maximizing of concentration and drying techniques confidential march 30, 2015 1 a title goes right...

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


• Anhydro has built

evaporators since 1951

• The first evaporator was a

natural circulation tubular

evaporator

Retrospect Evaporation Technology


Retrospect Recirculation Evaporator Type

• Circulation Evaporator

Example from 1951


• 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


• 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


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


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


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


Retrospect and Today’s Control System


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


Liquid Distribution System


Integrated Separator


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


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


VOKO and HOKO for High Capacities and 24/7


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


Heat Treatment – Example for Low,

Medium, and High-Heat


Heat Treatment Examples


Heat-Sensitive Products: WPC and Blood

Plasma

Design Features:

- Heat-treatment

- Low boiling temperature

- Low temperature difference

- Short residence time


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


50,000kg/h WE

Example: Potato effluent


Thank You for Your “Concentrated“ Attention


Optimized Drying of Milk and Whey

How to find the optimized Dryer

for

Milk and Whey powder


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


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


Spray Dryers Today, Form and Type


Dryer Components


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)

- ................


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


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


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


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


Non-Caking Whey/Permeate Dryer


Dairy Powders

Drying as a Philosophy


Test what you need

Thank You for Your Attention

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