short course: fundamentals of edible oil processing and...

Short Course: Fundamentals of Edible Oil Processing and Refining

Recent Developments Ken Carlson RBD Technologies, Inc.

General Trends Degumming/Neutralization

Bleaching Deodorization

Fat Modification Instruments & Controls

Quality Assurance

Topics

RBD Technologies Inc.

Fundamentals of Edible Oil Processing and Refining RECENT DEVELOPMENTS

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Cavitation Mixing Technology

Combined PLC/PLA Enzymes for Degumming

Separators with Integrated Direct Drive

Silica as alternative to Water Washing

Degumming/Neutralization



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EXAMPLE OF SYSTEM WITH WATER WASHING



To Bleaching or

Drying & Cooling

Wash water effluent

Wash water Receiver

Separator

Acid Lye

Gum/ soap

Gum/soap Receiver

Heater/ Cooler

Cavitation Mixer ?

Separator

Mixer

Wash Reactor

Cavitation Mixer ?

Enzyme ? (Degumming)

Degumming/ Neutralization

Reactor

Heater

Acid conditioned oil to Bleaching

Degummed or neutralized oil

to Bleaching

Water

Feed Oil


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CAVITATION MIXING TECHNOLOGY




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Arisdyne Systems Controlled Flow Cavitation™

Degumming and Neutralization with

Higher Yield and Less Chemicals

• Small footprint • Easy to install • Robust and durable • Adjustable capacity • Resists clogging



CAVITATION MIXING TECHNOLOGY


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COMBINED PLC/PLA ENZYMES FOR DEGUMMING




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INTEGRATED DRIVE SEPARATORS




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Alfa-Laval eDrive GEA/Westfalia directDrive

SILICA FOR REPLACING WATER WASH




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Bleaching


Re-use of Bleaching Clay

In-line Color/Solids Monitoring

Faster Filtration Silicate Adsorbent Fast Filtration High Activity Clay

Clay with Activated Carbon for removal of toxins (PAH’s, dioxins, etc.) and non-carotene based red/brown colors

R &D for Enzymatic Bleaching

Increasing use of Pulse Tube Filters


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EXAMPLE OF TRADITIONAL SYSTEM

Bleaching


Bleaching Reactor

Heater

Adsorbent Filters

Precoat/Heel Tank

Filtrate Receiver

HR

Spent Adsorbent

Safety Filters

Hot oil to Deodorizing

To vacuum

Adsorbent Hopper

Dosing System

Cooled oil to Storage

Filter Aid


Steam mixing ?

Pulse Tube Filters ?

Precoat or recycle ?

Slurry Tank ?

Carbon ?


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EXAMPLE OF “RE-USE” SYSTEM

Bleaching


Bleaching Reactor

Trim Heater

Adsorbent Filters (3-cycle operation)

Precoat/Heel Tank

Filtrate Receiver

Spent ads.

To vacuum

Earth Hopper

Earth Feeder

Safety Filters

Silica Feeder

Silica Mix Tank

Silica Hopper

Slurry Tank

To vacuum

Dryer

Heater

Filter Aid

Hot oil to Deodorizing

Vent Vent

Water

2nd (earth) Filtration

1st (silica) Filtration

Clean

A B C



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IN-LINE COLOR/SOLIDS MONITORING

Bleaching



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Bleaching


FASTER FILTRATION SILICATE ADSORBENT


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Bleaching


NEW PRE-BLEACHING ADSORBENT


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FASTER FILTRATION HIGH ACTIVITY CLAY

Bleaching



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Bleaching


CLAY WITH ACTIVATED CARBON


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Bleaching


R & D FOR ENZYMATIC BLEACHING


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Bleaching


INCREASING USE OF PULSE TUBE FILTERS


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Typical Systems

Two-stage scrubbers for concentration of FFA’s

Designs for recovery of micro nutrients (e.g. TocoBoost by Alfa-Laval)

“Clean” vs “Greasy” Vacuum Systems

Chilled Water Vacuum Systems

Ice Condensation Systems

Deodorization



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Deodorization


EXAMPLE OF SEMI CONTINUOUS SYSTEM

BFW Cooler Filters Heater

Polish Filters

Cooler

Distillate

HR Cooler

Anti-ox System

High Pressure Steam Generator

Scrubber

To Vacuum

RBD oil

To Vacuum

Pre-heated Boiler Feed Water ?

Nitrogen

Steam

Product Cooler

Boiler Feed Water

BFW Surge Tank

Double Thermo siphon

Loops ?

Bleached oil


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Heating/Cooling under Vacuum

Deodorization


EXAMPLE OF CONTINUOUS PC SYSTEM

HR Filters Heater

Polish Filters

Spar

ge S

team

N

itrog

en

Cooler

Distillate

Product Cooler

Alternating HR units ?

Heat-bleaching Section

Post Deodorizer

Anti-ox System

Distillate Receiver

Deaerator

Packed Column Stripping Section

Double Shell?

High Pressure Steam Generator

Back-up Heater

Final Heater

Scrubber

Cooler

To Vacuum

RBD oil

Bleached oil

Electric ?


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Heating/Cooling under Pressure

Cooler

High FFA Fraction

High Sterol Fraction

To Vacuum

Lo Temp Section

High Temp Section

Cooler

Vapor from Deodorizer

Deodorization


EXAMPLE OF TWO-STAGE SCRUBBER


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Deodorization


HODGEPODGE


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Alfa-Laval heat exchanger for continuous heating under vacuum

Alfa-Laval heat exchanger for continuous cooling under vacuum

Crown Double Shell Packed Column before assembly

Alfa-Laval “Soft Column”

Structured Packing for Columns & Scrubbers

DeSmet Qualistock “all-in-one” continuous deodorizer with internal heating/cooling under vacuum

Crown “DiFlow” SC Deodorizer

Alfa-Laval “SoftFlex” SC Deodorizer with packing

Steam

Cooling Water

Vapor from Deodorization


Greasy Cooling Water

“Greasy” System

“Clean” System

Clean water to Cooling Tower

Greasy water to Cooling Tower Effluent

Greasy water Cooler

Caustic

Barometric or surface

condensers ?

Steam

Hot Well Water Chiller

Deodorization


CLEAN VS GREASY VACUUM SYSTEMS


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Deodorization


EXAMPLE OF “GREASY” VACUUM SYSTEM


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Deodorization


EXAMPLE OF “CLEAN” VACUUM SYSTEM


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Cooling Water

Hot Well Effluent

Steam Ammonia to Chiller

Ammonia from Chiller

Start-up jet

Muffler

In use Melting Hot

ammonia


Ejectors

Melted fat

Ice Condensers Surface

Condensers

Deodorization


EXAMPLE OF ICE CONDENSATION SYSTEM

Design as per Graham


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Deodorization


EXAMPLE OF ICE CONDENSATION SYSTEM


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Hydrogenation Partial Hydrogenation replaced by fully hydrogenated fats

blended and interesterified with liquid oils Improved reactor agitator designs

New more efficient/selective catalysts

Interesterification Soap removal by filtration rather than washing in chemical process

Safer handling of catalyst Enzymatic replacing chemical process

Fractionation New Crystallizer Design

Fat Modification



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Hydrogenation


EXAMPLE OF TYPICAL SYSTEM

Reactor

Catalyst Filter

Precoat Tank

Spent Catalyst

Safety Filter

To vacuum

Filter Aid

Bleached oil

HR

Hydrogen

N2

To Post Bleaching

Drop Tank

Feed Tank

Flash Tank

Catalyst

Vent

Dual Reactors

For high capacity

Pulse Tube Filter ?

Agitator Design


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Hydrogenation


NEW CATALYSTS


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Reactor

Adsorbent Filter

Precoat Tank

Spent Adsorbent

Safety Filter

To vacuum

Dosing System

Filter Aid

Sodium Methoxide

Dosing System

Silica Earth

Citric Acid Dosing System

Heater

N2

N2

Interesterified oil

Drop Tank

Blended bleached oils

Interesterification


EXAMPLE OF BATCH CHEMICAL PROCESS

Pulse Tube Filter ?


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As per DeSmetBallestra

Blended RBD oils

Vacuum Dryer Buffer Tank

Heater Cooler

Enzyme Preparation

Tank

To vacuum

To vacuum

To vacuum

To vacuum

Novozymes Enzyme

Product Tank

Cooler

Safety Filters

4 –

6 In

tere

ster

ifica

tion

Reac

tors

Interesterification


EXAMPLE OF ENZYMATIC PROCESS

Interesterified Oils


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Dry Fractionation


Chilled Water Tank

Refrig System

Alternating Crystallizers

Cooling Water

Slurry Circulation Pump

Membrane type Stearin Filter

Stearin Melt Tank

Core Blow Tank

Stearin

Olein

Filter “Squeeze” Pump

Crude oil

Hot Olein Wash Tank

Cold Olein Rinse Tank

Olein Tank Fill Work Filter

Heater

Alternatives: drum filter

or centrifuges

EXAMPLE OF TYPICAL SYSTEM


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Fractionation


NEW CRYSTALLIZER DESIGN


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RTU Remote Terminal Unit (converts to digital data) PLC Programmable Logic Controller SCADA Supervisory Control Automation Data Acquisition HMI Human Machine Interface (PC) LAN Local Area Network WLAN Wireless Local Area Network

Fieldbus allowing multiple units per wire set as

well as two-way communication with digital HART type instruments with EDDL

Wireless instruments for remote locations

Handheld communicators for linking with SCADA system

Fieldbus Digital two-way data transfer (6 - 8 devices/cable) Ethernet Standard communications protocol for building LANs HART Highway Addressable Remote Transducer (communication protocol for smart hosts and devices) EDDL Electronic Device Description Language (for accessing instrument manuals in SCADA system)

Some common terms:

Instruments & Controls



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Quality Assurance


Fundamentals of Edible Oil Processing and Refining RECENT DEVELOPMENTS GET A COPY OF THIS PRESENTATION

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Thanks for Your Attention !

Thanks for Your Attention !



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short course: fundamentals of edible oil processing and...

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