Crushing plant in China, capacity 4.

000 tonnes / day

Operation Training
Desmet Ballestra Group
Oct 2013
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Desmet Ballestra
Group

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Desmet Ballestra

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 Technology Platform
Grains BioMass Oilseeds
1946

Milling Presses Preparation 1960

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

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Desmet Ballestra
Oils & Fats
Refining

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World Oil Production

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 The origin of oils and fats
Seed Oils

Sunflower
Rapeseed / Canola
Corn Soyabean

Palm Kernel
Tallow
Palm
Coconut

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 Oils&Fats Definition

Triglycerides are formed from a single molecule of glycerol, combined

with three fatty acids

Glycerol Fatty Acid

Monoglyceride
Triglyceride

Unsaturation

Monoglyceride
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Crude palm oil fatty acid
composition

Fatty acid content of palm oil

Type of fatty acid pct

Palmitic C16 44.30%

Stearic C18 4.60%

Myristic C14 1.00%

Oleic C18 38.70%

Linoleic C18 10.50%

Other/Unknown 0.90%

green: Saturated; blue: Mono unsaturated; orange: Poly unsaturated

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 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

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 RBD Palm Oil Quality

PARAMETER VALUE

FFA : 0.1% max

M&I : 0.1% max

IV (Wijs) : 50 – 55

M. Pt. 0C : 33 – 39

Colour (5 ¼“) : 3 or 6 Red max

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 Oil Refining Processes

R - Degumming Phosphatides, proteins,…

E
F - Neutralization Free fatty acids,...
I
- Bleaching Pigments, peroxides, soaps, metals,...
N
I - Winterization Waxes, saturated TG,…
N
G - Deodorization Odors, flavors, pigments (heat bleach)
Free fatty acids , pesticides, …

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 Physical Refining

CRUDE PALM OIL

Palm Oil require three of the five
steps on the previous page
DEGUMMING
•0.05-0.15% H3PO4 (85%)
•70-90°C, 1-15 min

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

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Overall view of bleaching

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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

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Pre-treatment

P534 doses acid into the oil

to make gums more easy to
remove
Silverson high shear mixer
blends oil and acid together

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Mixing and Heating

Bleaching earth
dosing system
Acid reaction
holding tank
Mixing of oil and
earth under
vacuum
Final heating
by steam coil
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Steam Agitation of
Bleacher

Bleacher holding
section is agitated
by steam avoiding
mechanical mixers
and seals

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Bleacher details

•Oil overflows from

heating compartment.
•Baffles in holding section
encourage a systematic
flow of oil.
•Carefully positioned
steam pipes prevent earth
settling.

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 Pressure Leaf Filters

Recycle
to
bleacher Oil feed from pumps
Bleached oil out
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Filter Details

Top cover
Cake vibrator
Leaves

Cake discharge valve

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Level Control
Bleached
oil flows
to 682B
Excess
overflows
back to
bleacher
682B outlet
valve controls
level
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Cake Drying

Steam dries
the cake
Oil and
steam
separate in
682A
629 scrubs
the exhaust
gas
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 Overview of Deodorising

Vacuum
PFAD
Bleached
Oil HP Boiler
Vapor Scubbing

Oil-Oil Heat HP Steam

Deaeration Heating Deodorisation
Exchange

Final
Cooling

RBD Oil

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PID of Deodorising

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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

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Counter-current flow in
Heat Recovery

Cooled
Deodorised Oil
overflows
Cold Oil
Heated Oil

Deodorised Oil
Enters from
above

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De Smet Qualistock
Deodoriser
Heat Recovery tray

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Final Heating

Oil flows from

the heat
recovery coils
to the final
heating
compartment

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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.

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 Fatty Acid Stripping

Heated oil overflows into stripping pack

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Structured Packing

Structured
packing is made
from folded metal
sheet

Liquid flows
down the metal
sheet

Vapour flows up
the space
between
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Deodorising Section

•The oil flows to the

deodorising trays.
•Sparge steam
removes volatiles
•High temperature
stabilises the oil and
removes colour
•Central chimney
carries vapours and
supports trays
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Deodorising by Gas Lift Pump

Steam enters the gas

Steam lift pump through a
central tube
Steam rises up the
tube drawing oil with
it
Oil is deflected
downwards by the
conical hat
Steam rises carrying
away impurities

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De Smet Qualistock Deodoriser
Deodorising tray

Deodorised oil buffer

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 Vapour rises through 814
scrubbing pack
Fatty matter is condensed in high efficiency structured packing by re-
circulating cooled distillate

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Vapour rises through
demister

Vapour passes
through demister to
catch small droplets
of oil before passing
to vacuum ejectors

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The demister is made
from knitted wire pads.

Droplets collect on the

wires

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 Ice condensing vacuum system

Barometric Condenser Dry Icing Condenser

Surface / direct contact Ice Surface

Surface
Condenser (30°C)
condenser Condenser
Surface
(condenser
-26°C) Noncondensables (8%)

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%)

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 Ice condensing vacuum system

Vertical design !
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Desmet Ballestra
Oils & Fats
Fractionation

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Dry Fractionation

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 Plant Performance

2000TPD 900TPD

100% Palm Oil 100% Palm Oil

IV 52 IV 52

20% Palm Stearin 80% Palm Olein 38% Palm Stearin 62% Palm Olein
IV 36 IV 56 IV 40 IV 60

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Overall view of Crystallisation

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Crystallization Principles

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 Dry Fractionation

Controlled crystallization of the melt + Filtration:

Purely physical process, no chemicals involved

‘Natural’ process under mild conditions

No pre / post-refining required

No oil loss

Fully reversible

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 Crystallization

1) Full melting 2) Initiate the nucleation 3) Control the crystal growth

(in supercooling conditions) (removal of heat/ control of viscosity)

To destroy the
« thermal memory »
of the fat

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 Crystallization principle

Oil crystallisation = complex physical process Palm Kernel Oil

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

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 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
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PALM
PALM OIL
OIL FRACTIONATION
FRACTIONATION
COOLING
COOLING CURVE
CURVE
70 Crystallisation =
exothermic
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Temperature (°C)

50

40
H cooling =
30
0.5 kCal / °C.kg
cooling
20 nucleation

10 crystallisation
H crystallisation =
agglomeration
50 kCal / kg
Time

Viscosity Oil temp Solid Fat Content

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 Oil controlled crystallisation
curve (Tirtiaux)

Dynamic
crystallizer with
vertical cooling
plates /coils
(Fractionnement
Tirtiaux)

oil temperature
controlled

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Industrial Tirtiaux cooling
Curve

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 Tirtiaux System
Crystalliser
New generation
dynamic crystallisers
used in oil
fractionation with
improved cooling
surface configuration

Vert. cooling tubes

1990-2000’s Tirtiaux (DB)

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Filtration

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Overall view of Filtration

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Filterpresses used in PO dry
fractionation

Membrane filter press

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Filterpresses used in PO dry
fractionation

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Filterpresses used in PO dry
fractionation

Top bar

Side bar
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 Filterpresses used in PO dry
fractionation

Chamber

Membrane filter plates 10-50 mm

Inflatable
Corner membrane
feed

KM – UM Chamber
Membrane KX
plate
Membrane RCplate
Plate

Empty chamber
design
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 Desmet Ballestra & R&D:
neverending effort to improve and develop

Laboratory

Pilot hall

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