Fenix Process Technologies Pvt. Ltd. FENIX Process Technologies

Oleochemicals Technology

Fat Splitting

Process
The empty volume of the tower is used as the reaction compartment. The crude fat passes as a coherent phase from the bottom to the top through the tower, whereas the heavier splitting water travels downward as a dispersed phase through the mixture of fat and fatty acid.

Degrees of splitting up to 99% can be reached. The continuous countercurrent high-pressure process splits fats and oils more efficiently than other processes in a reaction time of only 2–3 h. little discoloration of the fatty acids occur. As a result of the efficient internal heat exchange, this process affords high steam economy.

The utilities consumption per ton of feed is as follows (11).
Steam (6000 kPa) 190 kg
Cooling water (20_C) 3 m3
Electrical energy 10 kWh
Process water 0.6 m3

Fatty Acid fractionation

Process
The empty volume of the tower is used as the reaction compartment. The crude fat passes as a coherent phase from the bottom to the top through the tower, whereas the heavier splitting water travels downward as a dispersed phase through the mixture of fat and fatty acid. Degrees of splitting up to 99% can be reached. The continuous countercurrent high-pressure process splits fats and oils more efficiently than other processes in a reaction time of only 2–3 h. Little discoloration of the fatty acids occur. As a result of the efficient internal heat exchange, this process affords high steam economy.

The utilities consumption per ton of feed is as follows (11).
Steam (6000 kPa) 190 kg
Cooling water (20_C) 3 m3
Electrical energy 10 kWh
Process water 0.6 m3

Glycerine purification

Feedstock
Glycerin water from the splitting of fats and oils containing 12 to 25% glycerin ("saponification glycerin")

Products
Glycerin with 99.8% purity and pharmaceutical quality.

Process

  • Impurities - dissolved fatty material and proteins - are separated from the crude sweet water by the addition of mineral acids in a purification step; subsequently, the crude glycerin is treated with acid and neutralized.
  • In a continuous, multi-stage evaporation unit the glycerin water is concentrated by water evaporation to crude glycerin of approx. 88%
  • In a still, the glycerin is then distilled off the crude glycerin in a vacuum of approx. 15 mbar and at a temperature of approx. 160°C

Hydrogenation

Process
The reaction is conducted at approximately 25,000–30,000 kPa and 250–300_C. As hydrogenation is an exothermic reaction, care must be taken to control the reaction temperature to minimize side reactions leading to the formation of undesirable hydrocarbons. From the column, the reaction mixture is cooled, separating the hydrogen gas from the alcohol–methanol mixture. The hydrogen gas is recycled, and the alcohol–methanol mixture goes to the methanol-stripping unit where, at lower pressure, the methanol is stripped off, recovered, and recycled to the esterification or trans-esterification section. The crude fatty alcohol is filtered to separate the catalyst. A major portion of the catalyst is recycled, so that the consumption averages 0.5–0.7% of the alcohol produced. The filtered alcohol is subsequently treated with caustic soda to form soap with any unreacted ester. The alcohol is finally distilled to strip off any hydrocarbons formed, which amount to about 2–3%. The soap remains in the still bottoms.

Technical data for plant capacities of 50þ t/day are (11) as follows:

  • Distilled coco fatty acid 1050–1100 kg
  • Steam (ca. 15 bar) 170 kg
  • Cooling water (20_C) 27 m3
  • Electric energy 130 kWh
  • Fuel gas 1:1 106 kJ
  • Catalyst (copper chromite) 5 kg
  • Hydrogen (0_C, 100 kPa, depending on hydrogen purity and fatty acid specification) 230–300 m3
  • Boiler feed water 185 kg
  • Export steam (ca. 4 bar) 120 kg