brewery optimization – water reduction in cleaning operations linda a. rastani alfa laval inc....
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![Page 1: Brewery Optimization – Water Reduction in Cleaning Operations Linda A. Rastani Alfa Laval Inc. October 18, 2010](https://reader035.vdocuments.site/reader035/viewer/2022062511/55141738550346ec488b5391/html5/thumbnails/1.jpg)
Brewery Optimization – Water Reduction in
Cleaning Operations
Linda A. Rastani
Alfa Laval Inc.
October 18, 2010
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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
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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.
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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
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Comparing Static Spray Ball with Rotary Jet Head Cleaning with Cleaning with
Static Spray Ball Rotary Jet Head
Concentration
Time
Mechanics
Temperature
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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
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Energy Labelgy Label
G
A
<< Back to Total Cost of Ownership start page.
D
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www.alfalaval.comSlide 8
Static Spray Ball
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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
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www.alfalaval.comSlide 10
Rotary Jet Head Cleaning Technology
- Attack of residues
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www.alfalaval.comSlide 11
Mash Tun
Required number of Rotary Jet Heads
Type number
RJH 2
4 x 5.2mm, 50 USGPM @ 75 PSIG
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www.alfalaval.comSlide 12
Mash Tun
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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!
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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
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www.alfalaval.comSlide 15
Kettle
Required number of Rotary Jet Heads Cylindrical
Type number
RJH-BKV 34 x 7mm, 58 UGPM, 75 PSIG
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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
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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!
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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
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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
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n 1
year
pay
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Thank You