wim bleaching

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Desmet Ballestra Presentation 1 Recent Recent Developments Developments in in Bleaching Bleaching , , Deodorisation Deodorisation and and Physical Physical Refining Refining of of Oils Oils and Fats and Fats W. De W. De Greyt Greyt , V. , V. Gibon Gibon and M. and M. Kellens Kellens Desmet Ballestra Group Desmet Ballestra Group Zaventem, Belgium Zaventem, Belgium OFI Middle East 2008 OFI Middle East 2008 Technical and Commercial Conference Technical and Commercial Conference Hilton Hotel Hilton Hotel Abu Dhabi, UAE, April 15 Abu Dhabi, UAE, April 15 - - 16,2008 16,2008

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Page 1: Wim Bleaching

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

OFI Middle East 2008 OFI Middle East 2008 Technical and Commercial ConferenceTechnical and Commercial Conference

Hilton Hotel Hilton Hotel Abu Dhabi, UAE, April 15Abu Dhabi, UAE, April 15--16,200816,2008

Page 2: Wim Bleaching

Desmet Ballestra Presentation 2

OFI Middle East 2008 OFI Middle East 2008 Technical and Commercial ConferenceTechnical and Commercial Conference

Hilton Hotel Hilton Hotel Abu Dhabi, UAE, April 15Abu Dhabi, UAE, April 15--16,200816,2008

oils & fats

124 Mio Tons in 2006 124 Mio Tons in 2006

PO+ SBO = 55%

VEGETABLE OILS WORLD PRODUCTION

Page 3: Wim Bleaching

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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Page 4: Wim Bleaching

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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Page 5: Wim Bleaching

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)

OFI Middle East 2008 OFI Middle East 2008 Technical and Commercial ConferenceTechnical and Commercial Conference

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Page 6: Wim Bleaching

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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Page 7: Wim Bleaching

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,….)

Page 8: Wim Bleaching

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

Page 9: Wim Bleaching

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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Page 10: Wim Bleaching

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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Page 11: Wim Bleaching

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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Page 12: Wim Bleaching

Desmet Ballestra Presentation 12

ADSORPTION ADSORPTION

PROCESSESPROCESSES

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Page 13: Wim Bleaching

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

Page 14: Wim Bleaching

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

Page 15: Wim Bleaching

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

Page 16: Wim Bleaching

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

Page 17: Wim Bleaching

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

Page 18: Wim Bleaching

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

Page 19: Wim Bleaching

Desmet Ballestra Presentation 19

DEODORIZATION DEODORIZATION ––

STEAM REFININGSTEAM REFINING

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Page 20: Wim Bleaching

Desmet Ballestra Presentation 20

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$ %& %'� !( %) � � �*) �%$ *�'%�� *'�$ %� $ � +*- � � *� ) �

� �. %�� *& %� �� �$ %� $ � +*- � � *� ) ��

�!� ������ ������������ ������ ���"������������ �����"#$$!

�!� ��%�������� ���� ��%� ��%���� ��%������� ���%�� & ������ ������!

�!' �� (������� ���� ��%� ��%���� ��������� �� � ���!

$ %& %'� !( %) � � �*) �$ %� $ � +*- � � *� ) �� %�/ ) � '� , 0

�!)� �����% %��%���*�� %��� � ����������"���%����� ������"#$!

�!+�%,��� ��� ���% %,���� ����,�� %��%���*�� "��- �� �����,��"#$!

�!��������% ������� �����,���� ��� ��������%����� ����� ���.�% ���,� �!

Page 21: Wim Bleaching

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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Page 22: Wim Bleaching

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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Page 23: Wim Bleaching

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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Page 24: Wim Bleaching

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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Page 25: Wim Bleaching

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 )

Page 26: Wim Bleaching

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�! �� ���

Page 27: Wim Bleaching

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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Page 28: Wim Bleaching

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 �� ����������

Page 29: Wim Bleaching

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

Page 30: Wim Bleaching

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

Page 31: Wim Bleaching

Desmet Ballestra Presentation 31

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