Refineria del Centro is a company specialising in the manufacturing and commercialising of various food products, including edible and refined oils and fats. In 2014, the factory was extended with a new line to produce baker’s yeast.
Marcos Gervan, yeast plant manager at Refineria del Centro, said: “The HST turbocompressors are highly efficient, flexible, and deliver 100% clean air. They combine safety and ease of operation.”
Baker’s yeast is produced in a multiple-stage fed-batch process. Yeast propagation occurs in successive fermenters operated under aerobic conditions. In the mother and commercial fermenters, the yeast suspension is first introduced and mixed with nourishing media, consisting of molasses and other nutrients, under strong aeration from bottom diffusers.
Once yeast growth starts, the nutrients are fed incrementally which makes the level of liquid rise progressively. Air flow also increases as yeast cells multiply and require more oxygen. At the end of the fermentation, the nutrient feeding stops, and the tanks are progressively emptied and then cleaned and disinfected prior to the next batch. The feed rate of nutrients, temperature, pH, and aeration must be controlled for optimum yeast yield and product quality.
The right aeration is critical, as underaeration leads to excessive alcohol formation and overaeration to increased production costs. The air compressors must combine reliability, efficiency, and flexibility to cope with varying flows, which depend on the need for oxygen, and pressure, which depends on the liquid level.
At Refineria del Centro, the large-scale fermentation is conducted in two large tanks. For each tank, two process cycles can be selected:
Cycle 1 – Mother batch: duration of 34 hours, of which 26 hours of growth cycle with continuous air supply, and eight hours of emptying and cleaning without air supply. Cycle 2 – Commercial batch: duration of 22 hours, of which 16 hours of growth cycle with continuous air supply, and 6 hours of emptying and cleaning without air supply.For both tanks, Sulzer tailored the same package of three HST turbocompressors. Each set of compressors is controlled by one master control unit (MCU) to match the changing air needs during the complete cycles. After installation and startup, the Sulzer technicians continued regular visits on site, providing additional support for the best use of the equipment.
The HST turbocompressors have wire-to-air efficiency, which is said to guarantee optimal life cycle costs. Depending on the air flow needs and the liquid level in the fermenter, the MCU will operate one, two or three turbocompressors at their optimal operational points in order to maximise the energy savings.
According to Sulzer, the efficiency of HSTs also means that the delivered compressed air will have lower temperature than air generated by less efficient blowers. This will reduce the cooling costs, resulting in water and energy savings.
Thanks to contactless, wear-free active magnetic bearing (AMB) technology, the HSTs will adapt to flow and pressure variations as well as frequent starts and stops. With AMB, the HST turbocompressors do not require oil or any lubricant, so real oil-free and contaminant-free compressed air is delivered, and costly oil filtration systems are eliminated.
Since initial commissioning, the operational costs have been minimised, with low energy consumption and little service or maintenance. Maintenance of the HSTs consists of changing air filters every two years.