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ProSimTechs MODELLING & SIMULATION
Modelling & Simulation Solutions for
Vegetable oil Refining, Nutraceutical
and Oleochemical processes
The Deodorising process
2
Deodorising is by far the most energy
consuming stage along the overall vegetable
oil refining process.
On the other hand, the last overall refining
stage along the vegetable oil refining
process.
Also, it is a critical process in terms of the key
quality parameters of final oil.
What we want to get from a Deodoriser ?
Quality
To remove FFAs ?
To remove peroxides, aldehydes and ketones ?
What about the quality of the outlet streams ?
Do we have a given target of tocopherol
concentration in final oil ?
Do we have the same for the distillates ?
Process conditions
But also to use steam as less as possible
To minimize the energy involved
To reduce the waste water
Are a given set of deodorising conditions the same
from a deodoriser and another ?
What if the quality at the oil inlet changes, how
impacts on oil outlet and distillates ?
Do I have to change the deodorising conditions
(temp, sparge steam) ?
Which one first and what would be the new value
for each ?
Process
Type of Process
Vegetable oil
Equipment
Process condition
s
Lab results
Bleaching
Deodorising
Acid Degummin
g
Deodorising and Physical Refining Process
ProSimTechs MODELLING & SIMULATION
Do all deodorisers have the same performance ?
3
The Deodorising/Physical Refining Process Unit is one the
economic heart of today’s refinery. Small increases in yield can
bring significant gains in productivity and revenues.
Rigoruos process simulation studies have diagnosed operating
problems and helped improve the performance of all major
components of Deodorisers.
Each project is customized to provide the information needed
to optimize or troubleshoot your specific process. All testing is
performed while the unit is online and will not interfere with
normal unit operations or production scheduling.
Data collected can be used to identify operating parameter
changes to improve unit productivity, or gauge the accuracy of
process modeling and simulation.
A typical study employs a rigorous, accurate
and customized model of the process taking
into account the characteristics of the oil, the
flowsheet and the equipment (Deodoriser).
The starting information for the complete
study is the actual information managed by
the plant, for example:
Capacity of processing
Vegetable oil inlet-outlet composition –
Distillate composition
Flowsheet (P&IDs or PFDs) and
equipment characteristics.
Current process conditions
SECTIONAL
TRIM
VAPOR
FLOW
LIQUID
FLOW
ProSimTechs MODELLING & SIMULATION
4
Modelling and Process Simulation
Process modelling is the activity of building a
mathematical model of the process by describing its
fundamental physical and chemical relationships, by
means of equations.
Process simulation is one of the activities that one
can perform with that process model, using an
appropriate mathematical method to solve it.
Process modeling and simulation are
used to describe a physico-chemical
process as a set of physic-chemical
equations in order to perform all the
calculations involved in it, in a
powerful, accurate, reliable, quick way.
A point during the process of building the model of the vegetable refining process, is to
select the appropriate models for each main parts of simulation model:
Thermodynamic models: the fatty compounds requires a very specific
thermodynamic model, more over considering Unit Operations with liquid-vapor
equilibrium (LVE) processes.
Unit operations models rigorous: most of the key process equipments are quite
particular and non std designs (deodorising trays, packed columns, scrubbers).
Compounds (basic data and temperature dependent properties): quite complex
molecules, a few info available, predictive approach is required.
Flowsheet Streams 94
No of Components 15
Stream IDs 1 2 3 4 5 6 7 8 9 10 11
Labels ED oil RD oil880A RB
outl
881B RD
outlet1 FDA
881A RD
outl
Temperature C 100,0 226,2 155,8 229,6 40,0 0,0 243,6 155,8 30,0 36,0 109,0
Pressure bar 0,0025 0,002129 0,0022 0,002129 3 0 0,0015 0,0022 3 3 3
Enthalpy kcal/h -19936204 -16380971 -14630424 -16310434 -20447798 0 -1756602 -14630424 -879883840 -8,78E+08 -19054854
Vapor Mole Fraction 0,017944 0 0 0 0 0 1 0 0 0 0
Total Mole FlowRate kmol/h 51,61 47,04 77,94 47,13 47,04 0,00 26,55 77,94 12911,57 12911,57 47,04
Total Mass FlowRate kg/h 42562,0 41511,3 29370,4 41539,2 41511,3 0,0 1440,1 29370,4 232602,0 232602,0 41511,3
Total Std. Liq. Vol. FlowRate m3/h 47,59 46,42 32,88 46,45 46,42 0,00 1,56 32,88 232,60 232,60 46,42
Total Std. Vap. Vol. FlowRate m3/h 1156,72 1054,25 1746,95 1056,42 1054,25 0,00 595,15 1746,95 289395,31 289395,31 1054,25
Flowrates kg/h
Soybean oil 8001 41441,9 41436,0 8357,8 41436,4 41436,0 0,0 5,9 8357,8 0,0 0,0 41436,0
Water 62 16,6 0,0 0,1 0,0 0,0 0,0 413,3 0,1 232602,0 232602,0 0,0
Sodium Hydroxide 429 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0
Phosphoric Acid 474 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0
Oleic Acid 549 1049,6 35,8 16525,5 62,7 35,8 0,0 1013,8 16525,5 0,0 0,0 35,8
PhosphatidilColi 8002 0,3 0,3 0,0 0,3 0,3 0,0 0,0 0,0 0,0 0,0 0,3
TriNa Phosphate 985 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0
Na oleate 8003 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0
PA Ca salt 8004 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0
Phosphatidic aci 8005 1,5 1,5 0,0 1,5 1,5 0,0 0,0 0,0 0,0 0,0 1,5
Air 475 0,8 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0
TriCalcium Phos 8006 0 0 0 0 0 0 0 0 0 0 0
a-Tocopherol 8007 29,38913 17,14102 3115,846 17,62821 17,14111 0 5,782386 3115,846 0 0 17,14111
Sitosterol 8008 21,91007 20,55648 1371,233 20,69374 20,55651 0 1,353522 1371,233 0 0 20,55651
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
21,000
22,000
23,000
24,000
25,000
138 140 142 144 146 148 150 152 154 156 158 160 162 164 166 168 170 172 174 176 178 180 182
To
co
ph
ero
l co
nc (%
w/w
)
Hot Scrubber condensing Temperature (ºC)
Tocopherol conc (% w/w) in 1FDA
6,0
8,0
10,0
12,0
Spargingsteam (Kg/Tn)
SCREEN SHOT OF
A PROCESS
SIMULATION
OF DEODORISING
ProSimTechs MODELLING & SIMULATION
5
Study case: Bleached palm oil in Physical Refining /Deodorising
Studies of toco (‘pherols and ‘trienosl) concentration
Vitamin E is one of the most important phytonutrients in edible oils. It consists of
eight naturally occurring isomers, a family of four tocopherols (alpha, beta, gamma
and delta) and four tocotrienols (alpha, beta, gamma and delta) homologues.
Application of Tocotrienols Complex :
Tocotrienol complex can be
used in a variety of food and
drinks including cosmetic
products.
Global volume consumption of natural source vitamin E stood at 10.3 thousand metric
tons in 2012, is estimated at 10.9 thousand metric tons in 2013 and projected to be 18.1
thousand metric tons in 2020, thereby exhibiting a CAGR of 7.3% between 2012 and
2020. Estimated at US$611.9 million in 2013, Value demand for Natural Vitamin E,
worldwide, is set to cross the US$1 billion mark by 2019.
Natural sources Vitamin E market
Health Supplements
a) Soft Gel Capsules
b) Hard Shell Capsules
c) Vitamin Premixes
Functional
Food &
beverage
Cosmetic and
Personal Care
Products
Introduction
ProSimTechs MODELLING & SIMULATION
6
Study case: Bleached palm oil in Physical Refining /Deodorising
Studies of tocopherol concentration
Relevant information for the Modelling
Process conditions
Oil inlet temperature (ºC)
Final heating temperature (ºC)
Temperatures in heat recovery stages
Oil outlet temperature (design)
Vacuum at suction (mbar)
Final heating temperature (ºC)
Sparge steam distribution (Kg/h, or Kg/Tn)
Motive steam (Kg/h each stage)
Condensing temperature
Equipment
Type and general dimensions of
the main equipments
Heat exchange areas
Distillate/s composition
FFA as palmitic (%)
Tocopherol /tocotrienols (%)
TAG (%)
DAG (%)
MAG (%)
Sterols (%)
Vegetable oil inlet composition
FFA (%)
Tocopherol (ppm)
DAG (%)
MAG (%)
Water (%)
Sterols (%)
Vegetable oil outlet composition
FFA as palmitic (%)
Tocopherol/tocotrienols (ppm)
DAG (%)
MAG (%)
Water (%)
Sterols (%)
Relevant information for validation of first simulation run
FATTY ACID
α-TOCOFEROL
ProSimTechs MODELLING & SIMULATION
7
Objectives
Modelling of the process.
Simulation of a given scenario in terms of process conditions and oil inlet quality.
Validation of the modelling against plant.
Sensitivity studies and optimisation
To analyse different processing scenarios to get a toco’s enriched distillate.
To study a comparative OPEX analysis between the simulation scenarios.
Piping and instrumentation diagram (P&ID)
From the real P&Id of the plant, we
select the main streams of each type
of fluid, and the main equipment, to
make the process flow diagram.
A flowdiagram of the process with the
main streams is then built, in order to
be considered during the construction
of the simulation model of the
process.
70
High Pressure
boiler
Sparging
steam
Inlet oil pump
Bleached palm
oil
75
Stripping
Outlet oil pump
155
Deodorising
CWS
CWR
Economiser
Final cooler
Scrubbing
FAD circulating
pump
CWS
Cooler
48
Cooling water
pump
CWR
FAD
collecting
tank
8
Heat recovery
Final
heating
Superheater
1
Refined
palm oil
Crude palm oil
Crude palm oil
Vacuum system
Natural
gas
Combustion
gas
FAD
(FFA enriched)
4
Process Simulation Technics
Process Flow Diagram (PFD)
MODELLING, SIMULATION – SENSITIVITY ANALYSIS
1.0Physical Refining
DESCRIPTION
PROJECT
RevPROCESS UNIT Date 01-02-2011
Study case: Bleached palm oil in Physical Refining /Deodorising
Studies of tocopherol concentration
ProSimTechs MODELLING & SIMULATION
8
Once the model of the process and the first simulation is run, complete mass and
energy balances are imported from an excel sheet, to keep analysing the information
from the simulation and to study the performance of tocopherol and tocotrienol
stripping and concentration in distillate.
The toco(‘pherol and ‘trienol) in distillate was found to have a concentration of 0.70 %.
The market price of this distillate to sale it in the market of toco`s enriched distillate
market is to low in toco concentration, that is way the company wanted to research
some other processing scenarios to study from economic point of view the feasibility.
The idea and purpose of the present study is to analyse to alternative customised
processing routes to increase the toco`s concentration in distillate for the existing
plant, and finally to study a comparative OPEX in the different processing scenarios.
The following were the proposed processing routes to be analysed:
Processing scenarios to be simulated
Study case: Bleached palm oil in Physical Refining /Deodorising
Studies of tocopherol concentration
1. Stripping + Deodorising + Single Scrubber (base case)
2. Stripping + Deodorising + Double Scrubber
3. Stripping + Deodorising + Double Scrubber + NORES (Neutral Oil Recovery
System)
ProSimTechs MODELLING & SIMULATION
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A first simulation run was executed, after building the process model, in
order to analyse the current situation studying the 3 key elements of the
plant: vegetable oil processed, process, existent equipment.
The results of the first simulation run compared with a low error margin, and
area as follows:
1. Stripping + Deodorising + Single Scrubber (base case)
The more relevant information from simulation of base case is:
- The tocopherol/tocotrienol concentration in distillate (PFAD) as was measured is
confirmed by the simulation to be low and is the expected value under the current
situation.
- The FFA (measured by titration as palmitic acid) is around 86 %, also under the
magnitude of order the different lab analysis of the PFAD samples.
ProSimTechs MODELLING & SIMULATION
10
- On the other hand, TAG+DAG+MAG concentration in PFAD compared to
those with the simulation run, confirming indirectly that the global loss is under
specs.
Now, the first simulation study (case study 2) is executed, in under to study what is
achievable in case of the existing Physical Refining + Deodorsing + Single
Scrubber process is converted to a Double Scrubber, in order to get two spitted
distillates: a toco`s enriched distillate (from hot scrubber) and a FFA enriched
distillate (from cold scrubber).
In the following simplified flow diagram, the same relevant information from the
simulation run is shown:
After executing the simulation run, a sensitivity study was performed, in order to
find the optimum value of toco’s concentration in the toco enriched distillate. So,
in this case, around 5% is theoretically the highest toco concentration that is
feasible to achieve, considering the crude palm oil quality.
2. Stripping + Deodorising + Double Scrubber
ProSimTechs MODELLING & SIMULATION
11
The refined and deodorised palm oil quality is the same than the current
processing scenario (single scrubber). On the other hand, the FFA concentration
in the FFA enriched distillate from cold scrubber, increased from 86.2 % to 90.4
%, measured as palmitic acid, while the global loss remains the same.
As it can be seen from the former simulation run with the double scrubber, there is
an amount of TAG, DAG and MAG, coming with the vapors to the scrubbing
section from the Stripping section, that are condensed in the hot scrubber, jointly
with the tocos, because TAG and DAG have the lowest vapor pressure of the
compounds in this vapor stream.
So as result, TAG and DAG are acting as diluting effect, lowering the concentration
of tocopherols and tocotrienols in this distillate
The idea now is to study the effect of putting a NORES system, in between the
Stripping section and the Scrubbing section, in order to condense most of the TAG
and DAG compounds, aiming to increase the toco concentration in the distillate.
3. Stripping + Deodorising + Double Scrubber + NORES
ProSimTechs MODELLING & SIMULATION
12
Such as we can see from the simulation report, extracting the same relevant
information, as effect of removing certain fraction of TAG and DAG from the vapor
stream prior to be condensed in the hot scrubber, the toco (`pherols and `trienols)
concentration in the distillate increase by the double.
As the case study 2 (double scrubber) a sensitivity study was performed in order to
find the optimum ( maximum) value of toco concentration in the distillate.
In this case, around 11 % was the value theoretically feasible to achieve,
considering the palm oil inlet and the process conditions applied.
One important point has to be mentioned, and is that the sparge steam was
increased in order to strip the same amount of toco`s from the palm oil processed.
Another remarkable point in this process simulation scenario, is that the globall loss
reduced a bit compared to the Base case and the Double scrubber case, from 4.51
% to 4.47 % (around 0.04 % neutral oil gain), this is due the TAG and DAG
recovered from NORES come back to the deodorised palm oil.
Following, is a summary table of the relevant results that was compared:
Section Single
Scrubber
Double
Scrubber
Double
Scrubber +
NORES
FFA (as palmitic) conc in PFAD (%) 86.24 90.41 90.50
Toco’s concentration in PTOD (%) 0.79 5.52 10.91
GLOBAL LOSS (%) 4.51 4.51 4.47
NOL saving (points %) - - 0.04
OPEX comparative analysis of the simulation scenarios
Quality of the inlet crude
palm oil, plant capacity.
Product prices considered
for the economic analysis.
1- Quality specification of oil
Crude palm oil
FFA (by titration as palmitic) 3.77 %
Phospholipids ( as P) 20 ppm
Toco('pherol+'trienol) 900 ppm
Volatiles 0.10 %
Impurities 0,10 %
Plant Capacity 600 TPD
2- Price of vegetable oil and by-products
Crude palm oil 768 U$S/Ton
PFAD from Physical refining 710 U$S/Ton
PTOD 5 % from Physical refining 1,500 U$S/Ton
PTOD 10 % from Physical refining 2,500 U$S/Ton
RBD palm oil 790 U$S/Ton
ProSimTechs MODELLING & SIMULATION
13
Finally, considering the
comparative difference
between base case (Single
scrubber) vs Double
Scrubber and Double
Scrubber + NORES, and
making an annual
calculation (330 working
days/year), a huge annual
saving is achievable in
both cases, and even
higher in the last case
(double scrubber with
NORES
3- Operative cost of the different processes
Bleach/Deo Bleach/Deo Bleach/Deo
Single
Scrubber
Double
Scrubber
Double
Scrubber
NORES
U$S/Tn
OPEX per Tn crude palm oil 9.53 9.52 9.53
OPEX per Tn refined oil 9.99 9.99 10.98
OPEX x losses 36.08 36.11 39.12
OPEX total per Tn refined 46.07 46.10 46.76
RBD OPEX 813.92 813.94 814.60
Byproduct income per Tn RBD 32.78 35.95 37.01
Net OPEX 13.29 10.15 9.74
Double
Scrubber
Double
Scrubber +
NORES
U$S/Tn U$S/Tn
Difference distillates income 3.17 4.23
Difference Net OPEX vs Base case 3.14 3.55
Considering 330 working days and 600 TPD
Annual saving (USD) 622,043 702,351
OPEX for each process
simulation scenario (OPEX of
both Bleaching and
Deodorising was considered).
Note: the prices for utilities
and chemicals are general,
and the main purpose is to
make a comparative OPEX
analysis.
Certainly, this OPEX analysis is very sensitive to the price market of the
distillates for each processing scenario.
The palm oil inlet quality also has a big impact, mostly in terms of the
toco`s concentration and the DAG and MAG concentration.
ProSimTechs MODELLING & SIMULATION
14
The distillate valorisation due toco´s concentration plays a key role in terms of
OPEX analysis, due to a better market price, which is the main driver, in the lower
OPEX value.
Physical refining / Deodorising is a very complex process from the point of view
of the distillation.
Vegetable oil is a multicompound mixture
Quality of the outlet streams are very sensitive to the process conditions
Modelling and Simulation is an optimum and very valuable tool to predict and
analyse different scenarios and see “what if”
The information from a simulation run, sensitivity analysis and global optimisation
allows to have an in-depth knowledge on our process, then to make the appropriate
decision-making.
There is a new point of view to analyze your processes.
Let us exchange ideas.
prosimtechs.com
Remarkable facts/Summary
ProSimTechs MODELLING & SIMULATION
