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Alfa Laval in brief

Alfa Laval is a leading global provider of specialized products and engineered solutions. Our equipment, systems and services are dedicated to helping customers to optimize the performance of their processes. Time and time again.

We help our customers to heat, cool, separate and products such as , water, chemicals, beverages, foodstuffs, From fruit to - and beyond starch and pharmaceuticals. Solutions Our worldwide works closely with customers in almost 100 countries to help them Innovative, sustainable processing solutions for the stay ahead. that add value In response to challenges facing players in the competitive

palm oil milling, and modification industry, Alfa Laval has developed a range of innovative solutions that offer sustainable alternatives to traditional . The solutions have one thing in common – they add value.

PFT00521EN 1208 D3 PRO, Aldec, MBR, PAPX, PANX, VHE ECO, CompaBloc, SoftColumn, SoftColumn Dual-Strip, SoftFlex, TocoBoost, Iso-Mix, Iso-Mix, VHE ECO, CompaBloc, SoftColumn, SoftColumn Dual-Strip, SoftFlex, TocoBoost, PANX, D3 PRO, Aldec, MBR, PAPX, trademarks owned by Alfa Laval Corporate AB, Sweden. (AGT) are Treatment Ageratec and Advanced Glycerol and owned by Alfa Laval Corporate AB, Sweden. © 2012 Laval. Alfa Laval is a trademark registered

Palm oil processing 2 A versatile partner who Maximum uptime Global services thinks outside the box for your operation - close to you

Palm oil supply chain: The innovative Alfa Laval way to sustainable, high yield palm oil extraction, refining, fats modification and production t Wherever you are, Alfa Laval’s palm oil competence centres, offices and centres are never far away Micronutrients eatmen tion Enrichment processes tr ca erol erifi t yc st gl v. anse coBoos Ad Tr To Biodiesel distillation Oleochemicals uble scrubber D3 PRO all-in-one system Do tor Kuusankoski g tion r para SoftColumn Oil recovery Tumba Edmonton ry to Moscow ca ve th se Dual-Strip Heat recovery Kolding Lund Scarborough urifi para PFAD Copenhagen g /p er co ying l wi l Glinde re th se va tion of PFAD modifi cation Camberley Lodz tion & strippin tion Oil g, dr g Continuous deodorizing Lyon & Fontanil Dalian Carter Lake Indianapolis za ion & pressing ca cant in ltra Breda & Waalwijk st wi at fi t Monza Wuhan Shenyang Bangkok Greenwood Richmond uit handlin erili ge th de He tion Madrid Istanbul Chesapeake Fr St Di Clarifi Gum remo (Pre)- ca Poseung & coolin ifi New Delhi Houston Pressed wi degummed oi BPO Vacuum effl uent reduction with RBDPO treatmen er Qatar Shanghai Osaka CPO Degumming Bleaching st Lahore Hat Yai Fruit preparation palm oil Clarifi cation BPKO RBDPKO erol Jubail Hongkong cooling, chilling or ice condensing yc anse Yanbu Pune Kolkata Medan Kuala Lumpur Sandakan Mexico City gl Tr Dubai v. Mumbai Vizag Kaohsiung Bintulu Panama Ad Hyderabad Singapore r Bangalore Pontianak Caracas ze Chennai Pekanbaru Bogota r er Less spent Semi-continuous deodorizing Speciality fats Benjarmasin sterili to nt R cant fl ue bleaching earth Fats modifi cation Modifi ed Lima para mbrane SoftFlex Heat recovery Jakarta ry fromth se th de fi nal ef ors - MB n n ve th me with structured packing io io tion Townsville Sâo Paulo co te wi ring wi at at ca re sa ng wi erifi Johannesburg Oil en Anaerobicwate sludge action Perth Santiago de Aerobic Fr drogen rest Buenos Aires cond Hy te Sydney polishi In Melbourne Hamilton bioreact

Regional offices Parts & service centres Competence centres centres traction Crushing Ex CPO/CPKO: Crude palm oil/crude oil Kernel processing CPKO Bleaching BPO/BPKO: Bleached palm oil/bleached Challenge: Maximum uptime while Our distribution centres for spare Performance Agreements RBDPO/RBDPKO: Refi ned, bleached, deodorized palm oil/palm kernel oil Heat recovery constantly improving your processes parts ensure short delivery times. Our individually tailored service PFAD: Palm fatty acid distillate Downtime is a costly business. packages can include everything from To keep your operation up and We take care of your service needs basic maintenance to complete process running, a professional partner at our workshops or at your . Call optimization. Alfa Laval keeps of Your challenges are our inspiration takes care of your processing needs Our well-proven, energy efficient Your versatile solutions provider or optimizing processes in an existing If it’s a complete we take with the know-how to service your us 24/7 for technical assistance or the condition of your equipment, and Demand for palm oil and palm kernel – from milling and refining to fats solutions with capacities from pilot At Alfa Laval, we are both process one, we offer customized solutions that responsibility for the overall solution. equipment and systems plus a reliable a visit by a field service engineer. all services are planned in advance. oil is constantly increasing due to modification, from by-products and scale to 3,000 t/d and beyond enable engineers and equipment designers. benefit both your bottom line and the supply of spare parts are essential. Our services include system trouble their excellent nutritional and other related processes through to end- sustainable production of first-quality Our complete process lines are environment. shooting, retrofits, balancing of A Performance Agreement gives properties. To achieve growth in products. As specialists in centrifugal palm oil with lowest operating costs. engineered around our own well-proven Solution: 24/7 service decanters and separator bowls, you true peace of mind and full production it is essential to find new, separation, heat transfer and fluid Since they ensure highest yield with equipment, giving you the best possible Alfa Laval is much more than an Alfa Laval’s Parts & Service staff helps repairs, hands-on staff training, control over your service budget. more efficient ways to increase yield handling, we lead the way with lowest effluent discharge, you get the performance. They are modularized equipment supplier. We handle optimize and keep your operations and site . Let us handle the practicalities while and minimize negative impact on innovative, sustainable process most from the , which also and thus offer a high degree of flexibility , and turnkey on-line throughout the lifetime of you focus on your business. the environment. solutions that set new standards in benefits the environment. compared to all-in-one . deliveries. During project execution the equipment. To minimize downtime in your factory the industry. On the following pages we offer supervision of mechanical we provide spare conveyors and Leading the way you will find examples of our latest We think outside the box, finding new and electrical installation , Our service facilities for palm oil are rotating assemblies that you can use With palm oil know-how and experience . solutions to your process challenges. commissioning, testing and training of situated close to the main palm oil while your decanters and separators gained since the 1960’s, Alfa Laval Whether it’s a new plant, or upgrading your operational and maintenance staff. growing regions of the world. are being serviced.

2.a Palm oil processing 2.b Palm oil processing Palm oil processing 3 Crude palm oil with maximum yield D3 PRO in action

Alfa Laval’s D3 PRO combined clarification, purification and oil recovery process has been adopted by numerous crude palm oil mills across the world. Photo left: Since 2009 a D3 PRO process incorporating 3-phase decanters has been clarifying and purifying crude palm oil at a Malaysian with a total capacity of 80 tons FFB/h.

Milling

For decades Alfa Laval has provided D3 PRO process with 3-phase clarification/purification and oil recovery Larger scale production – with less Our self-cleaning separators can handle palm oil mills with efficient equipment water, energy and effluent up to 18 m3/h of feed in the mill. Light phase to convert sterilized and pressed palm Palm oil mills and refineries are fruit into crude oil, playing a key part increasing in size to meet the growing Separators for refining are available with in shaping the design of today’s Vacuum dryer demand in the world market. Hence, capacities of up to 85 m3/h. clarification room. Pure oil heater high capacity, high yield and energy

Clarification/purification efficient equipment is needed. Our latest decanter technology for Challenge: To achieve maximum 3-phase decanter clarification and purification can handle yield in a sustainable process Alfa Laval has therefore extended its a mill throughput of up to 90 tons fresh

A growing number of industry players Pressed oil Heavy phase portfolio with new, very large and fruit bunches (FFB) per hour, and are now calling for a process that can Discharged CPO to innovative separators and decanters. enables significantly reduced effluents Sand cyclones storage tanks recover more crude palm oil, minimize Vibrating screen and lower energy consumption. costs and optimize yield. It should also Oil recovery be simple to operate and sustainable. Oil tank Pure oil cooler Discharged effluent

Nozzle separator Solution: D3 PRO, all-in-one Large capacity separators for the palm oil mill

clarification/purification 18 PASX 710 The Alfa Laval D3 PRO process is a The “ready to go” light phase oil can other income sources. In the D3 PRO Energy efficient drying and cooling 16 combined 3-phase clarification/purifi- be sent directly to the vacuum dryer for process, oil from the heavy phase Centrifugal separation alone will PAPX 10 14 cation and oil recovery solution. It offers final moisture removal before refining can be further recovered using a not produce an oil sufficiently dry 12 /h a profitable alternative to traditional with no need for purification. nozzle separator. to be stored or to meet standard 3 PAPX 307 10 settling tank technology that requires This not only saves on equipment specifications from industry huge continuous clarification tanks for and maintenance, it also ensures Oil recovery associations like PORAM. The amount 8 Capacity, m Capacity, skimming pure oil and decanters/ consistent quality. from sterilizer condensate of dissolved water present in the 6 separators to recover oil from the Large amounts of water are used homogeneous oil phase depends on 4 underflow of the tank. D3 PRO can At the same time the cake and heavy during sterilizing and pressing of palm the amount of free fatty acid (FFA) in the 2 be configured as an automated system phase oil are separated and can be fruit. With an Alfa Laval nozzle separator oil and the temperature. The Alfa Laval 0 Purifier Nozzle separators for oil recovery, sterilizer capable of operating 24 hours a day, treated differently. The cake can be the residual oil can be recovered from vacuum dryer system utilizes vacuum condensate and sludge water. with minimum maintenance or re-used, e.g. as to generate the sterilizer condensate effluent. to create a potential for the water to go supervision. over into the vapour phase. Large capacity decanters for the palm oil mill

90 After de-sanding, the pressed palm oil D3 PRO – benefits With a temperature close to 90°C PANX 900 80 is fed to the 3-phase decanter. This is • Up to 30% reduction in water the oil leaving the dryer is more PANX 650 capable of high capacity separation consumption and effluent sensitive to oxidation and should 70 PANX 600 with no need for dilution water, which • Maximum oil recovery, higher be cooled before storage. An 60 50 means much less effluent for smaller, yield and profit Alfa Laval Plate Heat Exchanger is PANX 500 40 more manageable ponds. • Consistent separation and oil ideally suitable for cooling as well as PANX 934 PANX 350 quality – no unnecessarily long pre-heating before drying. An even 30 Capacity, tons FFB/h tons Capacity, holding time and exposure more energy-efficient solution is 20

to oxidation. heat recovery provided by an extra 10

economizer – the capital cost is often 0 recouped in a few months. The Alfa Laval PANX range of high performance 3-phase decanters for palm oil clarification and purification offers capacities from 30 to approx. 90 tons FFB/h.

4 Palm oil processing Palm oil processing 5 Efficient effluent treatment Up to 90% solids removed

An Aldec G2 decanter is used to dewater palm oil mill effluent (POME) and removes solids from the anaerobic ponds at an 80 t FFB/h palm oil mill in Malaysia. Thanks to automatic torque control, the decanter is able to deliver a consistent cake dryness.

Effluent treatment

Challenge: To reduce De-sludging of anaerobic ponds with a decanter and aerobic final effluent polishing with membrane bioreactors (MBR) effluent discharge from mills The use of anaerobic digestion as MBR a first-stage treatment of palm oil Recirculated biomass membrane effluent results in a gradual Settling & Final effluent accumulation of organic matter Raw effluent Cooling pond Anaerobic Dewatering by Decanter Aerobic ponds facultative that silts up the ponds. This makes from palm oil mill pond centrate pond Fish pond it difficult to achieve the desired, increasingly stringent discharge parameters. Submerged Cake membrane tank

Solution: Sludge dewatering using decanters Alfa Laval and supplies ‘Plug-and-play’ module bio-degradable chemicals. Removing Challenge: Meeting final effluent solutions based on decanters for The complete waste decanter module the solids decreases the organic discharge parameters dewatering palm oil mill effluent (POME) is equipped with a feed pump and loadings in the ponds, substan- Increasingly stringent final discharge and de-sludging of anaerobic ponds. a polymer dosing system. It can be tially reducing the biochemical parameters stipulated by local Alfa Laval’s membrane filtration unit commissioned quickly and easily demand (BOD) which, in turn, reduces environmental regulations are combines the best features from flat The latest decanter technology for on-site. silting. The module offers continuous posing problems for many palm oil sheet and hollow fibre membrane effluent dewatering, Aldec G2, has a operation with minimum supervision. mills. Continuously adding effluent into one solution with a completely new designation: new liquid outlet design that provides Located near the effluent ponds, ponds is not a sustainable solution. “Hollow sheet”. energy savings of up to 30% compared the decanter removes up to 90% of with its predecessor. the solids present by the addition of Solution: Effluent polishing with a Membrane Bioreactor (MBR) Membrane Bioreactors are a very passage of clean water, while trapping effective way to treat the effluent, and suspended solids, bacteria, pathogens to ensure correct discharge values and some viruses. The treatment is MBR – benefits before it is discharged to the water- sufficient to produce a permeate quality • Maximum BOD reduction and way or re-used. It is one of the most that is low in BOD and total solids. operation at high concentrations advanced technologies within municipal of mixed and industrial wastewater treatment. Saves space and costs • Complete retention of biomass The MBR process supports a high • Small footprint Decanters for sludge dewatering An Alfa Laval membrane filtration unit biomass concentration and increases • Low maintenance requirements – benefits can be added to existing settling ponds the removal of organic matter, thus • Automatic control of the • Energy savings of up to 30% for polishing of final effluent. Or it can reducing the size of biological tanks whole system • Solids removal of up to 90% be installed in a new plant and run as needed. This, together with a small • The membrane unit can be • Raises pond “performance” a MBR, where ponds are not needed, footprint, reduces overall construction integrated in the bioreactor, or • Modular design. as the MBR is a simple yet effective cost. The MBR process has low energy used to treat a side-stream from combination of an activated sludge requirements, and does not require high the bioreactors. biological treatment process and chemical consumption or high pressure. Mill effluent (left) before dewatering in a decanter. This separates it into 10% cake (middle), membrane filtration. The membranes which can be used as fertilizer, and 90% liquid centrate (right), that can be further polished to meet final effluent discharge parameters. act as a physical barrier, allowing the

6 Palm oil processing Palm oil processing 7 Patum

Since 1985 Patum Vegetable Oil, one of Thailand’s largest producers of edible palm oil and biodiesel, has used Alfa Laval equipment to upgrade and extend its first physical refining plant for improved quality and reduced energy consumption. In 2012 a completely new 1,500 t/d refinery was put into operation, comprising the latest Alfa Laval innovations: Gums removal with high speed separator and pre-filtration prior to bleaching, plus all the newest features in continuous deodorization, such as flexible retention time, double scrubber, chilled water closed loop, VHE economizer (under vacuum and stripping) and Compabloc plate heat exchangers.

Refining - Degumming and bleaching Heat recovery

Gum removal with separator and bleaching with pre-filtration Vacuum Bleaching Activated Challenge: Maximum heat recovery Solution 2: Pressurized economizing High speed earth carbon Cake drying Efficient economizing, utilizing heat from Some choose to conduct the Acid Retention mixer separator Day tank cooling one fluid to heat another fluid, economizing under pressure, a Acid mixer Pressure leaf Pressure leaf filter (main) filter (pre-filter) benefits overall process economy and more cost-efficient solution than using Steam Economizer Steam Steam reduces the plant’s carbon footprint vacuum. The duty in VHE ECO is due to reductions in the use of steam partially or fully replaced by an for heating, plus cooling water. economizer type where a hot pump Refined Bleaching Steam palm oil reactor The refinery process configuration provides pressure which is utilized to Gums Start-up heater Spent Spent determines how the optimal create efficient turbulence on the hot bleaching earth bleaching earth Condensate economizing should be conducted, side, thus enhancing the heat transfer. VHE Economizer with single deck. Refined palm oil Filtered, bleached palm oil and which equipment to use. and double deck. Economizer For this, Alfa Laval offers various types Crude oil Typically, the pre-filtration concept requires 3 filters, which change duties between acting as Solution 1: VHE Economizer of heat exchangers including plate, Refined palm oil main filter, pre-filter and regeneration/stand-by. For simplicity, only 2 filters are shown. for cooling under vacuum spiral, fusion-bonded and compact Some refiners prefer cooling under heavy duty. Each equipment type has Challenge: Reduce use of bleaching The reduced gum load to the bleacher possible to pre-filter the full oil flow, vacuum. Alfa Laval’s patented Vacuum its own characteristics regarding earth, oil loss, waste and MCPD enables less dosing of bleaching further reducing the bleaching earth Heat Exchanger Economizer (VHE ECO) efficiency, resistance to fouling, Traditional removal of gum, colour earth, and further increases final oil consumption. has for many years set the standard for resistance to thermal fatigue etc. and solid impurities from quality. Gums can be mixed with spent economizing in deodorization, where Our specialists advise you regarding crude oil using acid and bleaching bleaching earth or recycled upstream Mitigation of MCPD formation the cooling is conducted while stripping the best choice for your specific earth followed by filtration results in to the mill. A positive side effect of wet degumming the oil in a shallow vacuum tray. application. large amounts of spent bleaching earth with a separator is significantly reduced containing a lot of non-recoverable oil. Pre-filtration of acid-treated oil through content of chlorine compounds, that Our conventional VHE Eco is a double an already used filter before bleaching during deodorization can contribute deck construction which facilitates Solution: Gum removal with a is normally not viable as filter blocking, to the formation of the undesired very shallow liquid height during the separator and pre-filtration mainly by gum, allows only a small contaminants MCPD (monochloro- joint cooling/stripping. To meet the To minimize waste and oil loss, fraction of the oil to be pre-filtered. propanediol) compounds and demand for cost-effective processing, Alfa Laval recommends using an Gum separation now makes it esters thereof. we have designed a single deck energy-efficient high-speed separator to version, suitable for palm oil remove precipitated gum before Performance of different bleaching modes economizing at high capacities. the bleacher. 100 Spiral heat CompaBloc 90 Conventional acid exchanger. conditioning/bleaching compact heavy 80 Benefits Gum removal with separator duty heat 70 • Up to 15% less bleaching earth prior to bleaching exchanger. 60 • Oil loss reduction Combined gum removal 50 and pre-filtration • Can handle a wide range

Index 40 of gums 30 • Significant reduction of MCPD. 20 Actual consumption and oil loss depends on quality of 10 100% 92% 85% 100% 95% 88% crude palm oil, bleaching 0 earth and end specifications. Bleaching earth dosing Oil loss in cake and gum

8 Palm oil processing Palm oil processing 9 Comparison of consumption and effluent for different vacuum solutions

2,500 Dirty cooling tower 32°/37°C

Chilled water 4°/9°C 2,000 New trend in deodorization Partners in Water cooled screw R134a chiller Ice condensing -30°C 1,500 Water cooled NH3-refrigerator Reduction of vacuum 2454 Since 1989 when Suksomboon, Thailand, decided to expand from 2200 to downstream processing, Alfa Laval has been their chosen technical partner. effluent 1,000 Total cost of , flexibility and our ability to implement their ideas were 1029 500 775 key to the owners. Today, the palm oil complex includes refining (900 t/d), dry Steam consumption for the deodorizer’s vacuum 514 310 340 173 55 295 190 240 fractionation and for edible oil, olein, hard stearin and biodiesel. system and amount of vacuum effluent can be more 0 They were the first to adopt our new deodorization concept with post-stripping than halved using chilled water. Ice condensing Effluent (kg/h) Motive steam (kg/h) El power (kW) Cooling water (m3/h) Consumption figures for 1,000 t/day deodorizer. Vacuum system based on steam ejectors. (Dual-Strip) and an Iso-Mix rotary jet head for crystallizer cleaning. can further cut these by up to 85%. Data: Courtesy of Körting Hannover AG

Refining - Deodorization

Deodorization is a crucial part of all Challenge: Cost-effective continuous The retention is conducted in stacked Solution 3: retention section, while the post- Challenge: Physical refining with Reduction of vacuum effluent edible oil processing. Alfa Laval offers deacidification/deodorization baffle trays with continuous overflow. SoftColumn Dual-Strip for stripping removes all volatiles frequent stock changes The deodorizer’s vacuum system a variety of solutions for combined Removal of odours, pigments and high-capacity, mono-stock produced during the retention section. Minimizing cross-contamination in its standard configuration, i.e., Any existing continuous deacidification/deodorization in both volatile substances in a continuous Solution 2: Offering higher capacity with lower deodorizer can be retrofitted between batches and achieving lowest a 4-stage steam ejector system continuous and semi-continuous mode deodorization process should be as SoftColumn for flexible operation costs, our latest innovation SoftColumn The Dual-Strip concept enables to Alfa Laval’s SoftColumn possible operating costs. served by tower cooling water, with minimum stripping steam and the gentle and energy-efficient as possible. This flexible continuous deacidification/ Dual-Strip is a cost-effective economizing under pressure as well Dual-Strip process, reusing produces significant amounts of the old deodorizer as highest degree of heat recovery. deodorization solution addresses continuous deodorization solution as higher liquid height in the retention retention section (left), Solution: effluent slightly contaminated with Alfa Laval’s well-proven modular different end applications with minimum with post-stripping. trays. These offer both capital and supplemented by SoftFlex semi-continuous process organic matter. Alfa Laval offers concepts for continuous deodorization, utilities consumption. Oil retention is operational cost savings while new Dual-Strip The patented Alfa Laval SoftFlex a number of options, which can with heating and cooling under vacuum conducted batch-wise with transfer The Dual-Strip plant divides the maintaining high product quality. column (middle) semi-continuous deacidification and significantly reduce the amount of and VHE final in separate vessels, offer a high degree between trays by Alfa Laval’s patented stripping action into a pre-stripping heater (right). deodorization technology comprises a vacuum effluent. of flexibility compared to all-in-one Fast Draining Valve. The concept section and a post-stripping section The post-stripper also allows higher structured packing section inside the solutions. The structured packing offers flexible retention time over a (with the retention section in between). capacity in a certain diameter vessel. batch-wise flow mode. Stripping steam Closed loop cooling based on counter-current thin-film wide range, and is thus suitable for The pre-stripping removes most of the It is therefore especially suitable for injected to the other trays is reused in A closed loop cooling system can technology ensures that stripping steam processing different oil types or oil for volatiles in the feed before entering the extremely large capacities (more than the structured packing, thus lowering be installed, thus avoiding operating consumption and, thus, vacuum costs different applications. SoftColumn can 3,000 t/d), where the required vessel the steam consumption by 30-40%. a “dirty” cooling tower. are minimized. It has therefore become handle 2-3 stock changes per day. diameter (using single stripping) can the standard in the vegetable oil industry. no longer be transported but has to Economizing has been improved by Chilled water Vacuum be manufactured at the site. using our patented U-tube design for Using chilled water as a substitute Vapour Solution 1: the heat transfer areas. It provides up to for tower water in combination with Packed Column VHE final 30% higher heat transfer area in same a closed loop cooling system will heater Steam This continuous deacidification/ Steam space, resulting in less final heating reduce the effluent production by deodorization solution offers high requirement by high pressure steam. about 60%. The colder water used Double Distillate Fuel scrubber product quality while consuming a Retention tank for condensing reduces the com- section minimum of utilities. Alfa Laval was the High-pressure Batch transfer between trays is done by pression required before condens- first to introduce structured packaging steam boiler the same unique Fast Draining Valve as ing, which can be accomplished by technology as a standard part of the Condensate Pre- is used in the SoftColumn design. a single steam ejector (2 ejectors in stripper Water physical refining concept. SoftColumn Dual-Strip Bleached series are required for tower water). Distillate cooler continuous deacidification/ oil or fatty Steam acid Water deodorization for high capacity. Start-up distillate Ice condensing heater Vapour Condensate Freeze condensers can eliminate Recovered oil Vacuum the need for compression of the Post- High purity PFAD SoftColumn Dual-Strip benefits stripper SoftFlex benefits process vapour before condensing. Bleached oil Steam • Enables production of oil • Fast, automated stock changes with less FFA (free fatty acids) Tank Dual-Strip column with no loss of production time Alfa Laval offers solutions where compared to standard Economizer combined with double scrubber • Minimum cross-contamination the process vapour is cooled and deodorization technologies between batches solidified either via an ammonia • Lower energy consumption • Reduced energy consumption or glycol loop, chilled by Polishing filter • Improved oil quality. Water and lower fuel costs. refrigeration plant.

Water Refined, bleached, deodorized oil To/from crude palm oil economizer Final cooler

10 Palm oil processing Palm oil processing 11 Palm oil processing 11.a Move up the value chain World’s largest refinery Beyond Yield up, waste down When , the largest global processor of palm and lauric Natural palm oil E-vitamins, tocotrienols and tocopherols, typically used in oils, chose Alfa Laval solutions for its Pelintung 6,000 t/d refinery in Indonesia, PT Royal in Indonesia, an international supplier of edible oils and fats, replaced dietary supplements, health and beauty products, have high market prices. quality, safety, reliability and operating costs were in focus. In the bleaching their old inefficient refinery equipment with a new 500 t/d refinery for palm oil Scientific studies show that tocotrienols, only available in high concentrates and continuous deodorization plant spiral heat exchangers ensure maximum and palm kernel oil in 2008 with Alfa Laval bleaching and continuous deodorization in palm oil, are far more potent than tocopherols and have a heat recovery and product yield. A double scrubber reduces oil losses in plant. The results are higher yield, improved quality and a reduced wastage level. beneficial effect on a variety of medical conditions. deacidification by about 50%. In 2010 they added dry fractionation to produce oil.

Enriched product stream Fats modification

Concentration of PFAD tocotrienols with TocoBoost Reap the added value from PFAD Challenge: To add maximum value to Iso-Mix rotary jet heads for This allows most of the RBD oil from Other fats modification Palm oil fatty acid distillate (PFAD) is Existing vacuum system the raw material faster, cheaper crystallizer washing the refinery to be pre-cooled externally processes enriched in unsaponifiable components Recirculation Many palm oil producers have extensive The traditional way of melting left-over before feeding it into the crystallizer. • Hydrogenation, hardening of such as , squalene and untapped resources in the form of crystals inside the crystallizer by filling This shortens the cycle time of each soft oils or fractions Steam Water sterols. The ongoing hunt for these Heater TocoBoost Cooler under-exploited feed stock. Adding it with hot oil is very time and energy crystallizer considerably, thus increas- • Post-refining: Post-bleaching value adding products has increased Condensate Water efficient fats modification processes can consuming. ing capacity by 10%. It also enables and deodorization of refiners’ interest in separating PFAD High purity PFAD open new doors for producers to offer the cooling tower water circuit and the hydrogenated oil and fats Steam in the deodorization section to Palm fatty acid Economizer more products, reach new customer Crystallizers can be cleaned in place chilled water closed circuit to be kept • Chemical or enzymatic distillate (PFAD) Reboiler extract micronutrients as a source Water Condensate groups and harvest greater revenue. much faster using the innovative fully separated, so coils will have a interesterification, an alternative of additional revenue. Cooler Alfa Laval Iso-Mix rotary jet head longer lifetime. And cooling costs can to partial hydrogenation to modify Alfa Laval offers several solutions to Water This strengthens your company’s technology. Installed inside the be reduced by approx. 15% due to oils and fats by rearranging the recover these in high concentrations. Concentrated tocotrienols capability to deal with the effects crystallizer unit, it enables all internal lower temperature using external plate molecules. It can be of seasonal demand and individual surfaces to be washed using hot oil heat exchanger with tower cooling used to produce healthy fats Double scrubbing for increased Concentration of tocotrienols • Separation of from market fluctuations. to melt away crystals left over from water before it is necessary to switch without the undesired trans-fats. oil yield and high FFA purity with TocoBoost the unsaponifiable fraction the previous batch. to expensive chilled water. Today it is quite common to recover To achieve highest concentrations of Contact us to learn more PFAD distillate using a double especially high value tocotrienols, • Separation of tocotrienols from Solution: Dry fractionation, a direct, Alfa Laval’s dry fractionation pilot plant in Malaysia is used to customize a solution to suit about these. customer requirements to different types of feedstock, and for R&D. scrubbing system, which produces Alfa Laval has developed the TocoBoost the fatty acid fraction. natural way to add value

higher purity PFAD compared to a technology (patent pending). It Alfa Laval provides several complete Alfa Laval’s Iso-Mix rotary conventional single scrubber. It is also combines a double scrubber with a Oleochemicals flexible solutions for fats modification. We design and specify the most Efficient crystallization and accurate jet heads can also be more efficient in preventing carryover of separation section, and includes: We can also provide other distillation One is fractionation, a direct, natural suitable key components, such as process control ensure good used for fast and efficient organic matter to the vacuum system. processes to turn PFAD into oleo- way to modify palm oil to ensure that crystallizers, membrane filters, pumps separation of the liquid and stearin melting and washing of left-over crystals inside chemicals like C12/14, C16 and C18. it acquires greater value. Fractionation and instruments to ensure a reliable phases, resulting in greater yields the fats modification Alfa Laval offers various scrubber types: with gentle cooling of oils or fats in an and efficient production. All the and higher profitability. system’s crystallizer. accurately controlled process makes equipment is practical and easy to • “Hot wash bed”: Once through it possible to crystallize the hard install, operate and maintain. The flexibility to expand is another washing (partial condensation) of the content. feature of the system. The modular vapours before full condensing in a Price levels at different toco concentrations Process options include slurry type for design makes it possible to increase cold scrubber. The Alfa Laval dry fractionation plant palm oil, cake fractionation for palm production capacity to keep pace with 25 14,000 enables you to vary production rapidly kernel oil and fractionation. demand, by adding more crystallizers • “Full loop hot scrubber” circulating and efficiently to meet changes in and extending filter capacity. 12,000 the high temperature distillate 20 your customers’ requirements and Efficient, flexible crystallization fraction to recover high value specifications. It consists of a Our crystallizers use best vessel 10,000 micronutrients as separate 15 crystallizer, filtration section and engineering design and highest quality product streams. cooling water circuit (usually both materials. We offer double coil, fin type, 8,000 $/ton evaporative cooling tower and a or vertical tube versions, depending Configuration and achievable 10 chilled water module). on customer requirements in terms of

Toco concentrationToco % 6,000 concentration levels of micronutrients fractionation task, batch size, cooling Example of a crystallizer in the PFAD depend on the refiner’s 5 >10% surface and layout. for dry fractionation. 4,000 objective and scrubber configuration plus conditions in the oil deodorizing 0.5% 3% 0 0 section. Single scrubber Double scrubber TocoBoost

11.b Palm oil processing 12 Palm oil processing Palm oil processing 13 From fruit to food - and beyond Continuous biodiesel plant

The state-owned petroleum company ALUR in Uruguay has purchased two Alfa Laval Ageratec plants: Stage 1 (B2) for 16,000 TPY and stage 2 (B5) for 55,000 TPY. The feedstock is RBD oil with a provision for re-commissioning to low grade .

End-products Biofuel

Discover new palm oil applications Alfa Laval’s dedicated palm oil teams Challenge: An AGT system gives the freedom to Oil from palm fruit and kernels is a see it as our mission to support the Food and food ingredients To replace edible high-cost raw select any appropriate output, and to wonderful source of food and a variety industry in making the most of the materials with alternative inedible sell the oil directly after upgrading. It of other essential everyday products potential of this unique, natural raw low-cost feedstocks, while delivers treated oil as mono- di- and that improve the quality of our lives. material – in the most feasible, Mayonnaise minimizing environmental footprint ready for mixing as heavy Its nutritional and health value plus profitable and sustainable way. In Sauce/dressing Biodiesel is typically produced by . It can also be traded as an other inherent properties have been close collaboration with upstream / oil conventional transesterification plants oleochemical, or forwarded to off-site recognized and exploited for centuries. and downstream players as well Filling fats employing water wash technology. biodiesel producers. New applications are still being as and scientists we Vegetable cheese These depend heavily on high-cost discovered. continuously develop new, innovative Vegetable whipped cream edible feedstocks, leaving them processing solutions that pave the way Coffee creamer vulnerable to the price-volatile Collaboration between all players for new applications and end-products. Infant milk formulas (mother’s spot market for edible oils while Ageratec continuous lines Refined and modified palm oil and palm milk substitute) accumulating considerable costs for – benefits kernel oil can be further processed in Tap into our decades of experience Ingredients in cocoa water recovery and biodiesel drying Solution 2: • Directly applicable for traditional, many different ways and turned into from thousands of vegetable oil equivalents (CBE) through distillation. Ageratec “multi-feedstock” refined feedstock a wide variety of end-products – for installations worldwide, and let us substitutes (CBS) technology for biodiesel batch • Attractive alternative to today’s nutritional as well as other purposes. move up your value chain together. Emulsifiers (ingredients in food Solution 1: processing lines elderly plant design and non-food) Ageratec “virgin oil” transesteri- Ageratec esterification batch plants • Savings in project development/ fication technology for continuous make it possible to produce biodiesel site assembly Non-food biodiesel processing with significantly less environmental Health care An Alfa Laval Ageratec transesteri- impact, close to feedstock supply or Ageratec batch processing lines Pharmaceuticals fication plant for diesel consumers. Intended for medi- - benefits is delivered as a compact prefabricated um-scale production, each complete • Enables use of feedstocks with and detergents process on skids. It incorporates process line includes acid esterification, up to 10% FFA tyres innovative approaches to total alkaline transesterification and our ener- • Front-end acid esterification for Biofuel. contamination, sterol glucosides, and gy and cost saving wash process. direct conversion of any free fatty Tocotrienols Squalene / Sterols Pharma filtration issues. Our patented biodiesel acids (FFA) into methyl esters. Carotenoid-enriched Functionalfood wash process using high-speed Solution 3: • Plant logistics free from water products Dietary separators avoids energy intensive Advanced Glycerol Treatment and effluent supplements distillation, cutting energy demand (AGT) pretreatment process for Speciality fats Modified RBD and cost of distillation to around 50% of oleochemicals AGT pretreatment process Confectionery / NBD palm oil Bulk oleochemicals Cosmetics conventional water intensive The AGT process allows practically any – benefits Soap / Coatings etc. transesterification technology. inedible low-quality fats, oils and • Adds significant value to existing RBD palm olein / Mid-fractions / Stearin of vegetable or animal origin to become “waste products”

Frying oils / Salad oils feedstock for producing biodiesel. • Enables the producer to move Margarine stock RB palm oil / PFAD treated for biodiesel The feedstock can be used inside an into new, high-value product existing transesterification plant which segments available within the Biofuel applications Crude palm oil / Crude palm kernel oil previously required virgin oil for a work- field of biorefining ing production set-up. Downstream, the • Reduces the environmental producer can tap off the “biorefined” impact of plant operations. oil at different stages of production and upgrading.

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