Evaporation plant for the starch industry...• Boiling point shift • Purity of the feed product ... Types of evaporators • Falling film evaporator • Forced circulation evaporator

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


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


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



• Steam


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


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


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


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


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:



• 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



Isomerization

chromatography

hydration

Decolorization, desalination

Decolorization

Decolorization, desalinationcentrifugation

Evaporation

Drying

Sorbitol

Drying

Dextrose monohydrate

Starch factorywheat, corn, rye, potato, tapioca

gEA evaporation

gEA equipment


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


enzymatic treatment


Evaporation

Dextrose syrup

gEA evaporation



Dextrose syrup

hydration

Evaporation

Drying

Sorbitol

Sorbitol

A 2-effect plate evaporation plant, heated

using a thermal vapor recompressor, to

process sorbitol solutions.


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


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


enzymatic treatment


Evaporation

glucose syrup

gEA evaporation


A directly heated, co-current, 3-effect

plate evaporation plant with a

downstream vacuum cooler to

concentrate glucose syrup.



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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gEA Wiegand gmbh

Am hardtwald 1

76275 Ettlingen

germany

Tel +49 7243 705-0

Fax +49 7243 705-330

gea.com/contact

gea.com/food

Documents

Evaporation plant for the starch industry...• Boiling point shift • Purity of the feed product ... Types of evaporators • Falling film evaporator • Forced circulation evaporator