Design af effektive pulveranlæg
Indlæg til temadag: ”Mælkebaserede ingredienser”
Oktober 8, 2015
Carsten Juhl Jessen
Carsten Juhl Jessen
• MSc. Dairy Science & Technology, Graduate Diploma in
International Business (HD-U)
• More than 25 years international experience in Dairy
Powders & Nutritional Projects worldwide
• Deputy Division Manager, Food & Dairy, GEA Niro
• Prior assignments:
• Managing Director GEA Niro GmbH (D-A-CH)
• Sales Director CPS Powder Europe (DK, DE & NL)
• Sales Director APV Nordic Anhydro A/S
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engineering for a better world
GEA in Summary
GEA is a global leader in equipment and process technology providing innovative solutions
for smart food processing and for a more efficient use of energy resources.
Dairy Farming
Dairy Processing
Food
Beverages
SALES
Revenue
EUR 4.5bn (FY14)
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Operating EBIT Margin
11.4% (FY14)
Employees
>18,000 (Dec14)
Market Cap
>EUR 9.0bn (Apr15)
engineering for a better world
GEA in Summary
You are in touch with food processed by GEA equipment globally every day…
More than 60% of
Infant Formula is
being processed
through GEA Spray
Dryers.
Every 4th liter
of milk you are
consuming has been
processed through
GEA equipment.
Every 3rd instant
coffee production
line around the globe
has been built by
GEA.
Every 3rd chicken
nugget you are
eating has been
processed by our
equipment.
…we are all this and more every day!
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engineering for a better world
Mælkens anvendelse i Danmark
Mælkeanvendelse til Sød-,
skummetmælks pulver og Formula
produktion udgør ca 940,000 ton
(18% af mælke-indvejningen)
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engineering for a better world
Mælkens anvendelse i Danmark - Pulverproduktion
Total mælkeanvendelse &
mælkederivater til pulver
produktion udgør 3,9 mia kg
(>75% af mælkeindvejningen i
Danmark !)
Mælk og mælkederivater i
pulverform udgør > 40% på
tørstof basis
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engineering for a better world
Global Mælkeanvendelse - Pulverproduktion
Total mælkeanvendelse til
pulver produktion udgør 252
mio ton (>60 % af den globale
mælkeindvejningen !)
Over 35% på tørstof basis
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engineering for a better world
Spray anlæg – krav til design
1.
Optimal produkt kvalitet (pulver)
2.
Sanitært design
3.
Maximum sikkerhed (personale, anlæg, omgivelser)
4.
Høj effektivitet – investering og OEE
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engineering for a better world
Dairy Dryers – Average Capacity in Europe
8000
7000
6000
Kg/hour
5000
4000
3000
2000
1000
1960’s
1970’s 1980’s 1990’s 2000’s
2010 2011 2012 2013 2014
Year
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engineering for a better world
Store anlæg er mere effektive at drive og bygge
Donnellan et al. The Potential for scale economies in milk powder processing: an Irish study;
International journal of Dairy Technology. Vol 67, 2014
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engineering for a better world
Extensive use of CFD &
DRYNETICS™ for
Process Analysis
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CFD for Spray Dryer Analysis
CFD reliability
”Real life”
Time
1989
2008
DRYNETICS™
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2013
2014
engineering for a better world
Eksempler på nye udviklinger
• Kontinuerlig anlægsdrift (24/7)
• Avanceret overvågning af anlæg
• Anvendelse af model baseret proceskontrol
• Anvendelse af PAT teknologier
• Komponent udvikling (opskalering)
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engineering for a better world
24/7 operation giver mange fordele
• Reduktion af antal start-stop (pulver out of spec. / stand-by energiforbrug)
• 1 start-stop hver 10-14 dage – interval mellem CIP forlænges
• Påvirkning af inddamper og fødesystem skift
• Flere skift – mindre påvirkning ved større anlæg 100% -> 25%
• Optimale skift af inddampere og varmebehandlingssystem – lavere indhold af
termofile bakterier
• Tørrekammer pulverafsætninger reduceres
• Reduktion af farve påvirking af produktet
• Reduktion af uopløselige partikler i produktet
Operatørernes fokus
• Ikke længere start-stop, men optimering af anlæg og produktkvalitet
engineering for a better world
SPRAYEYE™ Spray Nozzle Supervision System
SPRAYEYE™ Visual
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SPRAYEYE™ IR (Patented)
engineering for a better world
SPRAYEYE™ Spray drying production example
IR Camera
detection
Remedy
‘Root cause’
Identified
Deposit formation
detected
Temperature rising
Alarm activated
Nozzle lance is
removed and replaced
Snapped O-ring
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engineering for a better world
GEA Niro Advanced Spray Dryer Control
SPRAYEYE™
DRYCONTROL™
Spray nozzle monitoring system
Identification of product build up
Control of spray pattern
Temperature alarm
Overall Spray Dryer control
Simulating control actions real time
Implementing the optimal control route
Squeeze and shift
POWDEREYE™
Humidity Sensor
A platform for in line laboratory tests
In line humidity sensor
Basis for optimisation of drying conditions
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Residual powder moisture for DRYCONTROL™
Scorched particles
Density
Colour
engineering for a better world
DRYCONTROL™ – Control structure
DRYCONTROL™
Controlled variables
• Exhaust air temperature
• Exhaust air humidity
• Powder residual moisture
Manipulated variables
• Feed flow
• Main air temperature
• Static Fluid Bed air temperature
Measured disturbances
• Ambient air humidity
• Feed changes
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Advanced Process Control and monitoring
engineering for a better world
GEA Niro POWDEREYE™
The POWDEREYE™ Purpose
• A system for in line measurement of
standard laboratory tests.
• Powder residual moisture
• Bulk and tapped density
• Scorched particles
• A system for relevant powder
measurements
• Protein %
• Lactose %
• Fat %
• Colour
• Powder Flowability
• Particle size
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engineering for a better world
GEA Niro MSD™ Dryer Size
400%
350%
Relative Capital Cost per Ton Powder
1 x Bagfilter
2 x Bagfilters
4 x Bagfilters
300%
250%
200%
150%
100%
50%
0%
0
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1000
TM
2000
MSD Dryer Size
3000
4000
engineering for a better world
Top section of GEA Niro SaniCIP™ Bag Filter
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engineering for a better world
Milk Processing Trends in Europe
The ”white wave” in EU, as a result of the quota abolition drives investments in
large processing facilities for high quality milk powder and Formulated
Nutritionals.
Focus are powders (milk / various ingredients and nutritionals) all intended for
growing populations with buying power in Asia/ME and Africa
This includes large investments in green field milk / nutritionals powder plants
(7-15 t/h range) and bolt on capacity to existing sites.
GEA delivers a quantum leap to EU dairies
In product quality, througput and efficiency (OEE)
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engineering for a better world