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9 Degumming
9 Water Degumming
10 Simple Acid Degumming
12 Special Degumming
14 Super- / Uni-Degumming
16 TOP-Degumming
18 Neutralization
18 Standard Neutralization
20 Neutralization of Undegummed Oils
21 Miscella Refining
22 Winterization
22 Wet Dewaxing
24 Cold Refining
25 Polishing Filtration
26 Fractionation
26 Dry Fractionation
28 Processing of By-Products
28 Soapstock Splitting
30 GEA Westfalia Separator serv&care
3
Oils and Fats Processing
Robust reliable efficient
4
Processing of e.g. Special applications
Soybean oil Ni-catalyst removal
Rapeseed oil Lecithin deoiling
Sunflower oil Bleaching earth deoiling
Animal fat Re-refining of used frying fats
Cottonseed oil
Corn oil Our competence in oleochemical applications
Fish oil Transesterification
(e.g. for making biodiesel)
Our core competence in edible oil refining Epoxidized oils
Press oil clarification Mono-/diglycerides
Degumming Fatty acids
Neutralization Glycerine
Dewaxing Soap
Fractionation Fatty alcohols
Soapstock splitting
5
Chemical Refining
Different Processes One Solution
Seed Beans
Animal
Pressing Extraction
feed
Soapstock
Neutralization Bleaching
splitting
Bleaching
Deodorization
Edible oil
The fields highlighted in the dark colour represent the core business of GEA Westfalia Separator Group
6
Seed Beans
Animal
Pressing Extraction
feed
Acid degumming
Winterization
Bleaching
Edible oil
The fields highlighted in the dark colour represent the core business of GEA Westfalia Separator Group
Physical Refining
7
Clarification of Press Oil
Continuous Economic
The oil which is discharged from expeller presses As a side effect of adding water, any phosphatides
has various solid content levels depending on the oil which are present are hydrated; these are then
seed type and the condition of the press. In order removed together with the solids.
to remove particularly large solid particles, the oil is
usually fed into a settling tank, which is also used In order to avoid oil losses, the solids are returned to
simultaneously as a buffer tank. In some installations, the press. The purified oil is either processed directly
a vibrating screen is used for precleaning, or the oil or, if it is stored or sold, it should be dried in a vacuum.
is taken directly from the press to the press oil clari-
fication unit. Many features for your benefit
Continuous solids separation
In order to support the separation process, the Low cost of automation
solids are wetted with hot water. A water quantity of Lower space requirement
1 percent in relation to the oil quantity is normally Simultaneous degumming
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 continu-
ously separates the solids from the oil.
Seed
Press cake
Press oil
Foots
recycle
Decanter
Screening tank
Cleaned Solids
crude oil
8
Water Degumming
Degumming
A smooth action pump is used for conveying the is a valuable side-product, which is used as an emulsi-
crude oil to a heat exchanger, which is used for heat- fier, e. g. in the food, animal feed, pharmaceutical and
ing the crude oil to the optimum process temperature. cosmetics industries.
A quantity of hot water corresponding to the con-
tent of phosphatides in the crude oil is added to the The degummed oil is either conveyed directly to the
oil and mixed intensively. A special dynamic mixer, refining stage, or it has to be dried in a vacuum if it
which simultaneously conveys the oil directly to the is stored or sold.
separator, is used for this purpose. The hydratable
phosphatides swell immediately due to the particu- Many features for your benefit
larly intensive mixing of oil and water, and no addi- Lecithin recovery
tional reaction time is necessary. Reduction of losses in the following
refining stages
A separator is used to continuously separate the phos- Prevention of tank bottoms in storage tanks
phatides 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
Vacuum
Sludge
Crude
oil
Degummed
Mixer Gums Separator oil
9
Simple Acid Degumming
Degumming
This degumming method is suitable for pretreating The heavy phase which contains phosphatides,
palm oil, palm kernel oil, coconut and olive oil as well proteins, pigments and other impurities is then
as animal fats with the aim of reducing bleaching separated. The oil which is treated in this way is
earth consumption in the physical refining process. generally sent directly to the bleaching stage and
This considerably improves the economy of this deacidified by means of distillation.
method.
Many features for your benefit
The crude oil is initially heated to the optimum Reduction of bleaching earth consumption
process temperature in a heat exchanger. A metering Better end product quality
unit is used for adding a small quantity of phosphoric Less fouling of downstream equipment
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.
10
Vacuum
Steam Acid Hot water
Holding Holding
tank tank Vacuum
dryer
Sludge
11
Steam Acid Lye Hot water
Holding Holding
tank tank Sludge
Crude oil
Mixer Mixer Gums Separator
Special Degumming
Degumming
This degumming method can be carried out with an appropriate reaction time, some of this acid is
slightly modified neutralization lines. Depending on neutralized with very dilute caustic soda and sufficient
the quality of the crude oil, it is possible to decide water is simultaneously added for hydration of the
whether the oil can be refined by chemical or physical phosphatides. The caustic and water are also mixed
means. However, with respect to the residual gum together with the oil in the next centrifugal mixer.
content, it is necessary to accept a compromise in The mixer conveys the oil through a hydration reactor
comparison with the more demanding acid degum- to the next heat exchanger, which heats the product
ming methods described in the following. to the corresponding separation temperature. Phase
separation then takes place in a separator to produce
The crude or water-degummed oil is initially heated gums and oil. The residual phosphatide content which
to the optimum hydration temperature. A small can be achieved in this way may be adequate for
amount of phosphoric or citric acid is then added some applications. In most cases, however, further
and intensively mixed in the centrifugal mixer. After reduction is recommended by means of washing the
12
Hot water Vacuum
Vacuum
dryer
Sludge
13
Super-/Uni-Degumming
Degumming
14
Cooling Steam
water Hot water
Hydration
tank
Sludge
Steam Vacuum
Vacuum
dryer
Gums
15
TOP-Degumming
Degumming
16
Lye Water Vacuum
Holding
tank
Vacuum
dryer
Mixer
Sludge Sludge
17
Standard Neutralization
Neutralization
This method is suitable for neutralizing predegum- A second caustic treatment of the neutral oils is only
med edible oils or oils which originally only have advisable in exceptional cases. This mainly applies
a low phosphatide content. The free fatty acids are to cottonseed oil, in order to remove most of the
saponified with caustic soda, and the sodium soap gossypol. This oil should always be neutralized in
is separated. 3-stage installations.
The oil is initially heated to the optimum process Depending on the subsequent bleaching method, the
temperature. In order to condition the non-hydratable neutralized and washed oil is subsequently vacuum-
phosphatides, a small quantity of concentrated phos- dried.
phoric acid is added and intensively mixed with the
oil. Following a brief reaction time, dilute caustic Many features for your benefit
soda is added in order to neutralize the free fatty Very reliable process, e. g. for poor-quality
acid and the phosphoric acid. After mixing with the crude oils
oil, the mixture is either conveyed directly to the High product quality guaranteed
first separator or it passes through a further reaction All oils can be processed
tank. The latter is recommended only for oils with
a relatively high phosphatide content. Self-cleaning
separators are mostly used for separating the sodium
Conditioning Neutralization
soap. However, the residual soap content in the
neutral oil is still too high for the subsequent process
Steam Acid Lye
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.
Holding
tank
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
Crude oil
water with citric or phosphoric acid. Mixer
Washing or re-refining
18
Sludge
Hot water
Vacuum
dryer
Sludge Sludge
Neutralized oil
Mixer Wash water Separator
Washing Drying
19
Neutralization of Undegummed Oils
Neutralization
This method has become established mainly in retention mixers, the oil is heated and added directly
the USA for refining soybean oil. The process is a to the first separator in order to separate the soap-
combination of degumming and neutralization. stock.
For conditioning the non-hydratable phosphatides, a The neutral oil is washed in order to further reduce
small quantity of phosphoric or citric acid is added to the residual soap content. For this purpose, a certain
the crude undegummed oil. In some cases, the acid is quantity of hot water is added to the oil, mixed in a
added in the feed tank with an agitator upstream of centrifuge and separated into wash water and oil in a
the installation; several hours reaction time must be separator. The residual humidity of the oil is further
taken into consideration. However, a more effective reduced in a vacuum drier.
method is to add the acid upstream of a centrifugal
mixer. The intensive mixing enables the reaction time Many features for your benefit
to be reduced to a few minutes. Dilute caustic soda is Prior water degumming not necessary
then added in order to neutralize the free fatty acids. Good end product quality
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
Holding
tank
Sludge Sludge
Crude oil
(conditioned
with acid)
Mixer Soapstock Separator Mixer Wash water Separator
20
Miscella Refining
Neutralization
Vacuum
Steam Acid Lye
Holding Holding
tank tank
Vacuum
dryer
Neutralized
Miscella
Sludge
Miscella
Mixer Mixer Soapstock Separator
Neutralized oil
21
Wet Dewaxing
Winterization
Some vegetable oils, such as sunflower or corn oil, acids are then neutralized with caustic soda. After the
contain waxes (long-chained fatty alcohols or fatty soapstock is separated in the first separator, the oil is
acid esters), which crystallize at lower temperatures conveyed to the actual winterizing stage.
and result in turbidity in the oil. Wet winterization A small quantity of caustic soda is again added in
in combination with neutralization is suitable for order to set a specific residual soap content in the oil.
removing these waxes. This soap is subsequently required as a wetting agent
during crystallization in order to bind the waxes to
The crude oil is initially neutralized (see under water. After mixing of caustic and oil, the product is
neutralization). This means that, in order to condition cooled to the crystallization temperature. Wax crystals
the gums, an acid is initially added and the free fatty form in two to four crystallization tanks connected in
Holding
tank
Sludge
Crude oil
Mixer
Mixer Mixer Soapstock Separator
Hot water
22
series. Due to the soap in the oil, these wax crystals Many features for your benefit
bind to the water, which is added to the crystallizers. Integration of winterizing in neutralization
In order to reduce the viscosity, the oil is carefully Fully continuous operation
heated and conveyed to a separator which continuously Removal of very high wax amounts possible
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.
Vacuum
Steam
Hot water
Vacuum
dryer
Sludge Sludge
Cooling
Wax Separator Wash water Separator
water Neutralized and
winterized oil
Water
Chilled
water
Crystallizer
23
Cold Refining
Winterization
This process is an alternative to winterization pre- The oil is gently heated to reduce the viscosity before
ceded by neutralization. However, use of the process the soapstock is separated in a centrifuge along
is confined to oils with a relatively low FFA content with the waxes. The dewaxed neutral oil has to be
as the oil losses are otherwise too high. Sunflower washed to reduce the soap content. It is first heated,
oil is therefore an ideal product for this application. the required wash water quantity is added and, after
thorough mixing with the oil, it is separated again
A small amount of acid is added to the crude oil in a second centrifuge. Finally, the oil is dried in a
without prior heating. After thorough mixing and vacuum dryer.
a short retention time the oil is cooled. The caustic
quantity required for neutralizing the free fatty acids Many features for your benefit
is admixed with the oil. The oil then flows through Compact installation
crystallizers with a residence time of several hours. Effective wax removal
Holding
tank
Sludge
Crude oil Mixer Chilled Mixer Crystallizer Hot water Soapstock/ Separator
water wax
Vacuum
dryer
Sludge
24
Polishing Filtration
Winterization
The wet winterizing method described above does The major advantage is that much less filter aid is
not guarantee that 100 percent of all waxes are always used and longer filter cycles are achieved.
removed. If particularly strict process guarantees are
applicable, additional polishing filtration is necessary Many features for your benefit
for cold-stable oils; this process is carried out either Minimizing consumption of filter aids
after bleaching or after deodorizing. Higher filtration speed
Longer filter cycles
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.
Pressure
leaf filter
Winterized
oil
Filter aid
Crystallizer
Bleached
or deodorized oil
Pre-coating Pre-coating
pump and
body feed tank
Mixer
Filter aid
Chilled
slurry pump
water
25
Dry Fractionation
Fractionation
26
Oil Olein
M Steam
Heating /
cooling
Heating / Melting
cooling vessel
Stearin
Crystallizer Condensate
27
Soapstock Splitting
Processing of by-products
During the chemical neutralization of oils and fats, and the neutral oil in the soapstock saponify. After
so-called soapstock (sodium soaps of the free fatty saponification, dilution water can be added in an
acids) is obtained as a by-product. This can be split intermediate tank before the soapstock is conveyed
into fatty acids and water by means of acidification to the actual splitting process. In the splitting tank, the
with strong acids (sulphuric or hydrochloric acid). pH value is reduced by adding a strong acid. The
Fatty acids are a valuable product in the animal feed, soapstock breaks down into fatty acid and water, which
soap and oleochemical industries. are then separated continuously in a static decanting
vessel. The split fatty acid can be directly processed.
The phosphatides, separated together with the The acid water is conveyed to a fat separator with an
sodium soaps during the neutralization process, upstream flotation chamber. The de-fatted water is
frequently have a significant effect on the splitting subsequently neutralized with caustic soda.
process during the formation of stable emulsions
during phase separation. This can be prevented to a Many features for your benefit
large extent by means of secondary saponification. Fully continuous operation
For this purpose, the soapstock is exposed to higher Lower level of emulsion
temperatures and pressures. During a reaction time
under these conditions, part of the phosphatides
Intermediate
tank
Splitting
tank
Saponification column
Decanting
tank
Soapstock
28
Available Drives for Edible Oil Separators
Gear drive
The conventional drive concept of the separators is
the worm wheel gear, fluid clutch and standard motor
with direct switching. The toothing of the worm wheel
gear was optimized in order to reduce the noise level.
Direct drive
Direct drive is the intelligent simplification in
separation technology. Direct drive is used in appli-
cations where the upper limit for gear loads has
been reached or when belt drive is undesirable.
Direct drive separators drive with virtually lossfree
power transmission. Less energy consumption, lower
maintenance and space mean increased performance
for production.
29
Your Partner for Reliability, Budget Control and
Efficiency
30
This service philosophy should be understood as the Customer benefit orientated service product
overall common service understanding, supporting solutions from GEA Westfalia Separator Group
the values, vision, mission and strategy of the GEA Your maintenance needs and requirements can be
and the Business Unit GEA Mechanical Separation. drawn together from our comprehensive service
portfolio. Every individual service plays a vital role
The name serv&care combines two in securing the reliability, cost control and efficiency
aspects of the modern service world of your centrifugal equipment.
serv stands for service, meaning concrete actions to
help in any way to maintain your equipment. Whether The serv&care service products
it is for Spare Parts supply, assistance using our Spare Parts
excellent Field Service Engineers or our factory autho- for protecting your investments
rized comprehensive repairs, all are covering your Field Service always nearby waiting to assist
requirements. The main values of these services are you, 24 hours a day, 365 days a year
speed and quality. Our worldwide service network Repairs care, precision and responsibility
serves as a basis to allow us to fulfill your require- from the manufacturer
ment. GEA Westfalia Separator Group offers on-time Rental Bowls/Exchange Parts
delivery of spare parts through our logistic hubs, local keep downtimes to a minimum
stock levels and a global network of highly trained Upgrades/Modernization latest design parts
and experienced Field Service Engineers and also and components engineered specifically for your
having the specialized machinery in our Authorized machine
Workshops for comprehensive and safe repairs that Condition Monitoring reliable information
only we can provide. care stands for the driving for optimizing the installation availability and
force of our service organization to be an innovative avoiding unscheduled downtime
and reliable partner. Together with you we strive to Service Level Agreements
find optimum solutions that fulfill and exceed your service packages for higher availability together
expectations. We are not only servicing the equip- with full budget certainty
ment, we offer solutions that satisfy the central task Customer Training modern training
to increase the reliability of your equipment, operates approaches with the aim of dealing with your
efficient processes and ensure that you meet your own own practical situations
corporate mandates for total quality. Factory Rebuilt Machines used separators and
decanters in First-Class quality
Our motivation is to supply complete and timely Applied Consulting optimizing and adjusting
support that is one step ahead of your support operations with the latest technical knowledge
requirements. care-thinking is the basis of our
self-understanding as the market leader and being
recognized as your first choice service provider.
More information:
www.westfalia-separator.com/service/
original-manufacturer-service.html
31
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
B_RR-13-08-0033 EN
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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.
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
50countries. Founded in 1881, the company is one of the largest providers of innovative equipment and
process technology. GEA Group is listed in the STOXX Europe 600 Index.