Brewery Optimization – Water Reduction in Cleaning Operations Linda A. Rastani Alfa Laval Inc. October 18, 2010
www.alfalaval.com 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
www.alfalaval.com The Optimal Cleaning Operation. 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.
www.alfalaval.com Slide 4 Action Time Chemical Concentration Temperature TACT Cleaning Parameters Reduce: Time, Chemicals & Temperature Improve: Action & Coverage Cleaning Impact (impingement) Action Surface Coverage Action Traditional TACT - Jet Head Approach
www.alfalaval.com Comparing Static Spray Ball with Rotary Jet Head Cleaning with Cleaning with Static Spray Ball Rotary Jet Head
www.alfalaval.com Slide 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
www.alfalaval.com Energy Labelgy Label G A << Back to Total Cost of Ownership start page. D
www.alfalaval.com Slide 9 Cleaning Technology d d t Wall Shear Stress under Turbulent Flow Conditions Min. 40 Pa at r = 11 cm Water Jet 2. High Wall Shear Stress Zone 3. Machine gearing makes the indexed criss-cross pattern 1.Pressure is the driving force 1.The flow is turning the tank cleaning machine 2.Pressure is converted to water jet velocity PVPV
www.alfalaval.com Slide 10 Rotary Jet Head Cleaning Technology Attack of residues
www.alfalaval.com Slide 11 Mash Tun Required number of Rotary Jet Heads Type number RJH 2 4 x 5.2mm, 50 USGPM @ 75 PSIG
www.alfalaval.com Mash Tun 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. Net Savings/Cleaning = 700 USG x # Boils (Or Cleaning Cycles) Example = 1 cleaning/day x 700 USG = 176,400 USG/yr (252 days) saved!
www.alfalaval.com Slide 14 Mash Tun 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
www.alfalaval.com Slide 15 Kettle Required number of Rotary Jet Heads Cylindrical Type number RJH-BKV 3 4 x 7mm, 58 UGPM, 75 PSIG
www.alfalaval.com Slide 16 Kettle RJH 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
www.alfalaval.com Slide 17 Kettle 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 Net Savings/Cleaning = 865 USG x # Boils (Or Cleaning Cycles) Ex: 1 cleaning/day x 865 USG = 217,980 USG/yr (252 days) saved!
www.alfalaval.com Slide 18 Kettle 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
www.alfalaval.com Slide 19 Benefits using RSH & 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 Less than 1 year pay-back