Recent Developments in Bleaching, Deodorisation and Physical

Transcription

OFI Middle East 2008
Technical and Commercial Conference
Hilton Hotel
Abu Dhabi, UAE, April 15-16,2008
Recent Developments in Bleaching,
Deodorisation and Physical Refining
of Oils and Fats
W. De Greyt, V. Gibon and M. Kellens
Desmet Ballestra Group
Zaventem, Belgium
Desmet Ballestra Presentation
1
oils & fats
Hilton Hotel
VEGETABLE OILS WORLD PRODUCTION
124 Mio Tons in 2006
PO+ SBO = 55%
2
Hilton Hotel
INCREASED DEMAND FOR FOOD USE
Year
1980
1990
2000
2010
2020
Expected growth rate
C onsum ption P opulation
D em and
k g/capita
B illion
M illion tons
12.8
15.3
18.3
20.9
23.8
4.4
5.3
6.1
6.6
7.4
56.8
80.5
110.5
139
175.3
~ 3-4 Mio TPY extra for
edible consumption
Oils and Fats
production
Yea r
1995
M illion tons
94.9
1998
103.1
2002
120.9
2005
144.5
~ 4-5 Mio TPY
extra production
3
Hilton Hotel
NON-EDIBLE USE OF VEGETABLE OILS
BIODIESEL ?!!
140
Million tons
120
81.4%
100
80
60
90.3%
89.4%
40
0
18.6%
10.6%
20
9.7%
1993/94
1999/00
2006/07
total
61,5
82,7
121,9
food
55
74,7
99,2
nonfood
6,5
8
22,7
Palm: 10 – Rape: 5 (BD)
4
Hilton Hotel
STRONG PRICE INCREASE FOR CRUDE OILS (FROM 2005)
1600
1400
Increase demand for food use (China, India)
Booming biodiesel market (Europe,USA)
Crude fossil oil
> 100 US$/barrel
Major vegetable oils price evolution
US$/ton
1200
Palm (Mal)
Soybean (US)
1000
Rapeseed (Rott)
800
Sunflower (Rott)
600
Peanut (Rott)
Cotton (US)
400
200
0
2003/04
2004/05
2005/06
2006/07
2007 July
0 US$/barrel
Production period
5
Hilton Hotel
QUALITATIVE SOLUTION : Food vs Technical Oils
Primary’ Oils for Human Consumption
* High Quality Commodity Oils (Soy, Rape, Sun, Palm, …)
* Specialty oils with high nutritional value (Olive, Fish, Flaxseed,…)
* Low Quality animal fats (tallow, lard, chicken, pig…)
* Side streams (FAD, acid oils, …) and used oils (Used Frying Oils)
* Oils from special industrial crops (Jatropha oil, Algae oil)
6
Hilton Hotel
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,….)
7
Hilton Hotel
STABILITY
FUNCTIONALITY
Frying Oils
Specialty Fats
Shortenings
Margarine
fats
Salad Oils
INCREASED ATTENTION FOR
NUTRITIONAL QUALITY OF
FOOD OILS AND FATS
Structured Lipids
NUTRITIONAL
QUALITY
8
Hilton Hotel
Cleaning
Cleaning // Drying
Drying
Cracking
Cracking
Seed
Seed
Speciality
Speciality Fats
Fats
Dehulling
Dehulling
Flaking
Flaking
Preparation
Interesterification
Interesterification
Margarine
Margarine
Fractionation
Fractionation
Modification
Soap
Soap
Biodiesel
Biodiesel
Meal
Meal
Solvent
Solvent Extraction
Extraction
Extraction
Crude
Crude
Oil
Oil
Hydrogenation
Hydrogenation
Frying
Frying oil
oil
Lubricants
Lubricants
Mechanical
Mechanical Extraction
Extraction
Degumming
Degumming
Neutralising
Neutralising
Refined
Refined
Oil
Oil
Oleochemical
Processes
Bleaching
Bleaching
Winterising
Winterising
Deodorising
Deodorising
Refining
9
Hilton Hotel
Crude Oil
Soybean oil
ica
em
h
C
fi
e
r
l
Ph
g
nin
ys
ic
al
re
Palm oil
fin
ing
Degumming
GUMS
Degumming
Neutralisation
SOAPS
Bleaching
Bleaching
SPLITTING
FFA
Steam refiningDeodorisation
Deodorisation
Refined Oil
10
Hilton Hotel
108
107
106
105
104
103
!
"
102
101
#
#
100
99
98
0
0.5
1
1.5
2
2.5
3
3.5
4
11
Hilton Hotel
ADSORPTION
PROCESSES
12
Hilton Hotel
$ % & % ' !( % )
*) % $ * '%
*' + % *) *) ,
*
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)
$ % & % ' !( % )
*)
$
+! * )
(1) Reduce adsorbent consumption (especially bleaching earth)
(2) Improve overall efficiency
(3) Reduce amount of solid waste and disposal costs
Combiclean
Process
13
Hilton Hotel
BLEACHING
Unit Operation in Refining with Highest Operating Cost
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
Processes to reduce Bleaching Earth Consumption
* Bleaching with pre-filtration over spent BE
10-20% BE saving
* Bleaching with silica pre-treatment
* Counter-current bleaching
30-40% BE saving
14
Hilton Hotel
Continuous bleaching
with pre-filtration
Bleaching
earth
Vacuum unit
cleaning
Pre-filtration
Polish filters
final filtration
steam
Bleached oil
From degumming
neutralisation
Spent bleach earth
Degummed
oil
..
.
.
.
.
.
.
..
bleacher
Sparge
steam
To deodorisation
Spent bleach earth
Leaf filters
Citric
acid
First Adsorption of
Metals, soaps,
Color pigments
Process with 3 filters :
1.
2.
3.
Prefiltration (used BE)
Effective filtration
Stand-by/cleaning
15
Hilton Hotel
Counter-current
bleaching process
Candle
filter
Vacuum unit
steam
Polish filters
From degumming
neutralisation
Recycling
spent earth
Bleached oil
Bleach
earth
Prebleacher
Degummed
oil
To deodorisation
Leaf filters
Citric
acid
Prebleaching with used BE
..
.
.
.
.
.
.
..
Final
bleacher
Sparge
steam
Spent bleach earth
16
Hilton Hotel
Prebleaching
More efficient use of BE
Vacuum unit
Active carbon
Bleaching
earth
Silica
Degummed
oil
final filtration
cleaning
Pre filtration
Filter press
..
.
.
.
.
.
.
..
Spent bleach earth
..
.
.
.
..
.
..
bleacher
Sparge
steam
Spent bleach earth
Leaf filters
Polish filters
acid
Adsorption of
P and soaps
COMBICLEAN process
Spent carbon
Final bleaching
Removal of contaminants
Bleached oil
To deodorisation
17
Hilton Hotel
(
* '% ) !+
%
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
18
Hilton Hotel
DEODORIZATION –
STEAM REFINING
19
Hilton Hotel
$ % & % ' !( % )
.%
*) % $ * '%
*& %
$% $
+ *-
*' $ % $
+ *-
* )
!
"
!
%
!'
%
(
$ % & % ' !( % )
!)
%%
!+ %,
!
%
%
%
*
%
%
+ *-
* )
"
,
,
&
!
!
%
% %,
%
" #$$!
%
*) $ % $
* )
%
% /)
%
%
' ,0
"#$!
*
" %
,
"#$!
. %
,
!
20
Hilton Hotel
Distillation
Operating
Parameters
Thermal Low pressure by chilled
water / Ice condensing
action
Temperature
Fatty acid
removal
Time
wanted
Continuous /
Semicontinuous
Trans
isomerisation
unwanted
Crossflow (tray) /
Countercurrent (pack)
Stripping steam
Tocopherol
removal
unwanted
Odor - Flavor
removal
wanted
Polymerisation
Pressure
Deodoriser
design
unwanted
Heat
bleaching
Shallow bed /
Deep bed
Economizing / Cooling /
Heating under vacuum
wanted
21
Hilton Hotel
Dual Temperature deodorizer : Principle
- Lower temperature - longer time (stage 1)
210
for mild deodorizing and moderate stripping
thermolytic/hydrolytic breakdown reactions
230
- Higher temperature - shorter time (stage 2)
for final stripping and heat bleaching
for controlled stripping of valuable minor
components
230 C
230 C
250 C
250 C
250
130 C
22
Hilton Hotel
Packed column
stripper
To FAD scrubber
+ vacuum unit
liquid phase (oil)
∆P : 0.1 -0.5 mbar/m
∆T : min. 1.3ºC / %FFA
H : 3-5 m
D : f (vapor load)
Structured packing
100-300 m2/m3
vapor phase (steam)
Counter-current contact oil/steam
Short residence time at high temperature
liquid phase
(stripped oil)
To deodorizer
23
Hilton Hotel
Features
!
1%$
'2 ( )
+ *!!% +
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
24
Hilton Hotel
' 3 !+ %
2 +% $ % $
+ *-
* )
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 )
25
Hilton Hotel
Ice Surface
Condenser (-26°C)
Surface
Ammonia
condenser
$
*
4!
Noncondensables
Surface
Surface
Condenser
condenser
Steam
(30°C)
Booster or pump
ejector
1 mbar
Spargefrom
steam
Vapor
(100%)
FA scrubber
Non-condensables
(8%)
Motive steam
(100%)
Motive
Steam
Effluent
Iced
vapor
Effluent
(108%)
Rest of
condensed
water
(92%)
(> 95%)
26
Hilton Hotel
Condenser
From FA scrubber
Cooling water
Condensation of steam
(into ice) on surface
condensers
Freeze
condenser
Compressor
To
de-aeration
Separator
Valve, open
Valve, closed
Vapour (vacuum)
LP steam
Low pressure can be
reached (< 2 mbar)
Refrigerant (ammonia)
Non-condensable gases
Condensate
Melt vessel
process vapor
De Smet
SUBLIMAX
water
ammonia
Strongly reduced odor
emission
10x less waste water
Nearly no motive steam but higher electricity consumption
27
5 2 '*
1 $% $
+* %+ 4
4
)
HP-steam
821 heating
"7
822 deodorising
modular design:
logical sequence of all operations
880A heat recovery
880B final cooling
water
6
Deodorised oil
801 deaeration
Bleached oil
LP-steam
vacuum
814 scrubber
FAD
28
Hilton Hotel
Qualistock deodoriser
Simplified
erection
less building
minimum
space
faster
installation
easy
maintentance
& access
29
Hilton Hotel
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
30
Hilton Hotel
31

Recent Developments in Bleaching, Deodorisation and Physical

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