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 2 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) 3 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! 4 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) 5 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 6 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 7 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 8 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 9 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 10 engineering for a better world Extensive use of CFD & DRYNETICS™ for Process Analysis 11 CFD for Spray Dryer Analysis CFD reliability ”Real life” Time 1989 2008 DRYNETICS™ 12 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) 13 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 15 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 16 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 17 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 18 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 19 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 20 1000 TM 2000 MSD Dryer Size 3000 4000 engineering for a better world Top section of GEA Niro SaniCIP™ Bag Filter 21 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) 22 engineering for a better world
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