Soybean Oil Process - How to Implement a Novel Project?

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1 Cuban Experiences on Cleaner Production as Innovative Solutions for the Food Industry By yeni Published: 10/20/ :48 Focus Themes: Technology and value addition To which sector/s of agribusiness does the solution apply? : Processing Please name: Cleaner Production Please describe the solution /project. : The adoption of the Cleaner Production (CP) as way to obtain environmental and economic benefits in the Cuban agro-alimentary sector has opened the doors for the generation of solutions or options that have changed the situation in a part of our industry. The application of the CP methodology provided by UNIDO has repercussion in each one of the dimensions of the sustainable development. Sample of this is, the reduction of the water consumption in the industrial processes leading to the positive impact on the ecosystem and people, allowing the conservation of this resource and at the same time reducing the production costs. We want to share three solutions or CP options implemented in a beverage industry after application of a CP project and other solution related with the application of technical software in the vegetable oil refining process; all of them focused to reduce the water consumption. The solutions are described below: - Beverage Industry: Ronera Central, belonging to Cuba Ron S.A. It counts with a Distillery to produce Alcohol A and a Rum factory where it produces Havana Club and Cubay rums. CP option 1. The reuse of wastewaters from the distillation columns as feed water for the steam boiler and as dilution water in the distillation process. (Distillery) This option consists on the recovery and reuse of 9,450 m3/year of water with about 869, kcal which were spilled to the environment, contributing with a polluting load of 6 t of COD/year. This water is a waste from the distillation columns and has the quality to be used as feeding water to low pressure boilers and also to be used again within the distillation process. CP option 2. The reuse of water generated at the process of refilling up of barrels in the same process. (Rum factory) About 1,080 m3/year of water from the process of refilling up of barrels are spilled after used. The refilling up process of a barrel could take from one to several days depending on the grade of dryness of wood and the need to be used. The storage of the water generated in this process in a tank and its treatment with NaClO to restore the microbiological properties until the permissible limits to be returned to the process constitutes the principle of this CP option. CP option 3. The reuse of water rejected from Reverse Osmosis System, for cleaning operations. (Rum factory) In the process of water treatment for the elaboration of rums using the inverse osmosis system are spilled to the environment around 2,400 m3/year of water coming from the first rejection stream. The characteristics of this stream allows that it may be used in the cleaning of the floors of the aging warehouse, as well as in the scrubbing of the vehicles of the self-driven park of the entity. This water is stored and reused according to the frequency of the cleaning operations of the mentioned areas. At this moment we are studying the application of the Pinch Technology to reach the integration and reuse of the wastewater streams mentioned in the options 2 and 3, as well as those coming from the processes of water treatment for ionic exchange using resins of exchange of sodium cycle that take place in the entity. - Oil and Fatty Industry: Alberto Alvarez Soybean Oil Refinery, called H2, located near Havana City Bay. 1 / 7

2 Solution 4. Use of simulation as a strong tool for process optimization. This option consists in the application of PRO II simulation software for optimization of the soybean oil refining process: implementation of proposed physical refining instead of existent chemical refining. The use of technical simulators provides, in a quick way, to predict the behaviour of a process attending the variations of its operational parameters, the optimization of these and the comparison of processes among other advantages that have to be supported by the process knowledge, the temperature dependent and not dependent properties of the substances that intervene, the operation parameters, the selection of the modules that simulates the equipment and the thermodynamic model that describes the process. In this case, the comparison between the chemical and physical processes using a simulation software, shows that the quality of the refined soybean oil obtained by both technologies is inside of the accepted one by the Alimentary Codex to edible vegetable oils. During the simulation were optimized the steam consumption. As a result we obtained that with the application of the physical process we obtain edible soybean oil with less global consumption of energy and less consumption of water compare with the process of chemical refinement. When eliminating the neutralization stage that is carried out during the chemical refinement, the emission of the residuals generated in this step ends. They are constituted by soaps, gums and wastewaters generated in the oil washing step. What problem or market opportunity did it address? : These CP project are focused to elevate the efficiency and competitiveness of our companies on a sustainable base. The first three options go specifically to the preservation of water, besides the reduction of the polluting load and the energy consumption they suppose. The fourth option is guided to obtain quick answers on the behaviour of a process allowing the taking of decisions. How was the solution developed? : The CP project developed in Ronera Central was carried out by a multidisciplinary team that kept in mind the following steps: - Step 1. Planning and Organization - obtain commitment of top management - involve employees - organize a team inside the company - identify barriers and solutions to the CP project - Step 2. Pre-assessment - compile and prepare basic information - preparing a process flow diagram - preparing material input-output quantification and characterization 2 / 7

3 - Step 3. Assessment - preparing a detailed material balance with losses - conducting cause diagnosis - generating options - screening options - Step 4. Feasibility analysis - conducting technical, economic and environmental evaluation - selecting feasible options To develop the simulation of the chemical and physical refining process was necessary: - define the units of measure - select the components - check the component s properties - define the thermodynamic model - built the process flow sheet - specify the process stream and unit data - run the simulation - view the results What were the implementing stages of the solution?: To implement the feasible CP options in Ronera Central was prepared a CP implementation plan which contemplated the material and financial resources, responsibilities and period of the execution and was decided the frequency of meetings to check the implementation plan established. The main material resources to implement the CP options were: CP option 1: pipes, accessories, a tank, a water pump and thermal insulation CP option 2: Pipes, accessories, a tank, NaClO, a dosification pump and a water pump CP option 3: pipes, accessories and a water pump In the solution 4 related with the simulation of the soybean oil refining process, the obtained results were compared with those of the real process as it is operating nowadays. The main element to be considered to the development and implementation were: PRO II simulation software, access to specialized databases of compounds or literature, process knowledge and good metrology in the process. 3 / 7

4 What challenges had to be overcome?: In both projects (CP project in Ronera Central and Simulation project) it was a challenge to achieve the total employee motivation and participation especially of those directly involved within the developing areas. In the project of the simulation the main challenges were the knowledge of the software and the process, the metrology to obtain the data of the real process and the dependent properties of the temperature of some components involved in the simulation. What are the lessons learned in implementing the solution? What factors were critical for its success? : In the execution of these projects we learned the significance of the motivation of the employees. It allows them to provide new ideas that improve the solutions or options generated during a project of CP. In the specific case of the simulation project we learned that the order of the established steps for its development and execution should not be violated if there is not a wide experience in the use of the software. If there are other solutions to a similar problem what makes this one different?: The solution to the environmental problems of an industry can be diverse but led as a CP project it guarantees the prevention and continuity of its improvement in the economic and environmental performance. The use of simulation software allows obtaining very quick answers of the behaviour of a process and the optimization of its parameters once developed the simulation of the process. How long was the duration of the project / how long was required for the solution?: The time that required the execution of the project of CP in Ronera Central until the stage of feasibility of the generated options was of 1 month. In an individual way the three options corresponding to this project had an approximate time of implementation of: - CP option 1: 20 days - CP option 2: 90 days - CP option 3: 30 days Which institutions / organizations are supporting the implementation of the solution? : Other Please name: Cuban Ministry for the Food Industry What are the key areas of impact?: Productivity Other Please Specify: Evironment How is the impact evaluated?: The economic, environmental and social impact of each option generated in a CP project is evaluated comparing the situation before and after the implementation. For the CP options, 1, 2 and 3 have that: CP option 1: The reuse of wastewaters from the distillation columns as feed water for the steam boiler and as 4 / 7

5 dilution water in the distillation process. (Distillery) - 28 % saving on water consumption in the distillery; - 30 % reduction on water specific consumption per volume of alcohol A produced (from 0.66 to 0.46 m3/hl alcohol A); - This option avoided the discharge from an equivalent polluting load to 6 t of COD/year; - Economic saving of 2, US$/year. CP option 2: The reuse of water generated at the process of refilling up of barrels in the same process. (Rum factory) - 8 % saving with respect to the Rum factory total water consumption; - This option avoided the discharge from an equivalent polluting load to 0.5 t of COD/year; - Economic saving of US$/year. CP option 3. The reuse of water rejected from Reverse Osmosis System, for cleaning operations. (Rum factory) - 17 % saving with respect to the Rum factory total water consumption; - This option avoided the discharge from an equivalent pollution load to 0.3 t of COD/year; - Economic saving of US$/year. The same procedure was used to evaluate the impact of the simulation project. The results were: Solution 4. Use of simulation as a strong tool for process optimization - With the existing equipment it is possible to perform the physical refining instead of chemical refining, changing properly the operational conditions (temperature and pressure) for the deodorization step. - Reduction of overall energy consumption in 30% in the process by assessing new arrangements as optimization tool. - Implementation of the physical refining at industrial installation allows: - zero consumption of caustic soda, - significant diminishing of oil losses (oil entrapped in neutralization waste), - avoidance of using 70 t of caustic soda annually in the process, - reduction of the polluting load discharged to Havana Bay, in 12 t COD/ year through the avoidance of soap waste formation; - avoidance of 25,000 t of CO 2 emissions due to reduction of fuel oil consumption, - reduction on 9,374 kg/d of water used to refine de soybean oil. 5 / 7

6 What was/is the budget allocated to design/implement your solution?: ,00 USD How was the solution financed?: Other Were alternative sources of finance considered?: No Please Specify: It was done with internal resources of the enterprises involved in both cases How can the sustainability of the solution be ensured?: The CP solutions developed for the rum industry are normally paid considering only the save in water consumption and this will be kept forever. Savings allowed with the use of the simulation software in the oil refining process also guarantee its sustainability. Are beneficiaries able / willing to pay for services?: Yes they were able and willing to do it. What are the future plans for the implementing institution?: To continue its application and search for new CP options. How will the implementing institution continue to provide services to beneficiaries?: Keeping in touch with the CP team created in each industry. Are there expansion plans for new services new potential beneficiaries?: Both. Can the solution be replicated/scaled up to cover other areas/regions/countries/groups/products? : Yes, all the solutions may be replicated and scaled up in other industries within the same sectors, that is, for the same technology, and also in different regions and countries. In which way can this be achieved and what resources would be needed in order to replicate/scale up the solution? : Resources are as shown in response to question what where the implementing stages of the solution? What should be considered in the implementation?: The same steps and resources mentioned before. Is a business plan or project document available?: Project Document Please Upload Documents: Cuba-PML.pdf Does the solution model offer opportunities for South-South cooperation? : Yes 6 / 7

7 Is there cooperation already ongoing with initiatives or projects in other places? : No What are the tools and elements needed for South-South cooperation?: Intergovernmental agreements How could South-South cooperation be implemented? : Intergovernmental agreements Youtube Videos: 7 / 7