Mass balance/Plant configuration
(NF
Acid Whey)
|
Component
|
Feed
|
Retentate
|
Avg.
Permeate
|
|
True
Protein [%]
|
0.46
|
1.52
|
0.00
|
|
NPN
[%]
|
0.16
|
0.28
|
0.07
|
|
Lactose
[%]
|
4.77
|
15.36
|
0.11
|
|
Acid
[%]
|
0.15
|
0.46
|
0.01
|
|
Total
Ash [%]
|
0.78
|
1.32
|
0.35
|
|
Fat
[%]
|
0.01
|
0.03
|
0.00
|
|
TS,
Sum [%]
|
6.33
|
18.97
|
0.54
|
|
Phosphate
PO4[%]
|
0.220
|
|
|
|
Calcium
Ca[%]
|
0.086
|
|
|
|
Magnesium
Mg[%]
|
0.009
|
|
|
|
Sulphate
SO4[%]
|
0.012
|
|
|
|
Sodium
Na [%]
|
0.056
|
|
|
|
Potassium
K [%]
|
0.042
|
|
|
|
Chloride
[%]
|
0.340
|
|
|
|
Other
[%]
|
0.015
|
|
|
|
Cap.
Avg. [l/h]
|
60,000
|
18119
|
65609
|
Key Figures
Total Protein (=True Protein + NPN) [%] 1.80
Degree of Demineralisation[%] 49.07
Lactose Recovery[%] 98.05
Diafiltration water 23728
Lit/hr
Feed
type:
Fresh
acid whey of good quality from the production of (pH 4.5 – 4.7).
Pre-treatment:
-
Skimming to < 0.06 % fat.
-
Heat treatment at 52 - 54°C for 15 sec.,
or equivalent, if needed to control the bacteriological quality.
(Alternatively, H2O2 (20 ppm) or sodium hydrogen sulphite
(50 ppm) may be added).
-
note:
-
The temperature must not at any time
exceed 60°C, as this will result in a decrease in capacity. Max. 2°C dt in the
heat exchanger.
-
Adjustment to NF-plant operating
temperature.
-
The inclusion of air must be avoided.
-
The addition of most types of de-foamers
is not acceptable.
Operating
conditions:
-
Feed and retentate composition as specified.
-
Feed rate: 60,000 Lit/hr
-Total feed/day: 1,080,000 Lit
- NF plant operating temperature: 10 degC
- Production time: 1x18 hr
NF
Plant configuration
Membrane:
Module: Spiral Wound,
Equipment specification – NF plant
Quality stainless steel is used for all
surfaces in contact with the product. All components in contact with the
product are of Food and Dairy standard. The equipment specification is
preliminary and changes might occur during final engineering
Twin
balance tank 2x200 l incl.:
1 Loose cover
1 Level switch
2 Level transmitter
Valve
manifold:
4 Change-over valves
2 Butterfly modulating valves including
electro-pneumatic positioner
1 Butterfly valve with actuator
Feed
pressure system:
3 Feed pumps
3 Frequency converters
1 Pressure transmitter
1 Flow transmitter including indicator
1 Triplex safety filter with automatic
change over including pressure transmitters in the input and output of the
filters
6 Re-circulation loops each incl.:
1 Stainless steel rack for NF modules
1 Re-circulation pump
1 Tubular heat exchanger
1 Temperature indicator
2 Pressure indicators
1 Flow indicator for permeate
1 Sampling valve
Retentate system:
1 Modulating
valves
1 Flow transmitter including indicator
1 Refractometer
Permeate
system:
1 Permeate pump
6 Butterfly modulating valves including
electro-pneumatic positioner (APV +Kinetrol)
6 Temperature controller
Additional
equipment for injecting water (Diafiltration) to the product to reach a higher
level of Demineralization
Equipment
for flush water:
1 Cut-off valve
1 Filter
1 Pressure switch
2 Adjustment valves
Equipment
for steam and cooling water:
7 Cut-off valves
6 Regulating valves
1 Steam filter
6 Water trap
2 Non return valves
1 Temperature indicator
1 Pressure indicators
1 Multistage centrifugal pump
Soft
water system:
2 Pressure indicator
2 Safety filter for water including
stainless steel housing
Pipes
and fittings:
Stainless
steel pipes and fittings for internal connections within the NF plant
Compressed
air hoses and fittings for internal connections within the NF plant
Pre-assembling
The
equipment will be mounted on a stainless steel frame as a complete unit just to
be connected with services and product pipes.
Fully-automatic
control system:
The
control panel is in mild steel and is placed in the control room. The panel is
built as a PLC based control system. Two number of PC’s with 19” monitor will
be utilized i.e. one for operating the plant and the other one for modifying
the parameters etc. The operator will be able to monitor and supervise all of
the necessary control parameters and take necessary actions from the control
panel. MCC panel and electrical cables from the panel to the plant are not in
the scope of supply.
The function of the panel
Automatic
regulation of the level in the feed tank.
Automatic
regulation of the feed pressure. The operator must adjust the pressure before
the regulator is set on automatic.
Automatic
regulation of the ratio of product inlet to retentate outlet (indirect
regulation of TS in the retentate). The operator must adjust the ratio before
the regulator is set on automatic.
Automatic
regulation of the plant temperature during production and cleaning..
Automatic
control of change-over valves in valve manifold.
Alarm
supervision with visual alarm and action of the following:
Temperature
alarm
Feed
pressure alarm
Level
alarm
Alarm
supervision with visual alarm of the following:
Concentration
alarm
The panel consists of:
PLC
type Siemens (S7-414)
PLC
based control system
Various
power supplies, fuses and clamps
Operating principles
The
plant is mainly operated from the panel and partly by operating service valves
etc. directly on the plant. On the monitor you can see the process values,
which is a part of the regulation loop. During start and stop of the plant and
during start and stop of production the operator must carry out some operation on
the OP panel, but during production and CIP the plant is self-supervised and is
able to take action on account of possible alarms.
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