Oils and fats Market with a future. Turning Ideas into Reality.

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Jeffery Anderson
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1 Oils and fats Market with a future Turning Ideas into Reality.

2 Agricultural feed stock processing Huge potentials Vegetable oil and its derivative products are now more sought after than ever. They form the basis for food, pharmaceutical and chemical products, energy in combined heat and power plants, and fuel for the transport sector. Demand for this product has been growing and is likely to continue due to the world s rapid population growth and rising living standards across wide sections of the emerging markets. The processing of raw material offers great potential to benefit from this demand. At the same time, feed stocks for the manufacture of vegetable oils are very diverse. For oil producers it is vitally important to identify appropriate partners with whom production facilities can be built and ensure a successful implementation of this project. Ferrostaal integrates all the relevant market players into projects and offers efficient solutions for both new and experienced producers, the agricultural industry and interested investors. We form consortia in which collaborations of trust form the basis of our relations with our partners. The technology we choose is the best for the project concerned. Where needed, individual financing solutions are provided and projects developed and designed. As an experienced EPC contractor we coordinate the engineering, procurement and construction for a smooth plant operation. 2

3 Oils and Fats Sustainable growth The demand for vegetable oils and fats continues unabated. Driven by the increasing consumption of high-quality edible oils for everyday food and the growing demands from the pharmaceutical and chemical industry, the market is developing its own momentum. According to forecasts from the Food and Agricultural Policy Research Institute, global production of vegetable oil from the four most important oil seeds soya, oil palm, rape and sunflower will have increased to around 142 million tonnes by The market for these oils is rising even faster. Besides a growing world population, rising living standards within emerging and developing markets is driving this demand, so that consumption of animal products (feedstuff and the like) and human products (cosmetics and washing soaps, etc.) is also increasing. This, in turn, has a positive effect on the need for high-protein products a by-product of edible oil production and a field in which Ferrostaal is also engaged. In addition to the huge demand for high-quality oils for human consumption, the further processing of these oils into oleochemical products like detergents, lubricants, cosmetics or biodiesel fuel is significant. Furthermore, new quality standards, such as energy awareness and more exacting environmental requirements, have stimulated the production of vegetable oils. This trend will, in turn, require the construction of many new industrial plants. As an experienced plant constructor, Ferrostaal has established itself in the edible oil and oleochemical sectors. During the last 35 years, we have constructed over 100 edible oil and various oleochemical plants, spread throughout 30 countries, including Russia, Brazil, Peru and Thailand. The range of services we provide varies from project development to project financing and management up to our role as experienced general contractor. Our plants combine a high level of environmental compatibility with low energy consumption criteria which are becoming increasingly important in times of diminishing resources Sum (million metric tonnes) FAPRI Worldwide edible oil production from the four most important oilseeds: soya, oil palm, rape and sunflower [from the graphic] 3

4 Processing technology From the seed to the final product Seed storage Seed Weighing bridge Railway unloading Reception Pre-cleaning Wet silo Seed dryer Silo storage Weighing bridge Truck unloading Extraction Oil clarification Extractor Desolventizer/ toaster Meal drier Meal cooler Oil screening Oil drying Oil filtration Decanter Distillation Water degumming Extracted oil Hexane condensation Absorption Hexane recovery Waste air scrubber Hexane storage Waste air Meal storage Setting pit Waste water Meal storage Truck loading Meal Whether as ingredients for food, pharmaceutical or chemical products, an energy source in combined heat and power plants or a fuel for transport, vegetable oils serve as an important primary material for countless products. Regardless of the raw material and the end product, Ferrostaal as project developer and general contractor organises the planning, financing, construction and commissioning of plants in the vegetable oil field. A wide range of application Most frequently used for further processing into vegetable oil are the oily seeds of soya, the oil palm, canola/rape and sunflowers. Apart from the oil, the meal that remains after production of the oil is also a valuable product used as a highprotein feedstuff in livestock farming. The so-called isolates contained in the meal can also be used as a food additive for human nutrition. Edible oil can be manufactured in different ways. In the case of soft seeds such as those from the sunflower, the oil is pressed from the oily seeds after treatment, producing a raw oil. In this case, however, since about eight per cent of the oil is left in the press cake, another process is often used: By means of solvent extraction, the raw oil is separated from the press cake after the treatment and prepressing of the seed, thus increasing the oil yield. The process varies slightly according to the raw material. In the case of soya, for example, the pressing can be completely dispensed with. The oil is extracted by means of solvents directly after the preparatory treatment of the raw material. Raw oils often contain substances that have a negative effect on the flavour, odour and shelf life of the oil. For this reason, practically all edible oils are nowadays refined. But refining is also important for the production of technical oil the higher the purity of an oil, the fewer the emissions when it is burnt. 4

5 Preparation Pre-pressing Daily bin Wheighing Cleaning Crushing Flaking Conditioning Pre-pressing Dehulling Flakes Press cake Press oil Hull pelletizing Hulls Refinery Degumming Gums Oil storage Neutralization Bleaching Deacidification Deodorizing Tank farm Ship loading Vegetable oil Soapstock splitting Dewaxing Used Bleaching earth Fatty acid destillat Fatty acid Waxes Transesterrification Fat splitting Glycerine water evaporation Fractionation/ distillation Glycerine distillation Hydrogenation Biodiesel Pure glycerine Fatty alcohol Hydrogenated fatty acid Distilled fatty acid Edible oil Edible oil is vital for human nutrition. It can be consumed without processing, but it is also used as a constituent in food. By means of special hardening processes, vegetable oil can be made into margarine. The meal left over from the production is used in agriculture as a high-grade feed. Oleochemicals For its use in pharmaceutical, chemical or fuel products, vegetable oil is treated in different ways to receive the desired raw material. Splitting breaks down the oil into its individual constituents, such as fatty acids and, in a further process step, fatty alcohols. From these elements, detergents, cleaning agents, cosmetics and other pharmaceutical products are manufactured. In the so-called transesterification process the structure of the vegetable oil is modified, producing methyl ester (biodiesel) and glycerine. Oil for combined heat and power plants Vegetable oil is also used as an energy source in combined heat and power plants. These are appreciably more efficient and more economical in consumption than conventional power plants, using up to 90 per cent of the primary energy that is largely lost in conventional plants. Biodiesel Biodiesel has already established itself in the market. Ferrostaal has recourse to its own technology for the manufacture of biodiesel and has received a worldwide licence for the Connemann process. This very economical technology allows fully continuous operation with minimal space requirements producing biodiesel of a quality above European standard. 5

Ferrostaal Managing industrial plant projects Our decades of experience as an EPC contractor for the construction of large industrial plants all around the world have distinguished Ferrostaal as

6 Ferrostaal Managing industrial plant projects Our decades of experience as an EPC contractor for the construction of large industrial plants all around the world have distinguished Ferrostaal as ideally suited for the design and construction of plants for the production of edible oil and oleochemical products. Our project development has supported our customers in forging new paths through the entire value chain. As project managers we ensure that plants are profitable on a long-term basis. Our services cover the entire process from planning to financing to turnkey handover. Development and financing Our services start at an early stage with the business idea. We put the project on a solid basis with feasibility studies, market analyses, a business plan and the search for strategic investors. In the contract phase we perform the preliminary work and devise strategies for the central questions. We are assisted by technology providers and engineering partners. In the financing phase we develop a customised, efficient and transparent financing strategy. In selected cases we also get involved financially. Project management Ferrostaal generally takes on overall responsibility for a project, frequently as the general contractor controlling the engineering, procurement and construction (EPC) of the plant right through to its commissioning. Risk management plays a central role here. Our project and quality management is certified in accordance with international standards. Based on transparency and trust our relationship with customers, suppliers and financial associates forms the basic principle of cooperation. Coordinating the partners In some projects we symbiotically join more than 100 partners. Our global sourcing is an important success factor here. We cooperate with the world s best suppliers of material and services, thereby guaranteeing the best possible cost and quality management. Our staff in over 40 countries systematically monitors the regional markets and thus supports our global sourcing activities. Precise knowledge of the creditworthiness and quality of the local providers ensures a solid basis for selecting the suppliers. As the general contractor we coordinate the work of all these partners, thus ensuring the high quality of the resulting products and services. Integration of complex systems Plants for the production of edible oil and oleochemicals are technically complex products. As a service provider acting in partnership, we reduce this complexity for our partners. The partnership does not have to end with the handover of the turnkey plant we also take on responsibility for maintenance and service. 6

Ferrostaal headquarters Ferrostaal locations worldwide In over 40 countries Ferrostaal has been linked to many of its customers by a long-standing partnership for 80 years.

7 Ferrostaal headquarters Ferrostaal locations worldwide In over 40 countries Ferrostaal has been linked to many of its customers by a long-standing partnership for 80 years. We know all the regions that are suitable for the economically attractive production of oils and fats. Together with our project partners, we select the right raw materials for successful projects according to the region. We have been at home there for decades. We contribute our market proximity, our experience and our international connections to ensure the success of our projects. This has made us into a world-renowned engineering specialist for vegetable oil plants. Contact Ferrostaal Industrieanlagen GmbH Industriestr Geisenheim Germany Phone Fax oilsandfats@ferrostaal.com 7

8 Ferrostaal Industrieanlagen GmbH Industriestr Geisenheim Germany Phone Fax

About the Company. Oil Seeds Processing Technology

About the Company. Oil Seeds Processing Technology About the Company Oil Seeds Processing Technology Solvent extraction - Miscella distillation - Meal desolventizing - Toasting, Drying, Cooling Oil Seeds Preparation - Conveying - Cleaning - Drying - Dehulling