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Process and utility systems integration and optimisation for ultra-low energy milk powder production

Author

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  • Walmsley, Timothy G.
  • Atkins, Martin J.
  • Walmsley, Michael R.W.
  • Philipp, Matthias
  • Peesel, Ron-Hendrik

Abstract

This study applies a Total Site Heat Integration approach in conjunction with a detailed process and utility model, to develop an innovative ultra-low energy milk powder plant design. The basis for the analysis is a state-of-the-art modern milk powder plant that requires 5265 MJ/tp of fuel and 210.5 kWh/tp (58.5 MJe/tp) of electricity. The model of the modern milk powder plant was validated against industrial data and changes to process and/or utility systems are targeted and implemented into the model to understand the impacts on thermal and electrical demands and emissions. Results show that seven significant changes are beneficial: (1) pre-concentration of milk to 30% using reverse osmosis, (2) a two-stage intermediate concentrate (30%) homogenisation to enable high solids (60%) spray drying, (3) an ultra-low energy Mechanical Vapour Recompression evaporator system, (4) spray dryer exhaust heat recovery, (5) condensing economiser for the boiler, (6) upgrade and integration of chiller condenser heat with hot water utility systems, and (7) recycling of air in the building ventilation system. These changes are estimated to reduce thermal energy use by 51.5%, electricity use by 19.0%, and emissions by 48.6% compared to a modern milk powder plant.

Suggested Citation

  • Walmsley, Timothy G. & Atkins, Martin J. & Walmsley, Michael R.W. & Philipp, Matthias & Peesel, Ron-Hendrik, 2018. "Process and utility systems integration and optimisation for ultra-low energy milk powder production," Energy, Elsevier, vol. 146(C), pages 67-81.
    • Handle: RePEc:eee:energy:v:146:y:2018:i:c:p:67-81
    DOI: 10.1016/j.energy.2017.04.142
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    References listed on IDEAS

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    1. Walmsley, Timothy G. & Walmsley, Michael R.W. & Atkins, Martin J. & Neale, James R., 2014. "Integration of industrial solar and gaseous waste heat into heat recovery loops using constant and variable temperature storage," Energy, Elsevier, vol. 75(C), pages 53-67.
    2. Walmsley, Timothy G. & Walmsley, Michael R.W. & Atkins, Martin J. & Neale, James R. & Tarighaleslami, Amir H., 2015. "Thermo-economic optimisation of industrial milk spray dryer exhaust to inlet air heat recovery," Energy, Elsevier, vol. 90(P1), pages 95-104.
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    6. Walmsley, Timothy G. & Atkins, Martin J. & Walmsley, Michael R.W. & Neale, James R., 2016. "Appropriate placement of vapour recompression in ultra-low energy industrial milk evaporation systems using Pinch Analysis," Energy, Elsevier, vol. 116(P2), pages 1269-1281.
    7. Perry, Simon & Klemeš, Jiří & Bulatov, Igor, 2008. "Integrating waste and renewable energy to reduce the carbon footprint of locally integrated energy sectors," Energy, Elsevier, vol. 33(10), pages 1489-1497.
    8. Walmsley, Michael R.W. & Walmsley, Timothy G. & Atkins, Martin J. & Kamp, Peter J.J. & Neale, James R., 2014. "Minimising carbon emissions and energy expended for electricity generation in New Zealand through to 2050," Applied Energy, Elsevier, vol. 135(C), pages 656-665.
    9. Matsuda, Kazuo & Hirochi, Yoshiichi & Tatsumi, Hiroyuki & Shire, Tim, 2009. "Applying heat integration total site based pinch technology to a large industrial area in Japan to further improve performance of highly efficient process plants," Energy, Elsevier, vol. 34(10), pages 1687-1692.
    10. Walmsley, Timothy G. & Walmsley, Michael R.W. & Tarighaleslami, Amir H. & Atkins, Martin J. & Neale, James R., 2015. "Integration options for solar thermal with low temperature industrial heat recovery loops," Energy, Elsevier, vol. 90(P1), pages 113-121.
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    Cited by:

    1. Klemeš, Jiří Jaromír & Varbanov, Petar Sabev & Walmsley, Timothy G. & Jia, Xuexiu, 2018. "New directions in the implementation of Pinch Methodology (PM)," Renewable and Sustainable Energy Reviews, Elsevier, vol. 98(C), pages 439-468.
    2. Bühler, Fabian & Zühlsdorf, Benjamin & Nguyen, Tuong-Van & Elmegaard, Brian, 2019. "A comparative assessment of electrification strategies for industrial sites: Case of milk powder production," Applied Energy, Elsevier, vol. 250(C), pages 1383-1401.
    3. Philipp, Matthias & Schumm, Gregor & Heck, Patrick & Schlosser, Florian & Peesel, Ron-Hendrik & Walmsley, Timothy G. & Atkins, Martin J., 2018. "Increasing energy efficiency of milk product batch sterilisation," Energy, Elsevier, vol. 164(C), pages 995-1010.

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