Objective
Using Ultra Osmosis technology to concentrate Acid Casein Whey by 4:1. This method is a direct substitution for the conventional evaporation using the Thermal Vapour Recompression system (operating on Steam) and a Demineralisation Plant.
Ultra-Osmosis is cross linked polymide membrane that has rejection characteristics which enable it to discriminate among low molecular weight species. The pore structure of the membrane is such that a separation between Sodium Chloride and Calcium Sulphate may be accomplished.
When compared to the conventional Thermal Vapour Recompression system, this method shows a 90% energy cost reduction resulting in an annual fuel saving of 2.164 TOE.
The project at full capacity reduces the annual demand for energy by more than 2,000 TOE which would be used to raise steam by means of Heavy Fuel Oil burning.
The waste stream from the plant is treated at the Effluent Plant already established for the Casein Factory.
The 9.88% of loss of protein is treated in the same way.
All effluent is treated to meet the terms of the discharge regulations of the Local Authority.
The payback for this installation depends principally on two factors :
(1) UTILISATION
Each hour of operation represents a saving compared to Thermal Vapour Recompression of UKL 35.66.
(2) THE FINAL USE OF DEMINERALISED WHEY
Higher prices markets give a shorter payback period. As Whey market prices are volatile, any decision on such factors must be taken in the context of the investors view of Whey price performance.
UTILISATION
Hours per year average Years Payback
6500 3.2
6000 3.5
55003.8
5000 4.2
4500 4.8
Hours utilised during the monitoring period were 2883. The limiting factor was the availability of Whey for this process.
PERFORMANCE ON ACID WHEY
Average volumetric concentration factor = 3.99
Feed conductivity = 9.45
Product conductivity (Conc.) = 8.94
Average feed pH = 4.51
Product pH = 4.37
FEED WHEY
Average total solids = 6.267
Average Protein in D.M. = 10.83
Average Ash In D.M. = 11.25
CONCENTRATE PRODUCT
Average total solids = 22.04
Average Protein in D.M. = 10.11
Average Ash in D.M. = 6.37
MINERAL REMOVAL as a percentage of Feed
Sodium = 69.49k%
Potassium = 74.04%
Chloride = 57.1%
Calcium = 6.34%
Magnesium = 0.78%
Phosphorous = 15.48%
ASH REMOVAL
* (1) Ask Loss = 43.37
* (2) Actual Ash Loss = 46.68 Product
44.11 Permeate
Note : * (1) % in D.M. feed Vs % in D.M. product
* (2) Ash feed Vs. Ash in product.
The Plant consists of a continuous feed and bleed type Ultra-Osmosis system with internal recirculation loops and a high pressure feed arrangement. The product enters a high pressure pumping stage capable of creating a pressure of approximately 3.5 MPA at the required flow rate. The product then passes sequentially through 5 circulation stages, or loops. Each of these loops contain its own recirculation pump and 50 spiral wound membrane elements totaling 6 m2 of membrane surface. These membranes are enclosed in 10 pressure vessels, each containing 5 elements. The flow pattern is a parallel operation through each pressure vessel. The system contain a total of 250 membranes elements (5x50) for a total effective membrane surface of 1500 m2. The internal volume of the system is 1700 litres and is completed with its own process control and automated C.I.P. system.
Ultra Osmosis has many of the characteristics of Reverse Osmosis in that the membrane is a thin film polyamide composite cast over a polysulfone substrate on a polyester backing which operates at pressures almost as high. In the range of 20 to 30 bar. The major difference and what makes the membranes so unique, is that the active layer has the ability to transmit some charged ions along with the water that it permeates. This effect allows mono-valent ions to be transported through the membrane with little resistance.
In whey, the mono-valent ions are chlorides, sodium and potassium.
The technique gives the dairy processor new opportunities to modify the balance of salts and ash in products by eliminating the most objectionable of the ash compounds.
Topic(s)
Call for proposal
Data not availableFunding Scheme
DEM - Demonstration contractsCoordinator
CO. KILKENNY
Ireland