High Fructose Corn Syrup
Related Project: 150,000 tons/year fructose syrup project of Yihai Kerry TEREOS
Related Project: 100,000 TPY F55 Fructose Syrup Production Line - Zhejiang Huakang
1. Preparation
Adjust the concentration of the starch to 36% by automatic attenuation with adding water and then sent to PH adjustment tank, add Na2CO3 solution continuously according to starch milk flow rate to adjust the PH and add part of the α-starch enzyme at the same time.
2. Liquefaction
Adjusted starch milk is pumped to 1st.jet cooker to have the 1st. liquefaction did with steam, the gelatinized starch solution is sent to the reaction tank and add the other part of liquefaction enzyme to the discharge line of the tank. After the solution is pumped to a continuous plug flow reactor to complete the liquefaction. The temperature is been cooling to 60℃ before goes to the Saccharification unit.
3. Saccharification
Add HCl continuously to adjust the PH value according to the hydrolysate flow rate, and has the saccharification with the help of an enzyme, during the process, stir it to make the saccharification goes evenly, after achieving the required DE value, the material is sent to the next unit.
4. Membrane filtration and deslagging filtration
The saccharified material contains lots of protein-based insoluble impurities. It adopts membrane and plate and frame filter press to filter out the insoluble impurities inside the solution to get clear glucose liquid.
5. Ion exchange refining
After the filtration of insoluble impurities, there still exist some soluble inorganic impurities in the saccharified material, they exist in the form of cation and anion, ion exchange aims to remove them, the cation inside the saccharified material is exchanged with the H+ of cation exchange resin, while the anion is exchanged with the OH- of anion exchange resin, then the exchanged H+ and OH- inside the saccharified material is combined to water, the inorganic impurities came to corresponding water for filtration.
Certainly, to keep the exchangeability of exchange resin, it usually uses acid and alkali to regenerate the cation and anion resin respectively when the exchangeability weakened.
6. MVR vacuum evaporation
The syrup after ion exchange go through an MVR evaporator to remove part of water to increase the concentration from about 31% to 48%
7. Isomerization
Adjust the PH of glucose syrup with a little Magnesium ion well and continuously sent to multiple immobilized isomerase columns, After the isomerization, part of the glucose turns into fructose to get F42 which the fructose content is 42%
8. F42 ion-exchange refining and polishing
The further ion exchange refining is to remove the inorganic impurities brought into the syrup since the adding of isomerase
9. F42 vacuum concentration
After ion exchange, the syrup goes through waste heat four effect vacuum falling film evaporator to remove part of water, the concentration is increased from 44% to 60%, or concentrated to 71% to produce F42 directly.
10. Chromatographic separation
Utilize the difference of adsorption and resolution speed of chromatographic resin to glucose and fructose, after goes through a chromatographic column of a part of F42 syrup collected at a different time during elution to get F86 syrup which the fructose content is 86% and glucose syrup. The glucose syrup back to glucose before evaporation and F86 syrup goes to the next process
11. Blending and F55 ion-exchange refining
Blend the other part of F42 syrup and F86 syrup in a certain proportion and mix well to get F55 syrup, one more time ion-exchange refining and polishing to is get better quality F55 syrup.
12. F55 vacuum concentration and filling
F55 syrup after ion exchange goes through four effect vacuum falling film evaporator to remove part of the water that the concentration is increased from 48% to 77%, the concentration of 77% glucose syrup after filling is finished product F55 syrup.