Starch from Corn Separation technology for cereals

engineering for a better world

GEA Mechanical Equipment

SCE 53

Always the Right Solution

Corn is worldwide the most important raw material for the production of starch and starch derivates, such as sugar syrups. The corn starch industry introduced centrifugal separation technology, because of the central economic significance and high environmental standard for such process lines. GEA Westfalia Separator Group supplies nozzle centrifuges as well as by-product dewatering decanter and has developed many ideas for the technological beneficial innovations; lately the introduction of the discdecanter and the SDA 500 (biggest nozzle separator of the world) with direct drive. In the following the possible applications of the GEA Westfalia Separator Group supplied centrifuges are described. Especially the integration of the GEA Westfalia Separator Group patented discdecanter PA 756 is shown.
Corn

The morphological structure of a corn kernel is illustrated by this cross section. A special steeping procedure is required for the selective mechanical disintegration of the structure. While the germ and the starch in the floury endosperm are released quite easily by gentle course grinding, the packed horny densely endosperm isolate

High throughput capacity due to optimised bowl and scroll design and improved flow patterns in the bowl Maximum bowl speeds Sophisticated drive concepts for highest dry substance values Low energy consumption due to low friction losses and improved flow patterns Ease of access to all relevant components reduces maintenance time, the bowl, scroll and bowl bearings are replaced and exchanged in a form of a complete cassette Cooling lubrication for the bowl bearings and automatic oil circulation lubrication for high running performance Liquid phase discharge via internal centripetal pump SDA 260 Two-phase technology combining various process stages: Washing Classification Concentration Desplacement washing High throughput capacity Clarifier bowl with closed feed and discharge Low energy consumption due to continuous discharge of the solids concentrate through special nozzles CIP cleaning at operating speed GEA Westfalia Separator discdecanter PA 756 Newest technology for gluten de-watering Highest throughput capacity Design for hydrohermetic feed Various cone angle of bowl Regulation of differential speed even for low Dn High torque because of 2-gear-drive Low energy concept Long operation time

requires a significant input of mechanical energy to the starch fraction.

Freshwater

By-product
Fine Fiber Dewatering
M

to drying
M

x
Hotwater

Millstarch Thickener
M M M

Middling

Primary

Gluten Thickener

Gluten Dewatering
Hotwater

Gluten

Starchmilk Evaporation

Starch Washing

Husks/Fiber Germs

Steeping To achieve an optimum wet milling result the corn is softened in a steeping process. This procedure is executed batch wise in steeping vessels, designed for about 40 48 hours residence time. Process water from the wet mill containing SO2 and a population of lactic acid bacteria is used as steepwater, which is pumped through the steeping system in counter current flow to the intaken corn. The steepwater is circulated via ECOFLEX heat exchangers to adjust the temperature of 48 50 C. By the end of the steeping period the corn should have absorbed water to about 45 % and released a certain portion of the dry substance as solubles into the steep water. The steepwater which has been in the steeping system longest is drawn off towards a steepwater evaporator.

Grinding and germ separation In a pre-milling operation the oil-rich germs are set free by gentle course grinding by means of toothed disc mills. The germ separation by means of Hydrocyclones is carried out counter currently in two stages with a second pre-milling operation in between. The germs are washed free of starch with process water by means of a counter current operated 3-stage gravity screen system. Afterwards the germ fraction is dewatered in a screw press up to a dry substance of approx. 50 %.

Disintegration and extraction The endosperm fraction passing the underflow of the last germ hydrocyclone unit is pre-dewatered on gravity screens in front of fine grinding mills to obtain an effective disintegration of the morphological endosperm structure into separable components. The slurry is pumped through a multi-stage bend screen system for starch extraction and counter current fiber washing with process water. The fiber fraction from the last extraction screen unit is splitted by means of bend screens into a crude husk fraction, which is efficiently dewatered by a screw press, and fine fiber fraction which is efficiently separated and dewatered by a decanter. Thereby a cumulation of fine fiber in the wet milling process is prevented.

Starch separation and washing The crude starch milk from fiber extraction still contains besides starch granules sus- pended material as insoluble protein (gluten) as well as solubles and colloids. A so called mill starch thickener is used to pre-concentrate the crude starch milk in front of the primary separator. This pre-concentrated mill starch slurry has to be separated into two fractions, the pure starch and the corn gluten. This is done by primary separation in a nozzle separator where the main starch / gluten separation takes place into 2 phases, the gluten water with the insoluble gluten and solubles but without starch and the starch milk with some gluten and solubles. As usual the starch is discharged through the nozzles while wash liquid is additionally fed in front of the nozzles for displacement of soluble and insoluble impurities. The final washing of the starch takes place in a 12-stage HOVEX multi-cyclone system in counter current flow with a minimum amount of fresh water added in front of the last hydrocyclone stage. The in-line centrifugal pumps are compensating the loss of operating pressure after each stage. For a constant operation and efficiency of the starch separation and washing system it is best to operate at a constant density, which is indicated and automatically controlled via the wash water pressure at the primary separator. A middling nozzle separator is used to clarify the starch and protein containing overflow from the starch washing system. The clarified water phase with low soluble potential is used as wash water for the primary separation. The starch and gluten leaving the middling separator is fed back in front of the primary separation.

Gluten concentration and dewatering The gluten water from primary separation contains insoluble gluten and solubles. The insoluble gluten has to be pre-concentrated in a nozzle separator before the gluten can be dewatered by centrifugal decanters. Decanters operate very efficiently with less concentrated gluten suspension, with the ability to achieve maximum dry substance and granular structure of the gluten discharge while the liquid phase is clarified to that extent, that it can be directly used as process water. 2-gear drive decanters are used with all constructional features which are necessary for optimum corn gluten dewatering.

Conventional Process for Corn Starch Recovery

Mill starch

Mill starch thickening

Process water

Middling separation

Primary separation

Starch washing

Gluten thickening

Starch dewatering

Gluten dewatering

Starch drying

Gluten drying

Corn starch

Corn gluten

GEA Westfalia Separator discdecanter

Two in one

The discdecanter makes the corn gluten dewatering profitable more than ever. With this revolutionary innovation GEA Westfalia Separator Group succeeded in using its know how of separator development for decanter technology. A disc stack in front of the

decanters liquid outlet provides high clarified liquid and therefore an extremely dry substance matter. The high quality of the protein powder which becomes obvious because of colour and consistency.

Bowl

Scroll

Disc stack

Solids

Overflow

Feed

Advantages of the discdecanter High feed capacity No cleaning water required for filter cloth No problems with filter cloth Higher dry substance of dewatered gluten (approx. 42 48%) Less floor space required Overflow has process water quality (2 Vol-% separable solids) Better drying conditions because of very fine powder Less energy needed for gluten drying

Drive Concepts for Separators

Different drive concepts are also available for the separators. Two drive concepts are in the programme: flat belt and direct drive.

Flat belt drive In this solution, the motor power is transferred to the spindle by means of an antistatic flat belt. Oil circulation lubrication ensures that bearings are continuously lubricated. This also means that the separator does not have to be shut down for an oil change. Compared to the gear drive, which is still used in older models, the motor power is transferred with up to 10 percent lower power losses. The belt itself can be replaced quickly and in a service-friendly manner without the bowl or motor having to be dismantled beforehand.

Direct drive system The direct drive is an example of intelligent simplification in separating technology. Wherever the upper limit for gear loads has been reached or belt drives are undesirable, our separators with direct drive permit virtually loss-free power transmission. This boost in performance simultaneously reduces the costs of energy, wear, maintenance and space. The required power is transmitted directly to the bowl spindle by a three-phase AC motor with frequency converter control via a torsionally elastic clutch. The spindle assembly is likewise supported by rubber-metal cushions. This makes possible lowvibration running at high bowl speeds. At a glance: Extremely space-saving design Avoidance of housing deformation High performance input Low maintenance requirement

2-Phase Separators for Applications in a Corn Starch Plant

As a combination of the traditional 2-phase separation with the latest machine technology
SDC 70 / 90 nozzle bowl centrifuge With or without washing device or concentrate recycling system SDC 70-..-107 Flat belt drive SDC 70-..-003 Direct drive SDC 90-..-107 Flat belt drive SDC 90-..-003 Direct drive SDC 70. Technical data and Installed power Number of nozzles Rated capacity feed Rated capacity wash water SDC 90. Technical data and Installed power Number of nozzles Rated capacity feed Rated capacity wash water capacity 70 kW 12 max. 130,000 l / h max. 20,000 l / h capacity 90 kW 12 max. 150,000 l / h max. 20,000 l / h

SDC 110 / 130 / 160 nozzle bowl centrifuge With or without washing device or concentrate recycling system SDC 110-..-107 Flat belt drive SDC 130-..-107 Flat belt drive SDC 130-..-003 Direct drive SDC 160-..-003 Direct drive SDC 200-..-003 Direct drive SDC 110. Technical data and capacity Installed power 110 kW Number of nozzles 18 Rated capacity feed max. 160,000 l / h Rated capacity wash water max. 40,000 l / h SDC 130. Technical data and capacity Installed power 132 kW Number of nozzles 18 Rated capacity feed max. 180,000 l / h Rated capacity wash water max. 40,000 l / h SDC 160. Technical data and capacity Installed power 160 kW Number of nozzles 18 Rated capacity feed max. 250,000 l / h Rated capacity wash water max. 40,000 l / h SDC 200-..-003 Direct drive Installed power Number of nozzles Rated capacity feed Rated capacity wash water SDA 260 / 300 / 500 nozzle bowl centrifuge With or without washing device or concentrate recycling system SDC 260-..-107 Flat belt drive SDC 260-..-003 Direct drive SDC 300-..-003 Direct drive SDC 500-..-003 Direct drive SDC 260. Technical data and capacity Installed Power 250 kW Number of nozzles 20 Rated capacity feed max. 500,000 l / h Rated capacity wash water max. 50,000 l / h SDA 300. Technial data and Installed Power Number of nozzles Rated capacity feed Rated capacity wash water SDA 500. Technial data and Installed Power Number of nozzles Rated capacity feed Rated capacity wash water capacity 315 kW 20 max. 400,000 l / h max. 50,000 l / h capacity up to 500 kW 20 max. 500,000 l / h max. 50,000 l / h

200 kW 18 max. 300,000 l / h max. 40,000 l / h

The feed and wash water volumes are based on water. The effective feed capacity depends both on the product and the process stage.

2-Phase Decanters for Applications in a Corn Starch Plant

As a combination of the traditional 2-phase separation with the latest machine technology
SCF 466-01-35 Clarifying decanter with centripetal pump and GEA Westfalia Separator summationdrive Technical data and capacity Bowl diameter 460 mm L/D 4 Bowl speed max. 3500 rpm Installed power 45 kW (37 kW with FC)

SCE 53.-01-34 Clarifying decanter with centripetal pump and differential gear drive Technical data and capacity Bowl diameter 530 mm L/D 4 Bowl speed max 3600 rpm Installed power 55 90 kW / FC

SCE 755-01-32 Clarifying decanter with centripetal pump and two-gear drive Technical data and capacity Bowl diameter 750 mm L/D 4 Bowl speed max. 2800 rpm Installed power 110 200 kW / FC

PA 756-00-32 discdecanter with additional disc stack for highly clarified liquid Technical data and capacity Bowl diameter 750 mm L/D 4 Bowl speed max. 2630 rpm Installed power 110 200 kW / FC

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GEA Mechanical Equipment

GEA Westfalia Separator Group GmbH
Werner-Habig-Strae 1, 59302 Oelde, Germany Phone: +49 2522 77-0, Fax: +49 2522 77-1794 www.gea.com

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 Printed in Germany Subject to modification Westfalia and Westfalia Separator are registered trademarks of GEA Mechanical Equipment GmbH. B_RR-12-06-0012 EN