Flexible bleaching

solutions
Alfa Laval bleaching processes for fats and oils
 Bleaching is one of the key processes
in fats and oils refining, designed to
remove not only pigments, but also
a wide range of other impurities.
Most crude fats and oils contain
impurities that have to be removed
for both commercial and health
reasons. Modern industrial bleaching
technologies are the way to do this.

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Flexible paths to
bleaching results

Bleaching – simple Efficient bleaching makes it possible to: and stability of your final product,
yet complex and therefore have to be removed
• remove certain pigments such as
to ensure that the product is
The bleaching of fats and oils is carotinoids and chlorophyll
commercially attractive.
normally carried out either after
• decompose and partially remove
alkaline refining or degumming,
oxidation products Bleaching agents
and prepares the oil for the final
deodorization process. In the case of • remove contaminants such as The most commonly used way to
crude palm oil, bleaching is the initial soaps and trace metals bleach fats and oils is to treat them
stage of the entire refining process. with surfactant powdery materials.
• remove traces of phosphatides
These bind (also known as “adsorb”)
At first glance, bleaching seems a
• remove polycyclic aromatic the pigmented substances in the oils
relatively simple process that consists
hydrocarbons and other pollutants. to the extensive surface area provided
of mixing the oil with a powder,
by them being in powdered form.
blending for a few minutes and then All these substances can have
removing the powder again. adverse effects on both the quality
However, this process is quite com-
plex both in theory and in practice.
And the term “bleaching” is in fact a Crude oil
somewhat misleading description for a
Physical refining Chemical refining
complex refining process in which the
removal of pigmentation is no longer Water
the most important purpose. Gums drying Crude lecithin
degumming

Getting rid of impurities Special Alkali Soapstock

Acid oil
The prime focus in modern bleaching degumming neutralization splitting
processes is now the removal of a Dewaxing Dewaxing
wide range of different impurities,
of which pigmentation is only one.
Such impurities can virtually be Bleaching Bleaching Hydrogenation
removed using new processes in
which combinations of different
bleaching agents are used to bind Deacidification/
Deodorization
deodorization
specific impurities. These are then
Fatty acid
removed when the bleaching agent is distillate
subsequently filtered out. Edible oil Edible oil

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 The basis for
modern bleaching

Modern bleaching processes use a Wide range of uses

substantial range of different bleaching Bleaching also reduces the number
agents in order to remove a wide of substances that can affect the
range of specific impurities, in addition taste and smell of the fats and oils.
to the pigments. It is therefore used in refining and
The agents normally used include: processing fats and oils that include
soybean, palm, rapeseed, sunflower,
• natural bleaching earths (used with palm kernel and coconut oils, as well
only limited colour-reducing effect as fish oil and lard.
but are particularly useful in treating
animal fats) However, the increasing quantities of
environmental pollutants and other
• acid-activated bleaching earths impurities often found in raw materials
(widely used for removing all kinds of all kinds mean that bleaching is
of impurities) rapidly becoming an obligatory part of
• activated carbon (used to remove treating all fats and oils.
Alfa Laval plate heat
polyaromatic hydrocarbons and to This means that bleaching is crucial exchangers are ideal for
ensure the removal of a wide range if you wish to ensure high-quality
heating and cooling the
oil efficiently, both before
of specific pollutants) products, and is therefore normally and after the bleaching
included in all refining sequences. process.
• synthetic amorphous silica
compounds (used largely in Heat recovery using an
The Alfa Laval advantage for bleaching economizer is also used
wet bleaching, with a focus on process operators includes: in cases where the oil
selectively removing phosphatides, subsequently undergoes
trace metals and soaps). • flexibility dewaxing.
• exceptional reliability
• low energy costs
• easy operation.

Dry bleaching has several distinct advantages. These include:

• lower initial investment compared with other • lower operating costs due to the use of plate
types of bleaching heat exchangers for heating and cooling which
reduces utilities consumption compared with
• easy, straightforward control and operation
shell-and-tube solutions
• only a minimum of space is required for
• minimal energy consumption.
installation

4
 Mixing in the best
At the Prikolotnoye Oil Extraction plant in the Kharkov region of Ukraine,
Alfa Laval supplied a complete dry bleaching plant with a multi-dosing
system. Due to the flexibility of the design and Alfa Laval technical expertise,
the company was also able to incorporate its own ideas about mixing and
dosing into the system.

“Alfa Laval really listened to what we wanted, supplied us with highly efficient
equipment, and made suggestions about how we could get the most out of it,”
said Andrey Nepochatov, head of the refinery plant. “The system works perfectly.”

Dry bleaching with bleaching earth, activated carbon steam-blowing the contents of these
Dry bleaching is the method or a mixture of these two. This is done filters.
traditionally used for fats and oils. under vacuum to prevent oxidation,
Filtered oil collects in the buffer tank,
Although most common in Europe and in the presence of sparging steam.
which operates under the same
and Asia, it is a process that industry This process is called dry bleaching, vacuum as the bleaching reactor.
experts throughout the world are because the bleaching reactor From there, oil goes via one of the
familiar with, and provides a viable operates at a vacuum of about 70 torr, polishing filters to the next process
solution in many processing situations. which greatly reduces the humidity in step, or to storage.
Before it is mixed with bleaching the oil.
If it proves necessary to build up a
earth, the oil is heated. If required, After bleaching, the bleaching agent filter cake in order to improve filtration,
a citric acid solution is mixed with is normally removed using pressure pre-coating can be accomplished by
the hot oil to bind trace metals and leaf filters. Naturally, the filter cake recirculating the oil through the filter
decompose any residual soaps. that accumulates here still contains via a precoating tank.
After this treatment, the oil is mixed oil. Much of this can be recovered by

Dry bleaching

Transportation Transportation Optional

system system

To atmosphere

Bleaching earth Activated carbon Cyclone

Vacuum
Dosing Dosing
unit unit
Acid mixer
Citric/
phosphoric
Steam
acid Day tank Pressure Pressure Oil
manifold
leaf filter leaf filter collector
Sparging
steam
Steam Steam
Bleaching
reactor
Bleaching
earth
Crude oil

Spent Spent
Steam
earth earth Slop oil

Economizer Heater
M Filter aid

Polishing filters
Vacuum

Pr ecoating
Water
tank
Cooler
Water
Buffer
tank
Bleached oil

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 Just add water

Wet bleaching Vacuum

Oil in Bleaching earth

As the name implies, wet bleaching is a bleaching process in from dosing unit
which water is added to the oil while it is in contact with the
bleaching agent in the bleaching reactor.

The presence of small amounts of water results in more efficient

use of the relatively expensive bleaching earth. This greater
efficiency results in lower earth consumption as well as reductions
of total oil losses.

This makes wet bleaching an attractive solution on account of the

Sparging
overall economics of the process, even though the investment steam
costs are slightly higher.

The water present during wet bleaching is introduced in the form

of a citric acid solution, or by taking wet oil from the separation
line. Adjustment is carried out by careful control of the operating
vacuum in the bleaching reactor to determine how much of the
water subsequently evaporates.

Even tiny amounts of water – anything in excess of 0.5% –

Oil outlet
remaining in the mixture after this will cause filtration problems
later on. The oil therefore has to be dried before filtration. Alfa Laval bleaching reactor

6
In terms of the equipment used, the basic difference
between wet and dry bleaching installations is
therefore whether or not a dryer is located between
the bleaching reactor and the filtration system.

The advantages of wet bleaching include:

• more efficient use of the bleaching earth

• easy to combine with a silica treatment process
• highly flexible
• low consumption of bleaching earth
• reduced oil loss during filtration.

Alfa Laval bleaching reactors

Under normal atmospheric conditions, mixing the
adsorbent into the oil results in rapid oxidation, due
The reactor is divided into three compartments to
to the large surface area of the active adsorbents.
ensure uniform reaction times and avoid oil flow short
It is important to avoid this, which is why the design
cuts inside the reactor.
of Alfa Laval bleaching reactors ensures that the oil
and bleaching earth are both deaerated before being It is not always possible to use steam to agitate the
mixed together. mixture. If not, the bleaching reactor can be equipped
with a mechanical agitation system.
The spray curtain of oil entering the bleaching reactor
from above, along with the special design of the Alfa Laval bleaching reactor designs are equally
reactor, prevents any of the bleaching agent being suitable for both dry and wet bleaching, with no
drawn up into the vacuum system above. modification necessary.

Wet bleaching
Transportation Optional
system

To atmosphere

Bleaching earth Cyclone

Vacuum Vacuum
Dosing
unit
500 torr 70 torr
Acid mixer
Citric/ Oil
Steam
phosphoric
manifold
collector
acid Day tank Pressure Pressure
Sparging Dryer leaf filter leaf filter
steam
Steam Steam
Bleaching
reactor
Bleaching
earth
Crude oil

Spent Spent
Steam
earth earth Slop oil

Economizer Heater
M Filter aid

Polishing filters
Vacuum

Precoating
Water
tank

Cooler
Water
Buffer
tank
Bleached oil

7
 Two into one does go
Two-stage bleaching At the second stage fresh adsorbent is then added
The two-stage bleaching process is essentially a to the treated oil until a new state of equilibrium is
combination of wet and dry bleaching, combined with reached. This oil then passes through a second
highly efficient two-step filtration. filtration stage.

The main idea behind two-stage bleaching is to

ensure that the dosing and filtration of the necessary
Two-stage filtration
adsorbents takes place between each stage of treating The filtration section in Alfa Laval two-stage bleaching
the oil. This means that the adsorption process can be takes place in two stages, featuring three alternating
made significantly more efficient. filters working in cycle for maximum efficiency, with the
almost saturated filter being used for prefiltration of the
This is because adsorption takes place on a con­ incoming oil.
tinuous basis until there is equilibrium between the
concentration of pigments and other impurities on This is because used bleaching earth from normal
the surface of the adsorbent and the concentration filtration processes still retains an estimated 20% of its
remaining in the oil. As soon as this equilibrium is adsorption capabilities. Alfa Laval two-stage filtration
reached, the adsorbent is filtered out of the oil. systems ensure more efficient exploitation of these
relatively expensive filtration agents.

Two-stage bleaching

Transportation Optional Transportation Transportation

system system system

Bleaching
earth/silica Bleaching earth 70 torr Activated carbon
Vacuum Vacuum Vacuum
Dosing Dosing
unit unit
Citric/
500 torr 70 torr
Acid mixer
phosphoric
acid Steam Pressure Steam
Day tank manifold manifold
leaf filter
Dryer
Sparging Sparging
steam steam

Bleaching Bleaching To atmosphere

reactor reactor

Cyclone
Crude oil Spent
Steam earth
Water

Cooler
Economizer Heater
Water Pressure Pressure Oil
leaf filter leaf filter collector

Bleached oil
Steam Steam

Polishing filters Bleaching

Vacuum
earth

Spent Spent
earth earth Slop oil
Buffer
tank

M Filter aid

Precoating
tank

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 On the customer’s wavelength
After carrying out a series of preliminary investigations and tests, under the supervision
of Production Manager Niels Jørgen Eriksen, Fiskernes Fiskeindustri A.m.b.a. in Skagen
(Denmark) awarded Alfa Laval the contract to deliver and install the process equipment
needed to ensure that there are no traces of toxic pollutants in the company’s fish oil
products.

Niels Jørgen Eriksen said, “The Alfa Laval project has met our needs, and we are definitely
satisfied with the results to date. The challenges involved in removing toxic pollutants
have shown us the clear benefits of talking to experts who are really on our wavelength.”

Using synthetic silica compounds Dosing systems

Two-stage bleaching is particularly relevant if The way the bleaching agent is added to the
you wish to use synthetic amorphous silica reactor is crucial for maximum efficiency. The
compounds as an adsorbent. These are particu- dosing of the bleaching earth is set by changing
larly effective for removing phosphatides, trace how frequently the two valves above and below
metals, gums and soaps. Using synthetic silica the dosing chamber open and close.
also makes it possible to cut back considerably
Alfa Laval dosing systems are designed to ensure
on wastewater from refining edible oils.
a smooth, proportional flow, with an accuracy of
The best performance using synthetic silica com- ±0.03% in relation to the oil flow.
pounds normally requires the presence of small
Alfa Laval provides the most straightforward
amounts of water. This means that it is possible
dosing solution currently available. It provides
to extend a wet bleaching plant by adding a
greater dosing accuracy, lower operating costs,
synthetic silica dosing system upstream.
less maintenance and fewer spare parts.
The advantages of two-stage bleaching include:

• the best bleaching results for oils otherwise Control systems

often considered difficult Alfa Laval supplies bleaching plants with a wide
selection of different levels of automation to
• possibilities for using less expensive bleaching
match customer requirements.
agents and first-stage adsorbents, thus
reducing operating costs These range from relatively simple manually
operated configurations with local control loops
• reduced bleaching agent loading, resulting in
to fully automated plants based on SCADA
lower costs
control technologies.
• high degree of flexibility.

Multiple dosing
Alfa Laval experience has shown that in many
fats and oils bleaching installations, the best
results are achieved by using a combination of
bleaching adsorbents. The percentages of the
different additives used are altered depending
on the type of oil, its quality and the adsorbents
used. This makes it possible to use a substantial
range of different adsorbents with different
characteristics.

As an example, Alfa Laval bleaching reactors can

be equipped with up to three dosing systems for
maximum flexibility.

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 Nonstop
Performance

10
Service counts We can also provide you with considerable savings
Alfa Laval operates with a highly sophisticated by ensuring full compliance with the relevant national
Nonstop Performance concept made possible by our and international regulations for design codes, safety
global service network and spare parts distribution procedures and best engineering practice.
centres in more than fifty countries throughout
Alfa Laval engineering services include:
the world.
• installation design in full accordance with
Our expertise ensures that any service work required is
international standards
carried out with the absolute minimum of disturbance
to operations. • installation supervision
• commissioning and start-up
Process know-how
• operator training
One of the key advantages of working with Alfa Laval
to install, update and extend your bleaching systems • documentation
and equipment is our extensive practical experience.
• comprehensive spare parts packages
Alfa Laval’s proven ability to design and calculate a
• operational, maintenance and service support.
wide range of process configurations to meet specific
customer requirements can provide you with the
benefits of our vast body of accumulated know-how. Full control
Alfa Laval has full control over the entire supply chain
Engineering services associated with the company’s equipment. This means
we can provide customers with prompt responses,
Alfa Laval provides a wide range of supplementary
excellent availability and lead times that are second
engineering services that can help ensure that your
to none.
new installation comes on line as quickly and efficiently
as possible.

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This is Alfa Laval
Alfa Laval is active in the areas of Energy, Marine,
and Food & Water, offering its expertise, products,
and service to a wide range of industries in some
100 countries. The ­company is committed to
optimizing processes, creating responsible growth,
and driving progress – always going the extra mile to
support customers in achieving their business goals
and sustainability targets.

Alfa Laval’s innovative technologies are dedicated to

purifying, refining, and reusing materials, promoting
more responsible use of natural resources. They
contribute to improved energy efficiency and heat
recovery, better water treatment, and reduced
emissions. Thereby, Alfa Laval is not only accelerating
success for its customers, but also for people and the
planet. Making the world better, every day. It’s all
about Advancing better™.

How to contact Alfa Laval

Contact details for all countries are continually up-
dated on our web site. Please visit [Link]
to access the information.

PFT00121EN 2004