Techno-Economic analysis of a Membrane Filtration Process for the Phenolic Compound Extraction

Techno-Economic analysis of a Membrane Filtration Process for the Phenolic Compound Extraction Rosa Micale*, Mario Enea*, Antonio Giallanza*, Giada La Scalia* *Dipartimento dell Innovazione Industriale e Digitale (DIID) - Ingegneria Chimica, Gestionale, Informatica, Meccanica, Scuola Politecnica, Viale delle Scienze Ed. 8, 90128 Palermo Italy (rosa.micale@unipa.it, mario.enea@unipa.it, antonio.giallanza@unipa.it, giada.lascalia@unipa.it). Abstract: Olive Oil Wastewater (OOW) is a by-product that represents an environmental and economical concern due to the presence of compounds with a high polluting rate and their significant disposal costs. To revaluate this byproduct, several methods to recover substances with a high added value such as phenolic compounds, which are currently recognized scientifically as molecules with a relevant antioxidant activity, have been proposed. In this paper the economical feasibility of a system based on the membrane filtration process for the phenolic compound extraction and the subsequent polyphenolic enrichment of the olive oil, have been assessed. In particular, the analysis of the investment profitability of a case study was presented to determine the optimal incremental price of the olive oil obtained by the enrichment process. Keywords: Olive Oil Wastewaters; Phenolic compound; Tecno-economic analysis. 1.Introduction Food manufacturer are aware that by reducing waste byproducts generated along the production chain, the double benefit of environmental protection and waste disposal costs reduction can be achieved. Such benefits have a direct positive effect on the profitability of business, especially when these by-products can be reused in the production of foods with health benefits (Hyde et al., 2001; Laufenberg et al., 2003). The growing interest in healthy food allowed several researchers to work on upgrading and improving the methods for reusing or recycling the by-products deriving from different food processes (Wang et al., 2007; Bräutigam et al., 2014). Olive Oil Wastewater (OOW) is a by-product of the olive oil extraction process, containing soft tissues of the olive fruit and the water used in the various stages of the oil extraction treatment. OOW constitutes a serious environmental problem for the Mediterranean countries because it represents a significant polluting waste due to its low ph, high solids and organic compounds, phytotoxic properties and resistance to biodegradation caused by its phenolic compounds (Zirehpour et al., 2012; Zagklis et al., 2013). On the other hand, phenolic compounds include a wide range of biological activities such as antioxidant (Manach et al., 2004), antibiotic/antiviral (Bravo, 1998), anti-inflammatory (Bravo, 1998), and protection from diseases (Scalbert et al., 2005). Nowadays, natural antioxidants are widely used in the pharmaceutical, cosmetic and food industry to substitute synthetic antioxidants that can cause or promote undesirable effects on human health, and also can contribute towards oxidative degradation of food (Fki et al., 2005; Lafka et al., 2011; De Marco et al., 2007). Olive wastewater is an excellent source of natural antioxidants and the European Regulation EU 432/2012 provides that olive oils which contain at least 5 mg of hydroxytyrosol and its derivatives (e.g. oleuropein complex and tyrosol) per 20 g of olive oil can be considered a healthy food. However, the quantity of hydroxytyrosol and its derivatives in Virgin Olive Oil (VOO), as well as in OOW, is affected by several agronomic factors (such as cultivar) and technological aspects (such as oil extraction conditions) (Angerosa et al., 2004). In particular, several olive cultivars are genetically characterised by a low fruit phenolic content and consequently the corresponding VOOs cannot guarantee some health advantages. Valls et al. (2015) have demonstrated that VOO enriched with phenolic compounds can offer additional health benefits compared with a standard VOO with moderate polyphenol content. In particular, the addition of polyphenols could improve the important health aspects of VOO while preserving the characteristic varietal flavour (Servili et al., 2011). In this context, OOW treatment that will allow phenols collection may lead to economic benefits (Garcia-Castello et al., 2010). One of the most promising methods for the treatment of OOW, considering effectiveness, environmental impact and cost, is membrane filtration (Zagklis et al., 2013). Membrane technology reduces the OOW organic load and the suspended solids content (Zirehpour et al., 2012; El-Abbassi et al., 2013; Russo, 2007). Microfiltration (MF) and Ultrafitration (UF) may be used as a primary treatment step, while Nanofiltration (NF) and Reverse Osmosis (RO) for the final treatment. With ultrafiltration, only a small amount of retentate (waste) is produced (permeate is 90 95% of the volume of the feed) and very high removal of lipids is achieved. Also, by choosing the appropriate pore size of the membrane used, the composition of the permeate can be controlled. Despite the fact that much research has been conducted to develop new methods for phenolic compounds 102

XXI Summer School "Francesco Turco" - Industrial Systems Engineering extraction, few economic analyses are reported in literature to evaluate the sustainability of these methodologies (Lipnizki and Field, 2001; Ruiz-Rosa et al., 2016) but none for the olive oil industry. In this study, a commercial MF membranes system was used to separate the polyphenols from oil substances and the economical feasibility to enrich the olive oil with low polyphenols content was investigated. In particular, the price of the enriched olive oil that allows having an affordable investment was determined. The remainder of this paper is organized as follows. Section 2 describes the system proposed for the phenolic compounds extraction referring to a case study. Section 3 shows the results obtained in terms of economical analysis and finally, Section 4 concludes the paper with a discussion on the proposed approach and an outlook into on-going research work. 2.2 Olive wastewater treatment The prototype of the olive wastewater treatment, reported in figure 1, was realized by Permeare S.r.l. (Milan) and its capacity is about 500 l/h of vegetable water. 2. Materials and method Figure 1: Olive wastewater treatment plant 2.1 Case study In the mill, the produced vegetable water with low content of material in suspension (particle size exceeding 1 mm) is accumulated in one or more tanks with a capacity of 500 litres. During the load in the tank it is necessary to add the pectolytic enzymatic preparation (Permazim ZE01). The quantity of preparation for each treatment was assumed to be 100 gr per m3 of OOW. The membrane treatments were microfiltration, ultrafiltration and reverse osmosis, as reported in figure 2. The olive oil wastewater used in this study was collected from an olive mill located in Sicily, south of Italy. The main cultivars are Cerasuola (63%), Biancolilla (20%) and Nocellara del Belice (17%). In table 1, the total quantity of olive used for the production of olive oil in 2015 and the process yields are reported. Table 1: Percentage yield of pomace oil, wastewaters and olive oil Cerasuola Nocellara del Olive Belice Biancolilla Pomace oil Wastewaters Oil Olive (q) 1,794.77 Yield (%) 569.77-484.30 1,281.89 1,851.06 523.59 44.98 64.89 18.38 Each cultivar has a specific chemical composition that influences the characteristics of the final product. In table 2 the phenolic compositions for the cultivar considered in this study are reported. The table shows that Cerasuola is the only one that reaches a total quantity of hydroxytyrosol and its derivatives more than 250 mg/kg while Biancolilla and Nocellara del Belice to reach this amount should be enriched in polyphenols. Figure 2: Flow-chart of phenolic concentrate production by OOW membrane treatment (Servili et al., 2011) Table 2: Polyphenolic compounds 357.94 Nocellara del Belice 200.25 3.29 3.32 173.37 2.25 5.23 66.97 1.15 2.07 29.89 45.56 44.84 270.37 17.94 22.12 114.52 12.01 13.78 58.90 Cerasuola Polyphenol (ppm) H- tyrosol Tyrosol 3,4-DHPEAEDA p-hpea-eda 3,4-DHPEA-EA Total amount (mg/kg) Biancolilla 157.58 103 Before the ultrafiltration section, the waters pass through a membrane with a porosity of 1 µm, which allows the removal of suspended solids (microfiltration). This section is composed by 3 membranes consisting in vessel with tubular type modules. When the treatment process starts, the pumps of the tubular section transfer the content of the tank in a work tank. The ultrafiltration section concentrates the macromolecules in the vegetation water and produces the permeate which is then concentrated through a reverse osmosis system. At the end of the ultrafiltration cycle, the concentrate is discharged from the work tank and sent to the pomace oil or in a storage tank for the disposal, while the permeate is sent in the internal tank of the reverse osmosis section. This section consists

of 6 modules of spiral osmosis membranes (4" x 40"). The reverse osmosis system gathers the substances present in solutions and produces a concentrate with a high content in polyphenols. Finally the Phenolic Concentrate can be utilised in the Virgin Olive Oil (VOO) extraction process (during malaxation) with the aim of improving VOO phenolic content or stored in controlled conditions to be marketed. The expected life of membranes is about 5 olive oil campaigns. All the membranes were purchased from Permeare S.r.l. (Milano, Italy). 2.3 Polyphenolic enrichment The chemical composition of the concentrate obtained from the phenolic compound extraction process strongly depends on the olive variety used and on the curing level at the milling time. The variety should be characterized by a medium-high phenolic compounds content (2,000-4,000 ppm per each litre of vegetation water) to obtain with the treatment process a crude phenolic concentrate of about 20,000 ppm. Table 2 shows that, for the case study considered, the only variety with a medium phenolic compounds is the Cerasuola (i.e. Hydroxytyrosol and its derivatives of about 270.37 mg/kg). For this variety, the drupes processed by the extraction system in 2015 were 179,477 kg (table 1), then considering the yields reported in table 1, the total amount of OOW are about 116,462 l and consequently it is possible to obtain 11,646.2 l of phenolic concentrate to enrich the variety Biancolilla and Nocellara del Belice. The enrichment with the phenolic concentrate, during the malaxation phase, was assumed to be 5%, 7.5%, 10%, 12.5% and 15%. Table 3 shows a summary of the possible enrichments for Nocellara del Belice and Biancolilla oils exploiting the total amount of polyphenols concentrate of the Cerasuola variety. Table 3: Summary of the possible enrichments for Nocellara del Belice and Biancolilla oils Cultivar Nocellara del Belice Polyphenols enrichment (l) 5% 7.50% 10% 12.5% 15% 2,848.8 4,273.3 5,697.7 7,122.1 8,546.6 Biancolilla 2,421.5 3,632.3 4,843.0 6,053.8 7,264.5 Total 5,270.3 7,905.5 10,540.7 13,175.9 15,811.0 88% 74% For the last two percentages, the total amount of the enriched oil corresponds to the 88% and 74% respectively of the produced oil. 3. Economic analysis The economic evaluation has been carried out on the basis of total capital investment (TCI, ), total operating cost (TOC, /year) and revenues from sale of enriched oils (R, /year). In this way, the economic profitability of the solutions obtained with different incremental prices has been evaluated and the results have been presented on the basis of the Net Present Value (NPV) and of the investment Payback time. More specifically, TCI costs have been evaluated as the sum of the costs of the phenolic compound extraction system and the refrigerated cell used to store the phenolic concentrate, while TOC costs have been calculated considering the costs of energy and enzyme consumption and membranes substitution. All the costs are reported in table 4. Table 4: Total capital investments and total operating costs Extraction Plant Refrigerated Cell TCI 152,500.00 7,200.00 TOC Energy 0.23 /kwh 0.23 /kwh Enzyme 40.75 /kg - Membranes (every 5 years) 13,200.00 - In particular the energy consumption for the extraction process is 10 KWh and for the refrigerated cell is 1.8 KWh. The cost of each membrane used in the ultrafiltration section is 2,000.00 while the cost of each membrane used in the reverse osmosis section is 1,200.00. Considering a 10 years (y) useful life, the costs and the enriched oil quantity for the different percentages are reported in table 5. Table 5: Ten years, TCI, TOC and enriched olive oil quantity for the different percentage y TCI ( ) TOC ( ) 0-159,700.0 Enriched oil (Kg) Phenolic enrichment (%) 5-7.5-10 12.5 15 1-4,636.8 52,359.0 50,034.0 47,322.0 2-4,636.8 52,359.0 50,034.0 47,322.0 3-4,636.8 52,359.0 50,034.0 47,322.0 4-4,636.8 52,359.0 50,034.0 47,322.0 5-17,836.8 52,359.0 50,034.0 47,322.0 6-4,636.8 52,359.0 50,034.0 47,322.0 7-4,636.8 52,359.0 50,034.0 47,322.0 8-4,636.8 52,359.0 50,034.0 47,322.0 9-4,636.8 52,359.0 50,034.0 47,322.0 10-17,836.8 52,359.0 50,034.0 47,322.0 The NPV analysis, reported in table 6 and in figure 3, shows that the investment is profitable when the oil price (9.50 /L) increases in 0.60 for scenario 1 (5%, 7.5% 104

and 10%) and scenario 2 (12.5%) while in 0.70 for scenario 3 (15%). Table 6: NPV for different percentages of enrichment as a function of the incremental oil price Incremental oil price ( /l) Scenario 1 Scenario 2 Scenario 3 0-208,389.06-208,389.06-208,389.06 0.1-171,614.29-173,247.27-175,152.07 0.2-134,839.52-138,105.49-141,915.08 0.3-98,064,75-102,963.70-108,678.08 0.4-61,289.98-67,821.91-75,441.09 0.5-24,515.21-32,680,12-42,204.10 0.6 12,259.56 2,461.66-8,967.11 0.7 49,034.33 37,603.45 24,269.88 0.8 85,809.10 72,745.24 57,506.88 0.9 122,583.87 107,887.03 90,743.87 1 159,358.64 143,028.82 123,980.86 1.1 196,133.41 178,170.60 157,217.85 1.2 232,908.18 213,312.39 190,454.85 1.3 269,682.95 248,454.18 223,691.84 NPV ( ) 300000 250000 200000 150000 100000 50000 0-50000 -100000-150000 -200000-250000 Net Present Value 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 Incremental Oil Price ( ) Figure 3: NPV trend for different scenarios Scenario1 Scenario2 Scenario3 Finally, enforcing four years payback time, a sensitivity analysis was conducted to establish the incremental oil price for the different scenarios. Figure 4 shows that for the first scenario the oil price should be incremented in 1.00 while for the second and third in 1.10. Payback time (years) 12 10 8 6 4 2 Payback time 0 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 Incremental Oil Price ( ) Scenario 1 Scenario 2 Scenario 3 Figure 4: Payback time for the different scenarios considered 4. Discussions and conclusions During the last years the interest in recovery, recycling and upgrading of residues from plant food processing has increased drastically. These food industries produce large volume of wastes, which represent a disposal and potentially environmental pollution problem. Nevertheless they are also promising sources of compounds that can be recovered and used as valuable substances by developing of new processes. Particularly, the reuse of these wastes to obtain functional foods is receiving increased attention. Despite several researches have been conducted to develop new methods for compounds extraction, few economic analyses are reported in literature to evaluate the feasibility of these methodologies. In this paper, the relevance of an economic analysis was highlighted and the results obtained showed the investment breakeven point in terms of incremental olive oil price. Three different scenarios based on the enrichment percentage calculated on the basis of the phenolic concentrate obtained with a membrane extraction system and of the total amount of the available olive oil, have been considered. The NPV was used as first economical indicator and subsequently the Payback time was analysed to refine the economical analysis. Results show that to obtain a positive NPV and a payback time not greater than four years, the minimum olive oil incremental price is 1.00 for the first scenario while 1.10 for the second and the third. These results have to be compared with a market analysis to verify if consumers can accept these incremental prices. Moreover, further investigations should be done to establish the market value of the phenolic concentrate because it could be more convenient to sell the concentrate rather than the enriched olive oil. Finally, results show a 90% reduction of waste product from VOO extraction processes, with significant advantages in terms of environmental impact and disposal cost reduction. References Angerosa, F., Servili, M., Selvaggini, R., Taticchi, A., Esposto, S. and Montedoro, G.F., (2004). Volatile compounds in virgin olive oil: Occurrence and their relationship with the quality. Journal of Chromatography A, volume 1054, issues1-2, pages 17-31. Bräutigam, K.R., Jörissen, J. and Priefer, C. (2014). The extent of food waste generation across EU-27: Different calculation methods and the reliability of their results. Waste Management and Research, volume (32), issue 8, pages 683-694. Bravo, L. (1998). Polyphenols: chemistry, dietary sources, metabolism, and nutritional significance. Nutrition Reviews, volume (56), pages 317-333. De Marco, E., Savarese, M., Paduano, A. and Sacchi, R. (2007). Characterization and fractionation of phenolic compounds extracted from olive oil mill wastewaters. Food Chemistry, volume (104), issue 2, pages 858-867. 105

El-Abbassi, A., Hafidi, A., Khayet, M. and García-Payo, M.C. (2013). Integrated direct contact membrane distillation for olive mill wastewater treatment. Desalination, volume (323), pages 31-38. European Regulation EU 432/2012. Establishing a list of permitted health claims made on foods, other than those referring to the reduction of disease risk and to children s development and health. Fki, I., Allouche, N. and Sayadi, S., (2005). The use of polyphenolic extract, purified hydroxytyrosol and 3,4- dihydroxyphenyl acetic acid from olive mill wastewater for the stabilization of refined oils: a potential alternative to synthetic antioxidants. Food Chemistry, volume (93), issue 2, pages 197-204. Garcia-Castello, E., Cassano, A., Criscuoli, A., Conidi, C. and Drioli, E. (2010). Recovery and concentration of polyphenols from olive mill wastewaters by integrated membrane system. Water Research, volume (44), issue 13, pages 3883-3892. Hyde, K., Smith, A., Smith, M. and Henningsson, S. (2001). The Challenge of waste minimization in the food and drink industry: a demonstration project in East Anglia, UK. Journal of Cleaner Production, volume (9), issue 1, pages 57-64. Lafka,T.I., Lazou, A.E., Sinanoglou, V.J. and Lazos, E.S. (2011). Phenolic and antioxidant potential of olive mill wastes. Food Chemistry, volume (125), issue 1, pages 92-98. Laufenberg, G., Kunz, B. and Nystroem, M. (2003). Transformation of vegetable waste into value added products: (A) the upgrading concept; (B) practical implementation. Bioresource Technology, volume (87), issue 2, pages 167-198. Lipnizki, F., Field and R.W., (2001). Pervaporation-based hybrid processes in treating phenolic wastewater: Technical aspects and cost engineering. Separation Science and Technology, volume 36, issue 15, pages 3311-3335. Manach, C., Scalbert, A., Morand, C., Rémésy C. and Jiménez L. (2004). Polyphenols: food sources and bioavailability. American Journal of Clinical Nutrition, volume (79), issue 5, pages 727-747. Ruiz-Rosa, I., Garciá-Rodriǵuez, F.J. and Mendoza- Jimenez, J., (2016). Development and application of a cost management model for wastewater treatment and reuse processes. Journal of Cleaner Production, volume 113, pages 299-310 Russo, C. (2007). A new membrane process for the selective fractionation and total recovery of polyphenols, water and organic substances from vegetation waters (VW). Journal of Membrane Science, volume (288), issue 1-2, pages 239-246. Scalbert, A., Manach, C., Morand, C., Rémésy C. and Jiménez L. (2005). Dietary polyphenols and the prevention of diseases. Critical Reviews in Food Science and Nutrition, volume (45), issue 4, pages 287-306. Servili, M., Esposto, S., Veneziani, G., Urbani, S., Taticchi, A., Di Maio, I., Selvaggini, R., Sordini, B. and Montedoro, G. (2011). Improvement of bioactive phenol content in virgin olive oil with an olivevegetation water concentrate produced by membrane treatment. Food Chemistry, volume (124), issue 4, pages 1308-1315. Valls R., Farràs M., Suárez M., Fernández-Castillejo S., Fitó M., Konstantinidou V., Fuentes F., López- Miranda J., Giralt M., Covas M., Motilva M. and Solà R. (2015), Effects of functional olive oil enriched with its own phenolic compounds on endothelial function in hypertensive patients. A randomised controlled trial, Food Chemistry, Volume 167, pages 30 35. Zagklis, D.P., Arvaniti, E.C., Papadakis, V.G. and Paraskeva, C.A. (2013). Sustainability analysis and benchmarking of olive mill wastewater treatment methods. Journal of Chemical Technology and Biotechnology, volume (88), issue 5, pages 742-750. Zirehpour, A., Jahanshahi, M. and Rahimpour, A. (2012). Unique membrane process integration for olive oil mill wastewater purification. Separation and Purification Technology, volume (96), issue 21, pages 124-131. Wang, H.H., Tan, K.T. and Schotzko, R.T. (2007). Interaction of potato production systems and the environment: A case of waste water irrigation in central Washington. Waste Management and Research, volume (25), issue 1, pages 14-23. 106