Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08B—POLYSACCHARIDES; DERIVATIVES THEREOF
  • C08B30/00—Preparation of starch, degraded or non-chemically modified starch, amylose, or amylopectin
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08B—POLYSACCHARIDES; DERIVATIVES THEREOF
  • C08B31/00—Preparation of derivatives of starch
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
  • B01J19/0053—Details of the reactor
  • B01J19/0066—Stirrers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
  • B01J19/18—Stationary reactors having moving elements inside
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
  • B01J8/08—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with moving particles
  • B01J8/10—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with moving particles moved by stirrers or by rotary drums or rotary receptacles or endless belts
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08B—POLYSACCHARIDES; DERIVATIVES THEREOF
  • C08B30/00—Preparation of starch, degraded or non-chemically modified starch, amylose, or amylopectin
  • C08B30/12—Degraded, destructured or non-chemically modified starch, e.g. mechanically, enzymatically or by irradiation; Bleaching of starch
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08B—POLYSACCHARIDES; DERIVATIVES THEREOF
  • C08B30/00—Preparation of starch, degraded or non-chemically modified starch, amylose, or amylopectin
  • C08B30/12—Degraded, destructured or non-chemically modified starch, e.g. mechanically, enzymatically or by irradiation; Bleaching of starch
  • C08B30/16—Apparatus therefor
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
  • B01J2208/00796—Details of the reactor or of the particulate material
  • B01J2208/00823—Mixing elements
  • B01J2208/00858—Moving elements
  • B01J2208/00867—Moving elements inside the bed, e.g. rotary mixer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
  • B01J2219/00761—Details of the reactor
  • B01J2219/00763—Baffles
  • B01J2219/00779—Baffles attached to the stirring means

Definitions

• the present invention relates to a method of modifying starch and starch derivatives in a continuous process.
• the invention further relates to the use of reactors in such methods.
• Starch is the principal carbohydrate component of higher plants and has many industrial applications. In the food industry, for example, starch is used, amongst other things, as a texturing agent, gelling agent, thickener and stabilizer. In paper manufacture, starch is used as a sizing agent, for improving printability, surface strength and solvent-resistance. Starch is also used in the fermentation and textile industries and in the manufacture of adhesives, detergents, cosmetics, pharmaceuticals, emulsifying and dispersing agents, inks and dyes, plastics, coatings and many other commonly used products.
• Such methods include hydrothermal treatment, hydrolysis, degradation (dextrinisation, acid-thinning, oxidation), esterification, etherification, stabilisation (e.g. by cross-bonding), etc.
• EP710670A1 describes a continuous chemical modification process according to which a starch powder and a reagent are introduced simultaneously into a reactor.
• a rotating screw within the reactor rapidly creates a fine, dynamic liquid layer, allowing the starch and reagent to interact.
• This method suffers from several drawbacks.
• starch has a tendency to accumulate on the reactor walls. Should the rotating speed be reduced sufficiently to allow for an acceptable contact time and to address the problem of runability, the starch and reagent could no longer be properly mixed, thereby again having a negative effect on reaction levels and final product quality.
• WO 97/13788 describes a process for the chemical fluidification of starches carried out under standard plug flow conditions, at temperatures at most equal to 77°C and with reaction times of up to 6 hours.
• This method also has several disadvantages. First of all, by the very nature of plug flow reactors, very little mixing of materials occurs. As noted above, this will have a negative effect on reaction levels. In addition, with temperatures not exceeding 77°C and because of the static movement of the starch particles through the reactor, they will not be properly dried, even if residence times are increased. Finally, because plug flow reactors in effect mimic batch process conditions, the disadvantages associated with the latter will not be overcome.
• a further example is US 4,021,927.
• This document describes a fluidising reactor wherein particles pass through an agitated zone before entering a number of heated, tubular reactors.
• this reactor does not allow for fluidisation to be maintained throughout the reaction meaning that the substrate may be unevenly reacted.
• the agitated and reactor zones are separate, fluidisation will not be maintained during heating.
• the reactor relies on gravity to transport the substrate from inlet to outlet) and particles may stick to the walls of the reactor thereby affecting runnability. Overall, this leads to an inefficient, non-homogeneous reaction.
• the present invention provides such a method.
• a method of modifying starch or starch derivatives comprising: introducing a continuous flow of starch substrate, gas and, optionally, one or more reagents, into a reactor, wherein the starch substrate:
• - has a moisture content between 0 and 45% by weight, preferably between 1 and 30% by weight;
• - has a residence time in the reactor of between 1 and 60 minutes, preferably of between 2 and 45 minutes;
• the starch substrate and the gas are introduced into the reactor in opposing directions; and in that - the reactor has a tubular body comprising a rotating shaft upon which is disposed one or a plurality of blades.
• the blade or blades will have a tip speed of between 2 and 30 m/s.
• the starch substrate may be selected from one or more native starches, starch derivatives, starchy materials such as flour and mixtures of two or more thereof.
• the starch substrate is introduced into the reactor in powder form.
• the reagent may be, for example, a chemical or enzymatic reagent selected from a hydrolysing agent, an oxidation agent, an acid, a dextrinisation agent, an alkylation agent, an esterification agent, an etherification agent, a cross-bonding agent and mixtures of two or more thereof.
• the reagent will be selected from a mineral acid such as HCl, H 2 SO 4 or H PO 4 , an organic acid such as citric acid, a peroxide such as hydrogen peroxide (with or without a catalyst such as copper), an oxidising agent such as persulfate and mixtures of two or more thereof.
• the reagent is added to the starch substrate before being introduced into the reactor.
• a method of preparing highly soluble starch comprising: introducing a continuous flow of starch substrate, gas and one or more reagents selected from a mineral acid, a peroxide and an oxidising agent, into a reactor, wherein the starch substrate has a moisture content between 1 and 30% by weight, a residence time in the reactor of between 2 and 45 minutes and is maintained at between 80 and 220°C, characterised in that the starch substrate and the gas are introduced into the reactor in opposing directions and in that the reactor has a tubular body comprising a rotating shaft upon which is disposed one or a plurality of blades.
• the starch produced according to this method will be from 70 to 100%) soluble in cold water, preferably from 75 to 100% soluble in cold water.
• a reactor for the modification of starch or starch derivatives said reactor having a tubular body comprising:
• the inlets are positioned such that the starch and gas are introduced into the reactor in opposing directions.
• Figure 1 is a schematic representation of a reactor unit according to a possible embodiment of the present invention.
• starch derivatives refers to any molecule produced by a modification or series of modifications - physical, chemical and/or genetic - to native starch. Accordingly, starch derivatives include (but are not limited to): enzyme or acid hydrolysed starches (such as maltodextrins, glucose syrups and hydroly sates); degraded starches (e.g.
• starches degraded by heat, oxidation, catalysts or acidification such as roast dextrin and thin-boiling starch
• pre-gelatinised starches starch esters (such as starch n-octenyl succinate); starch ethers; cross-bonded starches; retrograded starches; bleached starches; cationised or anionised starches; amphoteric starches; starch phosphates; hydroxyalkylated starches and alkali treated starches.
• starch esters such as starch n-octenyl succinate
• starch ethers cross-bonded starches
• retrograded starches bleached starches
• cationised or anionised starches amphoteric starches
• starch phosphates starch phosphates
• hydroxyalkylated starches and alkali treated starches any references herein to starch will be understood to include both native starch and starch derivatives.
• starch substrate refers to the actual product which is introduced into the reactor in a first step of the present method.
• the substrate may comprise one or more native starches, one or more starch derivatives or a mixture thereof. Preferably, it will consist of starch and/or starch derivative(s).
• the starch itself can be of any desired origin (potato, wheat, corn, rice, tapioca, pea, barley, etc.) and can be waxy or not.
• the substrate may also include (or consist of) other starchy materials suitable for use in a tubular reactor.
• An example of such materials is flour (e.g. potato flour, soy flour or a grain flour such as wheat flour).
• the substrate may be used in combination with one or more natural or synthetic polymers (such as cellulose or a hydrocolloide) and/or one or more organic or inorganic compounds. It may also be mixed with a buffer (such as NaOH).
• a buffer such as NaOH
• the substrate may be in powder or cake form and will have a moisture content of between 0 and 45% by weight, preferably between 1 and 30% by weight, even more preferably between 3 and 25%) by weight at its point of entry into the reactor. If the substrate has a moisture level higher than 45%, it should be at least partially dried before introduction into the reactor. Moisture levels can be controlled within the reactor if necessary (for example: by adding water or steam with the gas, by controlling reaction temperature and/or by extracting moisture e.g. using an extractor fan). Preferably, moisture levels of 0-15% by weight will be obtained at the reactor outlet.
• the reactor is a reactor having a tubular, preferably cylindrical, body within which is positioned a rotating shaft.
• the shaft is provided with one or a plurality of blades.
• blades By “one or a plurality of blades”, it is not intended to limit the reactor to any particular construction. Indeed, the blade or blades may just as well take the form of a number of separate paddles or of a single, helical blade disposed around the shaft in the manner of a screw thread.
• the blade or blades will preferably have a tip speed between 2 and 30 m/s, more preferably between 3 and 25 m/s, even more preferably between 4 and 20 m/s. In practice, the rotating speed and angle of the blades will be adjusted depending on the desired residence time of the substrate in the reactor.
• Residence time will be between 1 and 60 minutes, preferably between 2 and 45 minutes, even more preferably, between 10 and 30 minutes.
• the exact residence time will be determined for each reaction, taking into account various variable factors (e.g. nature of substrate, temperature of reactor, quantity and nature of reagent, speed of rotation, etc) and the type and extent of modification to be performed.
• the preferred residence time might be 4 minutes, for others, it might be 30 minutes.
• the blade or blades will convey the starch substrate from an inlet at one end of the reactor to an outlet at the other end in a continuous, plug-flow type manner.
• continuous as used herein is intended to distinguish the present method from a batch-type process.
• the starch will be heated to a temperature of between 50 and 220°C.
• this temperature is measured as the product temperature at the reactor outlet.
• it will be between 80 and 220°C, more preferably between 100 and 180°C, even more preferably between 100 and 160°C.
• reaction parameters such as moisture, pH and pressure
• moisture can be controlled by regulating the amount of liquid introduced into and/or extracted from the reactor.
• Moisture extraction can be achieved via a simple moisture outlet or, for instance, by using a moisture extractor fan.
• pH can be controlled with the use of buffers.
• Buffers can be introduced into the reactor with any one or more of the starch substrate, the reagent or the gas. They can also be introduced separately. According to one embodiment, buffers will be used to ensure that the reaction is carried out under alkaline conditions.
• Pressure can be controlled, for example, with the use of air-locks at the reactor outlets (e.g. at the product outlet and at the gas and/or moisture outlet) which prevent gas (i.e. air, steam, etc.) release until a certain pressure has been reached.
• the reactor comprises an inlet for the starch substrate. It also comprises a gas inlet positioned such that the starch substrate and gas are introduced into the reactor in opposing directions.
• the substrate and gas inlets do not necessarily have to be on geometrically opposing sides of the reactor, provided that they are sufficiently separated and angled such that, in use, the substrate flow and gas flow run counter-current to each other.
• the gas inlet may be of any type, allowing, for example, for gas to be pumped into the reactor or for it to be sucked in.
• the reaction may be carried out under vacuum.
• the reactor will comprise a gas and/or moisture outlet, positioned substantially opposite the gas inlet and preferably comprising one or more means for increasing gas and/or moisture extraction, such as an extractor fan.
• the gas inlet will be no more than e.g. an aperture or a one-way valve.
• a counter-current flow leads to better mixing of the starch substrate with any eventual reagents and in better control of residence times (because the substrate is prevented from passing too quickly through the reactor). Also, because of the resulting turbulence, each substrate particle will come into contact more often with the heated reactor wall leading to a more homogeneous reaction. What is more, particle temperature will increase more quickly thus accelerating the reaction rate and therefore decreasing reaction time.
• the counter-current flows also provides an efficient method of transporting reactants through the reactor whilst maintaining the substrate particles in a fluidised state (and therefore preventing them from settling and/or sticking to the reactor wall). This results in increased reaction efficiency and, consequently, reduced costs. In addition, it avoids the usual drawbacks associated with the use of batch reactors and with the continuous reactors of the prior art (e.g. runability).
• the gas used to create the counter-current may be any gas but will preferably be air, steam, nitrogen, carbon dioxide, an inert gas, controlled oxygen or a mixture of two or more thereof. It may include reagents such as oxidants (e.g. ozone), amines, neutralising agents or additives capable of modifying or controlling reaction conditions. For example, it may include a buffer such as NH 3 or SO 2 .
• the gas may also be heated before entry into the reactor.
• the gas will have a flow rate through the reactor of 0.2 - 10 m/s, more preferably of 0.2 - 2 m/s, even more preferably of 0.2-1 m/s.
• the reactor may comprise one or more additional inlets for the introduction, if desired, or one or more reagents (enzyme, catalyst, etc.).
• a reagent is not always necessary as the modification may simply consist of a physical modification (e.g. by heating).
• a reagent can be selected, for example, from any one or more of: a hydrolysing agent (such as ⁇ -amylase, ⁇ -amylase, glucoamylase or pullulanase), an oxidation agent (such as sodium hypochlorite or persulfate), an acid such as an acid-thinning agent (e.g.
• H SO 4 or H 3 PO or a dextrinisation agent (such as HCl), an alkylation agent, an esterification agent (such as acetic anhydride, vinyl acetate or n-octenyl succinate anhydride), an etherification agent (such as propylene oxide), a cross-bonding agent (such as phosphorous oxychloride, sodium trimetaphosphate or mixed anhydride of acetic and adipic acid) or other reactive compounds such as urea, proteins or phosphate compounds such as polyphosphates.
• a dextrinisation agent such as HCl
• an alkylation agent such as a dextrinisation agent
• an esterification agent such as acetic anhydride, vinyl acetate or n-octenyl succinate anhydride
• an etherification agent such as propylene oxide
• a cross-bonding agent such as phosphorous oxychloride, sodium trimetaphosphate or mixed anhydride of
• the reagent might be a mineral acid (such as H 2 SO 4 or H 3 PO 4 ), an organic acid (such as citric acid), a peroxide (such as hydrogen peroxide) and/or an oxidation agent (such as sodium hypochlorite or persulfate).
• a mineral acid such as H 2 SO 4 or H 3 PO 4
• an organic acid such as citric acid
• a peroxide such as hydrogen peroxide
• an oxidation agent such as sodium hypochlorite or persulfate
• the reagents can be added in the form of a solution, powder or gas and in amounts of 0.001-20%) by weight (based on total dry weight of starch). Preferably, they will be added in amounts of 0.001-10%) by weight and, even more preferably, in amounts of 0.01-3%) by weight. Again, the skilled person will be able to determine the appropriate concentration of reagent needed depending, for example, on the quantity of substrate to be modified, the desired level of modification, the nature and concentration of the reagent being used, etc.
• any eventual reagent or reagents can be introduced into the reactor via one or more separate inlets to that used for the starch substrate.
• the reagent is in the form of a gas, it will preferably be introduced into the reactor via the gas inlet.
• the reagent and the starch could be introduced via the same inlet.
• the reagent and starch may be mixed within the reactor or, in a preferred embodiment, they may be mixed before being introducing into the reactor.
• the method of the present invention may contain an initial step comprising forming a premix by combining reagent and starch substrate. The premix can then be introduced (as the starch substrate) into the reactor via a single inlet.
• the reactor so far described may be part of a larger unit (“reactor unit") comprising both upstream and downstream components.
• Upstream components could include, for instance, the already mentioned mixing chamber or a pre-modification chamber (e.g. if the starch substrate needs to undergo an initial modification before being introduced into the reactor, for example by cooking or by a hydrothermal treatment) while downstream components could include, for instance, a drying chamber, an insulated holding tank (where product temperature could be maintained thereby effectively extending reaction time), a recycling element or one or more further reactors.
• the unit as a whole may include more than one reactor according to the present invention (e.g. if several different modifications are necessary or if a longer residence time is desired).
• product issuing from one reactor can be passed (directly or indirectly) to one or more further reactors.
• they will preferably be disposed in series.
• FIG. 1 A possible reactor unit, in accordance with the present invention, is illustrated in Figure 1 in which (1) represents a counter-current reactor, (2) represents a finishing reactor, (3) represents the shaft-rotating motor, (4) represents a dust separator, (5) represents a condensator and (6) represents a heat exchanger.
• Starch substrate is introduced into the reactor via inlet (a).
• Gas (with or without reactant and/or water added at (f)) is introduced via inlet (c) and exits the reactor via outlet (d). It may then leave the reactor unit via exhaust (k) or be recycled to the heat exchanger via inlet (j).
• Modified starch product leaves the reactor via outlet (b).
• the product leaves reactor (2) via outlet (e). Condensate is released from the condensator via outlet (g).
• dust gathered at (4) may be recycled to the reactor at inlets (h) and/or (i).
• the present invention also provides for the use of a reactor or reactor unit as described for the modification (hydrolysis, degradation, esterification, etherification, heat moisture treatment, etc.) of starch or starch derivatives.
• Example 1 Method of producing low viscosity, low solubility starch:
• 150kg corn starch (C*Gel 03402 from Cerestar) at 11.5% moisture, 479.7 ml HCl (from Sigma-Aldrich) at 11.7 N and 15.5 L water were blended in a L ⁇ dige mixer for approximately 10 minutes at room temperature.
• the blend was then introduced, in a continuous flow of 150 kg/h, into a pilot-plant turbo-reactor having multiple blades with a tip speed of 9.3 m/s (and positioned at 2 cm from the reactor wall).
• a counter current of air heated to 150°C was introduced simultaneously at 0.5 m/s.
• the substrate was transported through the reactor in a plug-flow type movement and had a residence time in the reactor of approximately 4 minutes.
• the jacket temperature of the reactor was maintained at approximately 185°C such that the starch product reached a temperature of 117°C (measured at the reactor outlet). Brookfield viscosity and solubility of the product obtained at the outlet of the reactor were measured using the methods described below. The following results were obtained:
• the starch product obtained had a significantly lower paste viscosity (despite a relatively high dry substance) than untreated starch and a low solubility.
• a 2000 g sample was weighed and transferred to a dry 200 ml Kohlrausch flask.
• the flask was partially filled with water at 25 °C and shaken vigorously until the sample was completely in suspension.
• the suspension was then diluted to volume.
• the flask was stoppered and shaken gently while submerged in a water bath at 25°C for a total time of 1 hour.
• the suspension was filtered through a Whatman no. 2V paper. 50.0 ml of the filtrate was measured and transferred to a weighed evaporating dish.
• the filtrate was then evaporated until dryness in a steam bath and dried in a vacuum oven for 1 hour at 100°C.
• the residue was cooled in a desiccator and weighed to the nearest gram.
• the glass beaker was placed in a cooling bath (in which the water is maintained at 15- 20°C).
• the slurry was stirred using a plastic stirring rod together with a thermometer until a temperature of 40°C was reached.
• Viscosity (in mPas) was then measured in a Brookfield RVT series viscometer equipped with a no. 2 spindle. The measurement was made at 40°C and at 100 rpm.
• Example 2 Method of producing low viscosity, high solubility starch:
• 150kg corn starch (C ⁇ Gel 03402 from Cerestar) at 11.5% moisture, 312.4 ml HCl (from Sigma- Aldrich) at 11.7 N and 15.6 L water were blended in a L ⁇ dige mixer for approximately 10 minutes at room temperature.
• the blend was then introduced, in a continuous flow of 150 kg/h, into a pilot plant turbo-reactor having multiple blades with a tip speed of 5.0 m/s (and positioned at 2 cm from the reactor wall).
• a counter current of air heated to 150°C was introduced simultaneously at 0.5 m/s.
• the substrate was transported through the reactor in a plug-flow type movement and had a residence time in the reactor of approximately 30 minutes.
• the jacket temperature of the reactor was maintained at approximately 185°C such that the starch product reached a temperature of 125°C (measured at the reactor outlet). Brookfield viscosity and solubility of the product obtained at the outlet of the reactor were measured using the same methods as described above (except that a 270 g sample at 45% d.s. was used for the viscosity measurement). The following results were obtained:
• the starch product obtained had a significantly lower paste viscosity (despite a high dry substance) than untreated starch.
• the product also has a much higher solubility.

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• 2004
  • 2004-11-12 EP EP14163253.9A patent/EP2787009B1/en not_active Expired - Lifetime
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  • 2004-11-12 WO PCT/EP2004/012856 patent/WO2005047340A1/en not_active Ceased
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