Technologicalupdate

onedibleoilrefiningprocesses

VincentFiers‐DesmetBallestraGroup

OFITECHNICAL/SCIENTIFICCONFERENCE

Tuesday13thMay2014Istanbul‐Turkey

Edible Oil Refining : Where are we now ?

2

CrudeOil

Waterdegumming

AlkaliNeutralisation

Deodorization

RefinedOil

Soapstock

Spentbleachingearth

DeodorizerDistillate

MechanicalPressing

OILSEEDS

OilExtractionSolventExtraction

WDGOilAciddegumming

Bleaching

PhysicaldeacidificationDeodorization

AcidGums

DeoiledMeal

Gums LECITHIN

Chemical Physical

Bleaching

Current developments in edible oil refining

Improvedchemicalrefining*Implementationofnano‐reactortechnology

Enzymaticdegumming*Efficientdegummingandhigheroilyield;

*Missinglinkforphysicalrefiningofsoftoils?;

Bleaching*Fromsinglestagecolorremovaltomulti‐stageadsorptivepurification

Developmentsindeodorization*Moreefficientprocesses(lessoillosses,bettervalorisationofsidestreams)

*Milderdeodorization(lowertemperature–lowerpressure):ice

condensing

Interestremainsfora“nextgeneration”chemicalrefining

Stillmostwidelyappliedrefiningprocess*Independentofcrudeoilquality(‘forgiving’process);

*Usuallygivesgoodrefinedoilquality(‘effectofcaustic’);

*Mostsuitableprocessforstand‐alonerefineries;

But,withitsknowndrawbacks*Highneutraloillossesinthesoapstock(especiallyforhigherFFAoils);

*Difficultvalorizationoftheacidoil;

*Difficultandexpensivewastewatertreatment(environmentalissue);

Chemical Refining

Static Dynamic HighShear UltraHighShear (singlestage) (multi‐stage)

More efficient mixing

Howcanwefurtherimproveefficiency?

Higherenergyinputbutlowerchemicalsconsumption

MoreefficientGums/FFARemoval&LessMoreefficientGums/FFARemoval&LessSoapstockSoapstock

Hydrodynamic Nano Reactors®

• Uniqueinternalgeometry

• Generationofverysmall‘nano’bubblesinliquidstreams

• Liquids(homogeneous/heterogeneous)arefedtonano‐reactorwithhighpressurepump

• Mechanicalandchemicaleffects

Formationofveryfineemulsions Increasedsurfacearea Extremelyhighshearforces

Activationofatoms,molecules Disruptionofmolecularagglomerates

ProprietarydesignofCTI

Atruereactor,notjustabettermixer

HighPressurefeedpump Nano‐reactorassembly

Nano Neutralization

*Patentpendingprocess

*Add‐ontoexistingneutralizationline

500TPDNanoNeutralizationofsoybeanoilIndustrialdata

Nano Neutralization

Industrialplant:500TPD

• 0.1‐0.3%oilyieldimprovement

• 90%lessphosphoricacid

• 30%lesscausticsoda

• lesswashwater/silica

Nano Neutralization: proven advantages

Nano Neutralized vs conventional refined oil

QualityParameters

SoybeanOil

Industrial

Nano‐refined

Conventional

Chemicalrefined

FFA(%C18:1)

P(ppm)

Fe(ppm)

TransFA(%)

Color(R–51/4”)

Tocopherols(ppm)

OSI(hrat97.8°C)

0.02

<1

<0.05

0.53

1.2

815

15.5

0.02

<1

<0.05

0.57

1.2

792

15.7

Nano‐neutralizat°hasnonegativeeffectonrefinedoilquality

ComparisonofindustrialrefinedsoybeanoilsamplesComparisonofindustrialrefinedsoybeanoilsamples

11

1.Nano‐degummingofcrude/WDGoils

• Deepdegummingtoallowphysicalrefining

2.Nano‐degummingofpalmoil

• Replacingthe‘dry’phosphoricaciddegumming

•Alsosuitableinbiodieselfeedstockpretreatment

3.Enzymeassistednano‐degumming

Stillintestingphase

Other Potential Applications

Developments in deodorization

Improved Deodorizer design Qualistock +

HighstrippingefficiencyImprovedheatrecoveryLightfuelconsumptionReducedlossesandimproveddistillatequalitySplashoileliminated

Allmajorsectionscombinedintosinglevessel

Deodorizer design

Highstrippingefficiencyinadeepbeddeodorizerwithspecialdesignedsteamliftpumps

HighstrippingefficiencyHighstrippingefficiency

Deodorizer designDeodorisingDeodorisingbybyGasGasLiftLiftPumpPump

• Steamentersthegasliftpumpthroughacentraltube

• Steamrisesupthetubedrawingoilwithit

• Oilisdeflecteddownwardsbytheconicalhat

• Steamrisescarryingawayimpurities

Steam

GASLIFTPUMPINACTIONGASLIFTPUMPINACTION

Lightfuelconsumption(2.5to3.0kg/TLightfuelconsumption(2.5to3.0kg/Tforcontinuousdeodorizer)forcontinuousdeodorizer)

Deodorizedoilenteringtrayfromuppersection

Deodorizedoilleavingtraytocoolingsection

Coldbleachedoil‐in

Preheatedoil‐out

•Virtuallyclogfreelargeborepipes•Highlevelofheatrecovery

Deodorizer design

• Increasesacidityofthefattyaciddistillate

• Recoversvaluableby‐products(tocopherolconcentrates)

DoubleFattyAcidsCondensationSystemDoubleFattyAcidsCondensationSystem

Deodorizer design

Stripper/deodorizer with DOUBLE scrubber Stripper/deodorizer with DOUBLE scrubber NB Oil

CHEMICALDB Oil

PHYSICAL

FFA (% C18:1)Tocopherols (ppm)

0.11200

0.61200

NBD Oil DBD Oil

FFA (% C18:1)Tocopherols (ppm)

< 0.03511

< 0.03515

HOT DISTILLATE

FFA (% C18:1)Tocopherols (%)Yield (kg/ton)

7.521.792.55

14.818.232.52

COLD DISTILLATE

FFA (% C18:1)Tocopherols (%)Yield (kg/ton)

76.50 92.95 2.97 2.07 1.05 5.97

Dual condensation for tocopherol recovery

Qualityparameter Temperature Time Pressure Steam

Taste

Color(heatbleach)

FFAstripping

Transfattyacidformation

T o c o p h e r o l / s t e r o l

stripping

Contaminantremoval1

+

++

++

++

++

++

++

+

‐

++

‐

‐

+

‐

++

‐

++

++

++

‐

+

‐

+

+

Contaminants : Pesticides, PAH, dioxins

Legend : ‘-‘ : little or no effect, ‘+’ : ‘significant effect, ‘++’ : large effect

Deodorized oil quality : effect of process variables

Vacuum production in deodorization

Conventional deodorizers commonly operateat a pressure of 3-4 mbar

Empirical requirement for “good” deodorization:

8 m3 sparge steam /kg oil (230-250°C)

Trend to go to lower pressures: 4 > 3 > 2 > 1.5 mbar

1.5 > 1 > 0.5 mbareg. 240°C 3 mbar 10 kg/ton 780 m3/kg steam

2 mbar 6.7 kg/ton 1170

1.5 mbar 5 kg/ton 1560

1 mbar 3.3 kg/ton 2340

0.5 mbar 1.7 kg/ton 4680

Low deodorizing pressure

Benefits

‐Betterstrippingefficiency(atsamedeodorizingtemperature)

‐Samestrippingefficiency(atlowerdeodorizingtemperature)

‐Lowerdeodorizingpressuremaythereforeresultin:

‐lessunwanteddegradationreactions;‐moreneutraloillossesduetostrippingofvolatilemonoglycerides

Technology

‐Closedloopsystemswithchilledwater

‐DryIceCondensingsystems

Conventional vacuum systems

‐Combinationofsteamjetejectors(boosters),vapourcondensersandmechanical(liquid‐ring)vacuumpump

‐Highmotivesteamconsumption(60‐85%oftotalsteam)

Vacuum systems

CONVENTIONALDIRTYWATERVACUUMSYSTEM

‐Highsteamconsumption

‐Odourproblems

‐Higheffluentemission

CLOSEDBAROMETRICVACUUMSYSTEM

‐Highersteamconsumption

‐Reducedodourproblems

‐Highereffluentemission

Vacuum systems

CHILLEDBAROMETRIC

VACUUMSYSTEM

‐Reducedsteamconsumption

‐Reducedodourproblems

‐Reducedeffluentemission

‐Vacuumof1to1.5mbarinthedeodorizerispossible

Vacuum systems

ICECONDENSINGVACUUMSYSTEM

‐VeryLowsteamconsumption

‐Muchreducedodorproblem

‐Muchreducedeffluentemission

‐Vacuumof1to1.5mbar

inthedeodorizerispossible

Vacuum systems

ICECONDENSINGVACUUMSYSTEM

Condensationofsteamintoiceonsurfacecondensers

Lowpressurecanbereached(<2mbar)

Vacuum systems

Vertical tube

Topview

falling NH3film

‐ largetubediameterwithlargetubepitch‐ fallingfilm,constanttemperaturealongentiretube

‐ lowsystemrefrigerantmass‐ selfdraining,easytode‐iceandclean‐ nometal‐metalfriction,freeverticalmotion‐ longfreezingcyclespossible‐ compact:smallfootprint‐ peaksincoolingcapacityareminimisedbycontrolledcoolingfromhigh(forcleaning)tolow

operatingtemperatures‐ lowenergyconsumptionduetohighevaporationtemperaturesandfallingfilmprinciple

horizontal tube

Why vertical?

Sublimax

vapors

water

Ammonia

AmmoniaLesssensitivetofouling;Cantakeverydirtyvapors

‐icecondenseraspartialandeventotalvaporcondenser(steam&fatttymatter)

‐skippingcondenserindeodorizationsaves0.5‐1mbar!

Lowpressuredeodorizationat<1mbar

Benefits:

‐betterstrippingatlowertemperature

‐ betterusageofspargesteam(doublingofvolume)

‐ idealforheat‐sensitiveoils

Vertical design with falling film: Sublimax

EnergyEnergyconsumptionconsumptioninincontinuouscontinuousdeodorizerdeodorizer

Vacuumcostperyear(500tpd–Euro)

Vacuum systems

Utility consumption vacuum production/ton oil

Vacuum systemsEnergyEnergyconsumptionconsumptioninincontinuouscontinuousdeodorizerdeodorizer

Icecondenserisnotcheap,butCAPEXisnotkeyfactor,OPEXis...

Chi

lled

wat

erIc

e co

nden

ser

Cle

an c

oolin

g to

wer

Dirt

y co

olin

g to

wer

Euro

Investment and erection cost

HighCAPEX,lowOPEX,goodROI(<3years)C

hille

d w

ater

Ice

cond

ense

r

Cle

an c

oolin

g to

wer

Dirt

y co

olin

g to

wer

saving425

kus$/y

EuroInvestment and erection cost

Conclusions

Newdevelopmentsinedibleoilrefiningare/weremainlyimprovementsofwellestablishedunitoperations.Newtechnologiesareonlyimplementediftheyimprovethe(cost‐)efficiencyoftheprocess.Improvedvacuumsystems(chilledwater,icecondensing)allowbetterproductquality(lowtrans,betterretentionofnaturalanti‐oxydants…)Oilquality(andalsosustainability)becomesmoreimportantandmayleadtonewRefiningprocesses/concepts

ActiveR&Dmorethaneverrequiredinourindustry:

Sciencebehind(new)technologySciencebehind(new)technology

Thank youfor your attention!!!

Contact:

Ir.VincentFiers‐ProductManagerRefining‐DesmetBallestraGroup‐mail:VF@desmetballestra.com