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					                   Digital Re-print -
               January | February 2014
                                   Tech Focus - NIR


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F    14 | January - February 2014                                                                                  Grain &Feed millinG technoloGy



                                                                                                                           Tech focus


             Production
              control in
                                                      systems are small and
                                                      handy analytical instru-
                                                      ments which can be
                                                                                      NIR
                                                      directly mounted at the outlet of the press
                                                      and extraction installation for real-time meas-
                                                      urement of the oil and moisture content of
                                                                                                           team at Bunge: Here, the industrial spectrom-
                                                                                                           eters are used for continuous generation of
                                                                                                           the reference values for rapeseed processing.”


              rapeseed                                the press cake - 24 hours a day, seven days
                                                      a week. This is obtained by successive emis-
                                                      sion of light in the near infrared (NIR) region
                                                                                                           Transparency in just two hours
                                                                                                               The new analytical method allows Bunge


             processing
                                                      trough a vision panel. The light interacts with      to control the complete production proc-
                                                      the press cake which is transported by chain         ess for the first time - from the pressing of
                                                      conveyer and the reflected light is recorded         the rapeseed to the extraction. This whole

       using NIR technology                           by photo diode arrays. The important point is
                                                      that the composition of the reflected light is
                                                      subject to the oil and moisture content.
                                                                                                           process lasts around two hours and after
                                                                                                           this time span, Bunge can assess whether
                                                                                                           the process is running under optimal condi-
                                                          These measurement values are further             tions, i.e. whether the maximum amount of
                                                      processed by dedicated software which is             oil is exploited from the press cake. In the


    O
             ne fact in rapeseed process-             integrated into the industrial spectrometers.        case where there is room for improvement,
             ing is: the higher the exploita-         The measuring curve is displayed in real-time        the operator at the control room is able to
             tion in oil, the higher the profit.      to the operators at Bunge control room.              counteract undesirable development which
    Bunge Deutschland GmbH implements                 Furthermore, the measurement values are              prevents financial losses.
    and realises this basic principle through         directly integrated into the process control             “Traditional analytical methods provide
    real-time process-control with NIR-Online         system of Oil Mill Mannheim.                         the results after around one day and in the
    industry spectrometers.                               “Assuming the press cake exceeds the             past we were not able to tell whether the
                                                      accepted moisture level, the operator at             individual sampling was prone to outlier or
        Overall, 3,500 tonnes of rape seeds are       the control room can directly intervene to           whether the whole process was deficient,”
    processed day by day at Bunge Oil Mill in         ensure that the upstream rape seeds are              said Moritz Lücke.
    Mannheim, Germany with two identical              subject to stronger drying during steps of               “Throughout the whole time we were
    production lines. Production yields are 2,000     conditioning,” said Roland Bauer, assistant          virtually operating without knowledge of
    tonnes of rapeseed meal which is further          production manager for seed processing,              real-time information about the process
    used for feed processing and 1,500 tonnes         Bunge Germany.                                       parameters.”
    of raw oil for further biodiesel and refined          “This is because the higher the moisture             Those responsible at Bunge now know
    edible oil production after neutralization.       content of the press cake, the more difficult        about the true optimization potential of rape-
    Rapeseeds pass through a press resulting          it gets to exploit the oil in the subsequent         seed processing, thanks to continuous real-
    in press cake and press oil, representing         extraction step.”                                    time control of the pressing and extraction
    two-thirds of the profitable oil output of the        Direct indication about the final rate of oil    process - purposefully increasing the profit.
    oil seeds. In the next step, the oil from the     exploitation is provided by the measurement
    remaining press cake is further exploited via     values of the second NIR-Online spectrom-            The refinery should also benefit
    extraction process. This process is energy        eter, analysing the rapeseed meal at the end             In order to also benefit from the advan-
    and time demanding and, hence, Bunge has          of the extraction step.                              tages of real time process control during
    set a limit for the percentage of oil to be                                                            steps of refinery, the Oil Mill Mannheim plans
    tolerated to remain in the press cake.            Applicable in explosive                              the acquisition of additional NIR-Online
                                                      environments                                         industrial spectrometers this year. These sys-
    Deficits due to time-delayed                          Industrial spectrometers can also be used        tems are meant to be used during steps of
    sampling                                          under potentially explosive environment. For         de-sliming and neutralization of the pressed
        But when exactly has this percentage          example, during the extraction process using         oil for determination of the concentration
    been reached and when has the maximum             Hexane as a solvent, constituting another            of phosphorus and free fatty acids. The
    exploitation of oil been realised? “Previously,   important advantage for Bunge.                       potential for improving these processes are
    this question could not be answered satisfy-          “Other comparable analytical systems are         significant: each day Bunge produces 1,500
    ingly since for process control, the analytical   not vibration-free and have no ATEX Gas-             tonnes of raw oil from which 70 percent is
    methods were restricted to nuclear magnet-        Ex-certification. Instead, they are fitted into an   further processed for generations of biodie-
    ic resonance analysis and further laboratory      explosion-proof cabinet making it necessary          sel by an external company, 30 percent is
    methods,” said Moritz Lücke, production           to work with optical fibre in order to reach         used for edible oil generation at their own
    manager, Bunge Germany. “The results of           the true measurement position,” said Klaus           production site.
    these time-delayed methods only reflect a         Klawun, head of laboratory, Bunge Germany.
    given moment in time and, hence, real-time            “This is quite complex and results in far
    intervention to the process was not possible      weaker measuring impulse and inferior meas-             More inforMation:
    in the case that there was scope for increase     uring results compared to an NIR-Online                  Website:
    in exploitation.                                  device. Furthermore, the integrated software             www.bunge-deutschland.de
        This situation changed after application of   is characterized by high user friendliness and           www.nir-online.de
    NIR-Online industrial spectrometers. These        this is especially important for the laboratory
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        15 | January - February 2014                                                                                   Grain   &Feed millinG technoloGy         F
                                                        ProFoss has been on trial at a                                    B1, about 4000 tonnes of B2
                                                        Senwes facility in South Africa.                                  and 4500 tons of B3 grade, and
                                                        The solution consists of an NIR                                   lower amounts of lower grades.
                                                        analyser, a sample interface and                                      The process analysis system
                                                        special software for graphical                                    enables continuous monitoring of
                                                        display of the results.                                           wheat protein levels, allowing in-
                                                             It has been used at a group                                  line adjustment to regulate the
                                                        of silos next to a large mill. The                                blending and maintaining specific
          How to get the mix                            different silos contain different minimum
                                                        protein levels: 9 percent, 10 percent, 12
                                                                                                            protein levels during outloading. As indicated
                                                                                                            by the B1–B3 columns, this resulted in all the
        right with in-line NIR                          percent and so on. The sample interface is
                                                        installed in a pipe that delivers grain from
                                                                                                            lower grades being blended with higher protein
                                                                                                            grades, yielding B1 and B3 grades that were
             by Richard Mills, FOSS,                    the different silos onto a conveyor belt that       considerably higher than the initial stock level.
                          Denmark                       serves the mill.                                        “We successfully managed the optimiza-
                                                             The sample interface is installed by cutting   tion of all protein levels and the homogeneity


     S
           outh African grain suppliers Senwes          a hole in the pipe of about 10 cm diameter.         of quality in all wheat batches,” says Purnell.
           have tried out a new way of using near       It has a sapphire window that sits flush with       “As far I am concerned the ProFoss works
           infrared (NIR) analysis to optimize          the sides of the pipe, allowing the NIR unit to     very well for managing your grain quality as
     the use of increasingly scarce high-protein        take measurements on the grain as it flows by.      it monitors 100 percent of the batch being
     wheat in blends going into milling. The new             Measurements are made every few sec-           loaded and really keeps protein fluctuation
     instrument will now become a permanent             onds and the results are displayed on a             within a narrow band.”
     feature, helping to get the very best out of       computer in the control room, where they                She also points out that it is of course
     both high- and low-protein material.               can be viewed as a trend graph to make it           important to have the right quantities avail-
                                                        easy to keep track of the protein content. If,      able to maximize the usefulness of NIR
        In the fairy tale ‘Rumpelstiltskin’, a miller   for example, 11 percent protein is the target       analysis.
    boasts to a king that his daughter can spin         and the level starts to fall below that, then a         The trial completed, the plan is now to
    straw into gold.                                    little higher protein wheat can be added to         put the system into use on a permanent
        While nothing can make this enduring            stabilize the overall protein content.              basis. “We can see that the level of control
    dream come true, modern process analyti-                                                                and management of the protein level being
    cal technology in the form of an in-line NIR        Lower grade to higher grade                         shipped out is far superior to when it is
    analysis system is making a real difference             Manager of special products Mariana             controlled by a human being who does infre-
    to what millers can get out of wheat grain          Purnell describes how the ProFoss ana-              quent sampling and testing,” says Purnell.
    deliveries. It is not exactly turning straw into    lyser was installed at the Senwes facility in           “By gathering more precise data of pro-
    gold, but is perhaps the next best thing given      October 2012.                                       tein units leaving the silo, one can be assured
    the increasing scarcity of high quality wheat.          When the analyser was brought into use,         of a lower number of disputes related to
Corporate Banner process analysis solution called 1
        The new (190x132mm)(outlines)_Layout            there were just over 5000 tonnes of grade
                                                        23/12/2013 08:54 Page 1                             protein levels and subsequent downgrading."
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                                                                                        Production control in
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Description: Production control in rapeseed processing using NIR technology / How to get the mix right with in-line NIR
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