Short Course: Fundamentals of Edible Oil Processing and Refining. Recent Developments. Ken Carlson RBD Technologies, Inc.

Transcription

1 Short Course: Fundamentals of Edible Oil Recent Developments Ken Carlson RBD Technologies, Inc.

2 Topics General Trends Degumming/Neutralization Bleaching Deodorization Fat Modification Instruments & Controls Quality Assurance 2

3 Degumming/Neutralization Cavitation Mixing Technology Combined PLC/PLA Enzymes for Degumming Separators with Integrated Direct Drive Silica as alternative to Water Washing 3

4 Degumming/Neutralization EXAMPLE OF SYSTEM WITH WATER WASHING Cavitation Mixer? Acid conditioned oil to Bleaching Degumming/ Neutralization Reactor Degummed or neutralized oil to Bleaching Wash Reactor To Bleaching or Drying & Cooling Heater/ Cooler Cavitation Mixer? Heater Separator Mixer Separator Gum/soap Receiver Wash water Receiver Feed Oil Enzyme? (Degumming) Acid Lye Water Gum/ soap Wash water effluent 4

5 Degumming/Neutralization CAVITATION MIXING TECHNOLOGY 5

6 Degumming/Neutralization CAVITATION MIXING TECHNOLOGY 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 6

7 Degumming/Neutralization COMBINED PLC/PLA ENZYMES FOR DEGUMMING 7

8 Degumming/Neutralization INTEGRATED DRIVE SEPARATORS GEA/Westfalia directdrive Alfa-Laval edrive 8

9 Degumming/Neutralization SILICA FOR REPLACING WATER WASH 9

10 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 10

11 Bleaching EXAMPLE OF TRADITIONAL SYSTEM Carbon? Adsorbent Hopper To vacuum Slurry Tank? Dosing System Adsorbent Filters Safety Filters HR Heater Pulse Tube Filters? Bleaching Reactor Filter Aid Spent Adsorbent Hot oil to Deodorizing Steam mixing? Filtrate Receiver Degummed or neutralized oil Precoat/Heel Tank Precoat or recycle? Cooled oil to Storage 11

12 Bleaching EXAMPLE OF RE-USE SYSTEM Silica Hopper Earth Hopper Adsorbent Filters (3-cycle operation) Vent Silica Feeder To vacuum Dryer Water Vent Earth Feeder Bleaching Reactor To vacuum 2 nd (earth) Filtration 1 st (silica) Filtration Clean A B C Heater Trim Heater Silica Mix Tank Slurry Tank Spent ads. Filter Aid Filtrate Receiver Safety Filters Degummed or neutralized oil Precoat/Heel Tank Hot oil to Deodorizing 12

13 Bleaching IN-LINE COLOR/SOLIDS MONITORING 13

14 Bleaching FASTER FILTRATION SILICATE ADSORBENT 14

15 Bleaching NEW PRE-BLEACHING ADSORBENT 15

16 Bleaching FASTER FILTRATION HIGH ACTIVITY CLAY 16

17 Bleaching CLAY WITH ACTIVATED CARBON 17

18 Bleaching R & D FOR ENZYMATIC BLEACHING 18

19 Bleaching INCREASING USE OF PULSE TUBE FILTERS 19

20 Deodorization 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 20

21 Deodorization EXAMPLE OF SEMI CONTINUOUS SYSTEM Heating/Cooling under Vacuum To Vacuum Double Thermo siphon Loops? To Vacuum Scrubber High Pressure Steam Generator Pre-heated Boiler Feed Water? Distillate Steam Cooler BFW Surge Tank Nitrogen HR Cooler Product Cooler Polish Filters Bleached oil Anti-ox System Filters Heater BFW Cooler 21 Boiler Feed Water RBD oil

22 Deodorization EXAMPLE OF CONTINUOUS PC SYSTEM To Vacuum Heating/Cooling under Pressure Scrubber High Pressure Steam Generator Back-up Heater Final Heater Electric? Packed Column Stripping Section Double Shell? Deaerator Post Deodorizer Cooler Heat-bleaching Section Anti-ox System Distillate Receiver Bleached oil Filters HR Heater Alternating HR units? 22 Product Cooler Polish Filters Nitrogen Sparge Steam RBD oil Cooler Distillate

23 Deodorization EXAMPLE OF TWO-STAGE SCRUBBER To Vacuum Lo Temp Section High Temp Section Vapor from Deodorizer Cooler High Sterol Fraction Cooler High FFA Fraction 23

24 Deodorization HODGEPODGE Alfa-Laval SoftFlex SC Deodorizer with packing Structured Packing for Columns & Scrubbers Alfa-Laval Soft Column Alfa-Laval heat exchanger for continuous heating under vacuum Alfa-Laval heat exchanger for continuous cooling under vacuum DeSmet Qualistock all-in-one continuous deodorizer with internal heating/cooling under vacuum 24 Crown DiFlow SC Deodorizer Crown Double Shell Packed Column before assembly

25 Deodorization CLEAN VS GREASY VACUUM SYSTEMS Vapor from Deodorization Greasy System Vapor from Deodorization Clean System Barometric or surface condensers? Greasy Cooling Water Greasy water to Cooling Tower Steam Caustic Effluent Clean water to Cooling Tower Steam Cooling Water Hot Well Greasy water Cooler Water Chiller 25

26 Deodorization EXAMPLE OF GREASY VACUUM SYSTEM 26

27 Deodorization EXAMPLE OF CLEAN VACUUM SYSTEM 27

28 Start-up jet Deodorization EXAMPLE OF ICE CONDENSATION SYSTEM Design as per Graham Muffler In use Hot ammonia Melting Ejectors Ice Condensers Surface Condensers Vapor from Deodorization Ammonia to Chiller Ammonia from Chiller Melted fat Cooling Water Steam Hot Well 28 Effluent

29 Deodorization EXAMPLE OF ICE CONDENSATION SYSTEM 29

30 Fat Modification 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 30

31 Hydrogenation EXAMPLE OF TYPICAL SYSTEM Feed Tank Catalyst To vacuum Vent Catalyst Filter Pulse Tube Filter? Agitator Design N2 Hydrogen Safety Filter Flash Tank Reactor Dual Reactors For high capacity Spent Catalyst Filter Aid Drop Tank Bleached oil HR Precoat Tank To Post Bleaching 31

32 Hydrogenation NEW CATALYSTS 32

33 Interesterification EXAMPLE OF BATCH CHEMICAL PROCESS Sodium Methoxide Dosing System To vacuum Silica Earth N2 Adsorbent Filter Pulse Tube Filter? N2 Safety Filter Dosing System Spent Adsorbent Reactor Filter Aid Heater Drop Tank Blended bleached oils Citric Acid Dosing System Precoat Tank Interesterified oil 33

34 To vacuum To vacuum Novozymes Enzyme To vacuum Interesterification EXAMPLE OF ENZYMATIC PROCESS As per DeSmetBallestra Vacuum Dryer Buffer Tank Enzyme Preparation Tank Blended RBD oils Heater Cooler To vacuum 4 6 Interesterification Reactors Product Tank Safety Filters Cooler Interesterified Oils 34

35 Dry Fractionation EXAMPLE OF TYPICAL SYSTEM Membrane type Stearin Filter Alternatives: drum filter or centrifuges Stearin Melt Tank Alternating Crystallizers Stearin Core Blow Tank Chilled Water Tank Refrig System Fill Work Filter Hot Olein Wash Tank Cold Olein Rinse Tank Olein Tank Crude oil Olein Heater Slurry Circulation Pump Filter Squeeze Pump Cooling Water 35

36 Fractionation NEW CRYSTALLIZER DESIGN 36

37 Instruments & Controls Fieldbus allowing multiple units per wire set as well as two-way communication with digital HART type instruments with EDDL Some common terms: Wireless instruments for remote locations Handheld communicators for linking with SCADA system 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 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) 37

38 Quality Assurance GET A COPY OF THIS PRESENTATION 38

39 Thanks for Your Attention! 39 Thanks for Your Attention!