Science behind Technology1 Use of Nano Reactors in Edible Oil Processing in Edible Oil Processing...

Science behind Technology 1 www.desmetballestra.com

Use of Nano Reactors Use of Nano Reactors

in Edible Oil Processingin Edible Oil Processing

Wim De Greyt1, Marc Kellens1,Tim Kemper2 and Jim Willits2

1Desmet Ballestra Group, Zaventem, Belgium; 2Desmet Ballestra North America, Marrietta, GA

102nd AOCS Annual Meeting

May 1-4, 2011

Cincinnati, OH


EFFICIENCY

QUALITY SUSTAINABILITY

REFINING REFINING CONDITIONSCONDITIONS

Refiner’s Challenge

REFINING REFINING TECHNOLOGYTECHNOLOGY


Crude Oil

Water degumming

Alkali Neutralisation

Deodorization

Refined Oil

Soapstock

Spent bleaching earth

Deodorizer Distillate

Mechanical Pressing

OILSEEDS

Oil Extraction

Solvent extraction

WDG Oil

Acid degumming

Bleaching

Physical deacidificationDeodorization

Bleaching

Acid Gums

Deoiled Meal

Gums LECITHIN

Oil Refining Processes

Chemical Physical


Crude Oil

Water degumming


Deodorization

Refined Oil

Soapstock



Mechanical Pressing

OILSEEDS

Oil Extraction

Solvent extraction

WDG Oil

Acid degumming

Bleaching


Bleaching

Acid Gums

Deoiled Meal

Gums LECITHIN


Chemical Physical


Crude Oil

Water degumming


Deodorization

Refined Oil

Soapstock



Mechanical Pressing

OILSEEDS

Oil Extraction

Solvent extraction

WDG Oil

Acid degumming

Bleaching


Bleaching

Acid Gums

Deoiled Meal

Gums LECITHINDevelopments in Developments in

Wet oil pretreatmentWet oil pretreatment



Developments in degumming

Enzymatic Degumming

POTENTIEL YIELD GAIN PLC

0,00

0,50

1,00

1,50

2,00

2,50

3,00

0 200 400 600 800 1000 1200 1400

ppm P in crude oil

% o

il y

ield

ga

in (

ma

x)

DIGLYCERIDE INCREASE

NEUTRAL OIL INCREASE

TOTAL OIL INCREASE

soya

rape

* PL-C on high PL-containing crude oils (RSO, SBO)

* PL-A on crude/WDG oils

Fatty acid

P

Fatty acid

Fatty acid

P

Fatty acidPLC

A E I C

Main driver

Higher Oil Yield


Alkali Neutralisation - Degumming

Trend towards more intensive mixing

Static Dynamic High Shear Ultra High Shear (single stage) (multi-stage)

SilversonIKA

How to improve efficiency further ?

More intensive mixing requiring higher energy input

MORE EFFICIENT GUMS/FFA REMOVAL Using less chemicals


Nano Reactors

Nano Reactors

Generation, growth and collapse of bubbles

Release of large magnitudes of energy over small location(high energy density)

Locally very high temp/pressure with overall ambient conditions

‘Mechanical’ Effects

*High turbulence

*High shear forces

*Fine emulsions

‘Chemical’ Effects*Fragmenting of molecules

*Formation of radicals


POSSIBLE APPLICATIONS OF NANO REACTORS

1. Process intensification (faster-higher yield-more selective)

2. Cell disruption (biotechnology)

3. Microbial disinfection/destruction contaminants

4. Many other specific applications

Nano reactors

Can Nano Reactors be applied in Oil Processing ?

Ref : Gogate – Chemical Engineering and Processing 47 (2008),515-527


Acoustic Process

ACOUSTIC PROCESS (SONOCHEMISTRY)

*No industrial application due to inherent drawbacks

* Effect depends on distance from source (not uniform)

* Batch process, not suitable for large scale processing

* High energy requirement

* Generated by Ultrasound waves

*Tested successfully for degumming

Moulton and Mounts (1999)

> 90 % PL removal


Hydrodynamic Nano Reactors

HYDRODYNAMIC NANO REACTORS

* Less studied than ultrasound process

* Generated by passage of a liquid through a constriction

* Much more energy efficient than acoustic process

* Suitable for larger scale, continuous processes

Typical velocity and pressure profile in a hydrodynamic Nano reactor


Nano-Reactors

NANO-REACTORS * Unique internal geometry

* Generation of very small ‘nano’ bubbles in liquid streams

* Liquids (homogeneous/heterogeneous) are fed to nano-reactor with HP pump

* Mechanical and chemical effects

- Formation of very fine emulsions - Increased surface area - Strong shear forces

- Activation of atoms, molecules - Formation of radicals - Initiation of chemical reactions

* Reactor, more than just a good mixer

Proprietary design of CTI


Nano-reactor

NaOH

Nano-NeutralisationTM

Standard

Neutralisation

Nano-

Neutralisation


- Patent pending technology

- Add-on process to existing oil refinery neutralisation system

- Process benefits (industrial proven)

• No addition of H3PO4 (NHP converted in HP in nano-reactor)

• No acid retention tank

• Less NaOH required (no need for H3PO4 neutralisation)

• Less soaps in nano-neutralized oil reducing need for silica

or wash water

• Improved oil yield due to improved separation of soapstock

(Less neutral oil/no salts in soapstock)


Science behind Technology


www.desmetballestra.com15

Industrial plant : 500 TPD



Feedstock Water-degummed soybean oil(120-150 ppm P; 0.45-0.55% FFA)

Nano-neutralization Classical caustic refining

Process parameters -Phosphoric acid (ppm)-NaOH (% 16.6 °Be)

-Pressure (bar)-Temperature (°C)

0-1000.7

6075

850-9001.2

Refined Oil Quality -P-content (ppm)-Ca & Mg (ppm)-FFA (%) -Soaps (ppm)

1-3< 1

< 0.03< 100

6-8

< 0.05200-300

500 TPD Nano-neutralisation of soybean oil

Industrial data

Science behind Technology


www.desmetballestra.com17

Industrial plant : 500 TPD

Proven Process Advantages

- 90% less phosphoric acid

- 40-50% less caustic soda

- min. 0.2% extra refined oil yield

- less silica consumption


Other possible applications

1. Nano-degumming of crude/WDG oils

• Deep degumming to allow physical refining

2. Nano-degumming of palm oil

• Replacing the ‘dry’ phosphoric acid degumming

• Also suitable in biodiesel feedstock pretreatment

3. Enzyme assisted nano-degumming

Still in testing phase, not proven yet


Summary - Conclusions

* Efficiency, Quality and Sustainability are key criteria for new/improved processes in edible oil refining

* Enzymatic degumming meets all these criteria and is therefore being applied more

* Hydrodynamic Nano Reactors is interesting technology for edible oil refining

* Nano-neutralisation is being implemented on industrial scale

* Nano-degumming (in combination with enzymes) is tested on lab/pilot scale


Thank You For Your Attention

102nd AOCS Annual Meeting

May 1-4, 2011

Cincinnati, OH

Wim De Greyt1, Marc Kellens1,Tim Kemper2 and Jim Willits2

1Desmet Ballestra Group, Zaventem, Belgium; 2Desmet Ballestra North America, Marrietta, GA

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