in-line process control for oilseed industry21.03.2016 page 16 for internal use only on press cake...

Process Control for Oilseed Industry BUCHI NIR-Online

page 1 21.03.2016 For internal use only

In-line Process Control for Oilseed Industry

Rapeseed Crushing

Biodiesel

Refinery

Soybean Crushing

Sunflower Crushing


For internal use only page 2

21.03.2016

Today The BUCHI Group •  More than 500 employees worldwide •  Development and manufacturing in Flawil/Switzerland •  Own affiliates in 16 countries and •  Distribution partners in over 80 countries Worldwide leading position in different markets•  Pharmaceutical industry •  Food and beverage, feed industry •  Chemical industry •  Oils and fat industry •  Academia

Customers •  Scientists in research and development laboratories •  Students in universities •  QA-technicians in quality control laboratories •  Analytical chemists in service laboratories



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Evaporation Industrial Parallel Spray Drying & Melting Point Solutions Evaporation Evaporation Encapsulation

Product Range

Preparative Kjeldahl & Extraction NIR Chromatography Dumas Solutions

Solutions



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Quick-start calibrations • Milk & Dairy • Meat & Derivates • Milling & Bakery • Oil bearing crops

Calibration software: NIRCal Patented wizard auto calibration module

Production at-line solution: NIRMaster

Production on-line solution: NIR-Online

Accessories Laboratory flexible solution: NIRFlex N-500

BUCHI NIRSolutions to meet your demanding needs



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BUCHI NIR-Online Sensor



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For Manufacturing Plants Who

•  Are struggling raw materials consistency and quality

•  Are facing unstability in the process leading to significant losses

•  Are having to re-work products time to time due to quality issues

•  Are considering to optimize key operations along their production

chain



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For Manufacturing Plants Who Need

•  To continuously assess products and operations along

production chain

•  To monitor and control key operations in real time

•  To start/engage a cost saving exercise

•  To reduce risks to operators

•  To reduce downtimes

§  PRODUCTION DOCUMENTATION §  CONSISTENCY ASSESSMENT

…. ALLOWING KEY PARAMETER MONITORING/CONTROL

TARGET VALUE -/+ TOL.

…. PRODUCING CONTINUOUS READING/PREDICTIONS

NIR TECHNOLOGY PLACED IN PRODUCTION

… AND CONNECTED TO PROCESS CONTROL

1st advantage: Deviation detection

REAL TIME

NIR-ONLINE CONCEPT : PROCESS ANALYZER

2nd advantage: Process Optimization

500+ Instruments Already Installed Worldwide

Feed & Grain industry

Oil seeds industry

Milling industry

NIR-ONLINE Solution Made Of…

Grain

Powder

Liquid

PROCESS

Analog Output

Profibus

SX Center

PLC

§  1 Adapter to fit into the process

Connection to PLC (optional)

MODBUS

OPC

TCP/IP

Above conveyor

High Flow

§  Cables + Power Supply

§  1 Operating Software

§  1 Sensor

CONTROL



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Oilseed Industry At A Glance

FEED SUPPLEMENT



COOKED

SOYBEANS

Crude Soybean Oil EXTRACTED

MEAL

Conveyor chain Bypass sampler

At Conveyor chain At Redler side

After cooker Before/after dryer After conditioner At conveyor side

At control station On sampling probe At Conveyor

Oil Moisture Others

Moisture Others

Moisture Proteins Oil Hexane

Oil Moisture

Soybean Crushing Process RAW

SOYBEANS

HULLS

IMPURITIES

Direct in pipe or bypass

Phosphorous FFA Moisture

On line monitoring all along the crushing process from raw materials intake to crude oil.



EXTRACTED MEAL

PRESS CAKE

Sunflower Crushing Process RAW

SUNFLOWER SEEDS

Total Crude Oil

DEHULLED SEEDS

HULLS

IMPURITIES

MOISTURE

EXPELLER OIL

EXTRACTION OIL


Oil Moisture


Moisture Others




Moisture Oil



On line monitoring from dehulled seeds to crude oil.



Rapeseed Crushing Process

At control station On sampling probe At Conveyor

Oil Moisture Others


Moisture Others


Oil Moisture


Oil Moisture





On line monitoring all along the crushing process from raw materials intake to crude oil.



On Raw materials Example from real case

Soybeans at reception , EXAMPLE Range Accuracy*

Oil 13 – 23 % -/+ 0.5 % Moisture 5.8 -15.8 % -/+ 0.5 % see above Protein 29.6 - 41.4 % -/+ 0.9 %

* : Accuracy mainly depends on reference method reliability and consistency.

Rapeseeds at reception , EXAMPLE Range Accuracy*

Oil 37 – 49 % -/+ 0.4 % Moisture 4.5 -18 % -/+ 0.3 % see above Protein 17 – 27 % -/+ 0.4 %

MENU



On press cake

Press cake, production line, EXAMPLE Range Accuracy*

Oil 15 – 25 % -/+ 0.6 % Moisture 4 – 10 % -/+ 0.5 %

Example from real case


MENU



Oil in White flakes

White flakes, production line , EXAMPLE Range Accuracy*

Oil 0.3 - 1.6 % -/+ 0.1 %

Example from real case

In order to obtain the best achievable performances, it is critical to set a sampling point that provides representative samples from the process.


MENU



Final Meal

Rapeseed meal, production line EXAMPLE

Range Accuracy Oil 0.4 – 3.3 % -/+ 0.2 %

Moisture 7,2-14,2 % -/+ 0.3 % Protein 31,1-40.2 % -/+ 0.8 % Fibre 8.8 – 13.2 % -/+ 0.8 % Ash 4.5 – 9.1 % -/+ 0.8 %

Soybean meal, production line EXAMPLE

Range Accuracy Oil 0,5 - 6.5 % -/+ 0.3 %

Moisture 8.5 -14.7 % -/+ 0.5 %

Protein 33 – 51 % -/+ 1 %

Fibre 2.6 – 16.2 % -/+ 0.8 %

Ash 4.8 – 21.7 % -/+ 1.2 %

Example from real case NIR Online sensor placed on a side of a chain conveyor

MENU



OILSEED INDUSTRY - REFINING PROCESS

FFA IV Moisture Caroten Phosphorous,..

TFM Moisture Oil FFA

FFA IV Color



Refining Process Crude Oil – during neutralization process

Real time process control for oil (final)

Crude Rapeseed oil, production line EXAMPLE Range Accuracy

FFA 0.02 – 0.15 % -/+ 0.02 % Moisture 0 – 300 ppm -/+ 15 ppm

Phosphorous 130 – 290 ppm -/+ 20 ppm



Refining Process Soap stock

Soapstock control Oil remaining in this material (heavy phase from neutralization separator) is not easy to measure correctly, but it is a key parameter in chemical refineries to control losses.

Soapstock, EXAMPLE

Range Accuracy Oil 14 – 27 % -/+ 1.2 %

Moisture 30 -50 % -/+ 1 % FFA in TFM 30 – 70 % -/+ 2 %



Refining Process RBD (Refined Bleached Deodorized) Oil

RBD Oil, EXAMPLE

Range Accuracy FFA 0.045 – 0.09 % -/+ 0.05 % IV 50.6 – 52.5 -/+ 0.2

Color 1.7 – 3.0 -/+ 0.15



Biodisel Process NIR CONTROL POINTS

Biodiesel, production line EXAMPLE Range Accuracy

Total Glycerin 0.1 – 0.25 -/+ 0.02 Water in ppm 100 – 300 -/+ 30 Phosphorous 5 - 70 -/+ 5 Monoglyceride 0.4 – 0.8 -/+ 0.08 Diglyceride 0.1 – 0.5 -/+ 0.05 Triglyceride 0.01 – 0.8 -/+ 0.06

MENU



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Key Factors To Invest In NIR

1.  Production costs cutting technology: the Feed example

2.  Production processes optimization: Bakery example about out of specification detection in real time

•  «Using the wrong wheat flour into our process will cause damages of machinery. •  A single batch production failure costs us minimum 20.000 €.»

Process

control

Final produ

ct contr

ol

Raw materials like soy flour are paid according to protein content Check and pay the correct price

With instant check of final formulations chemical composition it is possible to use cheaper raw materials

Final product control

Raw material control



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ProcessOptimization

•  Soybean oil : 635 euros per metric tons (March 2015) •  X tons of soy beans flakes are processed everyday in a

crushing plant , let’s say X = 2500 •  If 0.1 % more oil could be extracted (better operations/

settings) then : •  2.5 tons of oil more everyday leading to > 1,500 euros/

day •  If 0.5 % more oil then saving is 8,000 euros/day

During processing in Oil seeds Industry Real case : Residual oil in white flakes after press

With 0.1 % improvement, makes ROI in maximum 60 days



Conclusions

•  With a large installed base Buchi NIR Online have acquired a comprehensive knowledge on how to successfully implement real time NIR measurement in the oil industry.

•  24/7 operations allowing a real time process monitoring.

•  Uncritical operation even in explosive environment

•  More points of control for more profit



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Thank you for your kind attention

Sana Shaikh Product Specialist – NIR BUCHI India Private Limited Email : [email protected]

in-line process control for oilseed industry21.03.2016 page 16 for internal use only on press cake...

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