Control Points in Oil Processing

Gerrit van Duijn

IUPAC-AOCS Workshop
Tunis
6 December 2004
 The Oils and Fats supply chain
agriculture
oil milling
selective
removal of
undesired
crude oils
components
and fats

OIL
PROCESSING

fat phase
modification
properties of the
physical
consumer properties
product
 Contaminants in the Oils and Fats Supply Chain

oil Pesticides
Seeds/fruits growing
cell

Poly Aromatic Hydrocarbons

Harvesting,storage oil Post harvest pesticides
and handling cell Dirt and "strange" seeds

Meal, Hexane
Oil milling Crude oil Lubricants/hydraulic oil
residue
Metals, dirt, etc.

Transport and handling

Crude oil Residues of previous cargoes
of crude oils

Transfer of contaminants to:

Refinery by-product
Oil refining/purification Refined oil Effluent
Solid waste
Air
 Crude oil risk matrix

Previous Cargoes
Mineral Oil
Pesticides

PAH
Soybean oil
Sunflower oil
Rapeseed oil
Corn oil
Palm oil
Palm kernel oil
Coconut oil

= high risk

= medium risk

= low risk
 Hazardous contaminants introduced by the process

Source Measure

Chemicals For food use

Pr
NEUTRALIZATION

oc er
es
w

s
at
Chemicals Food Grade
Bleaching earth Food Grade (Dioxine free)
BLEACHING
Active Carbon Food Grade

St
ea
Nickel To be removed

m
By- products Process control
MODIFICATION

Lu
Trans Process control

br
ic
an
H

ts
yd
ra
Chemicals Food Grade

ul
POST TREATMENT

ic
Earth/filter aid Food Grade

O
ils
Thermal Heating Oil Avoid or control

C
ont teri
Trans Process control
DEODORIZATION

ac
M
Dimers Process control

t
a
al
s
REFINED OIL Free water Avoid
STORAGE Foreign bodies Avoid + final filtration
 Impurities in crude - specifications in fully refined

General

IMPURITY UNIT TYPICAL LEVEL HIGH IN SPECIFICATION

CRUDE OIL FULLY REFINED

Free Fatty Acids % 0.5 - 5 Tropical oils 0.05 - 0.10

Peroxide Value meq/k g 10 Long storage 0.8
Taste - Strong All oils Bland
Phosphorus mg/k g 10 - 500 Seed oils 5
Soap mg/k g - From process 10
Moisture % 0.2 All oils 0.05
Dirt % 0.2 Seed oils Negative paper test

Red = food safety specification

 Impurities in crude - specifications in fully refined

Metals

IMPURITY UNIT TYPICAL LEVEL HIGH IN SPECIFICATION

CRUDE OIL FULLY REFINED

Iron - Fe mg/k g 10 Tropical oils 0.1

Copper - Cu mg/k g - 0.0
Nickel - Ni mg/k g 10 Hydrogenated oils 0.1
Arsenic - As mg/k g - 1.0
Cadmium - Cd mg/k g - 0.2
Mercury - Hg mg/k g - 0.1
Lead - Pb mg/k g - 0.1

Red = food safety specification

 Impurities in crude - specifications in fully refined

Contaminants

IMPURITY UNIT TYPICAL LEVEL HIGH IN SPECIFICATION

CRUDE OIL FULLY REFINED

Hexane mg/k g 100 - 1000 Extracted oils 1

Benz(a)pyrene ppb 0 - 50 Coconut oil 2.0
Pesticides ppb 0 - 10000 Seed oils LOD
Dioxines ppt 0.2 Fish oil 0.75
Trans % 0.2 Hydrogenated oils 1.0 - 1.5
Mineral oil (alkanes) mg/k g 5 - 25 Palm oil 1
Allowed previous cargoes mg/k g 0.2 - 50 Overseas oils LOD

Red = food safety specification

 Link table Oil Refining - quality components

s
Aci d

ols
us
Fatty

phor

p h er
xi de

ur
ls

e
Phos

Toco
Met a

C ol o
Pero
Free

T as t
D irt
Degumming P
Neutralisation C C C C
Bleaching + P P + + +
Deodorization P + + + +
Refined Oil Storage + +

C = chemical refining
P = physical refining
Link table Oil Refining - food safety components

ture

tals

s
H
M ois

y Me

y PA

icide
t PA

s
Heav

Heav

Tran
Free

Ligh

Pest
Degumming
Neutralisation C + *)
Bleaching P + + *)
Deodorization + + *) +
Refined Oil Storage +

+ *) Depending on pesticide type

 Link table Oil Modification
- quality/food safety components

st ers
cts

e
rodu

thyl
el

Soap
Tran

By p
Nick

(M )e
Hydrogenation + +
Post treatment +
Deodorization
Interesterification +
Bleaching +
Deodorization +
 Oil Refining Control Points

CRUDE OIL RECEPTION:

Contractual parameters Analysis QCP
Contaminants Analysis CCP
Previous cargoes Papers check CCP

DEGUMMING/NEUTRALIZATION:
Quality parameters Recipe QCP

BLEACHING:
Quality parameters Recipe QCP
Heavy PAH Active carbon CCP
 Oil Processing Control Points

HYDROGENATION:
Solid Phase Line Recipe QCP
Aromatic Fatty Acids IV - temperature CCP
control at high IV
Trans - low Recipe/catalyst CCP
- free Full hydrogenation CCP
Nickel Acid post-treatment CCP

INTERESTERIFICATION:
Solid Phase Line Components QCP
By- products Max. catalyst dosing, CCP
temperature
Soap/(M)ethylesters Recipe post-treatment QCP
 Control Points Deodorization:

Deodoriser parameters for:

- bland taste,
ph - removal of unwanted components
- retention of wanted components
ms
- reduced by-product formation

t
 Specific Steam Volume needed
to obtain good tasting product

13
Steam Volume (m3/kg oil)

12
11
10
9
8
7
6
5
180 200 220 240
Deodorization Temperature (deg.C)
 Deodorizer Relations

Relation between steam volume and

mass flow:
Vs = 4.62 x (273 + T)/ph x ms x t

Maximum steam flow to limit oil

loss by entrainment:
ph
ms (max) = 11.7 x A x wph
ms
in which:
Vs = steam volume (m3)
T T = temperature (C)
ph = vacuum pressure (mbar)
ms = steam mass flow (kg/h)
t = time (h)
A = oil surface area (m2)

t
 Minimum deodorization time for a good taste and
low oil loss

2.5
10 tons batch deodoriser
Minimum deodorization time (h)

A = 5.7 m2
2.0

Ph =
1.5 2 mbar
4 mbar
6 mbar
1.0

0.5

0.0
180 200 220 240
Deodorization temperature (C)
 Control points deodorization

100
- 4 mbar vacuum pressure
90
- Trans max. 1.5 %
80 8 - Physical refining
(FFA, PAH reduction > 90 %)
70
- Chemical refining
Reduction (%)

60 6

Trans (%)
50
trans
40 4
FFA
30
Light PAH

20 2
OP
pesticides
10
Tocopherols

0
200 210 220 230 240 250 260
Temperature (deg.C)
 A better quality Crude Oil

Less severe refining conditions

Higher retention of natural goodies

and less side-reaction products

Better quality end-product

Lower refining costs
Less control

Move control upstream in the

Supply Chain