Wim Bleaching

Desmet Ballestra Presentation 1
Recent
Recent
Developments
Developments
in
in
Bleaching
Bleaching
,
,
Deodorisation
Deodorisation
and
and
Physical
Physical
Refining
Refining
of
of
Oils
Oils
and Fats
and Fats
W. De W. De Greyt Greyt, V. , V. Gibon Gibon and M. and M. Kellens Kellens
Desmet Ballestra Group Desmet Ballestra Group
Zaventem, Belgium Zaventem, Belgium
OFI Middle East 2008 OFI Middle East 2008
Technical and Commercial Conference Technical and Commercial Conference
Hilton Hotel Hilton Hotel
Abu Dhabi, UAE, April 15 Abu Dhabi, UAE, April 15- -16,2008 16,2008
oils & fats
124 Mio Tons in 2006 124 Mio Tons in 2006
PO+ SBO = 55%
VEGETABLE OILS WORLD PRODUCTION
Year Consumption Population Demand
kg/capita Billion Million tons
1980 12.8 4.4 56.8
1990 15.3 5.3 80.5
2000 18.3 6.1 110.5
2010 20.9 6.6 139
2020 23.8 7.4 175.3
Expected growth rate
~ 3-4 Mio TPY extra for
edible consumption
Year Million tons
1995 94.9
1998 103.1
2002 120.9
2005 144.5
~ 4-5 Mio TPY
extra production
Oils and Fats
production
INCREASED DEMAND FOR FOOD USE
0
20
40
60
80
100
120
140
M
i
l
l
i
o
n

t
o
n
s
total 61,5 82,7 121,9
food 55 74,7 99,2
nonfood 6,5 8 22,7
1993/94 1999/00 2006/07
89.4% 89.4%
10.6% 10.6%
90.3% 90.3%
9.7% 9.7%
81.4% 81.4%
18.6% 18.6%
BIODIESEL ?!! BIODIESEL ?!!
Palm: 10 Palm: 10 Rape Rape: 5 (BD) : 5 (BD)
NON-EDIBLE USE OF VEGETABLE OILS
U
S
$
/
t
o
n
0
200
400
600
800
1000
1200
1400
1600
2003/04 2004/05 2005/06 2006/07 2007 July
Palm (Mal)
Soybean (US)
Rapeseed (Rott)
Sunflower (Rott)
Peanut (Rott)
Cotton (US)
Major vegetable oils price evolution
0 US$/barrel
> 100 US$/barrel
Crude fossil oil
STRONG PRICE INCREASE FOR CRUDE OILS (FROM 2005)
Production period
Increase demand for food use (China, India)
Booming biodiesel market (Europe,USA)
QUALITATIVE SOLUTION : Food vs Technical Oils
' 'Secondury Secondury' ' OiIs OiIs for for TechnicuI TechnicuI AppIicutions {e,g, iodieseI} AppIicutions {e,g, iodieseI}
* * Low Quality animal fats (tallow, lard, chicken, pig)
* Side streams (FAD, acid oils, ) and used oils (Used Frying Oils)
* Oils fromspecial industrial crops (Jatropha oil, Algae oil)
' 'Primary Primary Oils Oils for for Human Human Consumption Consumption
* * High Quality Commodity Oils (Soy, Rape, Sun, Palm, )
* * Specialty oils with high nutritional value (Olive, Fish, Flaxseed,)
TRENDS IN EDIBLE OIL PROCESSING
Increased need for more efficient processes (commodity oils)
* More cost efficient processes (lower investment & operating costs)
* Valorisation and/or reduction of by-products
* Flexible plants able to process wide range of different oils
* Larger capacities (economics of scale)
Increased demand for higher quality food oils
* Low or no trans FA (formed during refining and hydrogenation)
* Balanced FA composition (optimal ratio satured/mono-/polyunsaturated FA)
* High concentration of natural anti-oxidants (tocopherols) and phytosterols
* No contaminants (pesticides, PAH, dioxins, PCB,.)
STABILITY STABILITY
FUNCTIONALITY FUNCTIONALITY
NUTRITIONAL NUTRITIONAL
QUALITY QUALITY
Structured Structured Lipids Lipids
Frying Frying Oils Oils
Salad Salad Oils Oils
Specialty Specialty Fats Fats
Shortenings Shortenings
Margarine Margarine
fats fats
INCREASED ATTENTION FOR
NUTRITIONAL QUALITY OF
FOOD OILS AND FATS
Seed
Seed
Frying oil
Frying oil
Speciality Fats
Speciality Fats
Margarine
Margarine
Frying oil
Frying oil
Speciality Fats
Speciality Fats
Margarine
Margarine
Crude
Oil
Crude
Oil
Refined
Oil
Refined
Oil
Cracking
Cracking
Dehulling
Dehulling
Flaking
Flaking
Cleaning / Drying
Cleaning / Drying
Preparation
Cracking
Cracking
Dehulling
Dehulling
Flaking
Flaking
Cleaning / Drying
Cleaning / Drying
Preparation
Meal
Meal
Bleaching
Bleaching
Neutralising
Neutralising
Deodorising
Deodorising
Winterising
Winterising
Degumming
Degumming
Refining
Bleaching
Bleaching
Neutralising
Neutralising
Deodorising
Deodorising
Winterising
Winterising
Degumming
Degumming
Refining
Mechanical Extraction
Solvent Extraction
Solvent Extraction
Extraction
Solvent Extraction
Solvent Extraction
Extraction
Hydrogenation
Hydrogenation
Interesterification
Interesterification
Fractionation
Fractionation
Modification
Hydrogenation
Hydrogenation
Interesterification
Interesterification
Fractionation
Fractionation
Modification
Lubricants
Lubricants
Soap
Soap
Biodiesel
Biodiesel
Lubricants
Lubricants
Soap
Soap
Biodiesel
Biodiesel
Oleochemical
Processes
Oleochemical
Processes
Crude Oil Crude Oil
C
h
e
m
i
c
a
l

r
e
f
i
n
i
n
g
Degumming
Neutralisation
Bleaching
Deodorisation
Refined Oil Refined Oil
SOAPS
GUMS
FFA
SPLITTING
Soybean oil Soybean oil
P
h
y
s
i
c
a
l

r
e
f
i
n
i
n
g
Degumming
Bleaching
Steam refining-
Deodorisation
Palm oil Palm oil
98
99
100
101
102
103
104
105
106
107
108
0 0.5 1 1.5 2 2.5 3 3.5 4
7FFA
Direcf refining cosf
37
I7
Soybeon
PoIm
ChemicoI
PhysicoI
Cross-over
poinf
Cross-over point
shifts to Iower
FFA
PhysicuI refining
becomes more
uttructive
ADSORPTION
ADSORPTION
PROCESSES
PROCESSES
DEVELOPMENTS IN EDILE OIL REFININS - I
ADSORPTION PROCESSES
(1) Bleaching (adsorption of pigments, metals, polar components,.)
(2) Silica treatment (adsorption of soaps and gums, replacing water wash stage )
(3) Activated carbon treatment (removal of contaminants like PAH and dioxins)
DEVELOPMENTS IN ADSORPTION
(1) Reduce adsorbent consumption (especially bleaching earth)
(2) Improve overall efficiency
(3) Reduce amount of solid waste and disposal costs
Combiclean
Process
BLEACHING
Unit Operation in Refining with Highest Operating Cost
Processes to reduce Bleaching Earth Consumption
* Bleaching with pre-filtration over spent BE
* Bleaching with silica pre-treatment
* Counter-current bleaching
Main Objective : Reducing Bleaching Earth Consumption
* Cost 1 : Cost of bleaching earth (depending on origin and degree of activation)
* Cost 2 : Oil losses in spent bleaching earth (30-40% oil in spent BE)
* Cost 3 : Disposal of spent bleaching earth : can be a cost factor as well
10-20% BE saving
30-40% BE saving
Vacuum unit
Spent bleach earth
Bleaching
earth
Degummed
oil
steam
Citric
acid
bleacher
Leaf filters
Bleached oil
Polish filters
Sparge
steam
.
.
.
.
.
.
.
.
.
.
From degumming
neutralisation
To deodorisation
Spent bleach earth
Pre-filtration
final filtration
cleaning
Continuous bleaching
with pre-filtration
Process with 3 filters :
1. Prefiltration (used BE)
2. Effective filtration
3. Stand-by/cleaning
First Adsorption of
Metals, soaps,
Color pigments
Counter-current
bleaching process
Vacuum unit
Spent bleach earth
Bleach
earth
Degummed
oil
steam
Citric
acid
Final
bleacher
Leaf filters
Prebleacher
Bleached oil
Polish filters
Candle
filter
Recycling
spent earth
Sparge
steam
.
.
.
.
.
.
.
.
.
.
From degumming
neutralisation
To deodorisation
4
Prebleaching with used BE
Vacuum unit
Spent bleach earth
Bleaching
earth
Degummed
acid
bleacher
Leaf filters
Bleached oil
Polish filters
Sparge
steam
.
.
.
.
.
.
.
.
.
.
To deodorisation
Spent bleach earth
Pre filtration
final filtration
cleaning
Active carbon
Spent carbon
Filter press
Silica
oil
.
.
.
.
.
.
.
.
.
.
I
Adsorption of
P and soaps
Z
Prebleaching
More efficient use of BE
3
Final bleaching
4
Removal of contaminants
COMBICLEAN process
COMICLEAN PROCESS
1. INTEGRATED ADSORPTION PROCESS
- Modular and extendable with required/desired process stages
2.SEPARATE ADDITION OF EACH ADSORBENT
- Increases overall efficiency of each adsorbent (lower costs)
3. SPLITTING OF SOLID WASTE STREAMS
- Easier valorisation/disposal
- Pure Spent BE with no contaminants can be added to meal
- Spent AC with contaminants has to be treated as toxic waste
DEODORIZATION
DEODORIZATION
STEAM REFINING
STEAM REFINING
DEVELOPMENTS IN EDILE OIL DEODORIZATION
OJECTIVES OF DEODORIZATION
(I) Sfripping of voIofiIe componenfs (FFA, voIofiIe confominonfs, ,..)
(Z) Deodorisofion (fhermoI degrodofion ond sfripping of odor & fosfe componenfs)
(3) Heof 8Ieoching (fhermoI degrodofion of coIoring pigmenfs)
DEVELOPMENTS IN DEODORIZATION TECHNOLOSY
(I) Improved deodori;er design (oII-in-one, sfond oIone concepf,,.)
(Z)Peducing heof Iood (duoI femperofure deodori;ing, Iower pressure,,.)
(3) ConfroIIed sfripping of voIuobIe componenfs ond confominonfs (pocked coIumn)

Distillation Thermal
action

wanted unwanted

unwanted unwanted

wanted wanted
Temperature
Fatty acid
removal
Time
Trans
isomerisation
Stripping steam
Tocopherol
removal
Pressure
Polymerisation
Odor - Flavor
removal
Heat
bleaching
Continuous / Continuous /
Semicontinuous Semicontinuous
Crossflow Crossflow (tray) / (tray) /
Countercurrent Countercurrent (pack) (pack)
Shallow bed / Shallow bed /
Deep bed Deep bed
Economizing / Cooling / Economizing / Cooling /
Heating under vacuum Heating under vacuum
Deodoriser Deodoriser
design design
Low pressure by chilled Low pressure by chilled
water / Ice condensing water / Ice condensing
Operating
Parameters
Dual Temperature deodorizer : Principle
- Lower temperature - longer time (stage 1)
for mild deodorizing and moderate stripping
thermolytic/hydrolytic breakdown reactions
- Higher temperature - shorter time (stage 2)
for final stripping and heat bleaching
for controlled stripping of valuable minor
components
230 C
230 250 C
250 C
210 230 C
250 130 C
Packed column
stripper
P : 0.1 -0.5 mbar/m
T : min. 1.3C / %FFA
H : 3-5 m
D : f (vapor load)
Structured packing
100-300 m
2
/m
3
Counter-current contact oil/steam
Short residence time at high temperature
vapor phase (steam)
liquid phase (oil)
liquid phase
(stripped oil)
To FAD scrubber
+ vacuum unit
To deodorizer
Features
- Efficient stripping because of counter-current contact oil/steam
- Pressure drop over column can make stripping more difficult
- Short residence time at high temperature
Low trans formation, but no complete deodorization
Applications
- Stripping of tocopherols/sterols from vegetable oils
- Stripping of contaminants (pesticides)
- Partial deodorization of cocoa butter
PACkED COLUMN STRIPPER
LOW PRESSURE DEODORIZATION
- Deodorizing Pressure range : 2-5 mbar
- Low pressure required
* For stripping of volatile components (FFA, contaminants,)
* Protection against oxidation
- Trend for lower pressure during deodorization
* Allows same stripping at lower temp. and/or with less steam
* Lower pressure (1.5-2 mbar) with Dry Ice Condensing
* Cost factor (higher electricity consumption, but nearly no motive steam)
Sparge steam
(100%)
Motive steam
(100%)
Effluent
(92%)
Booster or pump
Surface
condenser
Non-condensables
(8%)
Effluent
(108%)
Surface
condenser
Ice Surface
Condenser (-26C)
Ammonia
Noncondensables
Motive
Steam
Rest of
condensed
water
1 mbar
Vapor from
FA scrubber
Iced vapor
(> 95%)
Steam
ejector
Surface
Condenser
(30C)
Dry Ice Condensution : PrincipIe
Compressor
Condenser
Separator
Cooling water
From FA scrubber
Vapour (vacuum)
Refrigerant (ammonia)
Non-condensable gases
Valve, closed
Valve, open
Melt vessel
Condensate
To
de-aeration
Freeze
condenser
water process vapor ammonia
LP steam
De Smet De Smet
SUBLIMAX SUBLIMAX
Condensation of steam
(into ice) on surface
condensers
Low pressure can be
reached (< 2 mbar)
Strongly reduced odor
emission
Nearly no motive steam but higher electricity consumption
10x less waste water
Bleached oil
821 heating
822 deodorising
801 deaeration
880B final cooling
water
Deodorised oil
LP-steam
HP-steam
814 scrubber
FAD
880A heat recovery
vacuum
modular design:
logical sequence of all operations
QUALISTOCk DEODORISER :SingIe vesseI - stund uIone concept
AII criticuI deodorizing steps
integruted in u singIe vesseI
Stund uIone concept :
No buiIding necessury
Simplified Simplified
erection erection
less building less building
minimum minimum
space space
faster faster
installation installation
easy easy
maintentance maintentance
& access & access
Qualistock deodoriser
Conclusions
Objective of new developments in edible oil processing :
(1) Increase Overall Process Efficiency
- Lower investment costs (more efficient, easier to install equipment)
- Lower operating costs (more efficient processes);
- Reduction/valorisation of by-products (spent BE, FAD,)
(2) Enhance Nutritional Quality of Food Oils
- Mild deodorizing conditions (less trans FA, less polymeric TAG)
- Removal of contaminants (AC treatment, stripping,)
- Lower pressure during deodorization

Wim Bleaching

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Wim Bleaching

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Desmet Ballestra Presentation 1

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