Technological solutions to mitigate 2/3-MCPD in crude palm oil production and palm oil chemical refining

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1 Technological solutions to mitigate 2/3-MCPD in crude palm oil production and palm oil chemical refining Oils & Fats Exhibition, Munich Food Safety Forum, September 14th, 2017 KLAUS-PETER EICKHOFF

2 Agenda 1 Palm oil figures and quality standards 2 Current discussion about MCPD and GE 3 Mitigation strategies for oil mills Conventional process ECO-D process CPO washing 4 Process changes for refining palm oil 5 Conclusions 2

3 Agenda 1 Palm oil figures and quality standards 2 Current discussion about MCPD and GE 3 Mitigation strategies for oil mills Conventional process ECO-D process CPO washing 4 Process changes for refining palm oil 5 Conclusions 3

the world. In 2016 around 65 Mio tons were produced.

4 Importance of Palm Oil 6% 4% 90% Palm Oil is the vegetable oil with the highest level of production in the world. In 2016 around 65 Mio tons were produced. The oil palm grows best in tropical countries with constant climate. 4

Estimated global palm oil production by countries Rank Country Production[1000 MT] 1 Indonesia 35.000,00 2 Malaysia 21.000,00 3 Thailand 2.300,00 4 Colombia 1.

5 Estimated global palm oil production by countries Rank Country Production[1000 MT] 1 Indonesia ,00 2 Malaysia ,00 3 Thailand 2.300,00 4 Colombia 1.175,00 5 Nigeria 970,00 6 Ecuador 560,00 7 Honduras 545,00 8 Papua New Guinea 522,00 9 Ghana 520,00 10 Guatemala 515,00 11 Côte d'ivoire 415,00 12 Brazil 340,00 13 Cameroon 270,00 14 Costa Rica 270,00 15 DR of the Congo 215,00 16 Mexico 110,00 17 Philippines 85,00 18 Angola 58,00 19 Dominican Republic 53,00 20 Peru 51,00 21 Benin 50,00 22 Guinea 50,00 23 Liberia 42,00 24 Sierra Leone 36,00 25 Venezuela 15,00 Total ,00 Region [1000 MT] [%] South East Asia Latin America Africa Source: US Department of Agriculture, Year of estimate

6 Image of palm oil under pressure Text über "Einfügen Kopf- u. Fußzeile" einfügen 6

7 New Challenge 2/3-MCPD and GE 3- MCPD GE 3-monochloropropanediol Glycidyl ester MCPD and GE are considered as carcinogenic, whereas GE in addition even as genotoxic These esters are not present in crude oil, but are contaminents formed during processing, mainly during deodorization at higher temperatures (>230 C). GE is formed when diglycerides are heated to more than 230 C Issue of deodorizer design and process adjustment MCPD is formed by the reaction of chloride with glycerides under high temperatures and acidic conditions Main precursor is chloride, which can be mitigated by wet processing Text über "Einfügen Kopf- u. Fußzeile" einfügen 7

8 What means improving palm oil quality today? Oil Mill The focusin themillistoachievemaximumyieldandtoproducecpo withinthestandardquality specification, which is: FFA below 5% Moisture and impurities below 0.25% Deterioration of Bleachability Index (DOBI) 2.3 min. (3.0 is a very good value) Normally a premium is paid for CPO with very low FFA (< 3%) to ensurelow refining loss CausesoflowDOBI andpoorcpo oilquality: Unripe fruit bunches Delay in fruit processing(raining season) Contamination of CPO with badly oxidised sludge oil Prolonged sterilisation time Over heating and prolonged retention time in vertical clarifier tank High dilution rate and high moisture content Long processing time in the mill 8

9 What means improving palm oil quality today? Refinery CPO So far physical refining is the most common process: Dry acid pretreat. 0.1% FFA (as palmitic) for RBD Moisture and Impurities 0.1% max. Colour Lovibond 5,25 cell max. 3 red Bleaching Features of physical refining Dry acid pretreatment Hydration of phospholipids and metal removal Bleaching Absorption of gums and undesired components with activated bleaching earth Stripping / Deodorization Removal of FFA, odor / smell and heat bleaching at high temperature of C under 2-4 mbar vacuum Significant influence on the formation of MPCD and Glycidyl Esters Deodorization RBD palm oil Palm Oil 9

10 Agenda 1 Palm oil figures and quality standards 2 Current discussion about MCPD and GE 3 Mitigation strategies for oil mills Conventional process ECO-D process CPO washing 4 Process changes for refining palm oil 5 Conclusions 10

11 Potential of different edible oils to form 3-MCPD and glycidyl ester Total production of edible oils in 2016: 180 Mio. t nflower 9% PKO 4% others 9% Rapeseed 14% Palm oil 35% ppm mg/kg (Median) 1 Soy 29% Palm oil Soy Rapeseed Sunflower 3-MCPD Source: USDA Statista GE Source: EFSA 11

12 Current status palm oil Food safety discussions about 3-MCPD and GE Comparably high content of MCPD and GE in palm oil MCPD and GE are suspected to be carcinogenic and genotoxic High pressure on food producers EFSA has been requested by the EU Commission for a risk assessment EFSA recommendation for TDI: 3-MCPD: 0.8 µg/kg body weight On discussion at EU level: 3-MCPD: 2 ppm (perspective < 1ppm in future) GE: 1 ppm Consumer groups and food safety organizations demand lowest possible concentration in refined oils 12

13 Value chain and production flow in palm oil processing Plantation Breeding Cultivation Harvest Storage and transportation Oil mill CPO recovery process Storage and transportation Refinery 13 Physical refining RBD Storage and transportation 13

14 Mitigation strategies Plantation Mill Refining MCPD & Glycidyl Esters Avoiding (removal) of precursors Avoiding of esters 14

15 Causes of 3-MCPD creation in palm oil processing Precursor for the creation of 3-MCPD in palm oil is primarily chlorine Sources of chlorine: Fertilizers and pesticides Saline soil Diluting water Steam Condensate Sludge oil 15

16 Agenda 1 Palm oil figures and quality standards 2 Current discussion about MCPD and GE 3 Mitigation strategies for oil mills Conventional process ECO-D process CPO washing 4 Process changes for refining palm oil 5 Conclusions Palm Oil 16

How to mitigate the esters in palm oil Plantation Breeding Cultivation Harvest Storage and Transport Avoiding or removing of precursors FFB are not suitablefor storage Metabolic process starts

17 How to mitigate the esters in palm oil Plantation Breeding Cultivation Harvest Storage and Transport Avoiding or removing of precursors FFB are not suitablefor storage Metabolic process starts directly after harvesting Formation of FFA and Diglycerides Getting lowest diacylglycerols(dags) content Harvest at optimum ripeness Minimization of chlorine containing substances in cultivation Pesticides Fertilizer 17

How to mitigate the esters in palm oil Oil mill Sterilization CPO recovery process Storage and Transport Avoiding or removing of precursors Shortest possible processing time in the mill Formation of

18 How to mitigate the esters in palm oil Oil mill Sterilization CPO recovery process Storage and Transport Avoiding or removing of precursors Shortest possible processing time in the mill Formation of FFA and Diglycerides No circulationof low grade oil Getting lowest diacylglycerols(dags) content Shortest possible sterilization time Use steam without chloride Minimization of chlorine containing substances Washingof FFB to remove chlorine Additional washing of CPO, ev. with slightly alkaline water 18

19 Agenda 1 Palm oil figures and quality standards 2 Current discussion about MCPD and GE 3 Mitigation strategies for oil milsl Conventional process ECO-D process CPO washing 4 Process changes for refining palm oil 5 Conclusions 19

20 Mitigation stategies in oil mills Conventional Process Dilution 20-40% to FFB Palm fruits Dilution Press Vertical clarifier Steam Condensate Sand trap Sludge Top oil Dilution Fibres Vibrating screen Live Steam Sludge tank Oil tank Steam Live Steam Buffer tank Sand De-sanding Purifier Sludge Live Steam Feed tank Vacuum dryer Oil to storage Cake Waste water to effluent 3-phase decanter Oil Recirculation Possible accumulations of chlorine into the oil by steam and diluting water 20

Mitigation strategies in oil mills Influence of centrifuges used feed H 2 O Feed Oil + H 2 O + Emulsion sludge water oil 3-phase machine, separate discarge of oil and water More effective,

2-Phase machine Needs high amount of dilution water Permanent supervision is necessary to avoid oil losses Poor oil quality higher recirculation High power consumption feed oil water No need

21 Mitigation strategies in oil mills Influence of centrifuges used feed H 2 O Feed Oil + H 2 O + Emulsion sludge water oil 3-phase machine, separate discarge of oil and water More effective, 5,400 rpm The separation efficiency can be adjusted Stable separation with discharge of the liquids under pressure No need for manual adjustment Drain Low speed horizontal separator 1,500 rpm 2-Phase machine Needs high amount of dilution water Permanent supervision is necessary to avoid oil losses Poor oil quality higher recirculation High power consumption feed oil water No need for manual cleaning or CIP Continuous cake discharge Lower solids content in the waste water Low water consumption Handling of solid enriched feed with higher viscosity is possible cake Palm Oil 21

22 Comparison different processes Centrifuges available for sludge de-oiling Star Bowl Centrifuge Nozzle Separator Oil content in light phase 30 % 80 % 80 % Dilution water consumption Solids discharge Availability due to nozzle blockage High Medium Low Slurry, contains all nutrients Very low Slurry, contains all nutrients 3 Phase Decanter Discharged as cake Good with CIP Very good Handling Complicated Easy Easy Oil losses in the heavy phase Medium/high Low Low Labor-intensity High Medium/low Low Price (investment) Very low Medium High 22

23 Agenda 1 Palm oil figures and quality standards 2 Current discussion about MCPD and GE 3 Mitigation strategies for oil mills Conventional process ECO-D process CPO washing 4 Process changes for refining palm oil 5 Conclusions 23

24 Mitigation strategies for oil mills ECO-D Process Dilution 0-5 % to FFB Live steam

25 Differences between conventional and ecod process Conventional palm oil process ECO-D Process Dilution water % to FFB < 5% to FFB Oil losses min. 0.4 % to FFB % to FFB FFA % more than ECO- D approx. 3% Retention time 8-10h in settling tank 1 hour Required space high low POME/slurry 0.65 m³/t FFB 0.45 m³/t FFB 25

26 ECO-D Process ECO-D -A System forthefuture Direct crude oil processing without vertical clarifier tank. Shorter processing route, product exposure to heat is substantially reduced. Best quality oil compared with conventional process is achieved. Ecological and simplified process without dilution water. Reduction in hot water consumption, energy and treatment costs - substantial cost savings. As no dilution water is required, the resultant effluent slurry is reduced to 15 ~ 20 % to FFB. Lower oil losses compared to conventional process, resulting in substantial savings. 26

27 Agenda 1 Palm oil figures and quality standards 2 Current discussion about MCPD and GE 3 Mitigation strategies for oil mills Conventional process ECO-D process CPO washing 4 Process changes for refining palm oil 5 Conclusions 27

28 Total chloride levels in palm oil products today Sample Average value(ppm) Range (ppm) Crude palm oil 7.29 (±5.9) RBD palm oil 2.46 (±0.9) RBD palm olein 2.30 (±1.1) RBD palm stearin 1.89 (±1.1) Source: MPOB Palm Oil 28

29 CPO Washing Features: Maximum removal of chlorines in the mill Mitigation of 3-MCPD esters in the refinery Removal of other contaminants (e.g. phospholipids) Best oil quality by oil cooling before storage Process target: Reduce inorganic chloride content from 8 15 ppm to 2 ppm Can be combined with conventional and ECO-D CPO recovery processes 29

30 Agenda 1 Palm oil figures and quality standards 2 Current discussion about MCPD and GE 3 Mitigation strategies for oil mills Conventional process ECO-D process CPO washing 4 Process changes for refining palm oil 5 Conclusions 30

How to mitigate the esters in palm oil Refinery Washing/ Degumming of CPO Bleaching Physical or chemical refining Washing/ Degumming of CPO Removal of inorganic chlorine and phoholipids Change from

31 How to mitigate the esters in palm oil Refinery Washing/ Degumming of CPO Bleaching Physical or chemical refining Washing/ Degumming of CPO Removal of inorganic chlorine and phoholipids Change from physical to chemical refining 2-stage neutralization for best possible oil quality Lower temperatures in deodorization stage lead to lower GE content Only a chemically neutralizedoil allows lower temperaturesin the downstreamdeodorizingstage. Very high deodorizationtemperaturescreate GE Minimization of MCPD Treatment of CPO with the aid of sodium hydroxide produces the best results in the reductionof chlorine and thus less contamination with 3-MCPD esters 31

32 CPO washing / degumming Features: Simple washing with 2 to 5 % demineralized water Acid addition not recommendable(precursor for MCPD formation) High shear mixing of oil and water recommendable Process achievements: Removal of inorganic chlorine < 2 ppm Cl in freshoils (e.g. FFA < 3 %) possible Reduction of phospholipids Removal of other impurities Reductionofbleachingearthconsumptionby30 50 % Text über "Einfügen Kopf- u. Fußzeile" einfügen 32

33 Chemical Refining / 2-Stage Neutralisation Features: Reliable process, even for worst crude oil qualities Can be also used for washing only in case of top CPO quality Process achievements: FFA content: < 0,1 % Soap content: < 100 ppm 3-MCPD mitigation: < 1 ppm possible 33

34 Additional advantages of chemical refining vs physical refining Longer shelf life of the trefined oil due to metal ions removal (higher oxidation stability) Reduction of bleaching earth consumption (up to 50%) Lower temperature in deodorizer possible < 220 C as opposed to C for FFA stripping / deodirization Effect of lower temperature: Mitigation of GE and 3 MCPD esters Premium price for chemically refined palm oil Soapstock is a by-product(soap production, fatty acid recovery by splitting) 34

35 Agenda 1 Palm oil figures and quality standards 2 Current discussion about MCPD and GE 3 Mitigation strategies for oil mills sconventional process ECO-D process CPO washing 4 Process changes for refining palm oil 5 Conclusions 35

36 Summary and Conclusions If you want to minimize MCPD and GE in palm oil, you have to start as early in the process as possible The most crucial factors in the mill are: oil quality and chloride content That makes ECO-D best process in terms of MCPD and GE mitigation (due to its shortest processing time, no dilution water and lowest FFA content For all conventional recovery processes: use 3-phase decanter due to lowest re-circulation volumes Use low quality oil only for producing oleo chemicals or biofuels Integrate CPO washing in your mill Change from physical to chemical refining 36

37 gea.com

Food Safety and Quality. Gerrit van Duijn

Food Safety and Quality. Gerrit van Duijn Food Safety and Quality Gerrit van Duijn 1 Presentation overview Food safety in the traditional supply chain Supply chains overview - Seed oil supply chain - Palm oil supply chain - Oil refining Food safety