evaporation plant for the starch industry...• boiling point shift • purity of the feed product...
TRANSCRIPT
Evaporation plant for the starch industry
Starch products from corn, grain, potato and tapioca
2 · EVAPORATION TEchNOlOgy
Evaporation technology in the starch industry
Thanks to extensive know-how,
numerous investigations in the GEA
research and development center and
the experience gained during many
diverse installation projects, GEA is able
to offer tailor-made plant concepts that
meet the individual requirements of our
customers.
GEA has a comprehensive portfolio of
machinery, equipment and know-how
to configure and install fully integrated
manufacturing lines for starch products.
In addition to evaporation plant, GEA
supplies technologies for agglomeration,
crystallation, starch and gluten
separation, dewatering and drying.
Fields of application for evaporation
plants in the starch industry
• Steep water and washing water
• Thin juices
• Glucose
• Fructose
• Dextrose
• Maltose
• Sorbitol
Raw substances for starch production
• Corn
• Wheat
• Rye
• Triticale
• Rice
• Potato
• Tapioca
• Millet
gEA delivers plant with plate, shell and tube evaporators for multiple applications in the starch industry.
EVAPORATION TEchNOlOgy · 3
Product-specific parameters
• Initial concentration and final concentration
• Max. permissible product temperature
• Residence time
• Portion of dissolved and undissolved solid matter
• Viscosity
• Boiling point shift
• Purity of the feed product
• Operating time between cleaning cycles
• Liquid distribution in the evaporator adjusted
to the product
For an economically designed evaporation plant,
investment and operating costs, have to be taken
into account. Moreover, the energy situation of the
complete factory has to be considered.
A significant amount of information is required and
many marginal conditions have to be taken into
account to find the best solution for each application.
Taking into consideration the following aspects, GEA
will offer the best plant design for each customer:
Wide range of evaporator types and plant arrangements
4 · EVAPORATION TEchNOlOgy
Energy saving options
• Heating by means of exhaust heat
(e.g. dryer exhaust steam)
• Multi-effect evaporation
• Thermal vapor recompression
• Mechanical vapor recompression
GEA checks the customer‘s energy situation prior
to designing the plant to be able to offer the best
solution. Plant designed by GEA represent the
highest quality and cost effectiveness. We strictly
observe all criteria with regard to the specific process
requirements, and make reliability and ease of
operation an absolute priority.
GEA means
• Experience gained during more than 100 years
of evaporator technology and with more than
4,000 successful projects all over the world
• Extensive product knowledge
• Reliable and easy-to-operate plant
• Short plant commissioning periods
• Numerous patents in Germany and abroad
• An internal R&D center with lab-scale pilot plant
• Worldwide distribution network
• Certification according to DIN EN ISO 9001
EVAPORATION TEchNOlOgy · 5
Treatment of process effluents in the starch industry
Water flows
During the production of starch, different process waters are
produced when decomposing the raw substances. These steep
waters and washing waters contain valuable nutrients such as
proteins and lactic acid.
Concentration
To recover these nutrients, the water is concentrated in the
evaporation plant.
Concentrations achievable in evaporation
Corn steep water 50-55 % DS
Washing water from wheat starch
production
25-40 % DS
Potato fruit water 60-70 % DS
The achievable final concentrations depend on the production
process and on the mechanical and enzymatic pretreatment.
Use of the concentrate
• Valuable fodder addition
• Fertilizers
• Agars for the production of antibiotics
• Raw substances for alcohol production
Types of evaporators
• Falling film evaporator
• Forced circulation evaporator
Heating by means of
• Dryer exhaust steam
• Mechanical vapor recompression
• Thermal vapor recompression
• Steam
6 · EVAPORATION TEchNOlOgy
Wheat
concentrate
Fodder
Residual process water
Pentosans
gluten
Bran from milling
Milling
Fiber extraction
A-starch washing
Dewatering
B-starch
gluten agglomeration
Dough preparation
Starch-gluten separation
A and B starch separation
A starch pre-washing
Drying
A-starch
Effluent evaporation
Corn
corn steeping
Starch-gluten separation
gluten concentration
gluten
Pre-milling
Starch washing
Dewatering Dewatering
concentrate
germs
Fodder
germ separation
Fine milling
Drying Drying Drying
Fiber extraction
Starch
corn steep water evaporation
Fiber dewatering
Fine fiber dewatering
Drying
gEA evaporation
gEA equipment
EVAPORATION TEchNOlOgy · 7
Concentration of potato fruit water
An evaporation plant for the
concentration of potato fruit water,
comprising two identical lines that
each has a single-effect, falling film
evaporator as a pre-evaporator, heated by
a mechanical, vapor recompressor, as well
as a 3-effect falling film forced circulation
finisher, heated using a thermal vapor
recompressor.
Overall evaporation rate: 152,000 kg/h.
Evaporation
Potatoes
Fruit water separation
Protein extraction
Protein drying
concentrate
Fertilizers
gEA evaporation
gEA equipment
8 · EVAPORATION TEchNOlOgy
Evaporation
Wheat
Starch-glutenseparation
concentrate
Drying
Fodder
Concentration of effluents from wheat starch
Evaporation plant for the concentration of waste water and effluents from wheat starch production,
heated by a mechanical vapor recompressor.
Evaporation rate: 30,000 kg/h.
gEA evaporation
gEA equipment
EVAPORATION TEchNOlOgy · 9
Concentration of corn steep water
Evaporation plant for the concentration
of corn steep water. Comprising a 3-effect
falling film, forced circulation evaporator
with vapor scrubber and heated using
dryer exhaust steam.
Evaporation rate: 20,000 kg/h. Evaporation
Corn
corn steeping
concentrate
Drying
Fodder
gEA evaporation
gEA equipment
10 · EVAPORATION TEchNOlOgy
Concentration of starch saccharification products
In the preparation of starch
saccharification products, thin juices
of different degrees of saccharification
and concentration are produced from
which fats or lipids and proteins are
separated and subsequently concentrated
in the evaporation plant. The amount
of degradation in the basic D-glucose
molecule is indicated by its DE value.
The higher the DE value, the greater
the proportion of D-glucose molecules
compared with its dry weight. GEA
has the product know-how to supply
evaporation plant for different DE values
and saccharification products.
• Dextrose (pure D-glucose, DE > 90)
• Glucose syrup (DE 20 to DE 65)
• Maltodextrin (DE 3 to DE 20)
• Maltose syrup
• Isoglucose syrup (fructose 42, 55 or 70,
the figure describes the fructose
content)
• Sorbitol (derived from D-glucose)
• Mannitol (derived from D-glucose)
GEA uses the following
evaporator types for concentration
• Falling film evaporator
• Plate evaporator
Heated by:
• Mechanical vapor recompression
• Thermal vapor recompression
• Steam
• Dryer exhaust steam
Starch milk Starch milk
liqufaction: acidification,
enzymatic treatmentReaction
SaccharificationWashing, drying
crystallization
Modified starch
Maltose syrup
glucose syrupDecolorization, desalination
Evaporation
Dextrose syrup
Fructose syrup hFS 42
Evaporation
Evaporation
Mixing
Fructose syrup hFS 95
Fructose syrup hFS 55
Isomerization
chromatography
hydration
Decolorization, desalination
Decolorization
Decolorization, desalinationcentrifugation
Evaporation
Drying
Sorbitol
Drying
Dextrose monohydrate
Starch factorywheat, corn, rye, potato, tapioca
gEA evaporation
gEA equipment
EVAPORATION TEchNOlOgy · 11
Dextrose
A single-effect falling film evaporation
plant with two parallel, multi-path
calandria (for two different starch
hydrolysates), heated using a common
mechanical vapor recompressor.
Evaporation rate: 22,000 kg/h. Saccharification
Starch milk
liqufaction: acidification,
enzymatic treatment
Decolorization, desalination
Evaporation
Dextrose syrup
gEA evaporation
12 · EVAPORATION TEchNOlOgy
Decolorization, desalination
Dextrose syrup
hydration
Evaporation
Drying
Sorbitol
Sorbitol
A 2-effect plate evaporation plant, heated
using a thermal vapor recompressor, to
process sorbitol solutions.
Evaporation rate: 4,300 kg/h.
heating steamcooling water
Venting
VapourProduc tconcentrateVapour condensate
1, 2 P late evaporator 3 P late condenser 4 P late heat exchange r 5 c ondensate tank 6 Thermal vapour
recompresso r 7 V acuum pump
1
4
5
6
7
44 4
2213
gEA evaporation
gEA equipment
EVAPORATION TEchNOlOgy · 13
Glucose
A 2-effect falling film evaporation plant
with mechanical vapor recompression
and a single-effect falling film evaporator
(finisher) with a thermal vapor
compressor and a vacuum cooler for
glucose DE30–DE55.
Evaporation rate: 49,300 kg/h.Saccharification
Starch milk
liqufaction: acidification,
enzymatic treatment
Decolorization, desalination
Evaporation
glucose syrup
gEA evaporation
14 · EVAPORATION TEchNOlOgy
A directly heated, co-current, 3-effect
plate evaporation plant with a
downstream vacuum cooler to
concentrate glucose syrup.
Evaporation rate: 25,000 kg/h.
EVAPORATION TEchNOlOgy · 15
GEA is a global technology company with multi-billion euro sales operations in more than 50 countries. Founded in
1881 the company is one of the largest providers of innovative equipment and process technology. GEA is listed in the
STOXX® Europe 600 Index. In addition, the company is included in selected MSCI Global Sustainability Indexes.
We live our values.Excellence • Passion • Integrity • Responsibility • gEA-versity
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