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Desmet Ballestra Presentation 1
RecentRecent DevelopmentsDevelopments in in BleachingBleaching, , DeodorisationDeodorisation and and PhysicalPhysical RefiningRefining
of of OilsOils and Fats and Fats
W. De W. De GreytGreyt, V. , V. GibonGibon and M. and M. KellensKellens
Desmet Ballestra Group Desmet Ballestra Group
Zaventem, BelgiumZaventem, Belgium
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Desmet Ballestra Presentation 2
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oils & fats
124 Mio Tons in 2006 124 Mio Tons in 2006
PO+ SBO = 55%
VEGETABLE OILS WORLD PRODUCTION
Desmet Ballestra Presentation 3
Year Consum ption Population Dem andkg/capita Billion M illion tons
1980 12.8 4.4 56.81990 15.3 5.3 80.52000 18.3 6.1 110.52010 20.9 6.6 1392020 23.8 7.4 175.3
Expected growth rate
~ 3-4 Mio TPY extra for edible consumption
Year M illion 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
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Desmet Ballestra Presentation 4
0
20
40
60
80
100
120
140
Mill
ion
tons
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 –– RapeRape: 5 (BD): 5 (BD)
NON-EDIBLE USE OF VEGETABLE OILS
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Desmet Ballestra Presentation 5
US$
/ton
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$/barrel
> 100 US$/barrelCrude fossil oil
STRONG PRICE INCREASE FOR CRUDE OILS (FROM 2005)
Production period
Increase demand for food use (China, India) Booming biodiesel market (Europe,USA)
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Desmet Ballestra Presentation 6
QUALITATIVE SOLUTION : Food vs Technical Oils
��� ������� �������� � ��� �� ������� ���� ���� ���� ��� � ��� ��� ����������� �� ������ ��� ��� ����������� �� �����
** 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)
��PrimaryPrimary’’ OilsOils for for HumanHuman ConsumptionConsumption
* * High Quality Commodity Oils (Soy, Rape, Sun, Palm, …)
* * Specialty oils with high nutritional value (Olive, Fish, Flaxseed,…)
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Desmet Ballestra Presentation 7
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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,….)
Desmet Ballestra Presentation 8
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STABILITYSTABILITY FUNCTIONALITYFUNCTIONALITY
NUTRITIONAL NUTRITIONAL QUALITYQUALITY
StructuredStructured LipidsLipids
FryingFrying OilsOils
SaladSalad OilsOils
SpecialtySpecialty FatsFats
ShorteningsShorteningsMargarineMargarine
fats fats
INCREASED ATTENTION FOR NUTRITIONAL QUALITY OF FOOD OILS AND FATS
Desmet Ballestra Presentation 9
SeedSeed
Frying oilFrying oil
Speciality FatsSpeciality Fats
MargarineMargarine
Frying oilFrying oil
Speciality FatsSpeciality Fats
MargarineMargarine
CrudeOil
CrudeOil
RefinedOil
RefinedOil
CrackingCracking
DehullingDehulling
FlakingFlaking
Cleaning / DryingCleaning / Drying
Preparation
CrackingCracking
DehullingDehulling
FlakingFlaking
Cleaning / DryingCleaning / Drying
Preparation
MealMeal
BleachingBleaching
NeutralisingNeutralising
DeodorisingDeodorising
WinterisingWinterising
DegummingDegumming
Refining
BleachingBleaching
NeutralisingNeutralising
DeodorisingDeodorising
WinterisingWinterising
DegummingDegumming
Refining
Mechanical ExtractionMechanical Extraction
Solvent ExtractionSolvent Extraction
Extraction
Mechanical ExtractionMechanical Extraction
Solvent ExtractionSolvent Extraction
Extraction
HydrogenationHydrogenation
InteresterificationInteresterification
FractionationFractionation
Modification
HydrogenationHydrogenation
InteresterificationInteresterification
FractionationFractionation
Modification
LubricantsLubricants
SoapSoap
BiodieselBiodiesel
LubricantsLubricants
SoapSoap
BiodieselBiodieselOleochemical
ProcessesOleochemical
Processes
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Desmet Ballestra Presentation 10
Crude OilCrude Oil
Chemical refin
ing
Degumming
Neutralisation
Bleaching
Deodorisation
Refined OilRefined Oil
SOAPS
GUMS
FFA
SPLITTING
Soybean oilSoybean oilPhysical refining
Degumming
Bleaching
Steam refining-Deodorisation
Palm oilPalm oil
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Desmet Ballestra Presentation 11
98
99
100
101
102
103
104
105
106
107
108
0 0.5 1 1.5 2 2.5 3 3.5 4
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Desmet Ballestra Presentation 12
ADSORPTION ADSORPTION
PROCESSESPROCESSES
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Desmet Ballestra Presentation 13
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$ %& %'� !( %) � � �*) �%$ *�'%�� *'�+% *) *) , �� *�
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 costsCombiclean
Process
Desmet Ballestra Presentation 14
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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
Desmet Ballestra Presentation 15
Vacuum unit
Spent bleach earth
Bleachingearth
Degummedoil
steam
Citricacid
bleacher
Leaf filters
Bleached oil
Polish filters
Spargesteam
..
.......
.
From degummingneutralisation 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
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First Adsorption ofMetals, soaps,Color pigments
Desmet Ballestra Presentation 16
Counter-current bleaching process
Vacuum unit
Spent bleach earth
Bleachearth
Degummedoil
steam
Citricacid
Finalbleacher
Leaf filters
Prebleacher
Bleached oil
Polish filters
Candlefilter
Recyclingspent earth
Spargesteam
..
.......
.
From degummingneutralisation
To deodorisation
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�
Prebleaching with used BE
Desmet Ballestra Presentation 17
Vacuum unit
Spent bleach earth
Bleachingearth
Degummed
acid
bleacher
Leaf filters
Bleached oil
Polish filters
Spargesteam
... ..
..
..
.
To deodorisation
Spent bleach earth
Pre filtrationfinal filtration
cleaning
Active carbon
Spent carbon
Filter press
Silica
oil
..
... .. ..
.
�
Adsorption ofP and soaps
�
PrebleachingMore efficient use of BE
�
Final bleaching
�
Removal of contaminants
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COMBICLEAN process
Desmet Ballestra Presentation 18
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�� ( �*�'%� ) �!+� �%� � �
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
Desmet Ballestra Presentation 19
DEODORIZATION DEODORIZATION ––
STEAM REFININGSTEAM REFINING
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Desmet Ballestra Presentation 20
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$ %& %'� !( %) � � �*) �%$ *�'%�� *'�$ %� $ � +*- � � *� ) �
� �. %�� *& %� �� �$ %� $ � +*- � � *� ) ��
�!� ������ ������������ ������ ���"������������ �����"#$$!
�!� ��%�������� ���� ��%� ��%���� ��%������� ���%�� & ������ ������!
�!' �� (������� ���� ��%� ��%���� ��������� �� � ���!
$ %& %'� !( %) � � �*) �$ %� $ � +*- � � *� ) �� %�/ ) � '� , 0
�!)� �����% %��%���*�� %��� � ����������"���%����� ������"#$!
�!+�%,��� ��� ���% %,���� ����,�� %��%���*�� "��- �� �����,��"#$!
�!��������% ������� �����,���� ��� ��������%����� ����� ���.�% ���,� �!
Desmet Ballestra Presentation 21
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 / SemicontinuousSemicontinuous
CrossflowCrossflow (tray) / (tray) / CountercurrentCountercurrent (pack) (pack)
Shallow bed / Shallow bed / Deep bed Deep bed
Economizing / Cooling / Economizing / Cooling / Heating under vacuumHeating under vacuum
DeodoriserDeodoriserdesigndesign
Low pressure by chilled Low pressure by chilled water / Ice condensingwater / Ice condensing
Operating Parameters
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Desmet Ballestra Presentation 22
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 minorcomponents
230 C
230 ���� 250 C
250 C
210 ���� 230 C
250 ���� 130 C
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Desmet Ballestra Presentation 23
Packed column stripper
∆∆∆∆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
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
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Desmet Ballestra Presentation 24
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
!� �1%$ ��� '2 ( ) �� � +*!!%+�
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Desmet Ballestra Presentation 25
'� 3 �!+%� � 2 +%�$ %� $ � +*- � � *� ) �
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� 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 )
Desmet Ballestra Presentation 26
Sparge steam(100%)
Motive steam(100%)
Effluent(92%)
Booster or pump
Surfacecondenser
Non-condensables(8%)
Effluent(108%)
Surfacecondenser
Ice Surface Condenser (-26°C)
Ammonia Noncondensables
Motive Steam
Rest of condensed
water
1 mbarVapor from FA scrubber
Iced vapor
(> 95%)
Steam ejector
Surface Condenser
(30°C)
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$ �*�� ��������� ���4�! �� ���
Desmet Ballestra Presentation 27
Compressor
Condenser
Separator
Cooling waterFrom FA scrubber
Vapour (vacuum)
Refrigerant (ammonia)
Non-condensable gases
Valve, closed
Valve, open
Melt vessel
Condensate
Tode-aeration
Freezecondenser
waterprocess vapor ammonia
LP steam
De SmetDe Smet
SUBLIMAXSUBLIMAX
Condensation of steam (into ice) on surface condensers
Low pressure can be reached (< 2 mbar)
Strongly reduced odoremission
Nearly no motive steam but higher electricity consumption
10x less waste water
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Desmet Ballestra Presentation 28
Bleached oil
821 heating
822 deodorising
801 deaeration
880B final cooling
water
Deodorised oil
LP-steam
HP-steam
814 scrubberFAD
880A heat recovery
vacuum
modular design:
logical sequence of all operations
5 2 � '*� � � �1�$ %� $ � +*� %+�4� ������������� �������������������
� ���� � ��������� 6 ���������
��������� ����� �����������
� �������������������4�
) ��"7 �� ����������
Desmet Ballestra Presentation 29
Simplified Simplified erectionerection
less buildingless building
minimum minimum spacespace
faster faster installationinstallation
easy easy maintentancemaintentance
& access& access
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Qualistock deodoriser
Desmet Ballestra Presentation 30
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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
Desmet Ballestra Presentation 31
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