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Design and Construction of Oil Expeller Press with Structural Analysis of

Screw with Ansys

Conference Paper · December 2016

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Md. Habib Ullah Khan Dipayan Mondal

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 International Conference on Mechanical, Industrial and Energy Engineering 2016
26-27 December, 2016, Khulna, BANGLADESH

ICMIEE-PI-160363
Design and Construction of Oil Expeller Press with Structural Analysis of Screw with Ansys

Md. Habib Ullah Khan, Dipayan Mondal, Shahidul Hoque

Department of Mechanical Engineering, Khulna University of Engineering & Technology, Khulna-9203, Bangladesh

ABSTRACT
This project work represents the design and construction of an oil expeller press, performance test of it with several raw
materials e.g. coconut, rape seed, sesame, sunflower seed and structural analysis of the screw. There are several processes
to extract oil from these e.g. chemical, centrifuge and mechanical. A mechanical oil expeller press was designed, constructed
& further analyzed with simulation software (ANSYS) in this research work. This expeller can be useful for small scale oil
extraction. ASME shaft design code was used in designing the screw shaft of the press. Locally available material (mild
steel) was used in manufacturing of the expeller. A 20 hp 3-phase electric motor was used for running the machine and the
rpm of the screw was maintained 140 rpm. A screw rotates inside the barrel of the press which creates pressure for the
extraction of oil. Raw material is feeded through hopper & compressed inside the barrel for oil extraction and the cake is
discharged through a choke mechanism outside. The pressure on screw was determined & applied in the created meshed
design in Ansys. From the achieved stress analysis it can be concluded that the screw used in this project is within safety
limit of stress. The expeller has an efficiency & capacity ranging between 68.2% and 85.22 gm/min~98.52 gm/min
respectively.

Keywords: ASME shaft design, Ansys, Mechanical Oil extraction, Stress analysis, Efficiency

1. Introduction For this heat generation it faces some common problem

Oil can be produced from coconut, sesame, sunflower including overheating, excessive thermal stress,
seed, rice, canola, camelina, soybeans, sugar cane, wood dimensional stability and other thermal related factors.
and rape seed. But oils aren’t get directly & so easily By analyzing through simulating software design
from these sources. They must be extracted in a process verification of parts used in screw presser can be
having particular purity factors so that they remain usable. modified and increase performance efficiency [5].
Several extraction process evolved over time & the main Limitation of our research is it will only discuss about the
two of them are mechanical & chemical extraction [1]. screw press extraction method yet there is another oil
Oil expeller is a device which can produce pressure by extraction method the solvent extraction. Solvent
rotating feed to expeller screw manually or automatically. extraction is quite efficient method for this purpose hence
Screw press method for oil extraction is a mechanical it discharges press cake having less than 1% oil content.
method for extracting oil from raw materials. Oil In spite of having high efficiency it possess some
extracted by screw pressing is used either as a food drawbacks. Firstly, solvent extraction process isn’t
product or as an industrial product. Food products suitable for small scale production. Secondly, it requires
include raw oil in dressings and made up to corn oil, a costly plant & equipments. Thirdly, the commercially
peanut oil, rice bran oil etc. One of the disadvantage of available hexane used in this process react with air to
screw pressing is the low oil recovery when processing yield explosive mixture. As our research goal isn’t
untreated seeds. But major concern is on it because it fulfilled by this method it’s further study is omitted [2].
requires less capital & it can be used for low production. In our research we introduced the simulation in purpose
Food oils typically found in the markets are refined, of stress & displacement analysis of the installed worm
bleached & deodorized known as RBD oils [2]. In screw shaft. Worm shaft is the heart of screw press as it supplies
press method seed is confined in barrel through hopper the pressure required for extracting oil from the raw
and extraction of the oil is accomplished by exerting materials. It is found from observation that the failure of
sufficient force on confined seed. Under this condition screw causes extra costs which is undesirable. In addition,
pressure is high enough to rupture the cells and force oil excess stress, bending, displacement may cause major
from the seed to come out. Extraction is accomplished by overhaul of the press. So to increase the life of screw
compressing the material in a container that has small press & efficient oil extraction it is necessary to find
perforations, either round or slotted that allow the liquid exact stress & bending of the screw blades. So to
component to leave. The residue of the material from determine these, simulation is introduced which is
which oil has been expressed exits from the unit and is performed by FEA (Finite Element Analysis) with
known as the cake. The seeds are continuously fed to the ANSYS software [3].
expeller screw which grinds, crushes and presses the oil
out as it passes through the machine. During this 2. Material and Method
operation for high friction co-efficient it generates a Locally available material mild steel was used in
higher amount of heat. Pressure involved in expeller construction of the oil expeller. In the construction of oil
pressing creates heat in the range of 140-210°F (60-99°C). expeller firstly it was designed and validity of stress

* Corresponding author. Tel.: +88-01912104224

E-mail address: [email protected]
checked in Ansys. After constructing the oil extraction Kt = Combined shock and Fatigue factor
barrel rectangular bars were placed surrounding it as it applied to Bending Moment
permits the passage of oil only and helps to create Kt = Combined shock and Fatigue factor
pressure inside the barrel. The choke mechanism was set applied to Torsional Moment
in the screw at the outlet of extraction barrel. It was Ss = Allowable Shear Stress in Shaft
adjusted accordingly to control the output of wastage and
to increase and decrease pressure accordingly. A 3.1.5 Load Lifted by Screw
reducing gear was used to reduce the rpm of the motor Dm 
and to increase the energy in the screw shaft. V-belt was tan  
We  2 cos  (3)
used for the transmission of power. 1   tan  cos 
Here,
Dm = Mean Thread Diameter
µ = Co efficient of friction
α = Tapering angle
θ = Tapering Angle
3.1.6 Pressure Lifted by Screw Thread
Ap  Dm nh (4)
We
Pr  (5)
Ap
Fig. 1. Main Parts of the Oil Expeller Here,
Fig.1 Main Parts of the Oil Expeller Ap = Pressing Area
h = Screw depth at maximum pressure end
3. Design Structural Analysis and Construction n = No. of Threads
3.1 Design
3.1.1 Design Criteria 3.1.7 Capacity
i. High oil extraction efficiency

ii. Low extraction loss Qe  60 Ds 2  d s 2 Ps N s (6)
iii. Better quality of oil 4
iv. Availability of construction materials Here,
v. Ensure maximum pressing of worm Ds = diameter of the screw thread
shaft ds = base diameter of the screw thread
Ps = Screw pitch
3.1.2 Findings Ns = rotational speed of the screw shaft
To Increase Pressure: Φ = filling factor
Reducing the length of the screw flight pitch in the ρ = bulk density
direction of the axial movement
Oil Releasing Through the Slots of the Barrel Cage: 3.1.8 Power
The gradually increasing pressure releases the oil which P  Ts   s (7)
flows out of the press through the slots provided on the
periphery of the barrel while the press-cake continues to 3.1.9 Torque on the Screw Shaft
move in the direction of the shaft towards a discharge f
tan  
gate installed at the other extremity of the machine. cos  n
T s Frm (8)
f tan 
3.1.3 Torque on Rotating Shaft 1
cos  n
63000hp
T (1) Here,
n
F = Axial Load
Here,
rm = Mean Thread Diameter
hp = horsepower of motor,
α = Screw Thread Lead Angle
n = motor rpm

3.1.4 Diameter of the Screw Shaft 3.1.10 Longitudinal Stress

PDm
l  (9)
16 ( Kb  Mb) 2  ( K t  M t ) 2 4t
D 
3 (2)
S s
Here, 3.1.11 Hoop Stress
D = Shaft Diameter PDm
H  (10)
Mb = Bending Load 2t
Mt = Torsional Load

ICMIEE-PI-160363- 2
Here,
P = Pressure
Dm = Mean Diameter

4.0 Design, Structural Analysis and Construction

4.1 Torque on Rotating Shaft
63000hp
T (11)
n
Here,
Horsepower of motor = 20 hp
Motor RPM = 1507
Hence, T = 836.09 in-lb or 94.465 Nm

4.2 Diameter of the Screw Shaft Fig.2 Screw of the Oil Expeller
ASME code of shaft design,
16 ( K b  M b ) 2  ( K t  M t ) 2 4.3 Load Lifted by Screw
D3  (12) Dm 
S s tan  
Here, We  2 cos  (14)
D = Shaft Diameter 1   tan  cos 
Mb = Bending Load Here,
Mt = Torsional Load Dm = Mean Thread Diameter = 0.05969 m
Kt = Combined Shock & Fatigue Factor µ = Co efficient of Friction = 0.15
Applied to Bending Moment α = Tapering angle = 15°
Kb = Combined Shock & Fatigue Factor θ = Tapering angle = 3°
Applied to Torsional Moment Hence, Load lifted by screw, We = 14.96 kN
Ss = Allowable Shear Stress in Shaft
Value of Kb & Kt for rotating shaft if applied to 4.4 Pressure lifted by screw thread
minor shock is Ap  Dmnh (15)
Kb = 1.5 ~ 2 We
Kt = 1.0 ~ 1.5 Pr  (16)
Assuming, allowable shear stress Ss = 400 Mpa or
Ap
N/mm2 Here,
.5S s Ap= Pressing Area
Now, Permissible,   (13) h = Screw Depth at Maximum Pressure or at discharging
fs
end = .085 m
Here, fs = factor of safety = 3 (Assuming) n = No. of Threads = 4
.5  400
Hence,   or τ = 66.67 N/mm2 Hence, Ap = 0.064 m2
3 It can also be determined from Solidworks Mass
Assuming, Belt drive maximum tension = 2.5 kN, µ = properties tools which was found to be 0.064 accurately
0.24, θ = 180° as the relation of Hall et al.
So, Pr = 2.34*105 Mpa
P1
Now,  e   e.24  2.125
P2 4.5 Capacity

2500 Qe  60 Ds 2  d s 2 Ps N s (17)
P2 = or, P2 = 1176.47 N 4
2.125
Here,
Torque, Mt = (P1 - P2) * radius Ds = diameter of the screw thread = 0.07493
or, Mt = 330882.5 Nmm ds = base diameter of the screw shaft = 0.034
Bending Moment, (P3-P4)*R2=Mt Ps = screw pitch 1.6
or, (P3-P4)*125 = 330882.5 Ns = rotational speed of the screw shaft = 137 rpm
So, P3 = 5000 N φ = filling factor = 0.8
P4 = 2352.94 N ρ = bulk density = 415 kg/m3
From, Bending Moment Diagram, Mb= 1185625.45 Hence, Capacity, Qe = 22.25 kg/min
Nmm
16 (1.5 1185625.45) 2  (1 330882.5) 2 4.6 Power requirement to drive the screw shaft
So, D3  (Khurmi & Gupta, 2004)
  66.67
Designed rpm of shaft = 140 rpm
or, d = 51.41 mm
2N
or, d = 2.02 in  (18)
60

ICMIEE-PI-160363- 3
or, ω = 14.66 rad/sec
Now, Power, P  Ts   s (19) 4.8 Rectangular Bar Design
f Rectangular bars surrounds the extraction chamber in a
tan   rigid way that it only allows oil content to pass through it
cos n
Again, Ts  Frm (20) & also helps to increase pressure. It was designed in
f tan 
1 Solidworks & checked for validity in the construction.
cos n
Here,
F = Axial Load
rm = Mean Thread Diameter
α = Screw Thread Lead Angle
f = co efficient of friction = 0.30
θ = 30°

Lead Angle
tan   (21)
2rm
Now, rm = .0295 m
Pitch, P = 1.6
Hence, tanα = 404.63 Nm Fig.5 Rectangular Bars
So, P = 404.63*14.66 = 5,931 kW
4.9 Pulley Design
4.7 Extraction Chamber Design Assumed rpm in the worm screw = 140 rpm through
The extraction chamber is designed based on the thin reduction gear & rpm in the pulley = 380
walled pressure vessel theory. According to this there are Motor sheave diameter, Dm= 6 in
2 types of stresses acting inside the vessel: Motor rpm = 1507
a) Longitudinal stress Hence, from the relation,
b) Hoop stress N1D1 = N2D2 (24)
the diameter of the pulley was found.
The diameter of pulley is, Dp = 23.79 in
In construction work the pulley diameter was 24 inch

Fig.3 Longitudinal and Hoop Stress

PDm
Longitudinal stress,  L  (22)
4t
PDm
Hoop stress,  H  (23)
2t
Here, P = Pressure
Dm= Mean Diameter
Since hoop stress is double than longitudinal stress.
Design is based on hoop stress.
Assuming, σH = 40 Mpa, P = 15 Mpa
Given, Dm= 64.7 mm
Hence, we get reasonable value of extraction chamber
thickness, t = 24 mm Fig.6 Pulley

4.10 Structural Analysis

Screw expeller is widely used for oil extraction in which
the screw is the main part. The extraction of oil, it’s
characteristics depends on this part. So a detailed analysis
of it is necessary for making the design effective & for
achieving better quality of oil. As finite element method
is cheap, most effective & very accurate it is used for the
detailed analysis for this research work. In this research
work the following software have been used e.g.
Solidworks & ANSYS. The result of this outcome may
be used for the further improvement of the screw.
Fig.4 Oil Extraction Barrel

ICMIEE-PI-160363- 4
 Fig.7 Screw for Structural Analysis
Fig.9 Maximum Shear Stress of screw
A 3-D model of the screw was developed in Solidworks
& saved as x_t format for exporting in ANSYS. Static 4.11 Constructed Screw Expeller
structural analysis system was used for the analysis of the
design. The model was imported using command import
external geometry file. Then the model was meshed using
advanced sizing function. The minimum edge length was
7.62 mm. There was 145,370 nodes & 94794 elements in
the mesh. Volume 5.1272e+005 mm³ & mass 4.0248 kg.
Structural Steel is used as the material of the screw.
Different parameters of structural steel are: Density ρ =
7,850 kgm-3, Tensile yield strength = 250 MPa,
Compressive yield strength = 250 MPa, Tensile ultimate
strength = 460 MPa. Rotational velocity of the screw is
140 rpm which is around X-axis in clockwise direction.
The other two ends are bearing support assumed as
frictionless support. These conditions defines the full Fig.10 Constructed Screw Expeller
conditions of the constraints.
5.0 Results Conclusion and Recommendation

80
3 phase motor
70 1507 rpm
60
50
Extracted oil

40
30 Coconut

20 Rape seed
Sesame
10
Sunflower seed
Fig.8 Meshed Design 0
0 100 200 300 400
The stress acting in each screw thread as determined Feed
previously now applied in the thread as per direction
satisfied. After defining the analysis setting simulation is Fig.11 Variation of Extracted oil with respect to feed of
carried on for maximum shear stress. By putting the raw
pressure consecutively 0.938 Mpa, 0.469 Mpa, 0.312
Mpa, 0.234 Mpa on each screw thread determined as From the above graphs it had been obtained that for each
from chapter 3 section 3.8 of this paper stress was of the raw materials variation of extracted oil with respect
analyzed in ANSYS as fig. 9 From the stress analysis it feed of raw approaches to a constant value and variation
is found that the maximum stress developed in the screw of extracted oil with respect to time increases almost
shaft is 1.40 MPa maximum and 0.00115 MPa minimum. proportionally. In this project work performance of the
The maximum stress occurs at the discharged end and the constructed expeller was tested for four different raw
minimum stress at the beginning or front of the screw. materials e.g. coconut, rape seed, sesame & sunflower
From these values obtained the screw can be designed seed. In all together the performance varied between
more effectively for efficient expelling of oil from raw
material and to achieve a long life too.

ICMIEE-PI-160363- 5
 26.6%~41.932% for Oil Expected Ratio (OER), IJRUT
66.5%~71.07% for Oil Extracted Efficiency (OEE), [6] Mr.Mangesh A Pachkawade, Prof.Pawan A
Chandak “A review on design and analysis of oil
60 expeller spares” Volume 1, Issue 5, December 2013,
IJRUT
50 [7] Salunkhe, D. K. World Oilseeds: Chemistry,
Technology, and Utilization. Van Nostrand
Reinhold, 1992
Oil Extracted (gm)

40
[8] Salunkhe, D. K. World Oilseeds: Chemistry,
Technology, and Utilization. Van Nostrand
30 Reinhold, 1992
Coconut
20 Rape seed

Sesame
10 Sunflower seed

0
0 2 4 6 8
Time (min)

Fig.12 Variation of Extracted oil with respect to time

94.398%~97.3% for Material Discharge Efficiency

(MDE), 85.22 gm/min~98.52 gm/min for Machine
Capacity (MCP). From the stress analysis the perfect
clearance between the screw & barrel can be determined
of the machine. The safe functioning of the screw was
also checked in ANSYS by applying the pressure on
thread. The efficiency of the machine could be further
improved by cutting inner grove of the bars for ease of
extracting oil from smaller seeds as rape seed, sesame etc.
It is efficient only for small scale production. Failure of
screw causes undesirable costs under excess stress and
bending deformation. Danger may occur frequently due
to any parts failure. Vibration is dangerous for this
machine causing annoying noise and destruction. It is
recommended to use chromium alloys instead of steel in
construction of screw as steel is harmful for human health.
From the calculation the motor required was 10 hp 3-
phase but a 20 hp 3-phase motor was used due to
availability.

REFERENCES
[1] Peter Beerens “Screw-pressing of Jatropha seeds
for fuelling purposes in less developed countries”
Eindhoven University of Technology, Department
of Sustainable Energy Technology
[2] PELİN SARI “Preliminary design and construction
of a prototype canola seed oil extraction machine”
MIDDLE EAST TECHNICAL UNIVERSITY
[3] Gopala Krishna A.G “Use of Low Temperature for
the Production of Superior Quality Rice Bran Oil”
Department of Lipid Science & Traditional
Foods,CSIR-Central Food Technological Research
Institute (CSIR),Mysore – 570 020
[4] Lawson, Harry W. Standards for Fats and Oils. Avi
Publishing Company, 1985
[5] Mr.Mangesh A Pachkawade, Prof.Pawan A
Chandak “A review on design and analysis of oil
expeller spares” Volume 1, Issue 5, December 2013,

ICMIEE-PI-160363- 6

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