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Best Practice of High-Quality Lecithin Production. From Miscella-Clarification to Lecithin-Powder
Barbara Harten– Application Sales Manager
PRACTICAL EXPERIENCE: OILSEEDS DEEP PROCESSING
TECHNOLOGIES (LECITHIN))
• Lecithin
• Water degumming
• Lecithin drying
• Crude oil clarification.
• Lecithin de-oiling
• Summary
Content
2 High Quality Lecithin Production
Basics of Lecithn
• Lecithin belongs to the phospholipids, one part of the molecule is hydrophilic the other part
hydrophobic
• Degumming =Removal of phospholipids (gums) from fats and oils
• Phospholipids are phosphorous containing organic substances
• The content of phospholipids are determined by analysing the phosphorous content in the oils and
fats
• Factor to convert phosphorous to phospholipids: 30
• Hydratable gums are removed by adding water
• The quantity of gums are depending on the extraction method of the oil from the seed;
only pressing leads to a low total gum content with high hydratable gum content
High quality lecithin production 3
Gly
ce
rol Fatty Acid
Fatty Acid
Fatty Acid P O O
O
O-
Phospatidyl choline (lecithine)
Composition of phospholipids
• Hydratable phospholipids
• Phosphatidyl choline (PC)
• Phosphatodyl inositol (PI)
• Non-hydratable phospholipids
(calcium, magnesium and iron salts)
• Phosphatitic acid (PA)
• Phosphatidyl etholamine (PE)
Remark: Simplified model, not all PA and PE are NHP
Soybean Oil Rapeseed Oil Sunflower Oil
Phosphor content [ppm] 400 - 1200 200 – 900 300 – 700
Phospholipids content [%] 1.0 – 2.9 0.5 – 2.3 0.8 – 1.8
Phospholipids
distribution
[%]
PC (MW 784) 47 27 29 – 52
PI (MW 861) 24 17 11 – 22
PE (MW 742) 20 17 17 – 26
PA (MW 699) 9 39 15 -30
High Quality Lecithin Production
High Quality Lecithin Production
• Market price of soybean meal –
300 – 500 US$ per ton
• Market price of dried lecithin –
600 – 1.200 US$ per ton
• Market price for lecithin granulate
– 2 – 10 US$ per kg
• Growing interest for lecithin
granulates / powder in food
industry
• Growing interestest in lecithin
from sunflower and rapeseed oil
0
500
1000
1500
2000
2500
3000
3500
Price in US$ per ton
Lecithin market
5
• Emulsifier for food products
• Bread
• Margarine
• Chocolate
• instant drinks
• Animal feed
• Emulsification, digestion and
binding of dust during production
• Fish Farming
• Non food applications / technical
applications
• Cosmetics
• Pesticides
• Paint industry etc.
• What is Lecithin used for
Lecithin Usage
High Quality Lecithin Production
• Target quality of Lecithin
• Light Color – influenced strongly by solids in
the crude oil
• Low content of solids
• Technical use:
< 0.3%
• Food products:
target < 0.1%
6
Water-Degumming
Pressing
Seed Beans
Animal feed
Press oil
clarification
Extraction Press-Cake
Wet-Gums
Oil
Meal
Lecithin-Drying
Refining
Crude-
Lecithin
Lecithin-Deoiling
Crude-Lecithin
Lecithin
Powder
Miscella-Clarification
Water degumming
7 High Quality Lecithin Production
Lecithin recovery process overview
Water Degumming
High Quality Lecithin Production
• Removes only hydratable phosphatides
• Wet gums can be dried in a lecithin dryer and sold
as lecithin
• Refining of degummed oils causes lower oil losses
• Pre-caution for soap-stock splitting for yield
improvement of the alkaline neutralisation
• Improve storage and transportation stability of the
oil
8
• Process achievements:
• Residual phosphatides:
non-hydratables + max. 0,1 % hydratables
• Oil loss: max. 35 % oil in dried gums
• Moisture:
< 0.5 % without vacuum drying
< 0.1 % with vacuum drying
Water Degumming
High Quality Lecithin Production
• Process parameters:
• Oil temperature: 75 - 90 °C
• Water addition:
corresponding to the phosphatide content
• Hydration time:
with high shear mixing not required
with static mixers min. 30 minutes
9
Loss formula for neutralization:
Total Loss= ffa + phosphatides+ moisture+ impurities+ 0,3 %
Loss=0,6 +1,25* Total Loss
Losses water degumming:
AI = 65 %= 35 % oil in gums
:
Loss calculation alkaline neutralisation
10 High Quality Lecithin Production
Typical quality for crude sunflower oil:
• ffa = 1 %
• P crude = 800 ppm= 2,4 %
• P water degummed= 100ppm=0,3 %
• Moisture = 0,2 %
• Impurities= 0,2 %
Neutralisation without water
degumming
Neutralization combined with water
degumming
TL = 1 +2,4+0,2+0,2 + 0,3= 4,3 %
Losses = 0.6+ 1,25 * 4,3 = 5,97 %
TL = 1 +0,3+0,2+0,2 + 0,3= 1,96 %
Losses = 3,05 %
Gum content in the gum discharge=
800 ppm P-100ppmP = 700 ppm P *
30 =2,1 % gums/35 %Oil content=
0,73 % oil loss + 2,1% gums =
Loss = 5,97 % Loss = 5,88 %
Loss calculation
11 High Quality Lecithin Production
Yield gain 0,09 %
Profit:
300 t/d = 100.000 t/a x 0.09 % x 800 € = 72,000 €/a
1000 t/d= 330.000 t/a x 0,09 % X 800 € = 237,600 €/a
Water-Degumming
Pressing
Seed Beans
Animal feed
Press oil
clarification
Extraction Press-Cake
Wet-Gums
Oil
Meal
Lecithin-Drying
Refining
Crude-
Lecithin
Lecithin-De-oiling
Crude-Lecithin
Lecithin
Powder
Miscella-Clarification
Lecithin drying
12 High Quality Lecithin Production
Lecithin recovery Lecithin recovery process overview
Effective Lecithin drying is necessary for:
• Storage stability
• Transportation cost
Best Practice Lecithin Drying
Important Factors :
• Temperature (∆ t low)
• Solid content in the lecithin in the dryer
• Design of the dryer (horizontal/vertical)
• Oil content
• Purity of the condensate
• High flexibility in terms of throughput capacity
• Low residence time in the dryer ( approx. 1 min)
Lecithin Drying
13 High Quality Lecithin Production
• Horizontal dryer and conical backward design :
One floor installation Is used for products , which agglomerate
to hard particles
example: lecithin form rape or sunflower seed,
particles are draught back to the feed side with milder
temperature less burning of particles
cheaper installation (one floor) easy maintained
Wider range of throughput capacity
Gap between the rotor and inner shell can be adjusted as
set up for different types of lecithin
• Vertical dryer :
Can be used for soy bean lecithin as this lecithin does not
intent to built hard particles
Cheaper apparatus
Design of Lecithin Dryer Short Path distillation
14 High Quality Lecithin Production
Water-Degumming
Pressing
Seed Beans
Animal feed
Press oil
clarification
Extraction Press-Cake
Wet-Gums
Oil
Meal
Lecithin-Drying
Refining
Crude-
Lecithin
Lecithin-Deoiling
Crude-Lecithin
Lecithin
Powder
Miscella-Clarification Oil
clarification
16 High Quality Lecithin Production
Lecithin recovery Lecithin recovery process overview
When it is needed to produce a high quality lecithin it is a condition that
the oil must be clarified before degumming. That means that all the
solid impurities must be removed prior the degumming process, like:
• Fibers
• Proteins
This can be mane in several ways:
1. Hydrozyclon
2. Crude oil filtration
3. Clarification of the crude oil with separators
4. Miscella clarification
Crude oil clarification / filtration
High Quality Lecithin Production 17
• Amount of Particles
• Particle Size
• Particle size is the main limit for the clarification / filtration technology
• Particle Size distribution analyse should be done
Influence Parameters on Clarification
18 High Quality Lecithin Production
5 µm – Limit of Crude Oil Clarification/Filtration
2 µm – Limit of Miscella Clarification
50 µm – Limit of Hydrocyclon 15 -
Crude Oil Filtration
19 High Quality Lecithin Production
Crude oil
Filtrated oil Filter
cake
Filter aid
• Use of filter aid
• A second filter or big intermediate tanks necessary
• Big installation area
• Specific manpower for operation and filter cleaning
• Needs steam for blowing the filter
• Oil losses in the spent filter aid
• Reposition for the filtering clothes
• Disposal of the filter cake
Risk= filter leakage
• In case of filter leakage the separators for degumming will have erosion
problems
• Filter aid and particles from the crude oil will contaminate the gum discharge
Crude Oil Filtration
20 High Quality Lecithin Production
Crude oil clarification
High Quality Lecithin Production
Soya flakes
Meal
Clarified oil
Hexane
EXTRACTION DESSOLVENTIZING DESTILLATION CLARIFICATION
21
High Quality Lecithin Production
• Continuous process
• No significant oil losses
• Without additional effluent stream
• Solids can be added to the
meal or returned to extractor
• Equivalent result as filtration
(Hexane insoluble in dried
lecithin typically 0.05 to 0.1 %)
• Low space requirement of the
installation
• No additional manpower required
• No oil losses in the filter aid
Crude oil clarification
Crude oil Clarified oil
Impurities
22
Soya flakes
Meal Clarified oil
Hexane
EXTRACTION DESSOLVENTIZING DESTILLATION + CLARIFICATION
Miscella clarification
High Quality Lecithin Production 23
Miscella clarification
High Quality Lecithin Production
Inert gas panel N2
Miscella Clarified
miscella
Impurities Model used by:
24
• No oil losses due to integration in extraction process
• No effluents
• No filter aid
• More efficient than crude oil filtration
(typically < 0.05% hexane insoluble in the dried lecithin)
• Low space requirement of the installation
• Now additional manpower required
• Additional advantage:
• Keeps the hexane distillation clean
(no cleaning during the year)
• Keeps steam economy constant
(no increase of vapor pressure to compensate fouling)
• Lighter Color of lecithin (Most important for lecithin quality)
Miscella clarification
High Quality Lecithin Production 25
Water-Degumming
Pressing
Seed Beans
Animal feed
Press oil
clarification
Extraction Press-Cake
Wet-Gums
Oil
Meal
Lecithin-Drying
Refining
Crude-
Lecithin
Lecithin-De-Oiling
Crude-Lecithin
Lecithin
Powder
Miscella-Clarification
Lecithin De-Oiling
26 High Quality Lecithin Production
Lecithin recovery Lecithin recovery process overview
28 High Quality Lecithin Production
Main Process
Overview Lecithin De-Oiling
Storage and Pre-
treatment of crude
lecithin
De-oiling
Drying
Grinding
Packing
Distillation
Rectification
Vent washing
Side process
Utilities
Cooling/chiller
Nitrogen Generation
Instrument air
Grinding
Lecithin De-Oiling
29 High Quality Lecithin Production
De-oiled
Lecithin
Acetone
Lecithin
Acetone / Oil
Miscella
Decanter Decanter
30 High Quality Lecithin Production
De-Oiling
The de-oiling is done in a two stage counter current
extraction using decanter the removal the oil/acetone mixture from
the lecithin.
Extraction temperature : 25 °C
M
M M
M
M M
4
7 8
1
2
6
Aceton
1
2
3
4
7
8
By means of a decanter centrifuge the oil containing acetone phase
is separated, and pumped to a storage tank
the acetone /oil mixer to the acetone recovery
The lecithin discharge of the first decanter is mixed with “fresh “acetone
( from the acetone rectification) and conveyed to the second decanter,
the lecithin discharge is pumped to the lecithin grinding,
the oil acetone phase back the first decanter
Crude Lecithin is mixed with the
Acetone /traces of oil containing
discharge of the second decanter
3
3
5
8
6
31 High Quality Lecithin Production
Storage and Pre-Treatment the Dried Lecithin
• The intermediate storage capacity
should be big enough for 48-72 h
storage time, each vessel must be
equipped with heating and cooling
system plus effective agitator
• During the filling of the vessel,
hydrogen peroxide is mixed with the
lecithin for disinfection
• Storage temperature 60 °C
32 High Quality Lecithin Production
Granulation
• The de-oiled lecithin from the discharge of the
decanter needs to be grind to enlarge the surface
• Only from grinded lecithin acetone can be
removed
33 High Quality Lecithin Production
Drying
• The drying of the lecithin is
done in two steps .
• Due to hazardous area caused
by the acetone, the first drying
is under nitrogen atmosphere
• Drying temperature 80-100°C
• The acetone is condensed by
means of ammonia and
recovered
Trockner 2
Trockner 1
• In the second dryer the acetone content is below the explosion point therefor
regular air can be used .
34 High Quality Lecithin Production
Grinding
• In the next step, the dried granulates are grinded to
powder by a fine impact mill.
• Due to the high dust content this process stage
needs to be
nitrogen purged under hazardous area regulation
• The high energy input leads to a high increase of the
gas circulation temperature therefore a cooling
system needs to be foreseen
• To protect the mill a metal protector is
installed upfront to the mill
35 High Quality Lecithin Production
Packing
• Can be done in 25 kg plastic bags
• As the lecithin is hydroscope, the packing
area must fulfill following ambient:
- max. 25 °C temperature
- max. relative humidity of 50-60 °C
36 High Quality Lecithin Production
Distillation of Acetone from Oil
• The distillation of acetone from oil is done in
a two stage falling film evaporator
• The oil can be mixed to the crude oil
• The acetone is condensed and convey to the
rectification stage
37 High Quality Lecithin Production
Rectification
• For the reuse of the acetone in the in the lecithin
de-oiling stage the acetone need to be purified
from water
• Even the dried lectin still contains water, which
would accumulate in the recycled acetone
• Max. acceptable water contend of the acetone for
de-oiling : ca. 0,5%
• Therefore a rectification of acetone from water is
permitted .
38 High Quality Lecithin Production
Vent Washing
• The vent need to be washed to prevent the
environmental from acetone vapours
• .the vent washing is done in 2 stages, as the wash
water temperature is responsible for effective
washing
• The first washing is done with cooled process
water, the second stage with ice water
39 High Quality Lecithin Production
Cooling
Cooling is necessary for many stages of the de-oiling
process:
For the removal of the acetone of the first drying step
of the lecithin
Ice water (2 °C) ) for the vent washing, condensation,..
• Lecithin is used for a lot of application in the food and feed industry. As a side effect the
quality of the lecithin especially in case of food use comes more into focus.
• Water degumming is well known since many decades for yield improvement of the
edible oil refinery and for better storage stability of the oil
• The by-product of the water degumming = wet gums are a valuable product. For selling
the water needs to be removed by a lecithin dryer, which need to be designed for best
quality lecithin
• To get a lecithin after the dryer with light color the impurities upfront to the water
degumming needs to be removed by
filtration
clarification
GEA propose the miscella clarification as the clarification effect is the best and the
availability in the oil extraction distillation is higher
• The de-oiling of the dried lecithin is the next step in the lecithin treatment but is also
quite cost intensive. Therefore it is only feasible for higher capacities and or special
markets.
Summary
40 High Quality Lecithin Production