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Appropriate placement of vapour recompression in ultra-low energy industrial milk evaporation systems using Pinch Analysis

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  • Walmsley, Timothy G.
  • Atkins, Martin J.
  • Walmsley, Michael R.W.
  • Neale, James R.

Abstract

This study focuses on applying Pinch Analysis to an industrial milk evaporator case study to quantify the potential energy savings. Modern milk evaporators are typically integrated using both mechanical and thermal vapour recompression technologies as the primary means for attaining a high level of energy efficiency. A significant step change in energy efficiency for milk evaporators is achieved in this study by appropriate placement of vapour recompression in a new improved two-effect milk evaporation system design. The Grand Composite Curve helps identify areas for process modifications and placements of vapour recompression that result in energy reduction. In particular, the innovative placement of Mechanical Vapour Recompression in the system unlocks significant energy, energy cost, and emissions savings. The new design requires 78% less steam (6397 kW) at the expense of 16% (364 kWele) more electricity use. The estimated cost savings associated with the improved design is $942,601/y and the emissions reduction is 3416 t CO2-e/y. Further energy efficiency improvements and cost savings of $1,411,844/y are gained through improved Total Site Heat Integration through recovery of waste heat from the dryer exhaust air and boiler return condensate streams.

Suggested Citation

  • 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.
    • Handle: RePEc:eee:energy:v:116:y:2016:i:p2:p:1269-1281
    DOI: 10.1016/j.energy.2016.04.026
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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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    Cited by:

    1. Zhang, Shiyou & Peng, Keming & Wei, Wenlong & Tang, Siqi & Yao, Jin, 2021. "The matrix method of energy analysis and energy-saving design on the electromechanical system," Energy, Elsevier, vol. 224(C).
    2. 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.
    3. Yong, Wen Ni & Liew, Peng Yen & Woon, Kok Sin & Wan Alwi, Sharifah Rafidah & Klemeš, Jiří Jaromír, 2021. "A pinch-based multi-energy targeting framework for combined chilling heating power microgrid of urban-industrial symbiosis," Renewable and Sustainable Energy Reviews, Elsevier, vol. 150(C).
    4. Lincoln, Benjamin James & Kong, Lana & Pineda, Alyssa Mae & Walmsley, Timothy Gordon, 2022. "Process integration and electrification for efficient milk evaporation systems," Energy, Elsevier, vol. 258(C).
    5. Ahmetović, Elvis & Ibrić, Nidret & Kravanja, Zdravko & Grossmann, Ignacio E. & Maréchal, François & Čuček, Lidija & Kermani, Maziar, 2018. "Simultaneous optimisation and heat integration of evaporation systems including mechanical vapour recompression and background process," Energy, Elsevier, vol. 158(C), pages 1160-1191.
    6. 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.
    7. Sharan, Prashant & Bandyopadhyay, Santanu, 2016. "Energy optimization in parallel/cross feed multiple-effect evaporator based desalination system," Energy, Elsevier, vol. 111(C), pages 756-767.
    8. Philipp, Matthias & Schumm, Gregor & Peesel, Ron-Hendrik & Walmsley, Timothy G. & Atkins, Martin J. & Schlosser, Florian & Hesselbach, Jens, 2018. "Optimal energy supply structures for industrial food processing sites in different countries considering energy transitions," Energy, Elsevier, vol. 146(C), pages 112-123.
    9. 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.

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