Hybrid Technology in the Starch Industry

Transcription

1 58. Starch Convention, Detmold April

2 What Does Hybrid Mean? Combination of Different Processes or Process Steps Each Process and Process Step itself Forms a Solution The Combination Forms a New Solution 2

3 Separation of Fat and Protein from Starch Hydrolysate 3

4 Mech. Separation Core Competence M-Div. Operating plants Mechanical Automation Mixing separation Heat Transfer Packing Storage technology Mechanical separation technology Electrochem. treatment Membrane technology Centrifugal separation technology Screening technology Therm. separation Sedim. flotation Centrifugal separation technology Filter centrifuges Trailing blade centrifuges Sedimentation centrifuges Basket centrifuges Other centrifuges Sedimentation centrifuges Separators Decanters 4

5 - Absolute Separation - Mechanical Separation Crossflow Filtration 5

6 Particel Size and Separation Technology Particel Size and Separation Technology Separation- Technology Molecule- Separator Micro-/Ultrafiltration Centrifugal Separator Decanter Micrometer (Log.- Maßstab) Angstrom (Log.-Maßstab) Molecule Weight (Dalton) < REM < Mikroskop < fürs Auge sichtbar 0,001 0,01 0,1 1, Gelöste Mineralien Pyrogen Aktivkohle Farbpigment Hefezellen Strand-Sand Relative Size of the common Materials Metall-Ion Zucker Virus Kolloid-Silica Albumin-Protein Bakterien Rote Blutzellen Mehl Haar 1 Angstrom = Meter = 10-4 Mikrometer 6

7 Simplified Flow Diagram 7

8 Process steps of Hybrid Technology! Mud Separator: Mud and heavy solid separation in front of membrane filtration! Membrane Unit: Final syrup filtration! Decanter: Retentat removal from membrane filtration 8

9 Syrup Spin Test fat / protein 1-15 % v/v unsaccharified dextrose, 0-5% v/v Generally unimportant for the complete process. Used as animal feed or recycled in the process The important phase for blocking membranes and filter As much as possible should be removed Quantity depends on raw material, process and season glucose syrup, 30, 50, 95 DE Valuable phase Maximum yield is necessary 9

10 Separation Higher Lower density density SYRUP MUD Settling time 5-10 min. Higher density SYRUP 10

11 Continuous Separation Continuous Feed 11

12 Centrifuge 12

13 Mud Separator: DA

14 DA Mud Machine 1. Feed 2. Inner bowl Space 3. Centripetal pump for light phase 4. Light phase outlet 5. Disc set 6. Outer bowl space 7. Nozzles 8. Concentrate catcher 9. Centripetal pump for heavy phase 10.Heavy phase outlet 14

15 Operating Characteristics Three-phase (double overflow) separation Light phase (light overflow) mud Middle phase (heavy overflow) clarified syrup Concentrate (underflow) syrup plus sediment Feed inside of disc stack Middle and light phases discharge trough centripetal pump Nozzle discharge about 1/3 of feed rate Back pressure on middle phase controls separation zone 15

16 Good Feed Good Product 16

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19 Membrane Cross Section 19

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21 Principle Membrane Filtration Theoretical x P 2 P 1 P 21

22 Principle Membrane Function Fundamental Cross flow conditions in a tubular membrane ~ 2000 mm/sec. ~ 0,5 mm/sec. 22

23 Different Ceramic Membrane Elemente s 23

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25 Ceramic Membrane Pore size und Structure Porendurchm. / μm Porendurchm./ nm Molekulargewicht / kd Elektronenmikroskopische Aufnahme der Porenstruktur einer Membran 25

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29 Simplified Flow Diagram 29

30 WS combined Hybrid Solution Separator SC 6 Retentat Membranefiltration Separator Permeat Batch Tank SC 150 Concentratedischarge Bentonitablauf 30

31 Decanter for Retentat Removal 31

32 Decanter Cross Section 32

33 Fluxrate (m³) WS Membraflow GmbH Combined System Centrifuge plus CMF Starting Fluxrate CMF & Separator Factor of Concentration CMF only Factor of Concentration CIP Time (h) 33

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