Reducing emissions at Olam Food Ingredients

Olam Cocoa BV, based in Koog aan de Zaan, is currently focusing on reducing emissions and improving the environmental performance of its cocoa facility. This facility has operated for over 100 years and is among the top 3 cocoa processors in the Netherlands. Direct roasting of the kernels of raw cocoa beans releases ammonia (NH3) and volatile organic compounds (VOCs) into the atmosphere via the chimney. From 2028, a maximum NH3 emission of 5 mg/Nm³ will be imposed on all companies. Olam is already set to meet these stricter emission requirements from October 2024. Iv was invited to join the implementation team, providing project management, procurement support, and construction management.

The main challenge is to significantly reduce ammonia emissions from the off-gas emitted during roasting. This reduction will be achieved via a multi-stage gas scrubber system.

The new installation must be commissioned within a limited timeframe, with as little downtime as possible. A 20-metre high, three-storey steel structure for large gas scrubbers will be built in an environment with limited space and access. Typically, scaffolding would be used, but this would take too long. Therefore, much preparatory work was conducted on the ground before the structure was moved into position. The structure was hoisted in sections, the heaviest weighing 13.5 tonnes. Consulting with the equipment supplier on accessibility and equipment placement was essential to achieving an optimum design.

The new installation will significantly reduce the off-gas emitted from the roasting process, aligning with future environmental regulations. Iv’s approach ensured limited disruption to production and kept costs for the client within budget. Once the cold and hot commissioning tests are completed, the installation will be fully operational, meeting all requirements.