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...
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Investment and erection cost
HighCAPEX,lowOPEX,goodROI(<3years)C
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saving425
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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:[email protected]