IDEAS home Printed from https://ideas.repec.org/a/eee/energy/v146y2018icp67-81.html
   My bibliography  Save this article

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

Author

Listed:
  • 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
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0360544217307053
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.energy.2017.04.142?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    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.
    3. Liew, Peng Yen & Lim, Jeng Shiun & Wan Alwi, Sharifah Rafidah & Abdul Manan, Zainuddin & Varbanov, Petar Sabev & Klemeš, Jiří Jaromír, 2014. "A retrofit framework for Total Site heat recovery systems," Applied Energy, Elsevier, vol. 135(C), pages 778-790.
    4. Ramírez, C.A. & Patel, M. & Blok, K., 2006. "From fluid milk to milk powder: Energy use and energy efficiency in the European dairy industry," Energy, Elsevier, vol. 31(12), pages 1984-2004.
    5. Hackl, Roman & Harvey, Simon, 2015. "From heat integration targets toward implementation – A TSA (total site analysis)-based design approach for heat recovery systems in industrial clusters," Energy, Elsevier, vol. 90(P1), pages 163-172.
    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.
    11. Xu, Tengfang & Flapper, Joris, 2011. "Reduce energy use and greenhouse gas emissions from global dairy processing facilities," Energy Policy, Elsevier, vol. 39(1), pages 234-247, January.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. 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.
    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. François Faraldo & Paul Byrne, 2024. "A Review of Energy-Efficient Technologies and Decarbonating Solutions for Process Heat in the Food Industry," Energies, MDPI, vol. 17(12), pages 1-50, June.
    4. 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.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    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. Tarighaleslami, Amir H. & Walmsley, Timothy G. & Atkins, Martin J. & Walmsley, Michael R.W. & Liew, Peng Yen & Neale, James R., 2017. "A Unified Total Site Heat Integration targeting method for isothermal and non-isothermal utilities," Energy, Elsevier, vol. 119(C), pages 10-25.
    3. Liew, Peng Yen & Theo, Wai Lip & Wan Alwi, Sharifah Rafidah & Lim, Jeng Shiun & Abdul Manan, Zainuddin & Klemeš, Jiří Jaromír & Varbanov, Petar Sabev, 2017. "Total Site Heat Integration planning and design for industrial, urban and renewable systems," Renewable and Sustainable Energy Reviews, Elsevier, vol. 68(P2), pages 964-985.
    4. Liew, Peng Yen & Walmsley, Timothy Gordon & Wan Alwi, Sharifah Rafidah & Abdul Manan, Zainuddin & Klemeš, Jiří Jaromír & Varbanov, Petar Sabev, 2016. "Integrating district cooling systems in Locally Integrated Energy Sectors through Total Site Heat Integration," Applied Energy, Elsevier, vol. 184(C), pages 1350-1363.
    5. 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.
    6. Zhang, Bing J. & Tang, Qiao Q. & Zhao, Yue & Chen, Yu Q. & Chen, Qing L. & Floudas, Christodoulos A., 2018. "Multi-level energy integration between units, plants and sites for natural gas industrial parks," Renewable and Sustainable Energy Reviews, Elsevier, vol. 88(C), pages 1-15.
    7. Chang, Chenglin & Chen, Xiaolu & Wang, Yufei & Feng, Xiao, 2017. "Simultaneous optimization of multi-plant heat integration using intermediate fluid circles," Energy, Elsevier, vol. 121(C), pages 306-317.
    8. Masera, Kemal & Tannous, Hadi & Stojceska, Valentina & Tassou, Savvas, 2023. "An investigation of the recent advances of the integration of solar thermal energy systems to the dairy processes," Renewable and Sustainable Energy Reviews, Elsevier, vol. 172(C).
    9. Jin, Yuhui & Chang, Chuei-Tin & Li, Shaojun & Jiang, Da, 2018. "On the use of risk-based Shapley values for cost sharing in interplant heat integration programs," Applied Energy, Elsevier, vol. 211(C), pages 904-920.
    10. Song, Runrun & Tang, Qikui & Wang, Yufei & Feng, Xiao & El-Halwagi, Mahmoud M., 2017. "The implementation of inter-plant heat integration among multiple plants. Part I: A novel screening algorithm," Energy, Elsevier, vol. 140(P1), pages 1018-1029.
    11. 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.
    12. Chang, Hao-Hsuan & Chang, Chuei-Tin & Li, Bao-Hong, 2018. "Game-theory based optimization strategies for stepwise development of indirect interplant heat integration plans," Energy, Elsevier, vol. 148(C), pages 90-111.
    13. Jamaluddin, Khairulnadzmi & Wan Alwi, Sharifah Rafidah & Abd Manan, Zainuddin & Hamzah, Khaidzir & Klemeš, Jiří Jaromír, 2022. "Design of Total Site-Integrated TrigenerationSystem using trigeneration cascade analysis considering transmission losses and sensitivity analysis," Energy, Elsevier, vol. 252(C).
    14. Faramarzi, Simin & Tahouni, Nassim & Panjeshahi, M. Hassan, 2022. "Pressure drop optimization in Total Site targeting - A more realistic approach to energy- capital trade-off," Energy, Elsevier, vol. 251(C).
    15. Hackl, Roman & Harvey, Simon, 2015. "From heat integration targets toward implementation – A TSA (total site analysis)-based design approach for heat recovery systems in industrial clusters," Energy, Elsevier, vol. 90(P1), pages 163-172.
    16. Liew, Peng Yen & Wan Alwi, Sharifah Rafidah & Ho, Wai Shin & Abdul Manan, Zainuddin & Varbanov, Petar Sabev & Klemeš, Jiří Jaromír, 2018. "Multi-period energy targeting for Total Site and Locally Integrated Energy Sectors with cascade Pinch Analysis," Energy, Elsevier, vol. 155(C), pages 370-380.
    17. 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.
    18. Varbanov, Petar Sabev & Fodor, Zsófia & Klemeš, Jiří Jaromír, 2012. "Total Site targeting with process specific minimum temperature difference (ΔTmin)," Energy, Elsevier, vol. 44(1), pages 20-28.
    19. Nahin Tasmin & Shahjadi Hisan Farjana & Md Rashed Hossain & Santu Golder & M. A. Parvez Mahmud, 2022. "Integration of Solar Process Heat in Industries: A Review," Clean Technol., MDPI, vol. 4(1), pages 1-35, February.
    20. Calvin Kong Leng Sing & Jeng Shiun Lim & Timothy Gordon Walmsley & Peng Yen Liew & Masafumi Goto & Sheikh Ahmad Zaki Bin Shaikh Salim, 2020. "Time-Dependent Integration of Solar Thermal Technology in Industrial Processes," Sustainability, MDPI, vol. 12(6), pages 1-32, March.

    More about this item

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:energy:v:146:y:2018:i:c:p:67-81. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.journals.elsevier.com/energy .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.