Slide 1: 3-MCPD and GE mitigation in palm oil processing
3-MCPD and GE mitigation in palm oil processing Alexey Shevchenko − Webinar 7 May 2020 07/05/2020 | © Alfa Laval 1 | www.alfalaval.com
Slide 2: Agenda
Agenda • A short introduction to Alfa Laval’s edible oil portfolio • Edible oil industry trends and focus • Introduction to the 3-MCPD and GE issues • 3-MCPD mitigation in more depth • Process routes to GE mitigation • Conclusion 07/05/2020 | © Alfa Laval 2 | www.alfalaval.com
Slide 3: Our edible oil process line portfolio
Our edible oil process line portfolio − Comprehensive solutions Biodiesel/HVO feedstock Crush and Clarify and Degum/ Bleach Deodorize Modify extract water degum neutralize/ Cooking oils dewax Modify by fractionation, Crude palm oil interesterification or Olive oil Bleaching (absorption) hydrogenatio
Slide 4: Industry trends
Industry trends 07/05/2020 | © Alfa Laval 4 | www.alfalaval.com
Slide 5: Industry trends and focus
Industry trends and focus − Shaping the future of margarine and shortening Population Industrial Health and Environmental growth margarine market wellness footprint Significant rise in vegan and More affordable, raw More health-conscious Focus on image, legislation vegetarian population plant-based
Slide 6: Introduction to 3-MCPD and GE issues
Introduction to 3-MCPD and GE issues 07/05/2020 | © Alfa Laval 6 | www.alfalaval.com
Slide 7: What are 3-MCPDE and GE?
What are 3-MCPDE and GE? • 3-monochloropropane diol (3-MCPD) • 3-monochloropropane diol ester (3-MCPDE) • Glycidyl ester (GE) 07/05/2020 | © Alfa Laval 7 | www.alfalaval.com
Slide 8: Why limit 3-MCPDE and GE exposure?
Why limit 3-MCPDE and GE exposure? Classified as process contaminants • 3-monochloropropane diol (3-MCPD) Possibly carcinogenic to humans1 • 3-monochloropropane diol ester (3-MCPDE) Harmful to kidneys (EFSA2 report 2016) • Glycidyl ester (GE) Probably carcinogenic to humans1 1 Classification by Inte
Slide 9: Glycidol and glycidyl ester
Glycidol and glycidyl ester Glycerol backbone 1 bonded fatty acid H H O H C O H H C O C CH3 H C H C O Epoxide ring O Epoxide ring formed at temp >220°C H C H C H H Glycidol Glycidyl ester (GE) 07/05/2020 | © Alfa Laval 9 | www.alfalaval.com
Slide 10: 3-MCPDE and GE have been around for decades
3-MCPDE and GE have been around for decades − But have gained more attention in recent years Known food contaminant in hydrolyzed vegetable proteins (HVP) and 1978 found in a wide range of daily food Glycidyl esters (GE) detected in palm oil but 3-MCPDs and GEs not 2008 found in virgin oils European
Slide 11: Reactions of glycidyl esters
Reactions of glycidyl esters Lipases + water Glycidyl esters Glycidol + fatty acids GEs are rapidly digested by gut lipases to form glycidol. Consequently, GEs should be considered as sources of glycidol exposure.1 1 Food Addit Contam Part A Chem Analytical Control Expo Risk Assess. 2013;30(1):69–79
Slide 12: EU legislation on GE affects supply chain
EU legislation on GE affects supply chain Glycidyl fatty acid esters expressed Maximum as glycidol level µg/kg Vegetable oils and fats placed on the market for the final consumer or for use as 1,000 an ingredient in food with the exception of 1.0 ppm the foods below Vegetable oils and fats destined
Slide 13: Malaysian Palm Oil Board licensing conditions
Malaysian Palm Oil Board licensing conditions − Effective 1 January 2021 Processed Processed Parameters Effective date palm kernel oil palm oil GE (max.) 1.0 ppm 1.0 ppm 1 January 2021 1 January 2021 until 2.5 ppm 31 December 2021 3-MCPDE (max.) 1.25 ppm 1.25 ppm* 1 January 2022 * Effective date for
Slide 14: Challenges in 3-MCPD/GE mitigation
Challenges in 3-MCPD/GE mitigation 07/05/2020 | © Alfa Laval 14 | www.alfalaval.com
Slide 15: Factors contributing to 3-MCPDE and GE formation
Factors contributing to 3-MCPDE and GE formation − Chloride and high temperature 3-MCPDE molecule • 3-MCPD and its esters are formed in heat-processed, fatty foods from glycerols or acylglycerides in the presence of chloride ions. Much of the 3-MCPDE found in foods is present as fatty acyl esters. •
Slide 16: Beware of GE migration into palm olein fractions
Beware of GE migration into palm olein fractions What happens in the dry fractionation process • RBD* palm oil GE = 0.6 ppm • Palm olein IV 56 GE = 0.75 ppm • Palm olein IV 64 GE = 0.9 ppm By regulation GE < 1 ppm GE suggested for RBD palm oil GE = 0.5 to 0.6 ppm * RBD = Refined, bleached and deodor
Slide 17: Process challenges
Process challenges − 3-MCPD and GE mitigations • Where and how to reduce chloride content to minimize 3-MCPD formation? • How to fit in 3-MCPD and GE mitigation into an existing site? • How to choose between the available GE mitigation options? • How to prepare for stricter regulations of the maximu
Slide 18: 3-MCPD mitigation
3-MCPD mitigation 07/05/2020 | © Alfa Laval 18 | www.alfalaval.com
Slide 19: Does chloride have a direct effect on 3-MCPDE levels?
Does chloride have a direct effect on 3-MCPDE levels? − Test conducted in refinery with different chloride levels 6 5 3-MCPD ester, mg/kg 4 3 2 1 0 0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Total chlorine content, mg/kg 07/05/2020 | © Alfa Laval 19 | www.alfalaval.com
Slide 20: Choosing the right mitigation method
Choosing the right mitigation method − Which method is best for you? Mitigation approaches • Reduce chlorine in fresh palm fruit bunches by changing fertilizers used Plantations • Reduce DAG in palm oil by ensuring milling within 48 hours – improve quality of crude palm oil • Wash fresh palm fruit b
Slide 21: Malaysian Palm Oil Board Circular
Malaysian Palm Oil Board Circular − 30 October 2019 Quality specifications for crude palm oil Level of total chloride in palm oil products Standard Average Range Specification Sample quality (ppm) (ppm) Free fatty acid (FFA) (as palmitic), % max. 5.0 2.623 to Crude palm oil 7.293 ± 5.988 Moistures a
Slide 22: Crude palm oil quality in different streams
Crude palm oil quality in different streams − Premium crude palm oil specification vs. oil from recovered streams Crude Condensate Empty fruit Quality palm oil oil bunch juice Free fatty acids (%) 3% max. 18.3–30.2% 14.4–21.8% Deterioration of Bleachability 2.8 min. 0.95–1.04 1.05–1.67 Index (DOBI)
Slide 23: Proven crude palm oil washing track record
Proven crude palm oil washing track record − Alfa Laval presence in the South-East Asian region 34 crude palm oil washing systems sold since 2017 Refinery Refinery Mill Mill 600 tons per day 100–1000 1000–3000 300 tons per day tons per day tons per day • IOI palm oil mill • Sarawak Oil Palms • PGEO
Slide 24: Up to 84% of chloride reduction post-washing
Up to 84% of chloride reduction post-washing − Actual field results from a crude palm oil washing installation at a palm oil mill Sample date CPO total chloride Percentage CI Treated water total Wastewater total Feed CPO Washed CPO reduction (%) chloride (ppm) chloride (ppm) 6/10/2018 5.952 0.626 89
Slide 25: Mass balance for crude palm oil washing
Mass balance for crude palm oil washing − Premium quality oil with low chloride content is the ultimate goal Crude palm oil in (A) mt/hr Wash water (D) 0.96 mt/hr Total feed mt/hr CPO 11.935 CPO 11.935 Moisture 0.053 Moisture 0.013 Dirt 0.012 Dirt 0.012 Total 12.000 Total 12.960 Crude palm oil out (
Slide 26: Storage time impacts oil quality
Storage time impacts oil quality − Longer storage time = higher organic chloride content and lower inorganic chloride content Sample stored at 50°C Chlorine (ppm) Inorganic chlorine Time: Consider the effect of long holding time and transit time on Organic chlorine chloride formation Time (months) *
Slide 27: Simple, powerful and efficient CPO washing
Simple, powerful and efficient CPO washing Vacuum Vacuum Reactor dryer Washing Mixer separator Water Heater From pure oil Steam tank To storage Water 07/05/2020 | © Alfa Laval 27 | www.alfalaval.com
Slide 28: Considerations: CPO washing for 3-MCPDE mitigation
Considerations: CPO washing for 3-MCPDE mitigation Mills • Early removal of chlorides most effective • Overall lower utility cost • Evaluate equipment maintenance cost (less cost if displacing existing purifiers) • Easier for effluent handling • Existing vacuum system can be used Refineries • Abilit
Slide 29: GE mitigation
GE mitigation 07/05/2020 | © Alfa Laval 29 | www.alfalaval.com
Slide 30: Glycidyl ester contributing factors
Glycidyl ester contributing factors Contributing factors Deodorizing temperature • High diacylglycerides (DAG) • High deodorizing temperature DAG 215°C 225°C 250°C (>220°C) 3% 0.6–1.0 2.2–3.5 3.0–7.5 • Long retention time in deodorizer • Hydrolysis at high temperature 5% 1.0–2.5 1.5–4.0 6–10 with st
Slide 31: Free fatty acid, monoglyceride and glycidyl ester
Free fatty acid, monoglyceride and glycidyl ester − Light molecules Free fatty acid (FFA) O H O C CH3 Monoglyceride (MAG) Glycidyl ester (GE) H O H O H C O C CH3 H C O C CH3 H C O H H C O Epoxide ring H C O H H C H H 07/05/2020 | © Alfa Laval 31 | www.alfalaval.com
Slide 32: Glycidol ester mitigation methods
Glycidol ester mitigation methods Method Comment Minimize formation in the Not sufficient to reach levels well below deodorizer: limit temperature 0.5/1 ppm for palm oils or similar, especially and residence time for low colour product requirements Re-refining with activated Can reach 0.2–0.3 ppm, b
Slide 33: Development of Alfa Laval deodorizing technology
Development of Alfa Laval deodorizing technology − A commitment to continuous development PalmFlex refining • Since 2018 • Low GE Dual strip refining • High quality palm oil • Since 2009 • Ability to use with low vacuum SoftColumn • Flexibility in processing systems refining temperature • Flexibilit
Slide 34: Alfa Laval PalmFlex – the optimum refining route
Alfa Laval PalmFlex – the optimum refining route Crude palm oil Chemical Physical refining refining Standard PalmFlex Soapstock Degumming and Washed water CPO washing neutralization Spent earth Bleaching Degumming Degumming Spent earth and bleaching and bleaching Bleached oil Bleached oil Deacidific
Slide 35: GE stripper designed specifically for GE removal
GE stripper designed specifically for GE removal Performance based on commercial scale plant data and Alfa Laval’s proprietary lipid property library References and the process simulator PRO II from SimSci. 1 L. P. Cunico, R. Ceriani, B. Sarup, J. P. O’Connell, R. Gani, “Data, analysis and modeling
Slide 36: Great flexibility with Alfa Laval PalmFlex refining
Great flexibility with Alfa Laval PalmFlex refining 1 2 3 4 5 Direct GE Bulk refining With high FFA The plant can The plant can stripper with for low colour, feed, the plant also operate also operate at GE <0.5 ppm, low FFA, can still operate above rated 70% turn-down low colour, low and superb at t
Slide 37: Achieve the highest quality
Achieve the highest quality − Optimal refined, bleached and deodorized (RBD) palm oil Quality of RBD Palm Oil Standard PalmFlex Free fatty acids (FFA) Max. 0.05% 0.03~0.04% Moisture and volatile matter Max. 0.05% Max. 0.03% (with refined oil dryer) Colour (Lovibond 5¼" cell) Max. 2.5 red / 25 yellow
Slide 38: How PalmFlex meets large refinery expectations
How PalmFlex meets large refinery expectations • Consistent high-quality oil • Continuous operation • Flexibility in operating choices • Low operating cost with high heat recovery • Safe and easy operation • Strong aftersales, service and support 07/05/2020 | © Alfa Laval 38 | www.alfalaval.com
Slide 39: Summary of benefits
Summary of benefits 07/05/2020 | © Alfa Laval 39 | www.alfalaval.com
Slide 40: Alfa Laval in 3-MCPD and GE mitigation technology
Alfa Laval in 3-MCPD and GE mitigation technology − Summary of benefits • Highly efficient chloride reduction at the mill and at the refinery with minimum oil losses • Proven Alfa Laval PalmFlex refining technology delivers highest oil quality at low operating costs while meeting stringent food safe
Slide 41: Q&As
Q&As 07/05/2020 | © Alfa Laval 41 | www.alfalaval.com
Slide 42: www.alfalaval.com
www.alfalaval.com