.1.4) ETP (Effluent Treatment Plant):

It is a plant that established for treating the waste water of the company. Any industry has a

waste wither if it is gas waste or water waste. Royal commission in Yanbu has very strict rules

about this so SOYA is applying this rules to avoid any problems that might happened. PH and

TDS (total dissolved solid).

Notes:

- To reduce the PH level we should add solpharic acid, this chemical is dangerous.

- For increasing the PH level we add coastic soda.

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- The proper range of PH should be around 7.

- There are some chemicals come in powder phase such as: polymars and coagulant, and

we convert them to liquid once we need them.

Procedure:

Waste water starts the journey from extraction area. First it goes to the equalization tank, this

tank has two pumps to push the water to the next stage, waste water should be maintained at

certain temperature to let the treatment process works properly and that done by the cooling

tower (minor cooling tower which located at the top of the ETP, this one is different from the

other main one). After that this water will continue until it faces the small oil separator (this

separator, will let the water goes down and the oil will rise according to its density. The water

will go to the next tank which is the slow mixing tank, here in this stage chemicals will be

provided to treat the water and maintain some important properties, these chemicals are

(polymers and coagulant), they work as separators to separate the oil from the water, obviously

this stage takes time to let the chemicals mix properly. When the water done with the slow

mixing it goes to the other mixing tank but this one is fast, also here to maintain proper range of

chemicals. Once the water has done of mixing, it starts to set in the primary settling tank (solid

particles will drop and go down), sludge holding tank will takes a place after that, also it has the

same job which is separating the small particles as well and keep them. Aeration tank is the next

stage which make the water aerated to keep it in a good situation also to dissolve the solid

particles, secondary settling tank will show afterwards. In this critical point filter feed tank will

take a place. Finally the water will end up in treated water tank for deposing the water to the sea

by specific valve. (Sketch is attached)

2.1.5) Air compressor.(attached)

2.2 & 2.3) Mechanical and Electrical:

Familiarization of work orders (attached)

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3. Production Department:

Most of the industries consider this area as the major area of the industry, many operations and processes

are involved, as we mentioned before this company takes the seeds from Brazil or US and process them

during certain operations to have at the end four main different products which are: Meal, Crude oil, Hulls

and Lecithin. However, providing these products cannot be done at one stage according to the processes

that should involve. As a result production and its operations can be separated or divided into the

following depending on their processes: Pre-cleaning, Preparation and Extraction.

3.1) Stages (Processes): 3.1.1: First process is Pre-cleaning: which has different steps, starting from the Day Bin and ends

with the Tempering Bin .Between these two there are some further internal operations, so we can

explain the Pre-cleaning area in detailed version in the coming pages. For now, we will go

through them briefly. Processes that involve in pre-cleaning as following:

-Day Bin is the starting point of the pre-cleaning.

-Rotary magnet has a major job which is clean the seeds or the soya bean from any external or unneeded

materials.

-Seed cleaner or as it known Screener to separate the seeds from any other attached things to make the

process easier.

-Dryer which plays major role in pre-cleaning.

-Tempering bin to save and store the dried seed.

3.1.2: After pre-cleaning, Preparation is the next process which also has some internal processes

such as:

-Cracking the seed and this operation is obviously to crack the seed into (4 to 8 or 9) small pieces by a

machine called CRACKER.

-De-Huller process comes directly after cracking. It functions to separate the cracked seeds from its hulls.

- Cooking by the COCKER to maintain a proper range of moisture in the seeds.

-Flaking process will come after we get the cocked seeds, FLAKER functions for this purpose to press

and increase the surface area of the seeds.

3.1.3: The third major process is The Extraction ( phones and cameras were not allowed in this

area ) , which has some specific stages and instruments involved like:

- Extractor, to take out the oil from the seeds .In this stage hexane will be provided.

-DTDC (desolventising, toasting, drying and cooling) to offer convenient meal.

- Distillation (Miscella Distillation) for dividing the oil from the Hexane.

-Hexane recovery to re-cycle the hexane that has been used in the process.

-Lecithin plant for the de-gumming process.

3.1.1) Pre-cleaning:

3.1.1.1) Day bin:

The day bin is the first point or it is the starting point of the production plant which located on pre-

cleaning section from general view , it has a capacity around 1000 tons.

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3.1.1.2) Rotary Magnet: Rotary magnet is a major step in any production plant. Here we are dealing with seeds so there is a

possibility to see some metals and another unneeded stuff within the shipment, as a result removing the

these metals will save the equipments and the instruments from major damages that might happened, and

that is done by the Rotary magnet.

3.1.1.3) Seed cleaner: This instrument functions to separate the seeds from the attached things such as: hulls, fines, trash and

dust. There is a dust collector at the top of this plant so this one will take the dust out, the other things will

pass through small outlets called meshes. This seed cleaner works with a full capacity of 140 ton/hour.

3.1.1.4) Dryer: Sketch about flowing process inside the dryer will be attached. Specifically, this large machine has seven

fans at the top to remove or discharge the unneeded hot air that flowing inside, cooling process by certain

tubes have a triangle shape takes a place as well. At the bottom there are four burners to do their jobs in

drying .So the dryer has major goal which is reducing and decreasing the range of the moisture content of

the seeds with almost 1.5 %.

3.1.1.5) Tempering bin: It is like a small storage for storing the dried seeds, there are three of them located next to each others.

Each has a capacity of 1200 tons. They have continuous function, on is filled the other is discharging and

vise versa, the third one is stand by. Once the seed gets to this stage that means it has finished the first

process of the production so preparation will start from this point.

3.1.1.6) Refining bin: As we mentioned before, the seed cleaner has a specific job to take the seeds out and removes the hulls

and fines. These hulls and fines have transferred to the bin called refining bin. This bin has a capacity

about 196 metric tons.

3.1.2) Preparation: Large area and it has its own equipments and processes as following:

3.1.2.1) Rotary Magnet: Considered as the starting point of the preparation .After storing the bean inside the tempering bins or the

refining bin , first question that might come to the mind is , are they clean enough to start the processes?

.Because of that confusion , rotary magnet has been installed to remove and catch any metals inside the

beans and separate them properly . In addition, rotary magnet has another important job which is protect

the weighing machine from any damages.

3.1.2.2) Weighing Machine or Weigher: Each plant has its own capacity .Preparation can stand 500 kg for every single batch; however some

industries might have different ways to measure or to scale the batches. To clarify more this Weigher will

separate each batch into two batches; each has capacity of 500 kg and measures them properly.

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3.1.2.3) Crackers: There are three large crackers in this preparation plant. They have specific job to crack the beans into (6-

8) pieces. The crackers might have different duties according to their plants, here in SOYA the purpose of

the crackers is to separate the seeds from the hulls. There are a lot of internal details and components

inside the cracker. According to the manual, the main components of the cracker are:

ROLLS OVERDRIVE MAIN DRIVE

FEEDER

FEED ROLL

MAIN DRIVE PENUMATIC

ROLL

ENGAGMENT

CYLINDER

FEED ROLL

DRIVE

PRODUCT

GUIDE PLATE

VIBRATION

ABSORBER

METERING

SIDE GATE

GAP

ADJUSTMENT

SIDE ROLL

WEDGE

BASE FRAME PERMANENT

MAGNET

GAP

ADJUTMENT

FOR FEED

SCRAPER

ROLL

BEARING

FEEDER DOORS ______

Feeder:

Should rolls the bean by certain motion at uniform rate past the permanent magnet into the crushing area,

the rotary quantity is regulated externally via the metering gap adjustment.

3.1.2.4) De-Huller and aspiration: This is the major process after receiving the cracked seeds. Its function is to separate the fines and the

seeds from each other and the hulls will be separated as well. On the top there is a blower to suck the

remaining fines. However, the cracked seeds will be collected in conveyor and got transferred to the

cooker.

3.1.2.5) Cyclone: A blower will suck the fines and the hulls as we mentioned, we can say by (vacuum), after they had been

sucked, all of them will be collected at a machine named Cyclone. Cyclone has a major job of separation

between the (fines + cracked seeds) and the light material (hulls). All hulls will get together and transfers

to the hulls hummer mill, at the end it will go the hulls bin.

3.1.2.6) Cooker: Cracked seeds will enter the cooker, this cooker has 10 trays and the beans should be heated at certain

temperature around 65 degree centigrade. Basically there are two ways to heat up the beans by direct

injection or indirect, also, the moisture range should be from 9 to 11 % or so. As a result the main purpose

of the cooker is to maintain the moisture at the range. At the end the cooked seeds will transfer to the

flakers through conveyor.

3.1.2.7) Flakers: This is one of the most important machines which has main purpose to increase the cross sectional area

which make the seeds easier to be extracted. Furthermore, those seeds should have certain size of

thickness around (.35 to .4).

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Generally flakers have the following parts:

-ROLLS.

-MACHINE FRAME WITH BEARINGS FOR THE ROLLS AND THE ROLLS PRESSING.

- FEEDING DEVICE.

-HYDRAULIC UNIT.

- SUPPLEMENTRY DEVICE.

3.1.3) Extraction:

3.1.3.1) Extractor: The flex comes from the preparation and go inside this huge machine (Extractor). Beans oil will be

extracted by spraying (counter flow) the hexane into the flex. As a result, combination of the hexane and

the oil will appear and this material called (Miscella) obviously it appears in a liquid phase. Mostly the

flex has a range of oil from 18 to 21%. Hexane has its tank so the extractor will be contacted to that tank.

Basically, the Extractor will output two things (Solid) which is the hexane + the flex, and (liquid) which

is the miscella hexane + oil. The first one will go to DTDC (Desolventising, Toasting, Drying and

Cooling); however the miscella will go to distillation unit.

3.1.3.2) DTDC (De-solventizing, Toasting, Drying and Cooling): This machine has eleven trays to do the duty, first five from the top are using in de-solventizing process ,

the temperature in this area is around ( 90 – 100 c ) , then the flex will move to the toasting area which

has three trays , also it has almost the same range of temperature . After that the flex will enters the dryer,

from its job you can know that the temperature in this area is the highest, usually from 103 to 105

degrees. In the last single tray for cooling process, hexane will evaporated when the temperature reaches

68 degrees. This process should output at the end meal without hexane.

3.1.3.3) Distillation Unit: Miscella that went out from the extractor will start a new journey in the distillation area. First it goes to

special tank to save it for a while until the SCADA system gives the permission to start the treatment.

Miscella faces the first stage which is the primary evaporation at this point miscella in range of

temperature around 60 degrees or so, it enters the evaporator from the bottom until it reaches the Jacket,

the jacket got injected by steam in temperature around 70 degrees so the evaporated hexane will be

transferred to the condenser and the rest of miscellla will continue to the second evaporation stage. Heat

Exchanger will show up as the first point of this stage and this exchanger has to increase the temperature

to 115 degrees so it can go to the stripper. Stripper considered to be the last stage of distillation unit here

more hexane will be evaporated and oil will be dropped, as a result we get almost pure oil. This pure oil

should visit the oil dryer after it got cleaned. Hexane percentage in the secondary evaporation is around

(75 to 80 %), however oil percentage is around (15 to 20%).

3.1.3.4) Solvent recovery or Hexane recovery: The whole evaporated hexane will go through different condensers just to make liquefied for reusing

process. There are six condensers five are regular and one is large each one got the vapor from different

sources, the water supplied condensers either by chilled water or cooled water from the cooling tower .

All the condensed hexane will be collected at the hexane tank.

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3.1.3.5) Absorption Area: There are a few vapor hexane remaining from the process and it didn’t go through the recovery so this

unit will take care of the rest of the hexane. Hexane will pass through column called oil stripping column

in this column mineral oil will be showered to the hexane (Vapor) so it will be heated after that in two

heat exchangers then it will go to the evaporator. The remaining hexane will be vacuumed and go to the

condenser, on the other hand, the usable mineral oil will be reused again for the same goal.

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4. Health, Safety and Environment Department (HSE):

Objectives: - Knowing how to deal with instruction of each instrument or machine from safety

perspective.

- Familiarization of different kinds of safety tools.

- Knowing the different kinds of polluted areas.

Safety:

Learning many things especially about any reaction anyone should take during any emergency

case. Safety is a major area which has a lot of procedures and regulation tools. Clarifying the

major procedures as following:

- General accident: minimizing the damages as much as it can be.

- Hot work area: such as (welding), giving the specification and the warning to the wilder

guy.

- Confined space.

- Cold work: such as (drilling, forging…ETC)

- Tag-out or lock out.

- Elevated places.

Regulation: - Wearing the suitable outfit for each area of the industry.

- Wearing helmets and leather gloves in specific areas.

- Walking on the sides of the industries roads.

- Knowing the speed limits for cars.

- Reading the tags or captions on the machines.

From environmental perspective:

There are four major areas that might be polluted:

- Land: trashes.

- Water: the wasted water from industries or power plant.

- Air: gases that go away from industries and how to minimize the damage and know the

limits.

- Noise: such as noises coming from transportation specially cars and machines.

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Conclusion: When I decided to take my training course, I applied to several big and small industries. Many people

advised me to go to a big company such as Aramco which made me hesitate about going to SOYA.

However, I decided to pick SOYA at the end and now I do not regret it at all. I gained so much experience

in a very short period. As a small industry, SOYA is still new comparing to other big companies. I was

able to observe some technical issues and how they can be fixed. Moreover, I was trained in most of the

departments since they are small and easy to be reached. Also, I was the first and only student to take a

summer training course in this company which was interesting to all of the supervisors. They were

teaching, guiding, encouraging me and observing how I will progress.

Finally, SOYA was the best choice to me for my training. I was guided by outstanding supervisors. I was

also surrounded by a great and hard-working staff that was helpful and friendly as well. Even though

there were some general issues because the company is considered to be new and not yet fully organized,

the work environment was very comfortable and appealing. I believe SOYA has a promising future and I

wish all the best for this industry.

19

Appendix

Figure 1: Switch Panel (Boiler)

Figure 2: Small condenser to check the water

in the boiler

Figure 3: Pipes that provide steam to the plant

(boiler plant)

Figure 4: Chiller (display screen)

Figure 5: Boiler

Figure 6: Chemicals used in the waste water

treatment

20

Figure 7: ETP (aeration system in waste water

tank)

Figure 8: Oil separator (manually)

Figure 9: ETP (fast mixing tank)

Figure 10: ETP (slow mixing tank)

Figure 11: Safety

Figure 12: Meal storage

21

Figure 13: Aeration system for the silos

Figure 14: The tunnel

Figure 15: Day bins

Figure 16: Conveyor (elevator)

Figure 17: Shipment scale

Figure 18: Silo

22

Figure 19: Cooling tower

Figure 20: Cooling tower (top view)

Figure 21: Veg crude oil tanks

Figure 22: Pumps (veg crude oil area) for

discharging or loading

Figure 23: Trucks for loading veg crude oil

Figure 24: Lecithin storage

23

Figure 25: Lecithin product

Figure 26: Filtration system for Lecithin

Figure 27: Lecithin plant (filling area)

Figure 28: Ship unloader

Figure 29: Fans at the top of the seed dryer

(pre-cleaning)

Figure 30: Burner at the seed dryer (pre-cleaning

plant)

24

Figure 31: Specifications for one of the motors

Figure 32: Proximity sensor (Switch)

Figure 33: Safety training (Fire extinguisher)

Figure 34: Extractor

Figure 35: Extractor (Side view)

Figure 36: Wire (Sample)

25

Figure 37: Workers trying to repair the tool by

taking it out from the cracker

Figure 38: Cracker while it is opened

Figure 39: Minor shutdown at preparation area

(Repairing & fixing the cracker)

Figure 40: Lecithin plant & oil tanks

Figure 41: Cyclone

Figure 42: Rotex

26

Figure 43: Rotex (Side view)

Figure 44: Screener (Rotex)

Figure 45: Cooker

Figure 46: Cooker (from upstairs)

Figure 47: Hammer mill

Figure 48: Hammer mill (Different one)

27

Figure 49: Flaker

Figure 50: Flaker (Different view)

Figure 51: Conveyor

Figure 52: Meal conveyor

Figure 53: Hulls conveyor

Figure 54: Cracker

28

Figure 55: Seed cleaner

Figure 56: Day bin

Figure 57: Cutting tool

29

References

1. My own notes and logbook

2. Company manual for (cooling tower)

3. YORK manual for (chiller)

4. GPS Group manual for (ship unloader)

5. Boiler manual

6. American Trainco (description for the boilers)

7. Different manuals from company.

8. Pictures was taken by my own camera.