Ion Exchange
Ion Exchange
Ion Exchange
SUGAR 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Softening of thin juice Decolorization of sugar syrup Inverted liquid sugar Non-inverted liquid sugar Inversion of saccharose Demineralization of inulin Quentin process Chromatography / Ion Exclusion
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
5 6 7 8 9
10 11 13
14 15
FRUIT JUICE 3.1 3.2 3.3 3.4 Demineralization of grape most Demineralization of apple and pear juice Demineralization of pineapple juice Debittering and deacidification of orange juice
17 18 19 20
FOODSTUFFS 4.1 4.2 4.3 4.4 4.5 Refining of food acids Softening of pectin juice Demineralization of gelatine juice Refining of glycerol Demineralization of whey
23 24 25 26 27
SUGAR
1.1 SOFTENING OF THIN JUICE
Depending on its origin, thin juice contains varying amounts of non-sugar substances, e.g. ash. During evaporation from 15 bx to 65-70 bx, there is a risk of scale formation. To prevent scale forming in the evaporation station, to produce soft molasses or to prevent precipitation of thick juices during storage, the alkaline earth ions can be removed with Lewatit cation exchange resins of differing acid strengths. Various methods can be used for this.
L E W AT I T
S 8528
S 1468
S 2528 S 2568
NaCl 250
H2SO4 105
NaOH 150
20 3
60 35
20 1
10 3
90 90 0.8 - 1.2
80 80 2.5 - 3.5
90 50 0.5 - 0.9
90 50 0.6 - 1.6
SUGAR
1.2 DECOLORIZATION OF SUGAR SYRUP
The color of sugar juice from beet and cane increases during the production process. Colorants such as caramel color bodies, melanoidines and melanine-polyphenol-iron complexes are formed. When producing refined sugar, various Lewatit adsorber resins based on styrene or acrylic polymers can be used to decolorize sugar syrups with more than 1000 ICU to meet all quality requirements in the sugar industry.
P R O C E S S F O R D E C O L O R I Z AT I O N O F SUGAR SYRUP
L E W AT I T
S6268
S 6328 A
S 6368
OC 1074
2 2
2 2
2 2
2 2
85 80
85 80
85 80
75 70
Decolorization and demineralization of raw sugar solutions with Lewatit ion exchange resins is essential for economical production of high-grade inverted liquid sugar syrups. Resins suitable for different operating conditions are required, depending on the application. It is advisable to use the resin arrangements outlined below.
ARRANGEMENT
DECOLORIZ.
D E C AT I O N I Z .
INVERSION
DEANIONIZ.
L E W AT I T
S 2528 S 2568
S 2328 K 1221
S 4328 S 4428
NaCl / NaOH
HCl
HCl
NaOH
200 / 10 200 / 10
80 - 100 50 - 60
80 - 100 50 - 60
60 - 80 50 - 60
2-3 2
3-5 2
0.5 - 2 2
3-5 2
70 - 80 20 - 80 20,000 ds*IC
30 - 40 20 - 40 0.9 - 1.2
30 - 40 20 - 40 -/-
30 - 40 20 - 40 0.8 - 1.0
SUGAR
1.4 NON-INVERTED LIQUID SUGAR
If liquid sugar syrups only have to be demineralized to improve the quality of the sugar, inversion should be avoided. This can be achieved by avoiding the occurrence of H+ ions. The process can run at temperatures of up to 60C, making it extremely suitable for tropical areas and plants where the dry substance is at least 60 brix. Subsequent inversion is possible on a case-by-case basis.
ARRANGEMENT
DECOLORIZATION
DEANIONIZATION
DECATIONIZATION
L E W AT I T
S S 6328A S 6368
S 8528 S 8227
REGENERANT QUANTITY [G/L] CO-CURRENT COUNTER-CURRENT FLOW RATE [BV/H] EXHAUSTION REGENERATION TEMPERATURE [C] EXHAUSTION REGENERATION CAPACITY [EQ/L]
NaCL / NaOH
NaOH
HCL
200/10 200/10
80 - 100 60 - 70
70 - 80
2 - 3 2
2 - 3 2
4 - 6 2
70 - 80 20 - 80 20,000 DS*IC
50 - 60 20 - 50 0.5 - 0.6
50 - 60 20 - 60 1.0 - 1.2
Hydrolysis of polysaccharides and oligosaccharides is catalyzed by H+ ions. Splitting sucrose leads to a mixture of glucose and fructose which rotates polarized light to the left. Consequently, this process is also referred to as inversion. The resultant mixture is inverted sugar which is processed into artificial honey and liquid sugar. Liquid sugar, in particular, has become more important as it is widely used to sweeten soft drinks.
The sugar syrup is passed through the resin bed at different flow rates and temperatures. The inversion rate is shown in the graph below.
Inversion rate [%] 908070605040302025C 30C 35C 40C 100Flow rate [BV/h] I 1,0 I 2,0 I 3,0 I 4,0 I 5,0 I 6,0
SUGAR
1.6 DEMINERALIZATION OF INULIN
Inulin (polyfructose) is a valuable sweetener for functional foodstuffs. It can also be used to produce fructose after enzymatic splitting of the polyfructose into its component parts (fructose). Inulin can be extracted from the beets of, for example chicory and tropinambur. The salt-rich raw thin juices have to be demineralized by ion exchange resins. Mixed bed arrangements with Lewatit resins are used for subsequent polishing of the fructose.
P R O C E S S F O R D E M I N E R A L I Z AT I O N O F INULIN THIN JUICE (15 BX) AND MB POLISHING OF FRUCTOSE (60 BX)
ARRANGEMENT D E C AT I O N I Z AT I O N D E A N I O N I Z AT I O N MIXED BED
L E W AT I T
S 1468
S 4268 S 4228
S 2568 / S 6368
REGENERANT QUANTITY [G/L] CO-CURRENT COUNTER-CURRENT FLOW RATE [BV/H] EXHAUSTION REGENERATION TEMPERATURE [C] EXHAUSTION REGENERATION CAPACITY [EQ/L]
HCl
NaOH
HCl / NaOH
100 55 - 65
80 45 - 60
3 2
3 2
2 2
20 - 25 20 - 25 0.8 - 1.1
20 - 25 20 - 25 0.7 - 0.8
40 - 45 20 - 40 -/-
11
It is known that the solubility of sucrose in molasses depends on the availability of different cations. Sucrose has higher solubility in alkali-ion-rich molasses (e.g. potassium) than in earth-alkali-rich molasses (magnesium). To take advantage of this principle, Na and K ions are exchanged for Mg ions using a strongly acidic macroporous cation resin. The exchange takes place before final crystallization of the thick juice. The Quentin process is mainly used for beet sugar and can increase the sugar yield by 0.3 - 0.5%.
QUENTIN PROCESS
L E W AT I T
S 2528 S 2568
FLOW RATE [BV/H] EXHAUSTION REGENERATION TEMPERATURE [C] EXHAUSTION REGENERATION CAPACITY [EQ/L]
1.5 1
13
SUGAR
1.8 CHROMATOGRAPHY ION EXCLUSION
Lewatit MDS types are monodisperse ion exchange resins with an uniformity coefficient < 1.1 and a particle size ranging between 320 and 370 m. The resins are commercially used in chromatographic separation processes e.g. simulated moving bed equipment. Different resin types are available for various separation processes mentioned below:
C H R O M AT O G R A P H Y
LEWATIT TYPE
FORM
BEAD SIZE
Na Na
350 m 320 m
Ca Ca
350 m 320 m
MDS 2368
Na
370 m
MDS 4368
FB/chloride
340 m
TP 207 fine
350 m
SWEETENERS
2.1 REFINING OF SYRUPS
The starch industry produces a variety of sweetener products from raw materials such as corn, wheat, potatoes, rice, cassava, etc. by enzymatic hydrolysis of starch. After adjusting the conversion level, Lewatit resins are used to refine the syrup. In the refinery the syrup is de-ashed and decolorized. Proteins and residual by-products can also be removed. For syrups with a low conversion level such as glucose, maltose and maltodextrin, as well as for syrups with a high conversion level such as dextrose or fructose (after isomerization) Lewatit resins are used in co-current or countercurrent arrangements, preferably in double-pass, merry-goround systems.
P R O C E S S F O R D E M I N E R A L I Z AT I O N OF SYRUPS
ARRANGEMENT L E WAT I T
DECATIONIZATION
DEANIONIZATION
S 2568 / MP 600 WS
R E M O VA L O F
Cations Proteins
Polishing
HCl
HCl/NaOH
80 - 100 55 - 65
70 - 80 60 - 70
3-4 2
3-4 2
3-4 2
40 - 60 40 - 60
40 - 60 40 - 60
40 - 45 20 - 40
-/-/-
15
Sugar alcohol from various Ni-catalyzed hydrogenated monoand di-saccharides is of enormous commercial interest for sweetening a wide range of products because it has low calorific value and does not cause dental caries. After hydrogenation, the raw polyol solution is decolorized and demineralized with ion exchange resin. Various arrangements can be used.
P R O C E S S F O R R E F I N I N G P O LY O L S
ARRANGEMENT
L E W AT I T
S 8528
S 2528 S 2568
REGENERANT
Special regeneration
HCl
process required
QUANTITY [G/L] CO-CURRENT COUNTER-CURRENT F L O W R AT E [ B V / H ] EXHAUSTION R E G E N E R AT I O N T E M P E R AT U R E [ C ] EXHAUSTION R E G E N E R AT I O N C A PA C I T Y [ E Q / L ]
-/-/-
80 - 100 50 - 60
70 - 80 40 - 50
80 - 100 60 - 70
2-3 2
1.5 - 2.5 2
2-3 2
2-3 2
40 - 60
40 - 60 20 - 60
40 - 60 20 - 60 0.5 - 0.7
40 - 60 20 - 60 0.3 - 0.4
-/-
0.9 - 1.0
17
FRUIT JUICE
3.1 DEMINERALIZATION OF GRAPE MOST
The production of both red and white grape most requires extensive decolorization and demineralization to prevent the salts overriding the typical taste of the reduced sugar content (15 - 20%). Refined most can be added to wine most before fermentation to produce high-quality wine. It is also used to blend fruit drinks, wine supplements and carbonated soft drinks. Non-functionalized adsorber resins are used to reduce polyphenolic colors, while conventional SBA types are used for non-selective color removal.
ARRANGEMENT
L E W AT I T
OC 1062 S 7768
S1468
NaOH / HCl
HCl
80 / 2 80 / 2
80 - 100 55 -65
60 - 80 / 100 50 - 60 / 40 - 50
80 - 100 55 - 65
3-5 2
3-5 2
3-5/5-8 2
10 2
20 - 30 20 - 30 -/-
20 - 30 20 - 30 0.9 - 1.2
20 - 30 20 - 30 1.0 / 0.4
20 - 30 20 - 30 1.0
FRUIT JUICE
3.2 DEMINERALIZATION OF APPLE AND PEAR JUICE
Apple and pear juice are used as blending juice in carbonated soft drinks. The juice contains approximately 12 % sugar as di- or mono-saccharides. Apple and pear juices also contain polyphenolic color components which are formed enzymatically during extraction. They can be removed with activated carbon or adsorber resins. Afterwards the clarified juice is demineralized with ion exchange resins. These juices are passed through a weakly anionic resin prior to demineralization because of their high free acid content.
ARRANGEMENT
DECOLORIZ.
NEUTRALIZ.
D E C AT I O N I Z .
DEANIONIZ.
L E W AT I T
OC 1062
S 4328 S 4528
S 4528
NaOH / HCl
NaOH
NaOH
80 / 2 80 / 2
70 - 80 60 - 70
80 - 100 55 - 65
70 - 80 60 - 70
3-5 2
3-5 2
3-5 2
3-5 2
20 - 30 20 - 30 -/-
20 - 30 20 - 30 1.2
20 - 30 20 - 30 1.0 - 1.2
20 - 30 20 - 30 1.0 - 1.2
19
Pineapple juice, primarily from waste trimmings, contains roughly 10 % sugar and extremely high quantities of citric acid and nitrogenous components. To allow use as canning syrup, demineralization and partial decolorization are necessary. In view of the high concentration of acid and salts, double-pass filtration is recommended.
ARRANGEMENT
D E C AT I O N I Z .
DEANIONIZ.
D E C AT I O N I Z .
DEANIONIZ.
L E W AT I T
S 2528 S 2568
S 4528
HCl
NaOH
80 - 100 55 - 65
70 - 80 60 - 70
80 - 100 55 - 65
70 - 80 60 - 70
3-5 2
3-5 2
3-5 2
3-5 2
20 - 30 20 - 30 1.4
20 - 30 20 - 30 1.4
20 - 30 20 - 30 1.0 - 1.2
20 - 30 20 - 30 1.0 - 1.2
FRUIT JUICE
3.4 DEBITTERING AND DEACIDIFICATION OF ORANGE JUICE
Orange juice, either freshly extracted or reconstituted juice, is neutralized using weak anion resins. The resin reduces free citric acid as well as more weakly dissociated acid such as ascorbic acid and folic acid. To recover valuable ascorbic and folic acid, it is advisable to overload the resin in order to ensure displacement by the stronger citric acid.
Another specific application for adsorber resin is debittering of orange juice. Orange juice contains 20-30 ppm bitter components like limonin or hesparadin which could otherwise be tasted.
P R O C E S S F O R D E M I N E R A L I Z AT I O N O F ORANGE JUICE
ARRANGEMENT
DEBITTERING
N E U T R A L I Z AT I O N
L E W AT I T R E M O VA L O F
NaOH / HCl
NaOH
80 / 2 80 / 2
70 - 80 60 - 70
2-4 2
5-6 2
40 - 60 40 - 60 -/-
40 - 60 40 - 60 1.0 - 1.1
21
23
FOODSTUFFS
4.1 REFINING OF FOOD ACIDS
Food acids such as citric- and lactic acid need to be demineralized after fermentation, mainly to eliminate sulfuric acid and sulfate ions. The typical dry substance content is 20 - 40 %. Additional freeboard is required as weakly basic anion resins can swell by up to 40 % (the resin is fully preloaded with food acid). During demineralization the food acid is displaced by sulfate ions. To improve resin capacity and utilize the full resin capacity, a double-pass system is recommended.
ARRANGEMENT
D E C AT I O N I Z AT I O N
D E A N I O N I Z AT I O N
L E W AT I T
S 1468 S 2568
S 4428
NaOH / NH3 70 - 80 / 35 60 - 70 / 30
1 2
1 2
50 20 - 30 1.0 - 1.1
50 20 - 30 0.8 - 1.0
FOODSTUFFS
4.2 SOFTENING OF PECTIN JUICE
Pectin is usually extracted from citrus peel by nitric acid. The acidic thin juice contains approximately 1% pectin, 2 % nitric acid and 300 - 400 ppm calcium ions. Calcium ions impair the quality of the pectin so the concentration of such ions needs to be reduced by ion exchange. Calcium ions can easily be removed with Lewatit S 1468 in the following process conditions.
SOFTENING
L E W AT I T
S 1468
1.5 - 3 2-3
45 - 55 45 - 55 1.0 - 1.2
25
The purpose of the refining process is to produce a high-purity gelatine (protein) with a molecular weight between 20,000 and 360,000 g/mol. This is achieved by chemical or thermal hydrolysis of collagen (chain of 18 different amino acids) into gelatine. The end-product should be soluble in warm water and have a reversible gelling effect. To meet the specifications of the photographic, food and pharmaceutical industries, demineralization with ion exchange resins is normally used.
P R O C E S S F O R D E M I N E R A L I Z AT I O N O F G E L AT I N E
ARRANGEMENT
D E C AT I O N I Z AT I O N
D E A N I O N I Z AT I O N
L E W AT I T
S 1468 S 2568
HCl
NaOH
80 - 100 55 - 60
70 - 80 60 - 70
5 - 10 2
5 -10 2
50 - 65 20 - 30 1.0 - 1.1
50 - 65 20 - 30 0.8 - 1.0
FOODSTUFFS
4.4 REFINING OF GLYCEROL
The function of the ion exchange resins in glycerine purification is to remove dissolved salts, acids and bases from the solution, which contains approx. 35 - 45% glycerol. Fatty substances, aldehydes, alcohols and other non-ionic impurities are not completely removed in this process. Macroporous Lewatit resins have greatly improved this situation: virtually all colored matter is adsorbed without irreversible fouling of the resins.
P R O C E S S F O R R E F I N I N G G LY C E R O L
ARRANGEMENT
DECOLORIZ.
D E C AT I O N I Z . D E A N I O N I Z .
BUFFER
L E W AT I T
S 6328 A S 6368
S 1468
NaCl / NaOHl
HCl
200 / 20 200 / 20
80 - 100 55 - 65
60 - 80 / 100 50 - 60 / 40 - 50
80 - 100 55 - 65
2-3 2
3-4 2
3-4/2-4 2
10 2
30 - 50 20 - 30 -/-
30 - 50 20 - 30 0.9 - 1.2
30 - 50 20 - 30 1.0 / 0.4
30 - 50 20 - 30 1.0
27
Alongside large amounts of interfering salts, whey contains valuable proteins and lactose. The recovery and processing of these substances is becoming more and more important. However, the whey has to undergo suitable treatment in order for the protein and lactose to be extracted and used. Effective resins for the demineralization of whey are the strongly acidic, gel-type Lewatit S 1468 combined with the weakly basic anion resin Lewatit S 4528 or Lewatit OC 1072. Because of its macroporous structure, Lewatit S 4528 also adsorbs voluminous, large-molecular anions. In addition, for full demineralization Lewatit Monoplus M 600 is used in the final position.
P R O C E S S F O R D E M I N E R A L I Z AT I O N OF WHEY
ARRANGEMENT
D E C AT I O N I Z . D E A N I O N I Z . D E C AT I O N I Z . D E A N I O N I Z AT I O N
L E W AT I T
S 1468
S 4528 OC 1072
S 1468
M+ M 600
HCl
NaOH
HCl
NaOH
80 - 100 55 - 65
70 - 80 60 - 70
80 - 100 55 - 65
80 - 100 50 - 70
5 - 10 2
5 -10 2
5 -10 2
5 -10 2
5 -15 20 1.2
5 -15 20 1.2
5 - 15 20 0.7
This news release contains forward-looking statements based on current assumptions and forecasts made by LANXESS Deutschland GmbH management. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future consolidated results, financial situation, development or performance of the company, and the estimates given here. The company assumes no liability to update such forward-looking statements or to adapt to future events or development. This information and our technical advice whether verbal, in writing or by way of trials are given in good faith but without warranty, and this also applies where proprietary rights of third parties are involved. Our advice does not release you from the obligation to verify the information currently provided especially that contained in our safety data and technical information sheets and to test our products as to their suitability for the intended processes and uses. The application, use and processing of our products and the products manufactured by you on the basis of our technical advice are beyond our control and, therefore, entirely your own responsibility. Our products are sold in accordance with the current version of our General Conditions of Sale and Delivery.