brewery optimization – water reduction in cleaning operations linda a. rastani alfa laval inc....
TRANSCRIPT
Brewery Optimization – Water Reduction in
Cleaning Operations
Linda A. Rastani
Alfa Laval Inc.
October 18, 2010
www.alfalaval.com
How do you conserve resources while effectively cleaning ?
The tank must be clean=> effective cleaning meets the following requirements:
• low consumption of fresh water
• low consumption of cleaning agents
• minimum of energy consumption
• Low amount and pollution level of waste water
• Reduce cleaning process time
www.alfalaval.com
The Optimal Cleaning Operation.
• turn around as quickly as possible.
• Using a minimum of water, chemicals, energy
• producing a minimum of waste water.
• Being able to validate the process.
www.alfalaval.comSlide 4
Action
Time
Chemical Concentration
Temperature
TACT Cleaning Parameters
Reduce: Time, Chemicals & Temperature Improve: Action & Coverage
Cleaning Impact(impingement)
Action
Surface Coverage
Action
Traditional TACT - Jet Head Approach
www.alfalaval.com
Comparing Static Spray Ball with Rotary Jet Head Cleaning with Cleaning with
Static Spray Ball Rotary Jet Head
Concentration
Time
Mechanics
Temperature
www.alfalaval.comSlide 6
Static Spray Ball Rotary Spray Head Rotary Jet Head
Coverage:
Means: Cascading Swirling fan Index Pattern
Effect: Partial Partial to full Full
Action: Low Medium High
% Resources used 100% 70-75% <50% in most cases
www.alfalaval.com
Energy Labelgy Label
G
A
<< Back to Total Cost of Ownership start page.
D
www.alfalaval.comSlide 8
Static Spray Ball
www.alfalaval.comSlide 9
Cleaning Technology
d dtWall Shear Stress under
Turbulent Flow Conditions
Min. 40 Pa at r = 11 cm
Water Jet
2. High Wall Shear Stress Zone3. Machine gearing makes the indexed criss-cross pattern
1. Pressure is the driving force1. The flow is turning the tank
cleaning machine2. Pressure is converted to water jet
velocity
P≈V
www.alfalaval.comSlide 10
Rotary Jet Head Cleaning Technology
- Attack of residues
www.alfalaval.comSlide 11
Mash Tun
Required number of Rotary Jet Heads
Type number
RJH 2
4 x 5.2mm, 50 USGPM @ 75 PSIG
www.alfalaval.comSlide 12
Mash Tun
www.alfalaval.com
Mash Tun
Standard cleaning
water rinse 10 Min
caustic recirc. 60 Min
water rinse 5 Min
acid recirculation 20 Min
water rinse 5 Min
Total 100 Min
100 USGPM = 1,600 USG per Cleaning
to drain.
RJM
water rinse 9 Min
caustic recirc. 18 Min
water rinse 9 Min
acid recirculation 9 Min
water rinse 9 Min
Total 54 Min
100 USGPM = 900 USG per Cleaning to drain.
Net Savings/Cleaning = 700 USG x # Boils (Or Cleaning Cycles)Example = 1 cleaning/day x 700 USG = 176,400 USG/yr (252 days) saved!
www.alfalaval.comSlide 14
Mash Tun
Added value by using Rotary Jet Heads
• Cleaning time can be reduced by 46 %
• Shorter down time
• Total costs can be reduced by 60 %
• Higher cleaning standard
www.alfalaval.comSlide 15
Kettle
Required number of Rotary Jet Heads Cylindrical
Type number
RJH-BKV 34 x 7mm, 58 UGPM, 75 PSIG
www.alfalaval.comSlide 16
KettleRJH BKV
• The heating surfaces are hard to keep efficiently clean
• Many have internal heaters which do have “difficult-to-clean areas”
• Many do have Static Spray Balls which do not clean well and use large fluid volumes and strong chemicals
www.alfalaval.comSlide 17
Kettle
Standard cleaning
water rinse 10 Min
caustic recirc. 90 Min
water rinse 10 Min
acid recirculation 20 Min
water rinse 10 Min
Total 130 Min
170 USGPM = 3,230 USG to drain
RJH - BKV
water rinse 13,5 Min
caustic recirc. 36 Min
water rinse 9 Min
acid recirculation 13,5 Min
water rinse 9 Min
Total 81 Min
175 USGPM = 2,365 USG to drain
Net Savings/Cleaning = 865 USG x # Boils (Or Cleaning Cycles)Ex: 1 cleaning/day x 865 USG = 217,980 USG/yr (252 days) saved!
www.alfalaval.comSlide 18
Kettle
Added value by using Rotary Jet Heads
• The cleaning time can be reduced by 37 %
• Shorter down time
• The costs can be reduced by 35 %
• Validation possibility
www.alfalaval.comSlide 19
Benefits using RSH & Jet Heads • Cleaning standard
– Repeatable high cleaning standard
• Volume of water, waste and detergents
– Up to 50% Flow reduction
– Up to 75% Water Consumption Reduction
– Up to 75% Detergent Consumption reduction
• Time
– Up to 50% Cleaning time reduction
– allowing more time for production
Cleaning
Production
Cleaning
Production
Less
tha
n 1
year
pay
-bac
k
Thank You