Comparison of Generally Applied Processes for Protein Separation with Common Starch Containing Raw Materials

Transcription

1 Comparison of Generally Applied Processes for Protein Separation with Common Starch Containing Raw aterials 61. Starch Convention, Detmold, 21. April 2010 Dr. Willi Witt Process

2 World Protein Production 2

3 World Protein eal Consumption illion Tons Protein eal Source: USDA 3

4 World Protein Production Estimated for 2010 Corn Gluten 3,2 ill. Tons per Year Wheat Gluten 0,9 ill. Tons per Year Potato Protein 0,1 ill. Tons per Year Soy Protein Isolate/Concentrate 0,9 ill. Tons per Year Total 5,1 ill. Tons per Year Source: USDA 4

5 olecular Protein Structure 5

6 What are Proteins Proteins are highly complex organic compounds Proteins are large molecules with high molecular weights They are composed of varying amounts of the same amino acids, which in the intact protein are united through covalent chemical linkages called peptide bonds A protein with a molecular weight of would contain about 850 amino acid residues Amino acids are classified as essential (incl. dispensable), and conditionally essential (conditionally indispensable) 6

7 What are Proteins The amino acids, linked together, form linear unbranched polymeric structures called polypeptide chains; such chains may contain hundreds of amino-acid residues; these are arranged in specific order for a given protein Reaction of amino acids to form a peptide bond R O R O R O H R O H2N C C OH + H2N C C OH -> H2N C C N C C OH + H2O H H H H Depending on the source, the protein has a different structure and combination of amino acids in its chemical make-up. Every protein molecule has a characteristic three dimensional shape or confirmation which is determining its properties Every protein molecule has a characteristic three dimensional shape or confirmation which is determining its properties 7

8 Protein Structure Primary Secondary Tertiary Quaternary alaaf 8

9 Protein Properties Water Binding Gel Forming Emulsifying Foaming Solubility Nutritive Value 9

10 Comparison of Raw aterials for Protein Processing from Carbohydrate Containing Plant 10

11 Protein Containing Plant Starch and Carbohydrates Containing Plant: Corn, Wheat, Rye, Barley, Oat, Rice Legume: Pea, Lupine Root: Potato, Tapioca, anioc Oil Containing Plant: Soy, Rape Seed, Sun Flour 11

12 Cross Section of diff. Types of Grain Barley Rye Wheat Oat Corn Rice Pea 12

13 Chemical Composition of the Different Raw aterials Starch Protein Fat Fiber % DS % DS % DS % DS Corn , Wheat ,5 2-3 Rye ,8-2,2 1,8-2,7 Pea ,2-10 Barley ,5-14,5 1,9-2,6 4,5-7,2 Oat ,5-5,8 11,5-14 Rice ,5-2,5 9,5-12,5 Potato

14 Processes for the Recovery of Proteins out of Different Raw aterials 14

15 Steps of Pre-Conditioning for Protein Recovery ain Issue: Opening of the Cell Structure Dry illing Cleaning Conditioning Grinding Sifting Air Classification Combined Processes Wet illing Cleaning Steeping Wet Grinding Extraction 15

16 Simplified illing Principal Kernel Endosperm Germ Bran 16

17 Wheat Short ill - (Roller Principal) Water Wheat Sif ter Roller ill Bran Finisher Flour aturation Tanks Bran Weigher Weigher 17

18 Wheat Short ill - (Ultra-Rotor Principal) Water Wheat aturation Tanks Bag Filter Exhaust Fan Buf fer Silo Bran Silo Wheat Flour Silo Rotary Valve Air Lock Sift er Flour Bran Bran Finisher Ultra-Rotor Weigher Weigher compressed air compressed air 18

19 illing Equipment Roller ill Plan Sifter Hammer ill Peeler Rubber Roll Peeler

20 Ultra Rotor for illing and Drying 20

21 Peeling Schule ühlenbau 21

22 Peeling of Wheat Kernels Before Peeling After Removing of the Outer Cell Wall after Cleaning and Humidifying of the Bran by Interaction of the Grain between Rotor and Screen 22

23 Air Classification 23

24 Air Classification Flour Feed 2 Sifter Wheal 3 Outlet Fine Fraction 4 Outlet Coarse Fraction 5 Aspiration 5 4 Fine Sifter 24 ALPINEHOSOKAWA Sifter ill

25 Different Types of Protein Recovery echanical Treatment Corn, Wheat Chemical Treatment Pea, Barley, Oat, Rye, Rice Thermal Treatment Potato 25

26 Solubility of Soy Protein Depending on the ph % N-Solubility ph of the Solution 26

27 Solubility of Rape Seed Globulin Protein AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA % N-Solubility ph of the Solution 27

28 Solubility of Rape Seed Protein % N-Solubility ph of the Solution 28

29 Corn Processing for Protein Recover 29

30 Corn Kernel Floury Endosperm Horny Endosperm Germ Flower Stalk Dark Surface Layer 30

31 Cross Sections of a Corn Kernel 31

32 Corn Gluten Lab Wash Test Volume (%) ais Ansatz Particle Diameter (µm.) 32

33 Typical Products Isolated from Corn and Yields Content of Yield [% DS] Starch % Gluten 5-6 % Germ 6-7 % Fiber 9-12 % Step Water 5-8 % Broken Kernels 1-4 % 33

34 Corn Processing into Protein and other Products Corn Steeping Grinding Germ Separation Fine Grinding Fiber Screening Starch Separation Washing Dewatering Drying Drying Germs Fibers Corn Starch Corn Gluten Steep Water 34

35 Process Steps with WS Key Equipment ill Starch ill Starch Thickening Process Water iddling Separation Primary Separation Starch Washing Gluten Thickening Starch Dewatering Gluten Dewatering Starch Drying Gluten Drying Corn Starch Corn Gluten 35

36 Corn Wet illing from Corn Germ Washing Germ Dewatering Dewatered Germs Steeping PW PW Grinding & GermSeparation Husks, Fibres, Starch, Gluten

37 Wet illing from Corn PW from illing Fibre Extraction Husk Dewatering Dewatered Husks Fibre Dewatering Dewatered Coarse Fibres Starch Primary Separation PW PW Starch Washing Gluten Concentration Gluten Dewatering Dewatered Gluten

38 Simplified Flow Sheet for Corn Gluten Dewatering with Decanter Hot Water Caustic Soda Gluten Concentrate Feed concentration (separable solids) TIC FIC Decanter feed conditions: QIC approx. 35 (30-50) g/l 4,7 (4,0-6,7) oz/gal Feed temperature C F ph-value 5,3-5,8 SO 2 content mg/kg NaOH-concentration 4-10 % hot water temperatur max. 65 C max 149 F Clarified Phase to Process Water Hot Water Dewatered Gluten 38

39 Requirements for Corn Gluten Ewatering in a Decanter ph-control for the range of approximately 5,3 5,8 equipped with ph measurement, control valve and caustic pump Temperature control for raising the temperature of the corn gluten to approximately C equipped with temperature measurement, control valve and plate heat exchanger Feed system for feeding the decanter equipped with eccentric srew pump, inductive flow meter and static mixer

40 Dewatered Corn Gluten 40

41 Continious High Pressure Corn Steeping Process Fine Solids Process Water Corn Steeped Corn Warm Water Features Short Steeping Time No SO 2 Low solubilisation of Solids and Proteins No Steep Water Evaporation Anaerobic Waste Water Treatment Plant Low Space Requirement Transport Circuit

42 High Pressure Disintegration for Selective Grinding of the Corn Endosperm Steeped Corn Processwater Corn Fibre Fragments ill Starch Coarse and Fine Fibres Working Princip of the Desintegration Valve High Pressure Desintegrator

43 Wheat Processing for Protein Recovery 43

44 Wheat Kernel 44

45 Wheat Short ill - (Roller Principal) Water Wheat Sif ter Roller ill Bran Finisher Flour aturation Tanks Bran Weigher Weigher 45

46 Grades of Flour Obtained from Wheat The iller can Produce a Type of Flour Quality suitable for the Wheat Starch Industry with a certain Extraction Rate. Flour illing Flour Extraction Rate [%] Whole Wheat Flour Straight Grade Flour Shorts and Bran Patent Flour Low Grade Flours ca % 46

47 Wheat Quality Depending on Flour Yield AAAAAAAAAAAAAAAAAAAAAAAAAAaaaaaa RT Volume Aleuron Layer Gluten Content Protein Content ineral Content Bran Endosperm Flour Yield 47

48 Flour Specification Typical Requirements for a Wheat Flour Suitable for Starch Processing. oisture approx. 15,0 % Protein (N x 5,7) approx. 12,0 % DS Ash approx. 0,63 % DS Fat approx. 1,5 % DS Crude Fibre approx. 1,5 % DS (all based on Dry atter) Wet Gluten approx. 28,0 % Flour Particle Size max. 3 % > 250 µm Amylogram approx. 500 Falling Number approx. 250 Wash Test A-Starch Potential > 70 % DS Starch Granule Size < 30 % < 10 µm 48

49 Wheat Flour Process Flour Water ixing Homogenizing Separation Washing Sieving Sieving Dewatering Recovery Washing Process Water Drying Gluten Fiber Starch Pentosans 49

50 Wet illing from Wheat Dough Preparation and Gluten Extraction Wheat Flour Water Pentosan Fraction to Fermentation 3 Phase Separation Dosing A-Starch Fraction to Starch Washing ixing Agglomeration Gluten Washing Gluten Finishing Vital Gluten to Dryer B-Starch Fraction

51 Dough ixer in Process Dough mixing 51

52 Slurry Preparation The high pressure introduced by a homogenizer ensures the necessary Energy Input for agglomerating the Gluten. Energy Input 52

53 Bend Screens for Gluten Separation 53

54 Vital Gluten Drying and Conditioning Gluten Drying Ring Duct Bag Filter Exhaust Fan Bag Filter Exhaust Fan Buffer Silo Air Lock Recycle Screw Filtrate Recycle Filtrate Pump Recycle Pump Feed Pump Disintegrator Sifter ill Heater Cooling Column Bagging 25 kg Wheat Vital Gluten Steam Condensate 54

55 Protein Structure Wheat Protein Rye Protein Source: argit Beck, Tagung für Getreidechemie,

56 Wheat Protein Aggregates 56

57 Protein Network after Agglomeration of the Protein bar=100 µm 57

58 Isolated Wet Wheat Gluten 58

59 Potato Processing for Protein Recover 59

60 icrographs of Potato and Root Cells

61 icrographs of Potato Cells 61

62 Processing of Potatoes into Proteins and other Products Potatoes Reception Washing & Storage Rasping De-Sanding Sand Fruit Water Removal Extraction Pulp Dewatering Starch Washing Starch Dewatering Pulp Byproduct Protein Waste Water Starch Drying Fresh Water Starch 62

63 Rasping All parts coming in contact with the product are made of stainless steel Reversible Rotation Direction Very Robust Design High Grinding Efficiency Easy Accessibility Blades robust for changing no rework Rasping Rasping 63

64 WS Decanters for Potato Starch Processing In the Potato Starch Process Decanters are mainly used for: CB 635 Fruit Water Removal Decanter Pulp Dewatering Decanter CB

65 Fruit Water Decanter Performance The Spin Test of the Different Decanter Flows Shows the Efficient Separation. Overflow Vol-% Ideal Separation Line Feed Vol-% 55 Vol% Gratings approx. 22,5 % DS ,1 99,8 % Fruit Water = 5 % soluble DS 0,2 % coagulated Protein and Fibres 0,1 Concentrate Dewatered Gratings approx. 45 % DS 65

66 Protein Recovery from Potato Fruit Water Residual Fruitwater to Evaporator Steam Acid Protein Coagulation Fruitwater Feed Pre heater Protein Dewatering CIP Recycle Protein Drying Caustic CIP System CIP Liquid 66

67 Protein Decanter Performance The spin Test of the Different Decanter Flows Shows the Efficient Separation. Overflow Vol-% Ideal Separation Line ,1 Feed Vol-% 85 % Water 12 % Separable Solids = 4 % DS ,1 Feed approx. 35 m³7h 99,7 % Process Water 0,3 % Separable Solids All figures are approximate and varying according to raw material and process design Concentrate Dewatered Protein approx. 40. % DS 67

68 Other Raw aterials for Protein Recover 68

69 Soy Flour Processing for Protein Recovery As Basic Process for other Starch and Carbohydrates Containing Raw aterials 69

70 Cross Section Soy Bean 70

71 Soy Protein Process White Flakes Protein Extraction Protein Extraction Sugar Removal Alcohol Extraction Protein Precipitation Protein Precipitation Protein Washing Conditioning odification Conditioning odification Conditioning odification Conditioning odification Protein Isolate Protein Concentrate Protein Concentrate Protein Concentrate 71

72 Soy Protein Process 72

73 Extraction of Soy Protein from Soy Flakes or Flour 73

74 Protein Precipitation and Washing 74 UHT Spray Dryer

75 embranfiltration in Protein Process Lines 75

76 Protein Precipitation and Washing 76

77 Pea Processing for Protein Recover 77

78 Some Pea Types 78

79 Composition of peas Dry Substance % (after Drying) Starch (%DS) % Sugars (%DS) 5-7 % Protein(%DS) % Fat (%DS) 0,6-5,5 % Fibres (%DS) 2,2-10 % Ash (%DS) 1,8-3,3 % Pod The great variations of the composition refer to the great variety of peas and growing conditions! Seed with Hull 79

80 Usage of Peas Different Pea types are used for: Animal Feed and Fish Feed (Chick Peas, Field Peas, ) Human Feed (Wrinkled Pea, Round Pea, Sugar Pea) Typicall usage of pea fractions: Protein for Human and Animal Consumption, Adhesives, Tensides Starch for Human Consumption, Plastics (Amylose) Fibres for Animal Feed Human Consumption (Dietary) 80

81 Processing of Peas into Proteins and other Products Pea Seed Dehulling Steeping Grinding Wet Grinding Air - Classification Pea Flour Concentrated Protein Flour Wet Process Line Wet Process Line Starch, Protein, Fibres Starch, Protein, Fibres 81

82 Pea Processing 82

83 Pea Processing Peas NaOH Steeping Disintegration Hot Water H 2 SO 4 Fruit Water Removal Pulp Dewatering Protein Precipitation and Dewatering 3-Phase Concentration and Washing Water Fine Fiber Screening Dewatering Fiber (to (to Dryer) Protein to to Dryer Starch to to Dryer 83

84 Rice Processing for Protein Recover 84

85 Rice Processing Rice Flour NaOH Steeping Disintegration Extraction Byproduct Dewatering Water 3-Phase Concentration and Washing Fine Fiber Screening H 2 SO 4 Byproduct (to (to Dryer) Dewatering Protein Precipitation and Dewatering Starch to to Dryer Protein to to Dryer Effluent 85

86 Protein Recovery From Ethanol Processes 86

87 Bioethanol The Dry ill Process

88 Protein and Oil Recovery in an Ethanol Plant

89 any Thanks for Your Attention!