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Brewery Optimization – Water Reduction in Cleaning Operations

Brewery Optimization – Water Reduction in Cleaning Operations. Linda A. Rastani Alfa Laval Inc. October 18, 2010. How do you conserve resources while effectively cleaning ?. The tank must be clean => effective cleaning meets the following requirements: low consumption of fresh water

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Brewery Optimization – Water Reduction in Cleaning Operations

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  1. Brewery Optimization – Water Reduction in Cleaning Operations Linda A. Rastani Alfa Laval Inc. October 18, 2010

  2. 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

  3. 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. The Optimal Cleaning Operation.

  4. Cleaning Impact (impingement) Action Action Surface Coverage TACT Cleaning Parameters Action Traditional TACT - Jet Head Approach Time Reduce: Time, Chemicals & Temperature Improve: Action & Coverage Temperature Chemical Concentration

  5. Comparing Static Spray Ball with Rotary Jet Head Cleaning with Cleaning with Static Spray Ball Rotary Jet Head

  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

  7. Energy Labelgy Label A G D << Back to Total Cost of Ownership start page.

  8. Static Spray Ball

  9. P≈V • Pressure is the driving force • The flow is turning the tank cleaning machine • Pressure is converted to water jet velocity t d d Cleaning Technology 2. High Wall Shear Stress Zone 3. Machine gearing makes the indexed criss-cross pattern  Water Jet Wall Shear Stress under Turbulent Flow Conditions Min. 40 Pa at r = 11 cm

  10. Rotary Jet Head Cleaning Technology • Attack of residues

  11. Mash Tun Required number of Rotary Jet Heads Type number RJH 2 4 x 5.2mm, 50 USGPM @ 75 PSIG

  12. Mash Tun

  13. 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. Mash Tun Net Savings/Cleaning = 700 USG x # Boils (Or Cleaning Cycles) Example = 1 cleaning/day x 700 USG = 176,400 USG/yr (252 days) saved!

  14. 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 Mash Tun

  15. Kettle Required number of Rotary Jet HeadsCylindrical Type number RJH-BKV 3 4 x 7mm, 58 UGPM, 75 PSIG

  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

  17. 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 Kettle Net Savings/Cleaning = 865 USG x # Boils (Or Cleaning Cycles) Ex: 1 cleaning/day x 865 USG = 217,980 USG/yr (252 days) saved!

  18. 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 Kettle

  19. Less than 1 year pay-back Benefits usingRSH & 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

  20. Thank You

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