The main factors influencing the crystallization process of crude phytosterols, such as the crystallization termination temperature, cooling rate, stirring speed, and number of recrystallization cycles, were systematically investigated in the present study. Six solvents were selected to extract phytosterols from corn oil deodorizer distillate, while the total phytosterol content and yield were used as evaluation indexes. The results indicated that the total phytosterol content in various solvents increased with higher crystallization termination temperatures, faster stirring rates, or a greater number of crystallization cycles. For the above three factors, taking ethyl acetate as an exemplar, the variations in total phytosterol content were from 70.24 % to 87.57 %, 84.13–92.81 %, and 96.43–99.91 %, respectively. However, under these conditions, the yield of total phytosterol decreased to varying extents. The total phytosterol content in various solvents decreased as the cooling rate increased, whereas the yield of total phytosterol showed varying degrees of increase. The morphological analysis of phytosterol crystals demonstrated that the crystal structure of phytosterol exhibits significant variation depending on the solvent employed, thereby influencing the separation and purification processes of phytosterol crystals. The Pearson correlation coefficient analysis revealed a strong correlation between the selected factors with the total phytosterol content and yield across various solvents. Furthermore, the heat map clustering results indicated that recrystallization using ethyl acetate had a significant effect compared to other solvents, achieving a total phytosterol content of 96.43 % and a total phytosterol yield of 94.25 %. This work holds considerable theoretical and technical significance for the industrialized and efficient production of high-purity phytosterol products. It also provides a feasible solution for the high-value utilization of by-products in vegetable oil processing.
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