aop food systems. air food water multi point intervention strategy
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AOP Food Systems
AIR
FOOD WATER
MULTI POINT INTERVENTION STRATEGY
TECHNOLOGY OVERVIEW
UV Ozone AOP PHI
UV
Know you’re ABC’s
UV-A, long-wave ultraviolet light in the 380 to 315 nm range
UV-B, medium-wave ultraviolet light in the 315 to 280 nm range
UV-C, short-wave ultraviolet light in the 280 to 100 nm range
UV-A 98.7% of all UV passing through the
atmosphere from sun is in the A region.
Both natural “Sun Tan” and artificial tanning lamps. Least harmful UV (…wrinkles).
Bug Zapper attractant (~365 nm).
Photocatalytic effect (very strong at 380nm)
UV-B Also passes through atmosphere (very
small amount…except when ozone holes occur).
Causes sunburn to the skin and can damage the eyes with over exposure.
Produces Vitamin D in the skin.
Too little exposure bad, to much also bad.
Photocatalytic effect (~280-300 nm).
UV-C 100% absorbed via atmosphere.
UV-C has highest energy of A,B, and C.
Quickly causes sunburn to the skin and can damage the eyes (flash burns).
Germicidal wavelengths (254nm)
Ozone producing wavelengths (185nm)
Strong Photocatalytic effect (can actually prevent catalyst deactivation)
UV Sources Sun
Low Pressure mercury lamps
Medium pressure mercury lamps
High pressure mercury lamps (metal halide lamps)
Very high pressure mercury and xenon lamps (pulsed lamps)
LED’s (emerging..not quite there)
UV-C (Commercial) Disrupts DNA and RNA effectively
“sterilizing” cell.
Line of site treatment (shadowing)
Minimum energy dose is required for kills
Easily determine treatment dose (published)
Energy level + time = kill dosage (CT value)
Germicidal UV (254 nm)
Effectiveness is dependent upon distance, intensity and exposure time
HVAC requires a large number to treat air
Very effective on stationary surfaces
Very good for liquid purification (if applied right)
Temperature sensitive (extremes reduce it)
Hazard due to glass and mercury
Generally very effective if applied and sized correctly
OZONE
Ozone Approved for Food Use
July 1997 – Ozone receives GRAS affirmation by the FDA
Prior to July 1997 ozone was only approved for potable and bottled water
June 2001 Ozone was finally approved by FDA for food contact.
Ozone “A Household Word”
No Longer only associated with the “Ozone Layer” or Smog.
Municipal and Wastewater Treatment. Ozonated and Carbon Filtered Drinking
Water. Becoming much more accepted by food
industry.
What Is Ozone?
Oxygen is O2 – A molecule containing two oxygen
atoms
Ozone is O3
– A molecule containing three oxygen atoms.
OZONE IS ACTIVATED OXYGEN
Why Use Ozone?
Safety Disinfection Odor Control Oxidation
– Inorganics– Organics
Turbidity / Micro flocculation
How is Ozone Generated?
Ultraviolet Light Rays – UV Light Rays from
the Sun Electrostatic
Discharge– Lighting Bolts
Generation
O1
O1O3
O3O2
O2
O2
Differences in UV & CD Ozone Generation
0.01 - 0.1% by weight – 0.1% =
1,000ppm No Air Pre-
treatment needed
0.5 - 5.0 % by weight– 5.0% =
50,000ppm Air Pre-
treatment necessary
Ozone Generation Technologies Ultraviolet Light Ozone Generation
– Typically ideal for air treatment applications, especially due to low mass transfer requirements.
– Require no air preparation.– Low maintenance and operating costs.– Not cost effective at single pass water
treatment or other very large demand systems.
– Low capital cost.
Ozone Generation Technologies Corona Discharge Ozone Generation
– Ideal for fluid treatment applications or very large air systems.
– Requires air preparation.– RGF only sells with oxygen systems.– Higher maintenance and operating costs.– Very effective at single pass water
treatment.– High capital cost (especially for small units).
AOP
Common Oxidants
* - Friendly Oxidizers
1 - Fluorine (F-)2 - Hydroxyl Radical (OHO)*3 - Ozone (O3)*4 - Chlorine (Cl-)5 - Bromide (Br-)6 - Hydrogen Peroxide (H2O2)*7 - Oxygen (O2)*
Advantage of “Friendly” Oxidizers
Reverts to O2, CO2 and H20 After Use
Does not leave residue (or add to TDS)
Respond Faster to Organics
Can be generated on Site
Increases Oxygen Content (for fluid applications)
What is AOP? AOP typically refers to Advanced
Oxidation Process.
In short, Advanced Oxidation is creating more powerful oxidizers from less powerful components via some external energy (typically UV…but not always!)
Products of AOP reactions are also sometimes referred to as reactive oxygen species (or ROS).
Common components used in AOP reactions include Water, Oxygen, Hydrogen Peroxide, Ozone, Chlorine Dioxide, UV light and photo catalytic surfaces.
There are multitude of reactions and pathways to produce advanced oxidation products.
Typical AOP/ROH products
OHo Hydroxyl Radical
O2- Super Oxide Ions
HO2 Hydroperoxides (includes H202)
Ozonide Ions O3-
PHOTO CATALYST
H2O2, O3Energy: UV/other
AOP’s
(Always exceptions: using ClO2, Fenton's reaction, Sonalysis, you can also get AOP’s)
Benefits of AOP’s AOP reacts up to 40 times faster than
ozone alone (Note that ozone reacts 3000 times faster than chlorine).
Attacks virtually all organic compounds.
Abstracts hydrogen from contaminants to form water.
Provides a redundancy of oxidizers.
The most powerful AOP product produced is the OHo (hydroxyl radical).
This reactant is 2nd only to Fluorine in reactivity
Very short lived
Is key benefit in forming other AOP compounds, especially important for production of hydroperoxides (disassociation of water) including formation of hydrogen peroxide.
PCO’s Photocatalytic Oxidation Reactor
Uses UV light striking a catalytic bed
Creates reactive “holes” on catalyst surface
In turn producing AOP’s
Typically targeted to VOC reduction
Usually air only (always exceptions!).
Treats only the contaminants that are brought to it.
Reactions take place on the surface of catalytic bed.
The higher the surface area, and the more UV energy that reaches it, the more efficient.
As surface area of the catalytic bed increases, limitations due occur (UV shadowing).
Retention times to treat VOC’s are applicable.
Very effective when applied properly.
Can be costly
TYPICAL PCO
Catalyst Structure (Honeycomb, etc..,)
UV Source
Flow
AO REACTOR Usually liquid only (again, always
exceptions).
Reactant is mixed with fluid stream before entering reactor (H202, O3).
Fluid with reactants enter UV reactor (basically a UV sterilizer on steroids).
Here the photocatalytic reactions occur (producing AOP’s).
Typically treats only the contaminants brought inside the reactor chamber (very targeted such as MTBE).
Can be very effective if sized correctly
Also expensive due to fluid handling and requirement for H202 and / or O3 addition
TYPICAL AO REACTOR
H2O2
O3 UV
Photohydroionization
(PHI)
PHOTOHYDROIONIZATION
Hydrogen based oxidizers created by exposing activated oxygen molecules to a hydrated catalyst containing four unique metals and 100-380 nm UV light (Photon Energy):
– Hydro-peroxides– Hydroxides– Super Oxide Ions– Ozonide Ions
Photohydroionization is the creation of hydro peroxides from a reaction that takes place between the UV light, air, and the catalyst.
These hydro peroxides or “friendly oxidizers” are very effective in breaking down both airborne and surface borne microbes.
The High Humidity of most Food Plants benefits these reactions.
PHI Cell
• Broad spectrum lamp
• Quad-metallic hydrophilic coating
• PPC sleeve
“Photo” Process
Broad spectrum UV lamp
Quad-metallic Hydrophilic coating
Optimal surface area
PHI Cell
Hydrated Coating
PPC Sleeve
The Lamp
Broad Spectrum
High Efficiency
100-380 nm
Long Life Coating
PPC The Protection
• Breakage Containment
• Non-Polar
• Insulating
• Wash Down Compatible
Hydrated Quad-metallic Catalytic Coating Rhodium, Titanium, Silver, Copper, Hydrating Agent
The Quad-metallic coating: has particular affinities, breaks bonds, releases electrons, holds and releases atoms, steals other electrons. absorbs water vaporIt changes everything but itself remains unchanged. It is a “Catalytic” process.
“Hydrophilic” means that
it attracts water,
(H2O from the air)
This creates an
abundance of hydrogen and oxygen
on the coating
Quad-metallic Hydrophilic Coating
Titanium dioxide (TiO2) is a multifaceted compound. It's the stuff that makes toothpaste white and paint opaque. TiO2 is also a potent photocatalyst that can break down almost any organic compound.
Titanium
Quad-metallic Hydrophilic Coating
Different catalysts do different things!
Vol. 05, INTERNATIONAL JOURNAL OF PHOTOENERGY, 2003
Enhanced activity of silver modified thin film TiO2 photocatalysts
This silver doped photocatalyst decomposes the pollutant 3-times faster than the un-doped TiO2.
Silver speeds up titanium reactions
It was postulated that silver enhanced the reduction potential of TiO2, … It was found that … the reduction potential of the photocatalytic system can be altered by varying the amount of silver doped onto the TiO2.
The amount of silver alters the photocatalytic system
Silver
Quad-metallic Hydrophilic Coating
Different catalysts do different things!
The Current Status of Catalysis by Silver R Schlögl, Fritz-Haber-Institut der Max-Planck-
Ges., Faradayweg. 4-6, D-14195 Berlin, GermanyElemental silver is a unique catalyst for selective oxidation reactions, … Four different species of atomic oxygen interacting in spectroscopically distinct ways with silver have been identified
Atomic Oxygen Species Adsorbed on Silver. V.I.Bukhtiyarov, Boreskov Institute of Catalysis, Lavrentieva prosp., 5,Novosibirsk, 630090, Russia This paper summarizes our efforts to study the nature of oxygen species adsorbed on silver and their reactivity
Silver has some unique abilities to work with energized forms of oxygen
Silver is an excellent electrical conductor
Silver is stable and will not itself oxidize in the course of creating and transporting oxidizers
Silver
Quad-metallic Hydrophilic Coating
Different catalysts do different things!
Copper, like silver, can improve the functions of titanium
Bull. Korean Chem. Soc. 1999, Vol. 20, No. 8
Photocatalytic Activity of Cu/TiO2 with Oxidation State of Surface-loaded Copper
the effect of oxidation state of loaded Cu on the photo-catalytic oxidation reaction. … it is expected that the loaded Cu may improve photocatalytic activity of TiO2,
SOLAR PHOTOCATALYTIC HYDROGEN PRODUCTION FROM WATER USING A DUAL BED PHOTOSYSTEM, Clovis A. Linkous, Darlene K. Slattery, Florida Solar Energy Center, University of Central Florida
…As it turned out, the more common copper Pc evolved the most
H2… our best H2-evolving photocatalyst was copper.
Copper has unique abilities to work with hydrogen
Copper
Quad-metallic Hydrophilic Coating
Different catalysts do different things!
Why the PHI Technology is Unique
By utilizing our broad spectrum lamp, we not only produce conventional AOP reactions on the cell surface, we also produce AOP reactions within the air that passes through the cell.
185 nm
O2
O2
O2
O2
O2
O2
185 nm emitted from cell
185 nm
Ozone
185 nm produces ozone
254 nm
254 nm breaks O3 into
to AOP’s
254 nm initiates ozone decomposition
Germicidal UV Light Rays
Hydroxyl Radicals OHo
Super Oxides O2-
Hydroperoxides H2O2
Ozonide Ions O3-
Hydroxides
OH
O3
OH
O3
O2
HO2
HO2
-
O2-
AOP FORMATION
Reaction pathways are complex and will vary greatly due to available reactants and location (for a specific target and point in time).
The PHI cell combines the features of a PCO with that of an AOR, plus more.
The following slide depicts just one possible reaction pathway of the PHI cell.
Chain BreakdownH2O2 + 2 O2
H2O2 + O3 + O2
HO2
H2O
O3O3
O2
O2
O2
H2O
OH
HO3
H+
HO4
O2
OH-
H+
UV Energy
With H2O, O3 and UV reaction continues
O2
-
-
PHI CELL ADVANTAGES
Uses germicidal UV for microbe inactivation.
Uses germicidal UV for Catalytic AOP reactions.
Uses the combination of UV wavelengths to produce AOP reactions in air.
AOP reactions inactivate microbes as well as destroy odors.
AOP reactants remain effective after leaving cell
PHI CELL ADVANTAGES
The PHI Cell produces and destroys ozone to facilitate the AOP reactions.
Typically greater than 87% of the actual produced ozone is decomposed in the AOP process.
Devices utilizing the PHI cells are not ozone generators, residual ozone produced is a by-product of the AOP process.
PHI CELL ADVANTAGES
Achieves higher kills (especially relative to levels), than ozone alone.
Proven outside studies on PHI effectiveness on Food Plant target organisms.
Food Safety Program
RGF's Photohydroionization Sanitation Process
Successfully used at:
Poultry processors
Pork processors
Grain processors
RTE processors
Beef processors
PRODUCT LINE FOCUS
Treatment of Food Contact Surfaces. Treatment of Food Product. Treatment of Air. UV Treatment of Brine and Chill
Water. Ozone contact systems for water.
SPECIFIC AREAS OF CONCERN
CONVEYOR SYSTEMS SLICING OPERATIONS PRODUCTION FLUID AIR - MICROBE AND ODOR CONTROL FINAL PACKAGING AREAS ICE MACHINES PLANT SANITATION
DEMAND FUELED BY:
ZERO TOLERANCE BY USDA/FDA FOR CERTAIN BACTERIA.
TREMENDOUS COSTS OF PRODUCT RECALLS.
LEGAL LIABILITY AND PUNITIVE DAMAGES.
CONSUMER DEMAND FOR FEWER CHEMICALS ON THEIR FOOD
BACTERIA AND VIRUSES MUTATING RESISTANCES AGAINST COMMON BIOCIDAL AGENTS AND ANTIBIOTICS
VALUE ADDED CHEMICAL FREE PRODUCTS
PHI on Surfaces
PHI PRODUCTS AND NON-PENETRATING PHOTOIONIZATION RAYS
PHI ON SURFACES Can be retrofitted into most existing
plant operations and conveyors. Does not use chemicals or other
consumables other than electricity. Leaves no residue. Does not require special permitting.
PHI CONVEYOR BELTS Conveyor belts are not always continuously
sanitized. Excellent benefits particularly in dry process
environments or near the end of the process line.
Protects from pathogen buildup each revolution.
Cross contamination….mitigation.
Examples of Conveyor and Surface Sanitation
Alternative Treatments Chemical sprays, which are costly and leave
residue. Frequent rinsing during shift (high labor, with
mixed results). Ozone spray (can be costly). UV only: Not as effective PHI approach,
offers no redundancy, has inherent shadowing issues, lamp breakage concerns.
PHI TUNNELS
PHI TUNNEL Systems provide 360 PHI treatment in synergy
with non penetrating radiation of product. Designed as a final intervention point just
prior to packaging or tenderizing. Provides excellent contact of the product
itself, as well as belt (interval set up). Contact time is based on production speed
requirements and particular unit design, they are typically held to a minimum of 10-12 seconds of contact under hood (fast lines require multiple hoods).
Has shown not to affect color, taste, or nutritive value (no change in free fatty acid).
Leaves no chemical residue. Treated product does not require any special.
consumer labeling. Low maintenance. Low energy consumption. Does not require lengthy specialized training. Tunnels are custom made to fit conveyors with
open weave belts and variable speed drives (some can be retrofitted, some not).
Pathogens cannot develop resistance. Lower cost than competing technologies. Don’t over sell the technology. Is not effective on all types of product.
- It is non penetrating (ground beef , post grind).
- If AOP gases cannot touch it, they wont kill it.
- Products with many overlaps or crevices are not a good fit.
Alternative Treatments Penetrating radiation treatment.
- Very high cost.
- Extensive training.
- Stigma of the process
- Ongoing labeling concerns
- Logistics issues (when outsourcing)
(although very effective)
LEAD OR DEPLETED URANIUM COLUMINATOR
RADIOACTIVE ISOTOPE CO 60
PENETRATING RAYS
Alternative Treatments Chemical sprays, which are costly, and leave
residue. Not always practical (dry products) Infrared Treatment
- High cost.
- Extensive training.
- High Energy use / cost.
- Product incompatibility (literally cooks surfaces).
Ultra High Pressure (UHP) “Cold Pasteurization”
- High purchase cost.
- Complicated training.
- High Energy use.
- Changes microscopic structure of some products (notably degrades proteins in meat causing color changes).
- Limited to batch process (not continuous)
- Typically good for high liquid content products. If air pockets, they collapse and fill with liquid, changes shape and size of product
Ozone spray, usually not an option due to the water addition, also off gassing concerns.
UV only: Not as effective PHI approach, offers no redundancy, has inherent shadowing issues, lamp breakage concerns.
Steam Pasteurization– Applies heat to food surfaces– Used mainly on pork and beef carcasses– Surface treatment only
Examples of PHI Tunnel Systems
Fully Understand the customers operation
Use Site Evaluations to capture pertinent information- Customers issues / data / requirements
- Product Type- Product Size- Maximum line speed *- Layout of location (sketch at minimum)- Available and/or preferred power
* You want to avoid your process impacting theirs.
Tunnel and Hood Sizing
Answer the easy questions first. Ensure material compatibility. Communicate, Communicate, Communicate
Recommend installations be done by I/R for these units.
Main reason is proper training, both safety and operational (units are simple, but due to inherent UV hazard, UV training is important).
Ideally communication is established very early with customer to ease install, the more that is completed upfront, the easier the install, and the happier the customer.
Tunnel and Hood Install
Ensure the USDA inspector has been made aware of the unit.
Units are inherently easy to install (when all is done correctly upfront).
Due to customization of units, most installs are different (field mount versus complete).
Units all use the same basic components, making understanding parts exchange very easy.
Each unit is shipped with a specific manual, each manual includes wiring diagrams and a specific spare parts list.
Install Details
A multiple cell unit may look complicated, but in essence, it only has multiple single components systems.
These component systems each require a cell, a ballast, a 4 pin ballast connector, and power supplied to the ballast to run (Basically, if you can trouble shoot and change a fluorescent light, you should be able to service these units).
All the connectors, o-rings, etc..have been standardized for these units, pay special attention to the cell and lamp part numbers (in manuals), as these change based on unit requirements.
Attach to the hoods and tunnels via standard tri-clamp fitting.
All designed as low voltage units (quick disconnect plugs).
These are the latest generation modules, and are to be the standard for your systems.
All internal parts will be interchangeable with the exception of the installed cell (these are sized for application).
PHI Modules (AOP Generator)
PHI Module
AIR
PHI TREATMENT OF AIR
Protects evaporator coils from pathogen buildup
Destroys air borne contaminants including mold, yeast, bacteria and viruses
Reduces employee absenteeism Reduces surface contamination Extends shelf life
Commercial HVAC In Duct Products (Plant offices, common areas, locker rooms)
Guardian Air HVAC Cell
REME HVAC Cell
ECO AIR
Food Applications
Kraft documented 93% Microbial Reduction
EPRI documented 94% Microbial Reduction
FSIS documented 90% Microbial Reduction
Wall mounted, stand alone unit.
PHI Rack System
Typical PHI Cell Reductions in air
Reduction Over 4 Day Period
020406080
100120140
1 2 3 4
Days 1- 4
CF
U/m
3
Bacteria and Mold CFU
2nd Day 71.2 %3rd Day 86.8 %4rd Day 95.4 %
BOS Bacteria Odor Abatement Systems
IMSB
TYPICAL CUSTOM UNITS
Large Lift Stations Roof Top A/C units Air Transport Systems Large Ice Units Container Refrigeration Units
FLUV Units
UV Fluid Treatment Design
– Low pressure UV lamps– Low heat generation– 35-40% of energy converted to
germicidal UV vs.8-10% with medium pressure
– Designed for 40 mJ/cm2 minimum energy at target rated flow
– Designed for turbid water
UV Fluid Treatment Germicidal UV
– “C” range of the UV light spectrum– 253.7 nm– Inactivates bacteria by inhibiting its
reproductive capability “sterilizes” them.
– Multi lamp reactors for both high and low flows
– In low turbidity and low absorbance situations flows can be increased.
Features Stainless Steel, Food Grade materials Lamp status indicators Wash down stainless steel NEMA 4 enclosures PPC containment (glass breakage) No flat surfaces No tool disassembly CIP capable Small Foot Print Integrated leak detectors (with relay contact) Can integrate with optional flow sensors and
temperature sensors
UV Fluid Treatment Products
– FLUV-20 unit is for flow rates up to 20 GPM
– FLUV-60 unit is for flow rates up to 60 GPM
– FLUV-200 (aka. HVUV) is for flow rates up to 200 GPM
FLUV-20SPECIFICATIONS: Model FLUV-20Material Stainless SteelElectrical 120 volt 8 ampsWeight 45 lbs.Flow rate 20 gpm (per unit)Max operating pressure 50 psiConnections 1 1/2” Sanitary (Tri clover style)Tube Diameter 4”UV Lamps 5
FLUV-60SPECIFICATIONS: Model FLUV-60Material Stainless SteelElectrical 120 volt 30 ampsWeight 90 lbs.Flow rate 60 gpm (per unit)Max operating pressure 50 psiConnections 2” Sanitary (Tri clover style)Diameter of tube 6”UV Lamps 14
FLUV-200 (aka HVUV)SPECIFICATIONS: Model FLUV-200Material Stainless SteelElectrical 120 volt 30 ampsWeight 375 lbs.Flow rate 200 gpm (per unit)Max operating pressure 50 psiConnections 3” Sanitary (Tri clover style)Tube Diameter 10”UV Lamps 31
Example Performance Data– Pork Chill Brine UV system– Chub Chill Glycol UV system– Marinate injection UV system
Typical Reductions
Turkey Marinate
Examples of before and after UV sample testing
Typical Reductions Turkey Marinate
UV Treated Mid-Run
UV Treated End-Run
Control Mid-Run
Control End-Run
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
13
7
10
00
0
605371
228
18600
11650
14500
TPC's
Turkey Marinate TPC Growth Study #1 (WB)
34°F Control Turkey Fluid WB- 1st BreakTPC's per Sample Dilution TPC's per Sample Dilution
Elapsed Time (days)
Energy Measurement through fluid
(uW)
Single Pass 1:1 1:10 1:100 1:1000
1 200 GPM TNC TNC 172 203 N/A 200 GPM TNC TNC 123 117 200 GPM TNC TNC 140 15
34°F Control Turkey Fluid WB- End of ShiftTPC's per Sample Dilutions TPC's per Sample Dilutions
Elapsed Time (days)
Energy Measurement through fluid
(uW)
Single Pass 1:1 1:10 1:100 1:1000
1 200 GPM TNC 71 5 ND3 N/A 200 GPM 392 42 3 ND7 200 GPM 273 31 1 ND
34°F UV Treated Turkey Fluid WB - 1st BreakTPC's per Sample Dilution TPC's per Sample Dilution
Elapsed Time (days)
Energy Measurement through fluid
(uW)
Single Pass 1:1 1:10 1:100 1:1000
1 200 GPM ND 1 ND ND3 4000.00 200 GPM ND ND ND ND7 200 GPM ND ND ND ND
34°F UV Treated Turkey Fluid WB- End of ShiftTPC's per Sample Dilutions TPC's per Sample Dilutions
Elapsed Time (days)
Energy Measurement through fluid
(uW)
Single Pass 1:1 1:10 1:100 1:1000
1 200 GPM ND ND ND ND3 5000.00 200 GPM ND ND ND ND7 200 GPM ND ND ND ND
NOTE: Control samples from the WB line had a very high percentage of mold growth.
UV System Validation
0
200
400
600
800
1000
1200
1400
1600
1800
0 2 4 6 8 10 12 14
TP
C
Sample Number
Baseline vs. Validation Brine Chill Application
With UV System
Without UV System
VALIDATION
BASELINE
0
100
200
300
400
500
600
1/5 1/6 1/7 1/8 1/9 1/10 1/11 1/12 1/13 1/14 1/15 1/16 1/17 1/18 1/19 1/20 1/21 1/22 1/23 1/24 1/25 1/26 1/27 1/28 1/29 1/30 1/31 2/1 2/2 2/3 2/4 2/5 2/6
CFU
's
Sample Date
Chub Chiller Glycol CFU History
UV Activation
520 CFU
UV System Validation
0
200
400
600
800
1000
1200
cfu
/ml
Hours of Production
No UV
UV Day 1
UV Day 2
UV Day 3
UV Day 4
UV System ValidationBrine Marinate Injection System
Typical Brine Injection Install
BRINE MAKE-UP TANK
FS54 UV FLUID STERILIZER
3/4 HP CENTRIFUGAL PUMP
UNTREATE BRINE
TREATED BRINE
FLOAT VALVE
WOLFTEC INJ ECTOR
1/32" STRAINER
DRUM FILTER
3" UNISOURCE
SERIES 2710
SANITARY HOSE
150 PSI
4" WIDE SS RETURN SLIDE
NOTE: ALL PIPING IS 1.5" OD SS UNLESS SPECIFICALLY MARKED.
PRODUCT INFEED
15hp Centrifical Pump
SAMPLE POINT #2Open Sump
(before UV system )
15hp Centrifical Pump
UV System BypassValve Set
Incoming Brinefrom outside brine mixing unit
(sytem refilled daily)
System Drain(open to floor drain)
Flow Meter
4" to 3" Tube diameter reduction
4" OD SS Tube
High Volume UV Fluid Sterilizer Unit
3" to 4" Tube diameter increase
SAMPLE POINT #11" sample valve
(after UV system)Chiller Sump
4" OD SS Tube
Chilling Cabinet
Set of (2) Triple Strainer Filters
Exit Flow
Dual Chamber Brine Chilling Unit
4" OD SS Tube
Brine Spayers
Product Racks
Typical Chiller Loop Install
What to ask? Speak with the customer and complete and SOC. Visit if feasible. Review micro data (if available).
– Pre processing.– During operation.– Post processing.– What are the target reductions (log or percentage).
Determine the water quality.– What does the water contain? Brine, Glycol, flavorings….– Flow rates, maximum and average flow.– Line Pressure.– Temperature.– Pre and post processing differences
OZONE
OZONE CONTACT SYSTEMS POOR QUALITY WATER FOR WASHING
PRODUCE POOR QUALITY CONTROL MEASURES HUMAN ERROR FACTORS POOR PROCESSING METHODS CHLORINE IS HAZARDOUS TO STORE CHLORINE CAUSES HEALTH PROBLEMS
IN PLANTS FROM EMISSIONS
OZONE CONTACT SYSTEMS CHLORINE EMISSIONS CAUSE
OXIDATION OF PLANT MACHINERY AND OTHER EQUIPMENT
SOME BACTERIA ARE RESISTANT TO IT
Competitive Technologies Chemicals; Sanova, peracetic acid
(Inspexx), chlorine and chlorine dioxide, quatenary ammonia– Except for chlorine they are expensive– Can create taste and color changes– Surface treatment only– No labeling requirements– Elevated COD levels in plant effluent– Storage and handling problems – Chlorine and caustic foaming agents,
corrosive to plant equipment– Difficult to maintain accurate method of
application
Assumptive Questions Do you use chlorine in your plant for sanitation or product washing? Are you interested in reducing chlorine consumption? Do you experience corrosion that you attribute to chlorine use? How much do you spend on chlorine per year? Are you required to document chlorine use? Do you swab product or equipment for pathogens during production? Do you experience spikes or ramping of bacteria on equipment or
product? Do you have shelf life issues? Do you have product returns as result of shelf life? What are the advantages for an anti-microbial, which does not require
storage or result in chemical residue on plant equipment or foodstuff? What are your concerns about cross contamination points such as
cutting surfaces, conveying surfaces or other product/equipment contact points?
Ozone System SizingWhy so many ?’s
System Sizing Factors
1. Applied Ozone Dosage
2. Total Ozone Demand
3. Flow Rate
4. Desired Residual
Applied Ozone Dosage(AOD Value)
Applied Ozone Dosage (ppm) = (CN x OR)
Where:CN = ppm of contaminant in
the waterOR = ppm of O3 required
to neutralize contaminant
Ozone Required(OR Value)
Contaminant O3 Practical
(ppm) (ppm)Iron(Fe++) 0.43 0.14-0.5Manganese (Mn++) 0.88 0.6-1.5Hydrogen Sulfide (H2S) 1.0 0.5-
1.5Unknown 0.5-1.5 0.5-1.5
Total Ozone Demand(TOD Value)
Total Ozone Demand (ppm) = AOD + MTF
Where:AOD = Applied Ozone DosageMTF = Mass Transfer Factor
Mass Transfer Factor (MTF Value)
MTF Value is based on Factors Affecting Transfer of Ozone into a liquid:
1 - Pressure2 - Temperature*3 - Bubble Size4 - Concentration of Ozone (% by
weight)*5 - Unknown Demand
* - Ozone Solubility Chart
Contact Time
- Flow Rate- Tank size (Contact Tank)- Delivery distance- Targeted reduction- Delivered Dosage required
4. CT Value
CT Value =C x T
Where:C = O3 Residual Concentration
T = Contact Time (time in contact with ozone prior to
measurement)
Measuring Ozone Residuals
DPD Colorimetric Test– Measures free oxidants
ORP Measurement– mV Readings unstable past 950
mV
Ozone Monitor– Expensive, high maintenance, – very accurate
Sizing Example
Question: What size ozone generator is required to eliminate iron and hydrogen sulfide?
Given: Flow = 10 gpmIron = 1.1 ppmHydrogen Sulfide = 0.44 ppm
Sizing Example
Applied Ozone Dosage Calculations: AOD = CN x OR
Iron: AOD = 1.1 x 0.43 = 0.473
ppm
Sulfide: AOD = 0.44 x 1.0 = 0.44 ppm
AOD Total = 0.913
ppm
Sizing Example
Total Ozone Demand Calculation:
TOD = AOD + MTF
AOD: AOD = 0.913 ppm
MTF: MTF = AOD For AOD <1
TOD: TOD = 0.913 + 1 = 1.913 ppm
Sizing Example
Ozone Generator Size Calculation:
OGS = TOD x FR x .012 x 19
TOD: TOD = 1.913 ppm
FR: FR = 10 gpm
OGS = 1.913 x 10 x .012 x 19
OGS = 4.36 gm/hr
Sizing Example(Cooling Tower)
Question: What size ozone generator is required for a Cooling Tower to provide disinfection?
Given: Flow = 150 gpmTonnage = 200 Ton
Sizing Example(Cooling Tower)
General Rules: Disinfection = 0.2 - 0.6 ppm = 4 - 10 gm / ton
Total Ozone Demand Calculation:
TOD = 0.6 ppm
Sizing Example(Cooling Tower)
Ozone Generator Size Calculation:
OGS = TOD x FR x .012 x 19
TOD: TOD = 0.6 ppm
FR: FR = 150 gpm
OGS = 0.6 x 150 x .012 x 19
OGS = 20.52 gm/hr
Ozone Contacting System
THE END
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