Professional Documents
Culture Documents
Sadanand Patel
HBTI-K
Refining (Physical/Chemical)
What is Deodorization?
Effect of Deodorization
Chemistry of Odour
Sources of Odour
Principles
Laws
Process Variables
Process Steps
Operation(Batch, Semi-continuous and Continuous)
Equipment
Effect of Deodorization on Oil Quality
Losses
Newer Developments
Utilities Consumption
Deodoriser safety
Layout of
Presentation
Refining
(Physical/Chemical)
OILSEEDS
Mechanical Pressing
Solvent Extraction
Oil Extraction
Deoiled Meal
Crude Ol
Gums
Water degumming
Soapstock
Chemical
Alkali Neutralisation
LECITHIN
Physical
WDG Oil
Acid Gums
Bleaching
Spent
bleaching earth
Deodorization
Deodorizer Distillate
Refined Oil
Acid degumming
Bleaching
Physical deacidification
Deodorization
What is
Deodorization?
This is usually the last stage of the refining process of edible oils
Quality defining process in the refining of oils to eliminate the FFA
and odoriferous substances.
Today, the process is still commonly named deodorisation, but the
objectives have become much broader than just the removal of offflavours.
Desirable
Actual deodorisation by removal of
different off-flavours
Its
Effects
Undesirable
Some unwanted side-reactions
cis-trans-isomerization,
polymerization,
conjugation, and so on
Chemistry of
Odour
Hydroperoxides
Factors
Primary
Oxidation
Products
Aldehydes,
Ketones, Diene
and triene
Decomposition
Secondary
Oxidation
Products
Acids, Epoxides,
Dimers, Oxirane
rings
Oxidation
Tertiary
Oxidation
Products
Sources of
Odour
Most vegetable oil retains characteristics
undesirable flavors & odors that obtain during
processing.
Peroxides
(primary
oxidation
products),
Hydrocarbons, Aldehydes, Ketones (secondary
oxidation products), Tocopherols, Sterols, FFA
are the main odoriferous
and volatile
compounds need to remove.
As a total, odoriferous components generally add
up to not more than 200 ppm.
Bleaching imparts Earthy flavors whereas
hydrogenation adds on odor and flavors that can
be described as undesirable.
Underlying
Principle
Difference in volatilities
Aldehyde/Ketone > FFAs > Squalene >
Tocopherols > Sterols > Sterols esters >
TAGs
Laws
Dalton's Law
describes the vapour
pressure of a mixture
as the sum of the
partial pressures of
its single
components
Stripping
Steam
Time
Pressure
Temperature
Process
Variables
Deodorization
Temperature
Temperature has its influence on deodorization because the vapour pressure is
directly proportional to it.
T Rate of removal of Volatile Substances
Short chain fatty acid deodorized at low temp and hydrogenated oil deodorized at
higher temp because of higher FFA content and distinctive odor it imparts.
Heat Bleach Effect is higher at higher temperature:
Deodorization
Pressure
If the pressure is decreased, the temperature required
also decreases because a lower vapour pressure is then
sufficient to ensure evaporation.
Reduced pressure helps to protect the oil from oxidation
because oxygen from the air is reduced almost to zero.
Deodorization
Time
The time necessary to separate a certain amount of undesired
components from the oil depends mainly on the speed with which
the necessary amount of stripping steam can be introduced
Deodorization time also increases with the height of the oil in the
deodorizer, i.e., with the thickness of the oil layer that the stripping
stream has to penetrate.
Stripping Gas
A Carrier to the Undesired Components
External pressure of the gas adds to the Vapour pressure of volatiles in deodorizer and
speed up their removal.
Stripping agents with the lowest possible molecular weights are selected. In most
cases, steam is the best solution, but sometimes nitrogen is preferred.
Since the surface area of the oil is increased by bubble formation, the mass transfer
and consequently the distillation rate is increased.
The height of the oil in the vessel also influences the consumption of steam because the
steam has to work against the hydrostatic pressure to be able to penetrate the oil
before being sucked off or distilling off from its surface.
where S is the total moles of steam, V, is the initial molar concentration of the volatile
component in the oil, and V, is the final molar concentration of the volatile component in the
oil. When the initial FFA content is low, as in the case of a classical deodorization, (Va- Vo)
becomes so small that the equation can be simplified as follows:
The amount of gas required for deodorization is directly proportional to the amount of oil
and the absolute pressure in the deodorizer and inversely proportional to the vapour
pressure of the pure volatile component at the process temperature and the overall
vaporization efficiency E.
On the surface of the steam bubbles, the oil/steam contact must be maximized; there the
sparge gas has its lowest specific volume, equivalent to the highest relative surface area.
Athanassiadis (1991) postulated that 300,000 m3 was a minimum contact area of oil/steam
for every kilogram of gas injected to ensure good deodorization efficiency.
Process
Optimization
To achieve a proper deodorization, an optimal deodorizing temperature, operating pressure,
and amount of stripping gas are required. These are determined not only by the type and state
of the oil (chemically or physically refined), but also by the deodorizer design.
Today, most deodorizers used in the refining of soft oils operate at temperatures between
230 and 26OoC, a pressure of 3 mbar or even lower, with a stripping steam consumption of
~10 kg/ton of processed oil.
Refining
chemical
physical
Temperature
230 250 C
240 265 C
Pressure
3 mbar
2 mbar
Sparge steam
5 15 kg/t
7 20 kg/t
Time
45 90 min
45 90 min
Final FFA
0.03 %
0.05 %
Trans-increase
0.5 1.5 %
0.7 2 %
Tocopherol retention
70 90 %
60 80 %
Source@alfalaval
Unit operations of
deodorization &
Processing Steps
Bleached Oil
Degassing
Heating Up
Deodorization
Cooling
Polishing
Deodorized Oil
Deaeration
Heating
Stripping
Thermal action
Cooling
Polishing
De-aeration
To avoid excessive oxidation and hence risk of polymerization.
Soft oils dissolve readily between 4 and 10% of their own volume of air and other
gases at ordinary temperature.
Solubility increase with increasing in temperature. The relation between solubility
(S) and temperature (t) can be expressed as:
The bleached oil is sprayed into a tank under reduced pressure. The lower the pressure applied,
the lower the residual oxygen in the oil. Usually the oil is heated to at least 80C and sprayed
into a tank, which is kept at a pressure of 40 mbar. Some refiners even use the low pressure of
the deodorizer or add some sparge steam in the spraying tank to improve deaeration.
Heating
Stripping
It is Conducted at a temperature between 230 and 260 oC, at a pressure between 2 and 4
mbar and under injection of 0.5-2% sparging steam. From a thermodynamic point of view,
the stripping agent takes over the part of the total pressure equal to its partial pressure. As
a consequence, the vapour-liquid equilibrium is reached at a lower molar fraction, xi,
resulting in the removal of significantly more volatile substances only.
Nitrogen
- inert and non-condensable gas
- lower losses (no hydrolysis) and higher distillate quality
- more powerful vacuum system required
- profitability is very uncertain
Steam (Superheated)
- most evident choice
- Boost up the vacuum when condensed
- But support hydrolysis
The sparge gas is introduced into the oil through special steam distributors. These can be
sparge coils with very fine holes (between 0.5 and 2.5 mm) or even sintered metal pipes
Thermal action
Cooling
Finally the oil is cooled in two stages.
First in the economizer, and then to the
specified final temperature. It then
undergoes polish filtration and is
transferred to subsequent processes,
storage or packaging
Oil Polishing
Oil polishing is done to remove any fine
particles of soaps , metallic salts rusts , filler
aids, polymerized oil or other solid
impurities. Horizontal plate filters have long
been used as polishing filters of choice for
deodorization.
Processing
Options
Batch Processing
Semi-Continuous Processing
Continuous Processing
- Vertical Deodorizer
- Horizontal Deodorizer
Thin Film Technology
Packed Column Technology
Dual Temperature Technology
Batch
Process
In
principle,
semicontinuous deodorization
is
an
automatically
controlled
batch-wise
process.
Used
when
frequent
feedstock changes of oil
sensitive
to
cross
contamination.
Steam produced in the
bottom deodorized oilcooling section is sent in a
closed thermo siphon loop
to the top bleached oil
heating section to heat the
incoming oil.
Main advantage is shorter
hold up time , and
disadvantage is less heat
recovery
than
the
continuous process.
Semi-Continuous
Processing
Continuous
Processing
Horizontal deodorizer
Continuous
Processing
Vertical deodorizer
Steam
Steam
Demister
VHE Final
Heater
Cooling water
Scrubber
Vacuum system
To hot well
SoftColumn
column
High pressure
steam boiler
Steam
Cooling
water
Deaerator
Cooling
water
Steam
Acid oil
Economizer
Heater
Oil in
Cooler
Steam
Citric acid
Polishing
filters
Oil out
Inlet
filters
Steam
Continuous
Processing
Equipment
Scrubber
Single Scrubber
Double Scrubber
Stripping Column
Horizontal Column
Vertical Column
Vacuum System
Ejector Booster
Ice Condensation
Scrubber
Composition of vapor phase
Volatile components (FFA, odor components)
Stripping steam
Non condensable gases (air.)
The volatile substances are condensed by creating an
intimate contact between the vapor and fatty acid
distillate circulating in the scrubber.
The distillate which is circulated is at its lower possible
temperature (just above its melting point).
Stripping
Column
The pre-treated and heated oil flows either by gravity or under pressure from the final
heater to the distributor on the top of the column. The distributor spreads the oil evenly
over the cross-section of the column. This oil then trickles down the structured packing,
flowing as a thin layer on this extended surface until it reaches the bottom of the column.
It then continues to the next process step. The counter current flow of the steam is
achieved via a steam distributor installed in the bottom of the column or from another
source. The oil in the column meets the stripping steam in a counter current flow.
The column is under vacuum, so exposing the oil to the vacuum at a high temperature
removes volatile substances and the steam carries them out to the vacuum outlet at the
top of the column. The height of the column is a function of the number of desired
distillation steps.
Horizontal
Column
Vertical
Column
Effect of Deodorization
on Quality of Oil
Losses by evaporation
Losses in
Deodorization
Losses by entrainment
Deodoriser distillate always contains
a certain amount of neutral oil
which has been mechanically
entrained from the oil.
Mechanical entrainment (carryover)
Newer
Developments
Thin Film
Technology
The first plant for large scale (250 MT/d) thin film seed oil deodorization was
started in 1996.
It had been known for some time that thin-film stripping theoretically had
considerable advantages over tray stripping. Because the steam passes over a very
thin oil film in a true counter-current operation, the contact between steam and oil
is optimized.
The surface area of the oil can be further increased by a special design of the
packed column. Other means to enhance mass transfer are eddy currents caused
by wall heat transfer in the falling film design or centrifugal action if rotating disks
are used.
However, there are still some major drawbacks,
Increased trans fatty acid level.
Removal of antioxidants and vitamins as a result of the very high effectiveness
of the operation.
Heat bleaching effect may be reduced
Dual Temperature
Technology
These deodorisers operate at two different temperatures in order to
reach the best compromise between required residence time for actual deodorisation (longer time
at lower temperature) and
heat bleaching and stripping of volatile components (shorter
time at higher temperature).
The dual-temperature concept has been successfully introduced on
an industrial scale. Both the low/high temperature and the
high/low temperature concept can be applied.
Ice Condensation
Vacuum System
Dual Scrubbing
System
Utilities
Consumption
Electric Power:
Steam(4 bar)
Heating Energy
9 m3 at T 6C
4 m3 at T 6 TC with ice condensation
Citric Acid:
Deodoriser
safety
The deodoriser is operated at the highest temperature of the refining plant. The oil is
kept under non-combustible conditions, due to the absence of air in the deodoriser. A
fire hazard is possible when air is entrained in the deodoriser at high temperature.
The following preventative measures should be used to avoid this situation:
Properly maintained equipment, to avoid air leaks. Trained personnel, to identify
air leaks and react to starting fires.
Well-established procedures for start-up, shutdown and maintenance.
The high-pressure boiler develops up to 90 bar pressure. Its condition and safety
system integrity must be periodically checked.