processing lines from gea westfalia separator for the edible oil … · 2018-12-06 · 6 gea...
TRANSCRIPT
GEA Mechanical Equipmentengineering for a better world
Processing Lines from GEA Westfalia Separator for the Edible Oil Industry
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GEA Westfalia Separator
4 OilsandFatsProcessing6 ChemicalRefining7 PhysicalRefining8 ClarificationofPressOil9 Degumming9 WaterDegumming10 SimpleAcidDegumming12 SpecialDegumming14 Super-/Uni-Degumming16 TOP-Degumming18 Neutralization18 StandardNeutralization20 NeutralizationofUndegummedOils21 MiscellaRefining22 Winterization22 WetDewaxing24 ColdRefining25 PolishingFiltration26 Fractionation26 DryFractionation28 ProcessingofBy-Products28 SoapstockSplitting30 GEAWestfaliaSeparatorserv&care
Table of Contents
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GEA Westfalia Separator
Vegetable oil is one of the most importantprimaryfoods.Thequalityofthefinalproductdependsontherefiningmethodandthenatureofthecrudeoil.GEAWestfaliaSeparatoroffersawiderangeofsolutionsdesignedtomaximizevalue, ranging from a separator with a dailycapacityof10tonnesforoperatorsofsmalloilmillstoseparatorswithcapacitiesofmorethan1600tonnesperdayforlargerefineries.
The production processes and technologiesusedmustbeasvariedasthedifferenttypesofoilprocessed.
GEA Westfalia Separator designs andmanufacturesa customized solutionwhich istailoredtomeettherequirementsofthespecificapplication.Thecentrifugeisalwaysfoundatthe heart of the installation. Whether a self-cleaning separator with a maximum level ofautomation or a discontinuously operatingsystem,everycustomerisabletofindthebestsolution ineconomicandtechnological termsfor thier specific production tasks. We notonlysupplythemechanicalseparationfacility,but also supply all other components andsystemsnecessaryforanefficientandreliableproductionline.
Oils and Fats Processing Robust – reliable – efficient
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GEA Westfalia Separator
Processing of oils including:• Soybeanoil• Canolaoil• Sunfloweroil• Animalfat• Cottonseedoil• Cornoil• Fishoil
Our core competence in edible oil refining:• Pressoilclarification• Degumming• Neutralization• Dewaxing• Fractionation• Soapstocksplitting
Special applications:• Ni-catalystremoval• Lecithindeoiling• Bleachingearthdeoiling• Re-refiningofusedfryingfats
Our core competence in oleochemical applications:• Transesterification (e.g.,formakingbiodiesel)• Epoxidizedoils• Mono-/diglycerides• Fattyacids• Glycerin• Soap• Fattyalcohols
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GEA Westfalia Separator
Chemical Refining Different Processes – One Solution
Twoprocesseshavebeendevelopedforrefiningedibleoilsand fats.Thedecisionas towhichprocessistobeuseddependsonthetypeandqualityofcrudeoiltobeprocessed.
Chemical refining is the traditional method,wherethefreefattyacidsofthecrudeoilsareneutralized with caustic soda. The resultant
sodium soaps are separated by means ofseparators. The neutral oils are subsequentlybleachedanddeodorized.Thismethodcanbeusedforreliablyrefiningvirtuallyallcrudeoils,includingoilsoflowquality,withtheexceptionofcastoroil.
The fields highlighted in the dark color represent the core business of GEA Westfalia Separator and are highlighted in this brochure.
Neutralization
Winterization
Bleaching
Deodorization
Edible oil
Soapstocksplitting
Split fatty acids
Pressing Extraction
Press oilclarification
Waterdegumming
Seed
Animal feed
Beans
Drying Lecithin
Bleaching
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GEA Westfalia Separator
Physical Refining
Inthealternativemethodofphysicalrefining,thefreefattyacidsareremovedbydistillationinonestageduringdeodorizing.Afundamentalcriterionforusingthismethodisthatthecrudeoils should be degummed as effectively aspossible.Thisisonlypossibletoalimitedextentwithsomecrudeoiltypes.Otheroils,forinstancecottonseedoilorfishoil,arefundamentallynotsuitableforphysicalrefining.
GEA Westfalia Separator is able to supplysuitable process lines for both processes; wehavelimitedourselvestotheprocessesinwhichcentrifuges are used, or which complementcentrifugelines.
The fields highlighted in the dark color represent the core business of GEA Westfalia Separator and are highlighted in this brochure.
Acid degumming
Winterization
Bleaching
Deodorization
Edible oil
Fatty acids
Pressing Extraction
Press oilclarification
Waterdegumming
Seed
Animal feed
Beans
Drying Lecithin
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GEA Westfalia Separator
Theoilwhichisdischargedfromexpellerpresseshasvarioussolidcontentlevelsdependingontheoilseedtypeandtheconditionofthepress.Inordertoremoveparticularlylargesolidparticles,theoilisusuallyfedintoasettlingtank,whichisusedsimultaneouslyasabuffertank.Insomeinstallations,avibratingscreenisusedforpre-cleaning.Inothers,theoilistakendirectlyfromthepresstothepressoilclarificationunit.
Inorder tosupport theseparationprocess, thesolidsarewettedwithhotwater.Awaterquantityof 1% in relation to the oil quantity isnormallyadequate.Thewaterismixedwiththeoil in thedecanter.Thedecanter–whichisahorizontalscroll-typecentrifuge–continuouslyseparatesthesolidsfromtheoil.
Clarification of Press Oil
Asasideeffectofaddingwater,anyphosphatidespresentarehydratedandthenremovedtogetherwiththesolids.
Inordertoavoidoillosses,thesolidsarereturnedtothepress.Thepurifiedoiliseitherprocesseddirectlyor, if it is storedorsold, it shouldbedriedinavacuum.
Many features for your benefit• Continuoussolidsseparation• Lowcostofautomation• Lowerspacerequirement• Simultaneousdegumming
Seed
Screw press
Press oil
Foots recycle
Screening tank
Press cake
Water
Cleanedcrude oil
Solids
Decanter
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GEA Westfalia Separator
Steam Hot water
Crude oil
Mixer Gums Separator
Sludge
Degummedoil
Vacuumdryer
Vacuum
Asmoothactionpump isused for conveyingthe crude oil to a heat exchanger, whichis used for heating the crude oil to theoptimum process temperature. A quantityof hot water corresponding to the content ofphosphatides in the crudeoil is added to theoilandmixedintensively.Aspecialcentrifugalmixer, which simultaneously conveys the oildirectlytotheseparator,isusedforthispurpose.Thehydratablephosphatidesswellimmediatelydue to the particularly intensive mixing ofoil and water, andnoadditional reaction timeisnecessary.
A separator is used to continuously separatethe phosphatides which are insoluble in oil.They are either added directly to animalfeed or dried in thin-film evaporatorsand sold in the form of lecithin. Lecithinis a valuable by-product, which is used as anemulsifier, e.g., in the food, animal feed,pharmaceuticalandcosmeticsindustries.
Water Degumming
Thedegummedoiliseitherconveyeddirectlytotherefiningstage,orithastobedriedinavacuumifitisstoredorsold.
Many features for your benefit• Lecithinrecovery• Reductionoflossesintherefiningstages
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GEA Westfalia Separator
Simple acid degumming is suitable forpretreatingpalmoil,palmkerneloil, coconutandoliveoilaswellasanimalfats.Thismethodofdegummingaims to reducebleaching earthconsumption in the physical refining process,makingthisanextremelyeconomicalmethod.
Thecrudeoilisinitiallyheatedtotheoptimumprocess temperature in a heat exchanger. Ameteringunitisusedforaddingasmallquantityof phosphoric or citric acid, which is mixedintensivelywiththeoilinacentrifugalmixer.Afterabriefreactiontime,hotwaterisaddedandmixed.
Simple Acid Degumming
The heavy phase which contains phosphatides,proteins,pigmentsandother impurities is thenseparated.Theoilwhichistreatedinthiswayisgenerallysentdirectlytothebleachingstageanddeacidifiedbymeansofdistillation.
Many features for your benefit• Reductionofbleachingearthconsumption• Betterendproductquality• Lessfoulingofdownstreamequipment
Steam Acid Hot water
Holdingtank
Holdingtank
Crudeoil
Mixer Mixer Gums Separator
Sludge
Vacuum
Vacuumdryer
Degummedoil
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GEA Westfalia Separator
This degumming method can be carried outwith slightly modified neutralization lines.Depending on the quality of the crude oil,it ispossible todecidewhether theoilcanberefinedbychemicalorphysicalmeans.However,withrespecttotheresidualgumcontent,itisnecessarytoacceptacompromiseincomparisonwith the more demanding acid degummingmethodsdescribedbelow.
The crude or water-degummed oil is initiallyheatedtotheoptimumhydrationtemperature.Asmallamountofphosphoricorcitricacidisthenaddedandintensivelymixedinthecentrifugalmixer.Afteranappropriatereactiontime,some
Special Degumming
of this acid is neutralized with very dilutedcausticsodaandasufficientamountofwateris simultaneously added for hydration of thephosphatides.Thecausticsodaandwaterarealsomixedtogetherwiththeoilinthenextcentrifugalmixer. The mixer conveys the oil through ahydration reactor to thenextheat exchanger,whichheatstheproducttothecorrespondingseparationtemperature.Phaseseparationthentakesplaceinaseparatortoproducegumsandoil.Theresidualphosphatidecontentwhichcanbe achieved in thiswaymaybe adequate forsome applications. In most cases, however,furtherreductionisrecommendedbymeansofwashingtheoil.
Steam Acid Lye Hot water Steam
Crudeoil
Mixer Mixer
Holdingtank
Holdingtank
Sludge
Gums Separator
If this is the case, a certain quantity of hotwaterisaddedtotheoil.Theyarethenmixedand conveyed to a second separator whichcontinuouslyseparatesthewashwater.
The oil which is virtually degummed is theneitherconveyeddirectlytothebleachingstage,or it is dried in a vacuum if it is to be soldorstored.
Many features for your benefit• Thisprocesslinecanalsobeusedfor neutralization(flexibility)
Hot water Vacuum
Vacuum dryer
Degummedoil
Sludge
Mixer SeparatorWash water
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GEA Westfalia Separator
After thecrudeoilhasbeenheated, speciallymodified phosphatides which subsequentlyfacilitatephosphatidehydrationcanbeadded.However, this is only necessary in exceptionalcases.Undernormalconditions,asmallquantityofcitricacidisaddedtothecrudeoilandmixedvery intensively with the oil. After a certainreactiontime,theoiliscooledandthenecessaryquantity of water is added for hydrating thephosphatides. After more reaction time inanagitatortank,theoil isheatedtoseparatingtemperatureandthegumsareseparatedfromtheoilinaseparator.
This concludes the super-degumming stage.However, depending on how the oil is to besubsequently treated, it may be necessary toremove the phosphatides more efficiently, asextremely fine particles cannot be separated.A further process stage, the uni-degummingmethod,hasbeendevelopedforthispurpose.
Theoiliscooledforasecondtimeandasmallamount of caustic soda is added. Mixing ofthe caustic with the oil in a special mixingtankisfollowedbyfurtherreactiontimeinanagitatortank,duringwhichthefinephosphatideparticlesagglomeratetoformlargerparticles.Thesecanbeseparatedinaclarifieraftertheoilhasbeenheated.Theoilissubsequentlydriedinavacuum.
The hydration and agglomeration ofphosphatides at low temperature producesa positive side effect for wax-containingoils (e.g., sunflower oil and corn oil).Some of the wax crystallizes and isseparated together with the gums. Thisproduces a considerable advantage in thesubsequentrefiningprocessoftheseoils.
Many features for your benefit• P-content<10ppmpossible• Canbecombinedwithpartialdewaxing
Super- / Uni-Degumming
Steam
Mixer Mixer
Crudeoil
Modifiedlecithin
Acid
Coolingwater
Lye
Mixingtank
Steam
Steam
Mixer
Coolingwater
Hotwater
Hydrationtank
Sludge
Gums
Gums
Separator
Mixingtank
Agglomerationtank
Clarifier
Vacuum
Vacuumdryer
Degummedoil
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GEA Westfalia Separator
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GEA Westfalia Separator
Steam
Mixer
Crudeoil
Holdingtank
Acid
Acid
Thecrudeoilisinitiallyheatedtotheoptimumprocesstemperatureandasmallquantityofacidisadded.Followingintensivemixingandabriefreaction time,someof theacid isneutralizedwith diluted caustic soda. After mixing in acentrifugalmixer,thegumsareseparatedfromtheoilinaseparator.
Becauseveryfinephosphatideparticlescannotbeseparated,acertainamountofwaterisagainaddedtotheoil.Followingabriefreactiontime,themixtureisconveyedtoahigh-performanceclarifierwhichisabletogenerateanextremelyhighg-force.Thisenablesthefineparticlestobecontinuouslyseparatedwiththewater.Inordertoavoidoillosses,thisphaseisrecycledintothefeedofthefirstcentrifuge,wherethefinegumparticlesareseparatedtogetherwithmostofthephosphatides.Theoilwhichisdegummedinthiswayissubsequentlydried.
Many features for your benefit• P-content<10ppmpossible• Shortretentiontimes• Verycompactinstallation
TOP-Degumming
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GEA Westfalia Separator
Sludge
SeparatorMixer
Sludge
Mixer
Gums Clarifier
Vacuum
Vacuumdryer
Degummedoil
Holdingtank
Lye Water
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GEA Westfalia Separator
This method is suitable for neutralizing pre-degummededibleoilsoroilswhichoriginallyonlyhavealowphosphatidecontent.Thefreefattyacidsaresaponifiedwithcausticsoda,andthesodiumsoapisseparated.
The oil is initially heated to the optimumprocess temperature. In order to conditionthe non-hydratable phosphatides, a smallquantity of concentrated phosphoric acidis added and intensively mixed with theoil. Following a brief reaction time, dilutedcaustic soda is added in order to neutralizethe free fatty acid and the phosphoric acid.Aftermixingwiththeoil,themixtureiseitherconveyed directly to the first separator or itpasses through a further reaction tank. Thelatter is recommended only for oils witha relatively high phosphatide content.Self -c leaning separators are mostlyused for separating the sodium soap.However, the residual soap content in theneutraloil is still toohighfor thesubsequentprocessstagesanditmustbefurtherreducedby one or two washings. For this purpose,hot water is added to the oil and intensivelymixed.Thesoapywashwaterisremovedinafurtherseparator.
In general, one wash stage is adequate. Asecondwashing isonlynecessary ifvery lowresidualsoapcontentsarerequired.However,alowresidualsoapcontentcanalsobeachievedby acidifying the wash water with citric orphosphoricacid.
Asecondcaustictreatmentoftheneutraloilsis only advisable in exceptional cases. Thismainlyappliestocottonseedoil,somostofthegossypolisremoved.Thisoilshouldalwaysbeneutralizedin3-stageinstallations.
Dependingonthesubsequentbleachingmethod,theneutralizedandwashedoilissubsequentlyvacuum-dried.
Standard Neutralization
Many features for your benefit• Veryreliableprocess,e.g.,forpoor-quality crudeoils• Highproductqualityguaranteed• Alloilscanbeprocessed
Steam
Mixer
Crudeoil
Lye
Steam
Mixer
Holdingtank
Acid
Separator
Conditioning Neutralization
Hotwater or Lye
Washing or re-refining
Wash water
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GEA Westfalia Separator
Separator
MixerVacuum
Vacuumdryer
Lye
Separator
Mixer
Sludge
SludgeSludge
Neutralization
Soapstock
Washing Drying
Wash water Wash water
Hot water
Neutralizedoil
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GEA Westfalia Separator
ThismethodhasbecomeestablishedmainlyintheUSAforrefiningsoybeanoil.Theprocessisacombinationofdegummingandneutralization.
For conditioning the non-hydratablephosphatides,asmallquantityofphosphoricorcitricacidisaddedtothecrudeundegummedoil.Insomecases,theacidisaddedinthefeedtankwithanagitatorupstreamof the installation.This involves several hours of reaction time.However, a more effective method is to addtheacidupstreamofacentrifugalmixer.Theintensivemixingenablesthereactiontimetobereducedtoafewminutes.Dilutedcausticsodaisthenaddedinordertoneutralizethefreefattyacids. Adequate water must be present withthecausticinordertohydratethephosphatides.Followingareactiontimeofseveralminutesinspecialretentionmixers,theoil isheatedandaddeddirectlytothefirstseparatorinordertoseparatethesoapstock.
Neutralization of Undegummed Oils
The neutral oil is washed in order to furtherreduce the residual soap content. For thispurpose,acertainquantityofhotwaterisaddedtotheoil,mixedinacentrifugeandseparatedinto wash water and oil in a separator. Theresidualhumidityoftheoilisfurtherreducedinavacuumdrier.
Many features for your benefit• Priorwaterdegummingnotnecessary• Highendproductquality
Steam
Crude oil(conditionedwith acid)
Lye
Separator
Sludge
Holdingtank
SoapstockMixer Mixer
Steam
Sludge
SeparatorWash water
Hot water
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GEA Westfalia Separator
This method was originally developed forneutralizingcottonseedoil.Itenablesmostofthegossypoltoberemovedwithsimultaneouslylowneutralizationlosses.
Themiscellawhichdischargesfromtheoilseedextraction stage ispre-concentratedeitherbyaddingthepressoilorduringthefirststageofhexaneevaporation.Themiscellatemperatureisthenbrieflysetbelowtheevaporationpoint,and the necessary quantity of caustic soda isaddedinordertoneutralizethefreefattyacids.Mixingisfollowedbyareactiontimeinspecialretentionmixers.Thesoapstockisseparatedintheseparator.Becauseofthehighspecificdensitydifferencebetweenmiscellaandsoapstock,theseparatingefficiencyisatitsoptimumlevelanditisnotnecessarytowashtheoilafterhexaneevaporation. If it is necessary to treat oilswith a higher phosphatide content, it isrecommended that an acid is added beforethecaustic.
Because of the risk of explosion posed byhexane,allinstallationparts,andinparticularthe centrifuge, are explosion-proof. Due tospecialsafetyconsiderations,thecentrifugeisblanketedwithinertgas.
Miscella Refining
Many features for your benefit• Lowlosses• Goodgossypolremovalforcottonseedoil• Nowastewaterifthesoapstockisadded toextractionmeal• Lessfoulingofhexaneevaporationcolumns
Mixer
AcidSteam
Holdingtank
Lye
Holdingtank
Mixer Soapstock Separator
Sludge
NeutralizedMiscella
Miscella
Sludge
Vacuum
Vacuumdryer
Neutralizedoil
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GEA Westfalia Separator
Somevegetableoils,suchassunflowerorcornoil,containwaxes(long-chainedfattyalcoholsorfattyacidesters),whichcrystallizeatlowertemperatures and result in turbidity in theoil. Wet winterization in combination withneutralization is suitable for removing thesewaxes.
Thecrudeoilisinitiallyneutralized,meaningthat in order to condition the gums, an acidis initially added and the free fatty acids arethen neutralized with caustic soda. After the
Wet Dewaxing Winterization
Steam
Crude oil
Lye
Separator
Sludge
Holdingtank
SoapstockMixer
Hot water
Mixer Mixer
Steam LyeAcid
soapstockisseparatedinthefirstseparator,theoilisconveyedtotheactualwinterizingstage.
Asmallquantityofcausticsodaisagainaddedinordertosetaspecificresidualsoapcontentin theoil.Thissoap is subsequently requiredas a wetting agent during crystallization inordertobindthewaxestowater.Aftermixingofcausticandoil,theproductiscooledtothecrystallizationtemperature.Waxcrystalsformintwotofourcrystallizationtanksconnectedinseries.
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GEA Westfalia Separator
Duetothesoapintheoil,thesewaxcrystalsbindtothewater,whichisaddedtothecrystallizers.Inordertoreducetheviscosity,theoiliscarefullyheated and conveyed to a separator whichcontinuouslyseparatesthewaxywater.Theoiliswashedagaininordertofurtherreducetheresidualsoapcontent.Forthispurpose,theoilisheatedandacorrespondingquantityofhotwaterisadded.Afterintensivemixing,itisseparatedin a further separator. Vacuum drying thentakesplace.
Many features for your benefit• Integrationofwinterizinginneutralization• Fullycontinuousoperation• Removalofveryhighwaxamountspossible
Wash water
Hot water
Steam
Separator
Sludge
Vacuum
Vacuumdryer
Neutralized and winterized oil
Sludge
Separator
Water
Wax Cooling water
Chilledwater
Crystallizer
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GEA Westfalia Separator
Thisprocessisanalternativetowinterizationpreceded by neutralization. However, use oftheprocessisconfinedtooilswitharelativelylowfreefattyacidcontentastheoillossesareotherwisetoohigh.Sunfloweroilisthereforeanidealproductforthisapplication.
Asmallamountofacidisaddedtothecrudeoilwithoutpriorheating.After thoroughmixingandashortretentiontime,theoiliscooled.Thecausticquantity required forneutralizing thefreefattyacidsisadmixedwiththeoil.Theoilthenflowsthroughcrystallizerswitharesidencetimeofseveralhours.Theoilisgentlyheated
Cold Refining Winterization
toreducetheviscositybeforethesoapstockisseparatedinacentrifugealongwiththewaxes.Thedewaxedneutral oil has tobewashed toreducethesoapcontent.It isfirstheated,therequiredwashwaterquantityisaddedand,afterthorough mixing with the oil, it is separatedagaininasecondcentrifuge.Finally,theoilisdriedinavacuumdryer.
Many features for your benefit• Compactinstallation• Effectivewaxremoval
Crude oil
Lye
Separator
Sludge
Holdingtank
Soapstock/wax
Mixer
Washingwater
Hot water
Mixer
Mixer
Acid
Separator
Sludge
Vacuum
Vacuumdryer
Neutralized and dewaxed oil
Hot water
Chilledwater
Crystallizer
Steam
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GEA Westfalia Separator
The wet winterizing method previouslydescribeddoesnotguaranteethat100%ofallwaxesarealwaysremoved.Ifparticularlystrictprocess guarantees are applicable, additionalpolishingfiltrationisnecessaryforcold-stableoils.Thisfurtherfiltrationprocessiscarriedouteitherafterbleachingorafterdeodorizing.
For this purpose, the oil is cooled again andallowedtocrystallizeforseveralhours.Itisthenfilteredusingfilteraid.Despitethisadditionalfiltration,theentirewinterizingmethodoffers
Polishing Filtration Winterization
economical advantages in comparison withmethodswhichonlyusefiltration.Themajoradvantageisthatmuchlessfilteraidisusedandlongerfiltercyclesareachieved.
Many features for your benefit• Minimizingconsumptionoffilteraids• Higherfiltrationspeed• Longerfiltercycles
Bleached ordeodorized oil
Chilledwater
Filter aidslurry pump
Mixer
Crystallizer
Pre-coatingpump Pre-coating
andbody feed tank
Filter aid
Pressureleaf filter
Winterized oil
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GEA Westfalia Separator
Oilsandfatsareamixtureofdifferenttriacyl-glycerols. If these mixtures contain a higheramountof saturated fatty acids, theproductstendtopartlycrystallizeatambienttemperature.Fractionationisaprocesstosplitfatsandoilsintoaliquidpart,theolein,andasolidfraction,thestearin.
Thefractionationprocessconsistsoftwostages,the crystallization and the separation of theoleinandstearin.Thecrystallizationisabatchprocesswheretheoil/fatisfirstheatedabovethemeltingpoint.Thenaslow,controlledcoolingtakesplace,followingaspecificcoolingcurveadapted to the kind of oil/fat. The aim is toproducestearincrystalswhichcanbeseparatedfromtheliquidoleinphase.Theprocessiscalleddryfractionationbecausethereisnodetergentorsolventaddedtotheproduct,asisthecaseinsomeotherknownprocesses.
This separation is done with a speciallydesignednozzleseparator.Thestearincrystals,having slightly higher density, are dischargedcontinuously through nozzles in the peripheryof the bowl. The lighter olein is clarified inthe disc stack of the bowl and continuouslydischargedfromthecentrifugeunderpressure.The stearin slides down into a meltingtank,whereitisliquefiedandpumpedtofurtherprocessingorstorage.
Many features for your benefit• Fullycontinuousstearin/oleinseparation• Adjustablestearinandoleinqualityduring separation• Lowinstallationandmaintenancecosts• Hermeticallyclosedsystem• Nocooledroomforseparatorrequired
Dry Fractionation
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GEA Westfalia Separator
M
Oil
Heating /cooling
Heating /cooling
Crystallizer
Nozzle separator
Meltingvessel
Olein
Steam
Heater
Stearin
Condensate
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GEA Westfalia Separator
Duringthechemicalneutralizationofoilsandfats,soapstock(sodiumsoapsofthefreefattyacids)isobtainedasaby-product.Thiscanbesplitintofattyacidsandwaterbymeansofacidificationwithstrongacids(sulfuricorhydrochloricacid).Fattyacidsareavaluableproductintheanimalfeed,soapandoleochemicalindustries.
The phosphatides, separated together withthe sodium soaps during the neutralizationprocess,frequentlyhaveasignificanteffectonthe splitting process during the formation ofstableemulsionsduringphaseseparation.Thiscanbepreventedtoalargeextentbymeansofsecondarysaponification.
Soapstock Splitting Processing of by-products
For thispurpose, the soapstock is exposed tohigher temperatures and pressures. Duringa reaction time under these conditions,part of the phosphatides and the neutraloil in the soapstock saponify. Aftersaponification,dilutionwatercanbeaddedinan intermediate tank before the soapstock isconveyedtotheactualsplittingprocess.Inthesplittingtank,thepHvalueisreducedbyaddingastrongacid.Thesoapstockbreaksdownintofattyacidandwater,whicharethenseparatedcontinuously inastaticdecantingvessel.Thesplit fattyacidcanbedirectlyprocessed.Theacidwaterisconveyedtoafatseparatorwithanupstreamflotationchamber.Thede-fattedwaterissubsequentlyneutralizedwithcausticsoda.
Many features for your benefit• Fullycontinuousoperation• Lowerlevelofemulsion
Water
Intermediatetank
Splittingtank
Saponification column
Heat exchanger
Soapstock
Condensate
Sulphuric acid
Steam
Floatationtank
Decantingtank
Split fatty acid
Caustic soda
Neutralizationtank
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GEA Westfalia Separator
Gear driveTheconventionaldriveconceptoftheseparatorsisthewormwheelgear,fluidclutchandstandardmotor with direct switching.The toothing ofthewormwheelgearwasoptimizedinordertoreducethenoiselevel.
Advantages of the gear drive•Norequirementforthefrequencyconverter•Reliabledesign•Suitabledesignforsmallmachines
Flat belt driveFlatbeltdrivecanbeusedfortheheavybowlsof larger machines. The power transmissionfromthe torque-controlledmotor to thebowlspindle is via a single flat belt without anintermediaryclutch.Thedesignisverysimpleandmaintenance-friendly.Thespindlecanberemoved together with the complete bearingassembly and can be serviced outside themachine.Thisconsiderablyreducesdowntimerequiredformaintenance.
Advantages of the flat belt drive•Longeroilchangeinterval•Longermaintenanceintervals•Lowermaintenancecost•Reducednoiselevel
Direct driveDirectdriveistheintelligentsimplificationofseparation technology.Directdrive isused inapplicationswheretheupperlimitforgearloadshas been reached or when a belt drive isundesirable.Directdriveseparatorsdrivewithvirtually loss-free power transmission. Lessenergyconsumption,lowermaintenanceandlessspacerequirementsmeanincreasedperformanceforproduction.
Advantages of the direct drive•Lowerspacerequirement•Lowermaintenancerequirement•Lowerenergycosts•Fewerwearingparts•Furtherreductionofnoiselevelcomparedto
theflatbeltdrive•Thedirectdrivemeetsallexplosion
proofrequirements
Available Drives for Edible Oil Separators
RSE 300 with direct drive
RSE 60 with gear drive
RSE 220 with flat belt drive
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GEA Westfalia Separator
Whereverseparatingtechnologytaskshavetobe carried out, our serv&care programassures comprehensive services right fromtheverybeginning.Inclosecooperationwithourcustomers,solutionsaredevelopedtomeetspecificneeds.
The customers benefit not only fromtraditional services such as inspection,maintenance, original spare parts and repairwork provided by the original manufacturer,butalsofrompro-activesolutionswhichavoidrisk, e.g., online and offline monitoring withourGEAWestfaliaSeparatorwewatch®.
Ensuring Maximum Process Efficiency, Availability and Budget Security with serv&care from GEA Westfalia Separator
Modernizationorupgradingtostate-of-the-arttechnology also provides the opportunity toboostservicesasrequired.
Training provided on site or in the moderntraining center of GEA Westfalia Separatorensuresthatourcustomer‘semployeesreceivetraining in the proper handling of high-techinstallations.Thisprovidesadditionalsafety.
Ourserv&careprogramprovidesformaximumprocessefficiencyandinstallationavailabilityaswellasbudgetsecurity.Andthesebenefitsareprovidedthroughouttheentirelifecycleoftheentireinstallation.
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GEA Westfalia Separator
Services performed by specialistsWhennormalequipmentuseresultsinwearandtear,westandbehindthequalityofourrepairservices.GEAWestfaliaSeparatorhastrained mechanics on staff that have theproprietaryknowledgetomakethenecessaryrepairs.Intrueemergencies,aresponseteamcanbequicklydeployedtoyourfacility.Sparebowlandscrollassembliesarereadilyavailableforyouruse,soprocess/productionlinesarenotidlewhilerepairsareunderway.Andwhenequipment needs to be repaired off-site, weoffertwofullservicelocationshereinNorthAmerica.OurfacilityinPatterson,CaliforniawasspecificallydevelopedtoservicecustomersbasedintheUnitedStatesandCanada.Here,decanter and separators of all sizes can berepaired.Thereisalsoalargepartsinventoryandaspeciallydesignedtrainingfacility. serv care
Service from the original manufacturer
•Serviceengineersmovequicklytothesite
•Extensiveservicenetwork
•Riskavoidedbyserviceprovidedbytheoriginalmanufacturer
•Pro-activesolutionswhichavoidrisk
•Upgradingtoboostperformance
•Stafftraining
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GEA Mechanical Equipment US, Inc.
GEA Westfalia Separator Division
Headquarters:100 Fairway CourtNorthvale, NJ 07647201-767-3900
Midwest:1707 N. Randall Road, Suite 355Elgin, IL 60123630-503-4700
South:4725 Lakeland Commerce Parkway, Suite 4 Lakeland, FL 33805863-603-8900
Southwest:2408 Timberloch Place, Suite C-4 The Woodlands, TX 77380281-465-7900
West Coast:Western Region Customer Support Center555 Baldwin RoadPatterson, CA 95363209-895-6300
GEA Mechanical Equipment Canada, Inc.
GEA Westfalia Separator Canada Division
835 Harrington CourtBurlington, ON L7N 3P3289-288-5500
Toll-Free: 800-722-662224-Hour Technical Help: 800-509-9299www.wsus.com
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and
process technology. GEA Group is listed in the STOXX® Europe 600 Index.
We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity