maximizing of concentration and drying techniques confidential march 30, 2015 1 a title goes right...
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COMPANY CONFIDENTIAL 1 March 30, 2015
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Maximizing of Concentration and Drying Techniques
muva 2nd INTERNATIONAL CONFERENCE Cologne, 24th March, 2015
COMPANY CONFIDENTIAL 2
Agenda
Presentation by
- Thomas Bühl, Sales and Service (SPX Anhydro)
- Ditlev Thyssen, Sales Manager (SPX Anhydro)
Agenda
- Maximizing of Concentration
Retrospect, Concentration
Today’s Falling Film Evaporator
Products and Features
Maximizing of Drying
- How to find the optimized Dryer for
Milk and Whey Powder
COMPANY CONFIDENTIAL 3
• Anhydro has built
evaporators since 1951
• The first evaporator was a
natural circulation tubular
evaporator
Retrospect Evaporation Technology
COMPANY CONFIDENTIAL 4
Retrospect Recirculation Evaporator Type
• Circulation Evaporator
Example from 1951
COMPANY CONFIDENTIAL 5
• First Falling Film Tubular Evaporator
was delivered in 1953
• Tube length for FFTE was 4 meters
• Tube diameter was 35 mm
• Separators were external type,
all the same size
• Pre-heater tubular coil
• Recirculation
• Heating: Direct heating or TVR
• Control system: Simple pneumatic
regulation
Retrospect Falling Film Evaporator Type
COMPANY CONFIDENTIAL 6
• In 1978 the Falling Film
design was changed
• Tube length for FFTE was
4 - 12 meter
• Tube diameter was 51 mm
• Separator was external
with individual sized
diameter
• Pre-heater tubular coil or
straight tube
• Control system:
Automatic PLC controlled
Retrospect Falling Film Evaporator Type
COMPANY CONFIDENTIAL 7
Retrospect Plate Evaporator type
• Anhydro has as
part of the APV
group supplied
plate evaporators
since 1986
• Falling Film Plate
FFPE
• Rising Falling Film
RFPE
• Forced Circulation
Plate FCPE
COMPANY CONFIDENTIAL 8
Today’s Falling Film Evaporator
• Today Anhydro is focusing on FFTE
evaporators
• Tube length: Between 4 and 22 meters
• Separators: Integrated type, all individual
sized
• Tube diameter is 51 mm
• Heat treatment systems: Plate heat
exchangers, tubular heat exchangers, and
direct contact heaters
• Heating: TVR or MVR
• Control systems: Fully automated systems
COMPANY CONFIDENTIAL 9
Running Costs for Different Types
of Evaporators
Plant type Specific
energy
consumption
kg/kg -
kW/kg
Energy con-
sumption per
hour
kg/h - kWh
Energy con-
sumption per
year
kg – kWh
Price per
energy unit
Euro
Total energy
cost per year
Euro
Index
3-effect Circ.
DS 0.40 8,000 40,000,000 0.021 840,000 167
3-effect TVR 0.24 4,800 24,000,000 0.021 504,000 100
4-effect TVR 0.18 3,600 18,000,000 0.021 378,000 75
5-effect TVR 0.14 2,800 14,000,000 0.021 294,000 58
6-effect TVR 0.12 2,400 12,000,000 0.021 252,000 50
7-effect TVR 0.10 2,000 10,000,000 0.021 210,000 42
MVR (fan) 0.012 240 1,200,000 0.09 108,000 21
Water evaporation
kg/h 20,000
Steam price EUR / kg 0.021
Electric power EUR / kWh 0.09
Production hours per day 20
Production days per year 250
COMPANY CONFIDENTIAL 11
New Design Advantages of Today
• Wide experience
• Unique liquid distribution
• Single pass operation
• Short liquid residence time
• Low temperature difference
• Gentle evaporation of heat sensitive products
• High-efficient separators
• Long running time between CIP-cleaning
• Full automatic CIP-cleaning
COMPANY CONFIDENTIAL 14
Heating Systems with MVR and Steam
Recompression MVR Heating
• MVR high-pressure fan
• MVR units are usually of the
high-pressure fan type
• Typically single units
• The fans are either
horizontal or vertical,
depending on local
conditions
Steam Heating w. TVR Ejector
COMPANY CONFIDENTIAL 15
Products and Features
• Dairy: VOKO and HOKO for high capacities
• Dairy: MVR HOKO
• Dairy: Permeate and Whey
• Dairy: Low Thermophile design
• Heat Treatments and
Concentration for Low, Medium and High-Heat Powder
• Heat-sensitive products:
WPC
Blood Plasma
• Potato Juice
• Membrane- and Evaporator Concentration
COMPANY CONFIDENTIAL 17
Dairy: VOKO and HOKO with Flash Cooler for
Permeate and Whey
VOKO and HOKO integrated solution
• 1 fan for Voko
• 1 fan for Hoko
• 1 multiple effect calandria
Saves installation and
maintenance costs
HOKO MVR type with fans in series
• Optimizing energy costs
• High flexibility
COMPANY CONFIDENTIAL 20
Heat-Sensitive Products: WPC and Blood
Plasma
Design Features:
- Heat-treatment
- Low boiling temperature
- Low temperature difference
- Short residence time
COMPANY CONFIDENTIAL 21
Membrane- and Evaporator Concentration
Whey and Permeate:
Membrane, NF or RO up to app. 18% TS, (>25%)
Skim-milk and Whole milk
Membrane, RO up to app. 18 - 22% TS, (>30%)
General Considerations:
- Permeate from membrane filtration
- Functional changes
- Evaporator operation time
- Feasibility
COMPANY CONFIDENTIAL 24
Optimized Drying of Milk and Whey
How to find the optimized Dryer
for
Milk and Whey powder
COMPANY CONFIDENTIAL 25
Final Powder Products Originating from
Whey
Whey
Sweet Whey
Acid Whey
Permeate
Non- caking
Permeate
Lactose
WPC 35 WPC 80
WPI
Demin.
Whey
Whey fat/ mix
Non- caking Whey
COMPANY CONFIDENTIAL 26
Whey is not just Whey
Sweet Whey
Blue/White
Mozzarella
Emmenthaler Cheddar
Soft cheeses
Acid Whey
Quark and other
fermented products
Acid cheese
Cottage cheese
Casein
COMPANY CONFIDENTIAL 29
Find the Optimized Dryer for Your Need
Criteria for Choosing
the right Drying Plant
Basic Thoughts:
- Products / Product groups
- Yield
- Specific quality features of the
finished product
- Agglomeration and form
- Product change / size of batches
- Customer-specific requirements
- Company development / future
products
- Flexibility
- Which type of energy is available
- Comparison with available products
(own and competitors’ products)
- Available machinery / building
- Governmental conditions /
requirements
- ...............
Variation Possibilities
- Type/design of the spray dryer
- Atomization (centrifugal/nozzle)
- Integrated fluid bed
- External fluid bed (static – dynamic)
- Air broom
- Hammer/wall sweep
- Isolation/hot room
- Cyclone, filter, or both, wet scrubber
- Filter with or without CIP
- CIP-cleaning possibilities of the plant
- Heat recovery and integration of heat
recovery systems
- Powder recycling (various possibilities)
- Powder dosing
- Gas dosing
- Control and automation
- Security concept (ex-protection)
- ................
COMPANY CONFIDENTIAL 30
Selection of the Optimal Dryer for Specific
Products
Air flow pattern:
Air discharge
location:
Atomization:
Powder type:
• Down and up
• Top
• Nozzle
• Agglomerated
Triple-A Dryer Conical Spray Dryer (CSD) Tall Form Dryer
Air flow pattern:
Air discharge
location:
Atomization:
Powder type:
• Helical flow, Top - Down
• Bottom
• Nozzle or Centrifugal
• High or Low density
Air flow pattern:
Air discharge
location:
Atomization:
Powder type:
• Plug flow, Top - Down
• Bustles
• Nozzle
• High density
COMPANY CONFIDENTIAL 31
Spray Dryer for Permeate and Acid Whey
FeedFines return
Air with fines
Cyclones
Pneum. transport
Fluid bed
Integrated fluid bed
Air inlet
Air
Powder outlet
Dryingchamber
Wall sweep
Centrifugal and
nozzle spray dryer
Filter can be CIP-
cleaned, and
cyclone fines return
COMPANY CONFIDENTIAL 32
Spray Dryer for Whey/Fat Mix
• Cooling of chamber wall
• Air broom means longer running hours and less down time
• Better than wall sweep for keeping the chamber wall clean
• No need for hammers
Inside view in Spray Bed Dryer with air broom
COMPANY CONFIDENTIAL 33
Tall Form Spray Dryer for WPC
898709
Tall form Spray Drying Plant
Features:
Big single particle
Low agglomeration
Low fines amount
Low drying temperature
Long time in free fall (residence time)
Low fouling