Westfalia Separator Food Tec

Mechanical Separation Division

Processing Lines for the Edible Oil Industry

Claiming the Top

List of Contents
4 6 7 8 9 9 10 12 14 16 18 18 20 21 22 22 24 25 26 26 28 28 30 Oils and Fats Processing Chemical Refining Physical Refining Clarification of Press Oil Degumming Water Degumming Simple Acid Degumming Special Degumming Super- / Uni-Degumming TOP-Degumming Neutralization Standard Neutralization Neutralization of Undegummed Oils Miscella Refining Winterization Wet-Dewaxing Cold Refining Polishing Filtration Fractionation Dry Fractionation Processing of By-Products Soapstock Splitting Westfalia Separator CapitalCare

Oils and Fats Processing

Robust Reliable Efficient
Vegetable oil is one of the most important primary foods and therefore requires maximum quality. The quality of the final product depends on the refining method and the nature of the crude oil. Westfalia Separator offers a wide range of solutions designed to boost value in this respect, ranging from a separator with a daily capacity of 10 tonnes for operators of small oil mills right through to separators with capacities of more than 1600 tonnes per day for large re-fineries. The practical production processes and technologies must be as varied as the different types of oil. Westfalia Separator Food Tec therefore designs and manufactures a customized solution which is tailored to meet the requirements of the specific application. The centrifuge is always to be found at the heart of the installation. Whether a self-cleaning separator with a maximum level of automation or a discontinuously operating system, every customer is able to find the best solution in economic and technological terms for his specific production tasks. We not only supply the mechanical separation facility; we of course also supply all other components and systems necessary for an efficient and reliable production line. Satisfied customers throughout the world have placed their trust in this know-how and technological potential, developed together with the customers in the course of demanding day-to-day operations.

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Processing of e. g.: Soybean oil Rapeseed oil Sunflower oil Animal fat Cottonseed oil Corn oil Fish oil

Special applications: Ni-catalyst removal Lecithin deoiling Bleaching earth deoiling Re-refining of used frying fats

Our competence in oleochemical applications: Transesterification (e. g. for making biodiesel) Epoxidized oils Mono- / diglycerides Fatty acids Glycerine Soap Fatty alcohols

Our core competence in edible oil refining: Press oil clarification Degumming Neutralization Dewaxing Fractionation Soapstock splitting

Food Tec

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Chemical Refining
Different Processes One Solution
Two processes have been developed for refining edible oils and fats; the decision as to which process is to be used depends on the types and qualities of crude oil to be processed. Chemical refining is the traditional method, where the free fatty acids of the crude oils are neutralized with caustic soda. The resultant sodium soaps are separated by means of separators. The neutral oils are subsequently bleached and deodorized. This method can be used for reliably refining virtually all crude oils, including oils of low quality, with the exception of castor oil.

Seed

Beans

Pressing

Extraction

Animal feed

Press oil clarication

Water degumming

Drying

Lecithin

Neutralization

Soapstock

Soapstock splitting

Winterization

Split fatty acids

Bleaching

Deodorization

Edible oil

Grey colour is the core business of Westfalia Separator

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Seed

Beans

Pressing

Extraction

Animal feed

Press oil clarication

Water degumming

Drying

Lecithin

Acid degumming

Winterization

Bleaching

Deodorization

Fatty acids

Edible oil

Grey colour is the core business of Westfalia Separator

Physical Refining
In the alternative method of physical refining, the free fatty acids are removed by distillation in one stage during deodorizing. A fundamental criterion for using this method is that the crude oils should be degummed as effectively as possible; however, this is only possible to a limited extent with some crude oil qualities. Other oils, for instance cottonseed oil or fish oil, are fundamentally not suitable for physical refining. Westfalia Separator is able to supply suitable process lines for both processes; we have limited ourselves to the processes in which centrifuges are used, or which complement centrifuge lines.

Food Tec

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Clarification of Press Oil

Continuous Economic
The oil which is discharged from expeller presses has various solid content levels depending on the oil seed type and the condition of the press. In order to remove particularly large solid particles, the oil is usually fed into a settling tank, which is also used simultaneously as a buffer tank. In some installations, a vibrating screen is used for pre-cleaning, or the oil is taken directly from the press to the press oil clarification unit. In order to support the separation process, the solids are wetted with hot water. A water quantity of 1 percent in relation to the oil quantity is normally adequate in this respect. The water is mixed with the oil in the feed pump to the decanter. The decanter which is a horizontal scroll-type centrifuge continuously separates the solids from the oil. As a side effect of adding water, any phosphatides which are present are hydrated; these are then removed together with the solids. In order to avoid oil losses, the solids are returned to the press. The purified oil is either processed directly or, if it is stored or sold, it should be dried in a vacuum.

Many features for your benefit Continuous solids separation Low cost of automation Lower space requirement Simultaneous degumming

Seed

Press cake Screw press Water

Press oil Foots recycle Decanter Screening tank Cleaned crude oil Solids

Water Degumming
Degumming
A gentle-action pump is used for conveying the crude oil to a heat exchanger, which is used for heating the crude oil to the optimum process temperature. A quantity of hot water corresponding to the content of phosphatides in the crude oil is added to the oil and mixed intensively. A special centrifugal mixer, which simultaneously conveys the oil directly to the separator, is used for this purpose. The hydratable phosphatides swell immediately due to the particularly intensive mixing of oil and water, and no additional reaction time is necessary. A separator is used to continuously separate the phosphatides which are insoluble in oil. They are either added directly to animal feed or dried in thin-film evaporators and sold in the form of lecithin. Lecithin is a valuable side-product, which is used as an emulsifier, e.g. in the food, animal feed, pharmaceutical and cosmetics industries. The degummed oil is either conveyed directly to the refining stage, or it has to be dried in a vacuum if it is stored or sold.

Many features for your benefit Lecithin recovery Reduction of losses in the following refining stages Prevention of tank bottoms in storage tanks

Vacuum

Steam

Hot water Vacuum dryer

Sludge Crude oil

Mixer Gums

Separator

Degummed oil

Simple Acid Degumming

Degumming
This degumming method is suitable for pretreating palm oil, palm kernel oil, coconut and olive oil as well as animal fats with the aim of reducing bleaching earth consumption in the physical refining process. This considerably improves the economy of this method. The crude oil is initially heated to the optimum process temperature in a heat exchanger. A metering unit is used for adding a small quantity of phosphoric or citric acid, which is mixed intensively with the oil in a centrifugal mixer. After a brief reaction time, hot water is added and mixed. The heavy phase which contains phosphatides, proteins, pigments and other impurities is then separated. The oil which is treated in this way is generally sent directly to the bleaching stage and deacidified by means of distillation.

Many features for your benefit Reduction of bleaching earth consumption Better end product quality Less fouling of downstream equipment

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Vacuum Steam Acid Holding tank Hot water Holding tank

Vacuum dryer

Sludge Crude oil

Mixer

Mixer

Gums

Separator

Degummed oil

Food Tec

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Steam

Acid

Lye Hot water

Steam

Hot water

Holding tank

Holding tank

Sludge

Crude oil

Mixer

Mixer

Gums

Separator

Mixer

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Special Degumming
Degumming
This degumming method can be carried out with slightly modified neutralization lines. Depending on the quality of the crude oil, it is possible to decide whether the oil can be refined by chemical or physical means. However, with respect to the residual gum content, it is necessary to accept a compromise in comparison with the more demanding acid degumming methods described in the following.

Vacuum

Vacuum dryer

Sludge

Wash water Separator Degummed oil

Many features for your benefit This process line can also be used for neutralization (flexibility)

The crude or water-degummed oil is initially heated to the optimum hydration temperature. A small amount of phosphoric or citric acid is then added and intensively mixed in the centrifugal mixer. After an appropriate reaction time, some of this acid is neutralized with very dilute caustic soda and sufficient water is simultaneously added for hydration of the phosphatides. The caustic and water are also mixed together with the oil in the next centrifugal mixer. The mixer conveys the oil through a hydration reactor to the next heat exchanger, which heats the product to the corresponding separation temperature. Phase separation then takes place in a separator to produce gums and oil. The residual phosphatide content which can be achieved in this way may be adequate for some applications. In most cases, however, further reduction is recommended by means of washing the oil. If this is the case, a certain quantity of hot water is added to the oil; this is then mixed and conveyed to a second separator which continuously separates the wash water. The oil which is virtually degummed is then either conveyed directly to the bleaching stage, or it is dried in a vacuum if it is to be sold or stored.

Food Tec

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Super- / Uni-Degumming
Degumming
After the crude oil has been heated, specially modified phosphatides which subsequently facilitate phosphatide hydration can be added. However, this is only necessary in exceptional cases; under normal conditions, a small quantity of citric acid is added to the crude oil and mixed very intensively with the oil. After a certain reaction time, the oil is cooled and the necessary quantity of water is added for hydrating the phosphatides. After a certain reaction time in an agitator tank, the oil is heated to separating temperature and the gums are separated from the oil in a separator. This concludes the super-degumming stage. However, depending on how the oil is to be subsequently treated, it may be necessary to remove the phosphatides more efficiently, as extremely fine particles cannot be separated. A further process stage, the uni-degumming method, has been developed for this purpose. The oil is cooled for a second time and a small amount of caustic soda is added. Mixing of the caustic with the oil in a special mixing tank is followed by a further reaction time in an agitator tank, during which the fine phosphatide particles agglomerate to form larger particles. These can be separated in a clarifier after the oil has been heated. The oil is subsequently dried in a vacuum. The hydration and agglomeration of phosphatides at low temperature produces a positive side effect for wax-containing oils (e. g. sunflower oil and corn oil). Some of the wax crystallizes and is separated together with the gums. This produces a considerable advantage in the subsequent refining process of these oils.

Steam

Modified lecithin

Acid

Crude oil

Mixer

Mixer

Cooling water

Lye

Mixing tank

Many features for your benefit P-content < 10 ppm possible Can be combined with partial dewaxing

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Cooling water

Steam

Hot water

Hydration tank

Sludge

Mixer

Gums

Separator

Steam

Vacuum

Vacuum dryer

Gums

Agglomeration tank

Clarifier

Degummed oil

Food Tec

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TOP-Degumming
Degumming
The crude oil is initially heated to the optimum process temperature and a small quantity of acid is added. Following intensive mixing and a brief reaction time, some of the acid is neutralized with dilute caustic soda. After mixing in a centrifugal mixer and the gums are separated from the oil in a separator. Because very fine phosphatide particles cannot be separated, a certain amount of water is again added to the oil. Following a brief reaction time, the mixture is conveyed to a high-performance clarifier which is able to generate an extremely high g-force thanks to its special design. This enables the fine particles to be continuously separated with the water. In order to avoid oil losses, this phase is recycled into the feed of the first centrifuge, where the fine gum particles are separated together with most of the phosphatides. The oil which is degummed in this way is subsequently dried.

Steam

Acid

Holding tank

Crude oil

Mixer

Many features for your benefit P-content < 10 ppm possible Short retention times Very compact installation

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Lye

Water Holding tank

Vacuum

Vacuum dryer Mixer Sludge Sludge

Mixer

Gums

Separator

Clarifier

Degummed oil

Standard Neutralization
Neutralization
This method is suitable for neutralizing pre-degummed edible oils or oils which originally only have a low phosphatide content. The free fatty acids are saponified with caustic soda, and the sodium soap is separated. The oil is initially heated to the optimum process temperature. In order to condition the non-hydratable phosphatides, a small quantity of concentrated phosphoric acid is added and intensively mixed with the oil. Following a brief reaction time, dilute caustic soda is added in order to neutralize the free fatty acid and the phosphoric acid. After mixing with the oil, the mixture is either conveyed directly to the first separator or it passes through a further reaction tank. The latter is recommended only for oils with a relatively high phosphatide content. Self-cleaning separators are mostly used for separating the sodium soap. However, the residual soap content in the neutral oil is still too high for the subsequent process stages, and it must therefore be further reduced by one or two washings. For this purpose, hot water is added to the oil and intensively mixed. The soapy wash water is removed in a further separator. In general, one wash stage is adequate. A second washing is only necessary, if very low residual soap contents are required. However, a low residual soap content can also be achieved by acidifying the wash water with citric or phosphoric acid. A second caustic treatment of the neutral oils is only advisable in exceptional cases. This mainly applies to cottonseed oil, in order to remove most of the gossypol. This oil should always be neutralized in 3-stage installations. Depending on the subsequent bleaching method, the neutralized and washed oil is subsequently vacuum-dried.

Conditioning Steam Acid

Neutralization Lye

Holding tank

Crude oil Hot water or Lye

Mixer

Steam

Mixer Wash water Washing or re-refining

Separator

Many features for your benefit Very reliable process, e.g. for poor-quality crude oils High product quality guaranteed All oils can be processed

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Sludge

Mixer

Soapstock

Separator

Vacuum

Hot water Vacuum dryer

Sludge

Sludge

Mixer Wash water Washing

Separator Drying

Neutralized oil

Food Tec

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Neutralization of Undegummed Oils

Neutralization
This method has become established mainly in the USA for refining soybean oil. The process is a combination of degumming and neutralization. For conditioning the non-hydratable phosphatides, a small quantity of phosphoric or citric acid is added to the crude undegummed oil. In some cases, the acid is added in the feed tank with an agitator upstream of the installation; several hours reaction time must be taken into consideration. However, a more effective method is to add the acid upstream of a centrifugal mixer. The intensive mixing enables the reaction time to be reduced to a few minutes. Dilute caustic soda is then added in order to neutralize the free fatty acids. It is necessary to ensure that adequate water is present with the caustic in order to hydrate the phosphatides. Following a reaction time of several minutes in special retention mixers, the oil is heated and added directly to the first separator in order to separate the soapstock. The neutral oil is washed in order to further reduce the residual soap content. For this purpose, a certain quantity of hot water is added to the oil, mixed in a centrifuge and separated into wash water and oil in a separator. The residual humidity of the oil is further reduced in a vacuum drier.

Many features for your benefit Prior water degumming not necessary Good end product quality

Lye

Steam

Steam

Hot water

Holding tank Sludge Crude oil (conditioned with acid) Sludge

Mixer

Soapstock

Separator

Mixer Wash water

Separator

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Miscella Refining
Neutralization
This method was originally developed for neutralizing cottonseed oil. It enables most of the gossypol to be removed with simultaneously low neutralization losses. The miscella which discharges from the oil seed extraction stage is pre-concentrated either by adding the press oil, or in the first stage of hexane evaporation. The miscella temperature is then briefly set below the evaporation point, and the necessary quantity of caustic soda is added in order to neutralize the free fatty acids. Mixing is followed by a reaction time in special retention mixers. The soapstock is separated in the separator. Because of the high specific density difference between miscella and soapstock, the separating efficiency is at its optimum level, and it is not necessary to wash the oil after hexane evaporation. If it is necessary to treat oils with a higher phosphatide content, it is recommended that an acid is added before the caustic. Because of the risk of explosion posed by hexane, all installation parts, and in particular the centrifuge, are explosion-proof. Due to special safety considerations, the centrifuge is even blanketed with inert gas.

Many features for your benefit Low losses Good gossypol removal for cottonseed oil No waste water if the soapstock can be added to the meal Less fouling of hexane evaporation columns

Vacuum

Steam

Acid Holding tank

Lye Holding tank Neutralized miscella Sludge

Vacuum dryer

Miscella Mixer Neutralized oil Mixer Soapstock Separator

Food Tec

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Wet-Dewaxing
Winterization
Some vegetable oils, such as sunflower or corn oil, contain waxes (long-chained fatty alcohols or fatty acid esters), which crystallize at lower temperatures and result in turbidity in the oil. Wet winterization in combination with neutralization is suitable for removing these waxes. The crude oil is initially neutralized (see under neutralization). This means that, in order to condition the gums, an acid is initially added and the free fatty acids are then neutralized with caustic soda. After the soapstock is separated in the first separator, the oil is conveyed to the actual winterizing stage. A small quantity of caustic soda is again added in order to set a specific residual soap content in the oil. This soap is subsequently required as a wetting agent during crystallization in order to bind the waxes to water. After mixing of caustic and oil, the product is cooled to the crystallization temperature. Wax crystals form in two to four crystallization tanks

Steam

Acid

Lye

Steam

Lye

Holding tank

Sludge

Crude oil

Mixer

Mixer

Soapstock

Separator

Mixer

Hot water

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Food Tec

connected in series. Due to the soap in the oil, these wax crystals bind to the water, which is added to the crystallizers. In order to reduce the viscosity, the oil is carefully heated and conveyed to a separator which continuously separates the waxy water. The oil is washed again in order to further reduce the residual soap content. For this purpose, the oil is heated, the corresponding quantity of hot water is added; after intensive mixing, it is separated in a further separator. Vacuum drying then takes place.

Many features for your benefit Integration of winterizing in neutralization Fully continuous operation Removal of very high wax amounts possible

Steam Hot water

Vacuum

Vacuum dryer

Sludge

Sludge

Wax Water

Separator

Cooling water

Wash water

Separator Neutralized and winterized oil

Chilled water

Crystallizer

Food Tec

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Cold Refining
Winterization
This process is an alternative to winterization preceded by neutralization. However, use of the process is confined to oils with a relatively low FFA content as the oil losses are otherwise too high. Sunflower oil is therefore an ideal product for this application. A small amount of acid is added to the crude oil without prior heating. After thorough mixing and a short retention time the oil is cooled. The caustic quantity required for neutralizing the free fatty acids is admixed with the oil. The oil then flows through crystallizers with a residence time of several hours. The oil is gently heated to reduce the viscosity before the soapstock is separated in a centrifuge along with the waxes. The dewaxed neutral oil has to be washed to reduce the soap content. It is first heated, the required wash water quantity is added and, after thorough mixing with the oil, it is separated again in a second centrifuge. Finally, the oil is dried in a vacuum dryer.

Many features for your benefit Compact installation Effective wax removal

Acid

Lye

Holding tank Sludge

Crude oil

Mixer

Chilled water

Mixer

Crystallizer

Hot Soapstock/ water wax

Separator

Steam

Hot water

Vacuum Vacuum dryer

Sludge

Mixer

Washing water

Separator Neutralized and dewaxed oil

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Pressure leaf filter Winterized oil Crystallizer Bleached or deodorized oil Pre-coating pump Pre-coating and body feed tank Filter aid

Mixer

Chilled water

Filter aid slurry pump

Polishing Filtration
Winterization
The wet winterizing method described above does not guarantee that 100 percent of all waxes are always removed. If particularly strict process guarantees are applicable, additional polishing filtration is necessary for coldstable oils; this process is carried out either after bleaching or after deodorizing. For this purpose, the oil is cooled again and allowed to crystallize for several hours. It is then filtered using filter aid. Despite this additional filtration, the entire winterizing method offers economical advantages in comparison with methods which only use filtration. The major advantage is that much less filter aid is used and longer filter cycles are achieved.

Many features for your benefit Minimizing consumption of filter aids Higher filtration speed Longer filter cycles

Food Tec

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Dry Fractionation
Fractionation
Oils and fats are a mixture of different triacylglycerols. If these contain a higher amount of saturated fatty acids, the products tend to partly crystallize at ambient temperature. Fractionation is a process to split fats and oils into a liquid part, the olein, and a solid fraction, the stearin. The fractionation process consists of two stages, the crystallization and the separation of the olein and stearin. The crystallization is a batch process, where the oil/fat is first heated above the melting point. Then a slow, controlled cooling takes place, following a specific cooling curve adapted to the kind of oil / fat. The aim is to produce stearin crystals which can be separated from the liquid olein phase. The process is called dry fractionation, because there is no detergent or solvent added to the product, as in case of some other known processes.

This separation is done with a specially designed nozzle separator. The stearin crystals, having slightly higher density, are discharged continuously through nozzles in the periphery of the bowl, whereas the lighter olein is clarified in the disk stack of the bowl and likewise continuously discharged from the centrifuge under pressure. The stearin slides down into a melting tank, where it is liquefied and pumped to further processing or storage.

Many features for your benefit Fully continuous stearin /olein separation Adjustable stearin and olein quality during separation Low installation and maintenance costs Hermetically closed system No cooled room for separator required

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Oil Steam

Olein
M

Heating / cooling Nozzle separator Heating / cooling Melting vessel Stearin Crystallizer Condensate Heater

Food Tec

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Soapstock Splitting
Processing of by-products
During the chemical neutralization of oils and fats, so-called soapstock (sodium soaps of the free fatty acids) is obtained as a by-product. This can be split into fatty acids and water by means of acidification with strong acids (sulphuric or hydrochloric acid). Fatty acids are a valuable product in the animal feed, soap and oleochemical industries. The phosphatides, separated together with the sodium soaps during the neutralization process, frequently have a significant effect on the splitting process during the formation of stable emulsions during phase separation. This can be prevented to a large extent by means of secondary saponification. For this purpose, the soapstock is exposed to higher temperatures and pressures. During a reaction time under these conditions, part of the phosphatides and the neutral oil in the soapstock saponify. After saponification, dilution water can be added in an intermediate tank before the soapstock is conveyed to the actual splitting process. In the splitting tank, the pH value is reduced by adding a strong acid. The soapstock breaks down into fatty acid and water, which are then separated continuously in a static decanting vessel. The split fatty acid can be directly processed. The acid water is conveyed to a fat separator with an upstream flotation chamber. The de-fatted water is subsequently neutralized with caustic soda. Many features for your benefit Fully continuous operation Lower level of emulsion

Water

Sulphuric acid

Intermediate tank Splitting tank Split fatty acid Saponification column Steam Heat exchanger Condensate Flotation tank Soapstock Neutralization tank Effluent Decanting tank Caustic soda

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RSE 60: Separator with Gear Drive. Capacity: max. 150 t / d

RSE 300: Separator with Direct Drive. Capacity: max. 1200 t / d

RSE 220: Separator with Flat Belt Drive. Capacity: max. 800 t / d

Food Tec

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Westfalia Separator CapitalCare Increased Availability, Budget Reliability, Process Efficiency

Westfalia Separator CapitalCare draws on decades of experience in the rendering of services related to centrifugal separation technology.
For investors, this means increased availability, maintenance and repair for fixed prices and the possibility of boosting process efficiency. Westfalia Separator CapitalCare supports customers installations and develops solutions to production problems before they occur. Westfalia Separator CapitalCare means: comprehensive service right from the very first discussion. Working closely with customers, suitably qualified specialists identify solutions which are specifically tailored to their requirements. From project planning, production and assembly, right through to comprehensive support for their systems, customers receive comprehensive protection with Westfalia Separator CapitalCare. Optimum support guaranteed In advanced training programmes and training sessions on site or in Westfalia Separators modern training centre, customers employees learn how to handle high-tech installations. If a technical problem does occur or a spare part is required, a quick response is guaranteed. Westfalia Separator has more than 50 sales and service companies and a further 60 sales partners worldwide.

Quality is Westfalia Separators programme Of course, separators and decanters can be used in even more areas of application than beverage technology, dairy technology and vegetable oil processing. Westfalia Separator is one of the leading companies in the world in the field of mechanical separation technology and also operates in numerous other fields. Please, request information as required concerning processing systems for applications in the chemical, pharmaceutical and biotechnology industries, oils and fats recovery, the starch industry, industrial biotechnology, marine, energy, oilfield industry and environmental technology.

Do not react take pro-active measures With Westfalia Separator CapitalCare, customers not only benefit from traditional services such as inspection, maintenance, original spare part procurement and repair; they also benefit from pro-active solutions which avoid risk, e.g. online and offline monitoring with Westfalia Separator WEWATCH, support, modernization, or upgrading to reflect state-of-theart technology and offer the option of boosting performance as required.

Food Tec

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Beverage Technology Dairy Technology Oils and Fats Processing Chemicals, Pharmaceuticals and Biotechnology Oils and Fats Recovery Starch Technology and Industrial Biotechnology Marine Energy Oilfield Industry Environmental Technology Engineering Second Hand Machinery Cross-Flow Filtration with Ceramic Elements Service

The information contained in this brochure merely serves as a non-binding description of our products and is without guarantee. Binding information, in particular relating to capacity data and suitability for specific applications, can only be provided within the framework of concrete inquiries. Printed on chlorine-free bleached paper 9997-9801-030/1007 EN Printed in Germany Subject to modification

Westfalia Separator Food Tec GmbH Werner-Habig-Strae 1 59302 Oelde (Germany) Phone +49 2522 77-0 Fax +49 2522 77-2089 [email protected] www.westfalia-separator.com

Westfalia Separator Food Tec

Take the Best Separate the Rest A company of GEA Group