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Operation Training
Desmet Ballestra Group
Oct 2013
1
Desmet Ballestra
Group
2
Desmet Ballestra
3
Technology Platform
Grains BioMass Oilseeds
1946
Feed Solvent
Rosedowns 1988
Liquefaction
Milling Extraction
1990
Fermentation Animal Feeds Crude Oils
1994
Mazzoni
Distillation Esterification Refining Oleochemicals
CMB
2004
Ballestra
BioEthanol BioDiesel Edible oils Fatty Acids Fatty Alcohols
Stolz
Allocco
2007
Fat Modification Saponification Surfactants
Frings A 2008
Edible fats Soap Detergents
4
Desmet Ballestra
Oils & Fats
Refining
5
World Oil Production
6
The origin of oils and fats
Seed Oils
Sunflower
Rapeseed / Canola
Corn Soyabean
Palm Kernel
Tallow
Palm
Coconut
7
Oils&Fats Definition
Monoglyceride
Triglyceride
Unsaturation
Monoglyceride
8
Crude palm oil fatty acid
composition
Other/Unknown 0.90%
9
Crude palm oil quality
PARAMETER VALUE
MOISTURE & IMPURITIES : 0.25 % max.
FFA : 5.0 % max.
IV : 50-55 (typ. 52)
PV : 10 max.
AnV : 5 max.
Fe : 4 ppm max.
Cu : 0.2 ppm max.
CAROTENE : 500 ppm min.
E(1%,1CM,269 MICRONS) : 0.6 max.
DOBI : 2.3 min.
P : 15 ppm max.
SOAP : nil
10
RBD Palm Oil Quality
PARAMETER VALUE
IV (Wijs) : 50 – 55
M. Pt. 0C : 33 – 39
11
Oil Refining Processes
12
Physical Refining
BLEACHING
•0.6-1.2% BLEACHING EARTH
•90-110°C, 20-40 min
•30-100 mbar
DEODORIZATION
•250-270°C, 45-90 min
•2-4 mbar
•0.5-1.5% STRIPPING STEAM
RBD OIL
13
Overall view of bleaching
14
Heat Recovery by plate
heat exchanger
•Oil enters and is heated to
degumming temperature by heat
exchange with deodorised oil
•Steam heating is used at start up
when no heat recovery is available
15
Pre-treatment
16
Mixing and Heating
Bleaching earth
dosing system
Acid reaction
holding tank
Mixing of oil and
earth under
vacuum
Final heating
by steam coil
17
Steam Agitation of
Bleacher
Bleacher holding
section is agitated
by steam avoiding
mechanical mixers
and seals
18
Bleacher details
19
Pressure Leaf Filters
Recycle
to
bleacher Oil feed from pumps
Bleached oil out
20
Filter Details
Top cover
Cake vibrator
Leaves
Steam dries
the cake
Oil and
steam
separate in
682A
629 scrubs
the exhaust
gas
23
Overview of Deodorising
Vacuum
PFAD
Bleached
Oil HP Boiler
Vapor Scubbing
Final
Cooling
RBD Oil
24
PID of Deodorising
25
Oil Feed and Heat
Recovery
•The oil
enters buffer
802.
•It is pumped
through a
series of coils
•Hot oil
outside the
coils heats
the oil inside
26
Counter-current flow in
Heat Recovery
Cooled
Deodorised Oil
overflows
Cold Oil
Heated Oil
Deodorised Oil
Enters from
above
27
De Smet Qualistock
Deodoriser
Heat Recovery tray
28
Final Heating
29
Final heating using high
pressure steam generator
65 bar g / 282°C
One generator per
deodorizer
Fully closed loop
Deodorizer temperature
controlled by firing rate
Not normally classified as
a boiler.
30
Fatty Acid Stripping
31
Structured Packing
Structured
packing is made
from folded metal
sheet
Liquid flows
down the metal
sheet
Vapour flows up
the space
between
32
Deodorising Section
34
De Smet Qualistock Deodoriser
Deodorising tray
35
Vapour rises through 814
scrubbing pack
Fatty matter is condensed in high efficiency structured packing by re-
circulating cooled distillate
36
Vapour rises through
demister
Vapour passes
through demister to
catch small droplets
of oil before passing
to vacuum ejectors
37
The demister is made
from knitted wire pads.
38
Ice condensing vacuum system
Booster
Booster
Surface
condenser
Booster Surface Condenser
Booster or pump
Sparge (30°C)
Sparge steam
Steam
(100%) Sparge Steam
Sparge steam
(100%) (100%)
(100%)
Non-condensables
(8%)
Motive steam
Motive Steam
(1200%)
Motive steam Effluent
(750%) Motive Steam
(100%) Effluent
(108%)
(100%) (102%)
Effluent
Effluent
(92%)
(92%) 200%
Effluent
Effluent
(1300%)
(850%)
39
Ice condensing vacuum system
Vertical design !
40
Desmet Ballestra
Oils & Fats
Fractionation
41
Dry Fractionation
42
Plant Performance
2000TPD 900TPD
20% Palm Stearin 80% Palm Olein 38% Palm Stearin 62% Palm Olein
IV 36 IV 56 IV 40 IV 60
43
Overall view of Crystallisation
44
Crystallization Principles
45
Dry Fractionation
No oil loss
Fully reversible
46
Crystallization
To destroy the
« thermal memory »
of the fat
47
Crystallization principle
Polymorphism: α , β’ , β
Intersolubility in solid state SSS/SUS - SUU/UUU
25 µm
Control of crystallisation:
Oil temperature controlled
Water temperature controlled
Delta temperature Oil/Water
48
Fractional crystallization of TAG
Oil can be considered as a solution of TAG in TAG:
• high melting TAG (e.g. PPP) are solute
• low melting TAG (e.g. OOO) are solvent
• similar TAG can intersolubilize
Consequences:
• No melting point, but melting range
• Non-ideal solubility (e.g. eutectics)
4949
Crystallization
80
PALM
PALM OIL
OIL FRACTIONATION
FRACTIONATION
COOLING
COOLING CURVE
CURVE
70 Crystallisation =
exothermic
60
Temperature (°C)
50
40
H cooling =
30
0.5 kCal / °C.kg
cooling
20 nucleation
10 crystallisation
H crystallisation =
agglomeration
50 kCal / kg
Time
Dynamic
crystallizer with
vertical cooling
plates /coils
(Fractionnement
Tirtiaux)
oil temperature
controlled
51
Industrial Tirtiaux cooling
Curve
52
Tirtiaux System
Crystalliser
New generation
dynamic crystallisers
used in oil
fractionation with
improved cooling
surface configuration
54
Overall view of Filtration
55
Filterpresses used in PO dry
fractionation
56
Filterpresses used in PO dry
fractionation
57
Filterpresses used in PO dry
fractionation
Top bar
Side bar
58
Filterpresses used in PO dry
fractionation
Chamber
Inflatable
Corner membrane
feed
KM – UM Chamber
Membrane KX
plate
Membrane RCplate
Plate
Empty chamber
design
59
Desmet Ballestra & R&D:
neverending effort to improve and develop
Laboratory
Pilot hall
60