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Biorefinery of sunflower whole plant can be conducted with water using a nine modules Clextral Evolum HT 53 twin-screw extruder (TSE). Aqueous extraction of oil is an environmentally cleaner alternative technology to solvent extraction. TSE carries out three unit operations: conditioning and grinding, liquid/solid (L/S) extraction and L/S separation. The compressing action by the reverse screws (CF2C) is essential for L/S separation. Positioned in module 9, CF2C screws push part of the mixture upstream against the general movement in TSE, and this counter pressure ensures the L/S separation efficiency above the metal filter, located in eighth position. Oil is extracted in the form of two emulsions, stabilized by phospholipids and proteins, and usable as co-emulsifiers in cosmetic industry. An aqueous extract containing water-soluble components from whole plant is also generated; it could be recycled. As a mixture of fibers and proteins, the cake can be moulded by thermo-pressing into boards, usable in the furniture and building industries. In this study, fractionation was conducted from next inlet flow rates: 54 kg/h solid and 183 kg/h water (3.4 L/S ratio). The screw speed varied from 249 to 124 rpm, corresponding to a filling coefficient (ratio of the solid inlet flow rate to the screw speed) from 217 to 436 g/h rpm. The filling coefficient directly affects the L/S separation efficiency. The latter can be estimated from next experimental data: the outlet flow rates of both cake and filtrate, the cake moisture content, the residual contents of oil and water-soluble components in the cake, and the extraction yields in dry matter, lipids and water-soluble components. For low filling coefficients (i.e. high screw speed), the L/S mixture compression in CF2C screws is insufficient, not allowing a satisfactory L/S separation. Conversely, for high filling coefficients (i.e. low screw speed), solid particles accumulate more upstream from the pressing zone, obstructing part of the filtering screens and thus reducing the filtration surface. A less efficient L/S separation is then observed. From the experimental data evolution, optimal screw speed was estimated at 182 rpm using a second order polynomial regression, corresponding to a filling coefficient of 297 g/h rpm. Extraction yields in dry matter, lipids and water-soluble components were 22%, 49% and 40%, respectively. Such filling would lead to a specific mechanical energy of 103 W/h kg whole plant processed.

Biorefinery of sunflower whole plant is conducted according to an aqueous process using a twin-screw extruder. Aqueous extraction of oil is looked upon as an environmentally cleaner alternative technology to solvent extraction. Twin-screw extruder carries out three unit operations continuously: conditioning and grinding of whole plant, liquid/solid extraction and liquid/solid separation. Extraction efficiency depends on screw speed, and input flow rates of whole plant and water. In best conditions, oil yield is 57%, and residual oil content in cake meal is 14%. These conditions lead to the co-extraction of proteins, pectins and hemicelluloses. Oil is extracted in the form of two oil-in-water emulsions stabilized by phospholipids and proteins at interface. They could be used as co-emulsifiers for creams production in cosmetic industry. An aqueous extract containing part of the water-soluble constituents from whole plant, mainly proteins and pectins, is also generated. It can be recycled to the process. As a mixture of fibers and proteins, the cake meal can be moulded by thermo-pressing. Denser fiberboards have promising mechanical properties in bending. They could be used in furniture industry. Fiberboards with the lowest densities are more fragile but they could be used for their heat insulation properties in building industry.

International audience; Twin-screw extrusion is an original solution for the biorefinery of sunflower whole plant according to an aqueous extraction process. In best operating conditions, oil yield is 57% and residual oil content in the cake meal is 14%. Oil is extracted in the form of two oil-in-water emulsions stabilized by phospholipids and proteins at interface. The cake meal would be suitable for use in animal feeds and for energy production in pellets burning furnaces. As a mixture of fibers and proteins, it is also considered as a natural composite. It can be processed into biodegradable agromaterials by thermo-pressing. During molding, part of residual oil is expressed (until 41% of oil from whole plant), leading to the increase of the total oil extraction yield (aqueous extraction in twin-screw extruder and expression during thermo-pressing): until 81% of oil from whole plant. Panels have promising mechanical properties in bending (until 12 MPa for stress at break). They are usable as inter-layer sheets for pallets, for their sound and heat insulation properties or for the manufacturing of containers by assembly of panels. Their hydrophobic character (8% for residual oil content in the panels) makes them resistant to water.

Twin-screw extrusion is an original solution for the biorefinery of sunflower whole plant according to an aqueous extraction process. In best operating conditions, oil yield is 57% and residual oil content in the cake meal is 14%. Oil is extracted in the form of two oil-in-water emulsions stabilized by phospholipids and proteins at interface. The cake meal would be suitable for use in animal feeds and for energy production in pellets burning furnaces. As a mixture of fibers and proteins, it is also considered as a natural composite. It can be processed into biodegradable agromaterials by thermo-pressing. During molding, part of residual oil is expressed (until 41% of oil from whole plant), leading to the increase of the total oil extraction yield (aqueous extraction in twin-screw extruder and expression during thermo-pressing): until 81% of oil from whole plant. Panels have promising mechanical properties in bending (until 12 MPa for stress at break). They are usable as inter-layer sheets for pallets, for their sound and heat insulation properties or for the manufacturing of containers by assembly of panels. Their hydrophobic character (8% for residual oil content in the panels) makes them resistant to water.

The objective of this study was to evaluate the feasibility of an aqueous process for the biorefinery of sunflower whole plant using a twin-screw extruder. Aqueous extraction of oil was chosen as an environment-friendly alternative to the solvent extraction. The extruder was used to carry out three essential unit operations: grinding, liquid/solid extraction, and liquid/solid separation. Wringing out the mixing was effective. However, drying of the cake meal was not optimal. Lixiviation of cotyledon cells was also incomplete. Extraction efficiency depended on operating conditions: screw rotation speed, and input flow rates of whole plant and water. In the best conditions, oil yield was 57%. Residual oil content in the cake meal was 14%. These conditions leaded to the co-extraction of proteins, pectins, and hemicelluloses. The corresponding protein yield was 44%. Oil was extracted in the form of two oil-in-water emulsions. These hydrophobic phases were stabilized by phospholipids and proteins at interface. An aqueous extract containing part of the water-soluble constituents, mainly proteins and pectins, was also generated. As a mixture of fibers and proteins, the cake meal was molded by thermo-pressing. Panels produced had interesting mechanical properties in bending. The obtained fractions may have applications as bases for industrial products., Proceedings of the 18th European Biomass Conference and Exhibition, 3-7 May 2010, Lyon, France, pp. 1481-1489

Fractionation of sunflower whole plant is carried out with water in a twin-screw extruder. An extract and a raffinate are produced in a single step. Oil extraction yield is 55%. Lipids are extracted in the form of two oil-in-water emulsions: the higher hydrophobic phase and the lower one. Stability of both hydrophobic phases is ensured by the presence at interface of surface-active agents co-extracted: phospholipids and proteins. Pectins and non pectic sugars complete the dry matter of the lower hydrophobic phase. Hydrophobic phases may have applications for non food uses: biolubricants market, transport of active principles (odours, colours, bactericides, antifungals), and treatment of hydrophilic surfaces. They can be also used for oil production because their demulsification with ethanol is efficient. Oil recovery produces also a precipitate containing proteins with tensioactive properties. The extract contains also a hydrophilic phase (aqueous phase). This largest phase is an extract of the soluble constituents from whole plant: proteins from kernel, pectins from pith and head, and hemicelluloses from stalk. Valorization of hydrophilic phase is difficult because it is much diluted. Nevertheless, it would be potentially recyclable for aqueous extraction. It would be also possible to use it for the production of proteins with surface-active properties and pectins. The raffinate (cake meal) is rich in fibres and proteins with thermoplastic properties. It would be suitable for use in animal feeds and for energy production. It is also a natural composite, and it can be manufactured into biodegradable agromaterials by compression moulding. Panels can be used as inter-layer sheets for pallets or for the manufacturing of containers.

Biorefinery of sunflower whole plant can be conducted with water by thermo-mechano-chemical fractionation in a Clextral BC 45 (France) co-penetrating and co-rotating twin-screw extruder. An extract and a raffinate are produced separately and in a single continuous step. The arrangement of screw profile makes possible to define three successive zones along the barrel, in which the three unit operations of the aqueous extraction process are taking place. (I) The grinding zone consists of a succession of 10 monolobes paddles, and 5 bilobe paddles. It ensures the conditioning and the grinding of solid matter. (II) The extracting zone begins with water injection. It is composed of a second series of 5 bilobe paddles to mix liquid and solid. (III) The pressing zone is the place where liquid/solid separation is realized. Screw configuration is then arranged with reversed pitch screws used to place pressure on the liquid/solid mixture, and positioned immediately downstream from a filter section. Representation of liquid/solid transport inside the barrel is performed thanks to (i) the measuring of the filling of each screw element after visual observation, (ii) the characteristics of the corresponding solid, and (iii) the modelling of the contribution of each screw element to the residence time distribution of solid and liquid phases. Consequently, twin-screw extruder can be represented as the association of a grinder, a liquid/solid extractor, and a liquid/solid separator, in which material exchanges are intensified. Thus, it is possible to predict the evolution of mean residence times of liquid and solid in the three zones of twin-screw extruder with the main operating variables: screw rotation speed, and inlet flow rates of whole plant and water. The decrease of both screw rotation speed and inlet flow rate of whole plant, simultaneously with the increase of inlet flow rate of water, causes the increase of liquid to solid ratio in the extracting zone, and the increase of residence time of solid in the pressing zone. These operating conditions (60 rpm for screw rotation speed, 5.0 kg/h and 20.3 kg/h for inlet flow rates of whole plant and water, respectively) are favourable to an efficient contact between liquid and solid (8.2 for liquid to solid ratio), and to the liquid/solid separation (156 sec for residence time of solid inside the separator). Oil yield is then around 55%, and residual oil content of the cake meal is only 13% of dry weight. The oil is extracted in the form of oil-in-water emulsions. The emulsion stability is ensured at interface by surface-active agents: phospholipids, proteins, and pectins. Extracts are also made up of a hydrophilic phase. This major fraction contains water-soluble components: proteins, and pectins. Raffinates are rich in fibres, and they have also a significant content of proteins with thermoplastic properties. They can be manufactured into biodegradable agromaterials by compression moulding.

Twin-screw extrusion is a powerful solution for biorefinery of sunflower whole plant. Thermo-mechanical fractionation and aqueous extraction are conducted simultaneously. A filter is outfitted along the barrel to collect a filtrate and a cake meal. Best oil yield is 57%. Proteins are also partly extracted, just as pectins. The cake meal is relatively moist (63%), and it is first dried. It is largely composed of fibers (58%). Oil content is 14% (40% of oil in whole plant). Protein content is 7% (51% of proteins in whole plant). As a mixture of fibers and proteins, this natural composite is successfully processed into biodegradable agromaterials by thermo-pressing. During moulding, macromolecular structure of proteins is transformed. Effects of pressure and temperature result in their glass transition. Proteins ensure the agromaterial cohesion. Fibers entanglement also acts like reinforcement. Stress at break and elastic modulus increase with temperature, pressure and time chosen for thermo-pressing. Highest flexural strength at break and highest elastic modulus are 11.5 MPa and 2.2 GPa. Density is then 1.04, and the corresponding panel is also the most resistant to water. Because of its promising mechanical properties, it would be usable as inter-layer sheet for pallets or for the manufacturing of containers.