AOP Food Systems

AIR

FOOD WATER

MULTI POINT INTERVENTION STRATEGY

TECHNOLOGY OVERVIEW

UV Ozone AOP PHI

Know you’re ABC’s

UV-A, long-wave ultraviolet light in the 380 to 315 nm range

UV-B, medium-wave ultraviolet light in the 315 to 280 nm range

UV-C, short-wave ultraviolet light in the 280 to 100 nm range

UV-A 98.7% of all UV passing through the

atmosphere from sun is in the A region.

Both natural “Sun Tan” and artificial tanning lamps. Least harmful UV (…wrinkles).

Bug Zapper attractant (~365 nm).

Photocatalytic effect (very strong at 380nm)

UV-B Also passes through atmosphere (very

small amount…except when ozone holes occur).

Causes sunburn to the skin and can damage the eyes with over exposure.

Produces Vitamin D in the skin.

Too little exposure bad, to much also bad.

Photocatalytic effect (~280-300 nm).

UV-C 100% absorbed via atmosphere.

UV-C has highest energy of A,B, and C.

Quickly causes sunburn to the skin and can damage the eyes (flash burns).

Germicidal wavelengths (254nm)

Ozone producing wavelengths (185nm)

Strong Photocatalytic effect (can actually prevent catalyst deactivation)

UV Sources Sun

Low Pressure mercury lamps

Medium pressure mercury lamps

High pressure mercury lamps (metal halide lamps)

Very high pressure mercury and xenon lamps (pulsed lamps)

LED’s (emerging..not quite there)

UV-C (Commercial) Disrupts DNA and RNA effectively

“sterilizing” cell.

Line of site treatment (shadowing)

Minimum energy dose is required for kills

Easily determine treatment dose (published)

Energy level + time = kill dosage (CT value)

Germicidal UV (254 nm)

Effectiveness is dependent upon distance, intensity and exposure time

HVAC requires a large number to treat air

Very effective on stationary surfaces

Very good for liquid purification (if applied right)

Temperature sensitive (extremes reduce it)

Hazard due to glass and mercury

Generally very effective if applied and sized correctly

Ozone Approved for Food Use

July 1997 – Ozone receives GRAS affirmation by the FDA

Prior to July 1997 ozone was only approved for potable and bottled water

June 2001 Ozone was finally approved by FDA for food contact.

Ozone “A Household Word”

No Longer only associated with the “Ozone Layer” or Smog.

Municipal and Wastewater Treatment. Ozonated and Carbon Filtered Drinking

Water. Becoming much more accepted by food

industry.

What Is Ozone?

Oxygen is O2 – A molecule containing two oxygen

atoms

Ozone is O3

– A molecule containing three oxygen atoms.

OZONE IS ACTIVATED OXYGEN

Why Use Ozone?

Safety Disinfection Odor Control Oxidation

– Inorganics– Organics

Turbidity / Micro flocculation

How is Ozone Generated?

Ultraviolet Light Rays – UV Light Rays from

the Sun Electrostatic

Discharge– Lighting Bolts

Generation

O1

O1O3

O3O2

O2

O2

Differences in UV & CD Ozone Generation

0.01 - 0.1% by weight – 0.1% =

1,000ppm No Air Pre-

treatment needed

0.5 - 5.0 % by weight– 5.0% =

50,000ppm Air Pre-

treatment necessary

Ozone Generation Technologies Ultraviolet Light Ozone Generation

– Typically ideal for air treatment applications, especially due to low mass transfer requirements.

– Require no air preparation.– Low maintenance and operating costs.– Not cost effective at single pass water

treatment or other very large demand systems.

– Low capital cost.

Ozone Generation Technologies Corona Discharge Ozone Generation

– Ideal for fluid treatment applications or very large air systems.

– Requires air preparation.– RGF only sells with oxygen systems.– Higher maintenance and operating costs.– Very effective at single pass water

treatment.– High capital cost (especially for small units).

Common Oxidants

* - Friendly Oxidizers

1 - Fluorine (F-)2 - Hydroxyl Radical (OHO)*3 - Ozone (O3)*4 - Chlorine (Cl-)5 - Bromide (Br-)6 - Hydrogen Peroxide (H2O2)*7 - Oxygen (O2)*

Advantage of “Friendly” Oxidizers

Reverts to O2, CO2 and H20 After Use

Does not leave residue (or add to TDS)

Respond Faster to Organics

Can be generated on Site

Increases Oxygen Content (for fluid applications)

What is AOP? AOP typically refers to Advanced

Oxidation Process.

In short, Advanced Oxidation is creating more powerful oxidizers from less powerful components via some external energy (typically UV…but not always!)

Products of AOP reactions are also sometimes referred to as reactive oxygen species (or ROS).

Common components used in AOP reactions include Water, Oxygen, Hydrogen Peroxide, Ozone, Chlorine Dioxide, UV light and photo catalytic surfaces.

There are multitude of reactions and pathways to produce advanced oxidation products.

Typical AOP/ROH products

OHo Hydroxyl Radical

O2- Super Oxide Ions

HO2 Hydroperoxides (includes H202)

Ozonide Ions O3-

PHOTO CATALYST

H2O2, O3Energy: UV/other

AOP’s

(Always exceptions: using ClO2, Fenton's reaction, Sonalysis, you can also get AOP’s)

Benefits of AOP’s AOP reacts up to 40 times faster than

ozone alone (Note that ozone reacts 3000 times faster than chlorine).

Attacks virtually all organic compounds.

Abstracts hydrogen from contaminants to form water.

Provides a redundancy of oxidizers.

The most powerful AOP product produced is the OHo (hydroxyl radical).

This reactant is 2nd only to Fluorine in reactivity

Very short lived

Is key benefit in forming other AOP compounds, especially important for production of hydroperoxides (disassociation of water) including formation of hydrogen peroxide.

PCO’s Photocatalytic Oxidation Reactor

Uses UV light striking a catalytic bed

Creates reactive “holes” on catalyst surface

In turn producing AOP’s

Typically targeted to VOC reduction

Usually air only (always exceptions!).

Treats only the contaminants that are brought to it.

Reactions take place on the surface of catalytic bed.

The higher the surface area, and the more UV energy that reaches it, the more efficient.

As surface area of the catalytic bed increases, limitations due occur (UV shadowing).

Retention times to treat VOC’s are applicable.

Very effective when applied properly.

Can be costly

TYPICAL PCO

Catalyst Structure (Honeycomb, etc..,)

UV Source

Flow

AO REACTOR Usually liquid only (again, always

exceptions).

Reactant is mixed with fluid stream before entering reactor (H202, O3).

Fluid with reactants enter UV reactor (basically a UV sterilizer on steroids).

Here the photocatalytic reactions occur (producing AOP’s).

Typically treats only the contaminants brought inside the reactor chamber (very targeted such as MTBE).

Can be very effective if sized correctly

Also expensive due to fluid handling and requirement for H202 and / or O3 addition

TYPICAL AO REACTOR

H2O2

O3 UV

Photohydroionization

(PHI)

PHOTOHYDROIONIZATION

Hydrogen based oxidizers created by exposing activated oxygen molecules to a hydrated catalyst containing four unique metals and 100-380 nm UV light (Photon Energy):

– Hydro-peroxides– Hydroxides– Super Oxide Ions– Ozonide Ions

Photohydroionization is the creation of hydro peroxides from a reaction that takes place between the UV light, air, and the catalyst.

These hydro peroxides or “friendly oxidizers” are very effective in breaking down both airborne and surface borne microbes.

The High Humidity of most Food Plants benefits these reactions.

PHI Cell

• Broad spectrum lamp

• Quad-metallic hydrophilic coating

• PPC sleeve

“Photo” Process

Broad spectrum UV lamp

Quad-metallic Hydrophilic coating

Optimal surface area

PHI Cell

Hydrated Coating

PPC Sleeve

The Lamp

Broad Spectrum

High Efficiency

100-380 nm

Long Life Coating

PPC The Protection

• Breakage Containment

• Non-Polar

• Insulating

• Wash Down Compatible

Hydrated Quad-metallic Catalytic Coating Rhodium, Titanium, Silver, Copper, Hydrating Agent

The Quad-metallic coating: has particular affinities, breaks bonds, releases electrons, holds and releases atoms, steals other electrons. absorbs water vaporIt changes everything but itself remains unchanged. It is a “Catalytic” process.

“Hydrophilic” means that

it attracts water,

(H2O from the air)

This creates an

abundance of hydrogen and oxygen

on the coating

Quad-metallic Hydrophilic Coating

Titanium dioxide (TiO2) is a multifaceted compound. It's the stuff that makes toothpaste white and paint opaque. TiO2 is also a potent photocatalyst that can break down almost any organic compound.

Titanium


Different catalysts do different things!

Vol. 05, INTERNATIONAL JOURNAL OF PHOTOENERGY, 2003

Enhanced activity of silver modified thin film TiO2 photocatalysts

This silver doped photocatalyst decomposes the pollutant 3-times faster than the un-doped TiO2.

Silver speeds up titanium reactions

It was postulated that silver enhanced the reduction potential of TiO2, … It was found that … the reduction potential of the photocatalytic system can be altered by varying the amount of silver doped onto the TiO2.

The amount of silver alters the photocatalytic system

Silver



The Current Status of Catalysis by Silver R Schlögl, Fritz-Haber-Institut der Max-Planck-

Ges., Faradayweg. 4-6, D-14195 Berlin, GermanyElemental silver is a unique catalyst for selective oxidation reactions, … Four different species of atomic oxygen interacting in spectroscopically distinct ways with silver have been identified

Atomic Oxygen Species Adsorbed on Silver. V.I.Bukhtiyarov, Boreskov Institute of Catalysis, Lavrentieva prosp., 5,Novosibirsk, 630090, Russia This paper summarizes our efforts to study the nature of oxygen species adsorbed on silver and their reactivity

Silver has some unique abilities to work with energized forms of oxygen

Silver is an excellent electrical conductor

Silver is stable and will not itself oxidize in the course of creating and transporting oxidizers

Silver



Copper, like silver, can improve the functions of titanium

Bull. Korean Chem. Soc. 1999, Vol. 20, No. 8

Photocatalytic Activity of Cu/TiO2 with Oxidation State of Surface-loaded Copper

the effect of oxidation state of loaded Cu on the photo-catalytic oxidation reaction. … it is expected that the loaded Cu may improve photocatalytic activity of TiO2,

SOLAR PHOTOCATALYTIC HYDROGEN PRODUCTION FROM WATER USING A DUAL BED PHOTOSYSTEM, Clovis A. Linkous, Darlene K. Slattery, Florida Solar Energy Center, University of Central Florida

…As it turned out, the more common copper Pc evolved the most

H2… our best H2-evolving photocatalyst was copper.

Copper has unique abilities to work with hydrogen

Copper



Why the PHI Technology is Unique

By utilizing our broad spectrum lamp, we not only produce conventional AOP reactions on the cell surface, we also produce AOP reactions within the air that passes through the cell.

185 nm

O2

O2

O2

O2

O2

O2

185 nm emitted from cell

185 nm

Ozone

185 nm produces ozone

254 nm

254 nm breaks O3 into

to AOP’s

254 nm initiates ozone decomposition

Germicidal UV Light Rays

Hydroxyl Radicals OHo

Super Oxides O2-

Hydroperoxides H2O2

Ozonide Ions O3-

Hydroxides

OH

O3

OH

O3

O2

HO2

HO2

-

O2-

AOP FORMATION

Reaction pathways are complex and will vary greatly due to available reactants and location (for a specific target and point in time).

The PHI cell combines the features of a PCO with that of an AOR, plus more.

The following slide depicts just one possible reaction pathway of the PHI cell.

Chain BreakdownH2O2 + 2 O2

H2O2 + O3 + O2

HO2

H2O

O3O3

O2

O2

O2

H2O

OH

HO3

H+

HO4

O2

OH-

H+

UV Energy

With H2O, O3 and UV reaction continues

O2

-

-

PHI CELL ADVANTAGES

Uses germicidal UV for microbe inactivation.

Uses germicidal UV for Catalytic AOP reactions.

Uses the combination of UV wavelengths to produce AOP reactions in air.

AOP reactions inactivate microbes as well as destroy odors.

AOP reactants remain effective after leaving cell

PHI CELL ADVANTAGES

The PHI Cell produces and destroys ozone to facilitate the AOP reactions.

Typically greater than 87% of the actual produced ozone is decomposed in the AOP process.

Devices utilizing the PHI cells are not ozone generators, residual ozone produced is a by-product of the AOP process.

PHI CELL ADVANTAGES

Achieves higher kills (especially relative to levels), than ozone alone.

Proven outside studies on PHI effectiveness on Food Plant target organisms.

Food Safety Program

RGF's Photohydroionization Sanitation Process

Successfully used at:

Poultry processors

Pork processors

Grain processors

RTE processors

Beef processors

PRODUCT LINE FOCUS

Treatment of Food Contact Surfaces. Treatment of Food Product. Treatment of Air. UV Treatment of Brine and Chill

Water. Ozone contact systems for water.

SPECIFIC AREAS OF CONCERN

CONVEYOR SYSTEMS SLICING OPERATIONS PRODUCTION FLUID AIR - MICROBE AND ODOR CONTROL FINAL PACKAGING AREAS ICE MACHINES PLANT SANITATION

DEMAND FUELED BY:

ZERO TOLERANCE BY USDA/FDA FOR CERTAIN BACTERIA.

TREMENDOUS COSTS OF PRODUCT RECALLS.

LEGAL LIABILITY AND PUNITIVE DAMAGES.

CONSUMER DEMAND FOR FEWER CHEMICALS ON THEIR FOOD

BACTERIA AND VIRUSES MUTATING RESISTANCES AGAINST COMMON BIOCIDAL AGENTS AND ANTIBIOTICS

VALUE ADDED CHEMICAL FREE PRODUCTS

PHI on Surfaces

PHI PRODUCTS AND NON-PENETRATING PHOTOIONIZATION RAYS

PHI ON SURFACES Can be retrofitted into most existing

plant operations and conveyors. Does not use chemicals or other

consumables other than electricity. Leaves no residue. Does not require special permitting.

PHI CONVEYOR BELTS Conveyor belts are not always continuously

sanitized. Excellent benefits particularly in dry process

environments or near the end of the process line.

Protects from pathogen buildup each revolution.

Cross contamination….mitigation.

Examples of Conveyor and Surface Sanitation

Alternative Treatments Chemical sprays, which are costly and leave

residue. Frequent rinsing during shift (high labor, with

mixed results). Ozone spray (can be costly). UV only: Not as effective PHI approach,

offers no redundancy, has inherent shadowing issues, lamp breakage concerns.

PHI TUNNELS

PHI TUNNEL Systems provide 360 PHI treatment in synergy

with non penetrating radiation of product. Designed as a final intervention point just

prior to packaging or tenderizing. Provides excellent contact of the product

itself, as well as belt (interval set up). Contact time is based on production speed

requirements and particular unit design, they are typically held to a minimum of 10-12 seconds of contact under hood (fast lines require multiple hoods).

Has shown not to affect color, taste, or nutritive value (no change in free fatty acid).

Leaves no chemical residue. Treated product does not require any special.

consumer labeling. Low maintenance. Low energy consumption. Does not require lengthy specialized training. Tunnels are custom made to fit conveyors with

open weave belts and variable speed drives (some can be retrofitted, some not).

Pathogens cannot develop resistance. Lower cost than competing technologies. Don’t over sell the technology. Is not effective on all types of product.

- It is non penetrating (ground beef , post grind).

- If AOP gases cannot touch it, they wont kill it.

- Products with many overlaps or crevices are not a good fit.

Alternative Treatments Penetrating radiation treatment.

- Very high cost.

- Extensive training.

- Stigma of the process

- Ongoing labeling concerns

- Logistics issues (when outsourcing)

(although very effective)

LEAD OR DEPLETED URANIUM COLUMINATOR

RADIOACTIVE ISOTOPE CO 60

PENETRATING RAYS

Alternative Treatments Chemical sprays, which are costly, and leave

residue. Not always practical (dry products) Infrared Treatment

- High cost.

- Extensive training.

- High Energy use / cost.

- Product incompatibility (literally cooks surfaces).

Ultra High Pressure (UHP) “Cold Pasteurization”

- High purchase cost.

- Complicated training.

- High Energy use.

- Changes microscopic structure of some products (notably degrades proteins in meat causing color changes).

- Limited to batch process (not continuous)

- Typically good for high liquid content products. If air pockets, they collapse and fill with liquid, changes shape and size of product

Ozone spray, usually not an option due to the water addition, also off gassing concerns.

UV only: Not as effective PHI approach, offers no redundancy, has inherent shadowing issues, lamp breakage concerns.

Steam Pasteurization– Applies heat to food surfaces– Used mainly on pork and beef carcasses– Surface treatment only

Examples of PHI Tunnel Systems

Fully Understand the customers operation

Use Site Evaluations to capture pertinent information- Customers issues / data / requirements

- Product Type- Product Size- Maximum line speed *- Layout of location (sketch at minimum)- Available and/or preferred power

* You want to avoid your process impacting theirs.

Tunnel and Hood Sizing

Answer the easy questions first. Ensure material compatibility. Communicate, Communicate, Communicate

Recommend installations be done by I/R for these units.

Main reason is proper training, both safety and operational (units are simple, but due to inherent UV hazard, UV training is important).

Ideally communication is established very early with customer to ease install, the more that is completed upfront, the easier the install, and the happier the customer.

Tunnel and Hood Install

Ensure the USDA inspector has been made aware of the unit.

Units are inherently easy to install (when all is done correctly upfront).

Due to customization of units, most installs are different (field mount versus complete).

Units all use the same basic components, making understanding parts exchange very easy.

Each unit is shipped with a specific manual, each manual includes wiring diagrams and a specific spare parts list.

Install Details

A multiple cell unit may look complicated, but in essence, it only has multiple single components systems.

These component systems each require a cell, a ballast, a 4 pin ballast connector, and power supplied to the ballast to run (Basically, if you can trouble shoot and change a fluorescent light, you should be able to service these units).

All the connectors, o-rings, etc..have been standardized for these units, pay special attention to the cell and lamp part numbers (in manuals), as these change based on unit requirements.

Attach to the hoods and tunnels via standard tri-clamp fitting.

All designed as low voltage units (quick disconnect plugs).

These are the latest generation modules, and are to be the standard for your systems.

All internal parts will be interchangeable with the exception of the installed cell (these are sized for application).

PHI Modules (AOP Generator)

PHI Module

PHI TREATMENT OF AIR

Protects evaporator coils from pathogen buildup

Destroys air borne contaminants including mold, yeast, bacteria and viruses

Reduces employee absenteeism Reduces surface contamination Extends shelf life

Commercial HVAC In Duct Products (Plant offices, common areas, locker rooms)

Guardian Air HVAC Cell

REME HVAC Cell

ECO AIR

Food Applications

Kraft documented 93% Microbial Reduction

EPRI documented 94% Microbial Reduction

FSIS documented 90% Microbial Reduction

Wall mounted, stand alone unit.

PHI Rack System

Typical PHI Cell Reductions in air

Reduction Over 4 Day Period

020406080

100120140

1 2 3 4

Days 1- 4

CF

U/m

3

Bacteria and Mold CFU

2nd Day 71.2 %3rd Day 86.8 %4rd Day 95.4 %

BOS Bacteria Odor Abatement Systems

TYPICAL CUSTOM UNITS

Large Lift Stations Roof Top A/C units Air Transport Systems Large Ice Units Container Refrigeration Units

FLUV Units

UV Fluid Treatment Design

– Low pressure UV lamps– Low heat generation– 35-40% of energy converted to

germicidal UV vs.8-10% with medium pressure

– Designed for 40 mJ/cm2 minimum energy at target rated flow

– Designed for turbid water

UV Fluid Treatment Germicidal UV

– “C” range of the UV light spectrum– 253.7 nm– Inactivates bacteria by inhibiting its

reproductive capability “sterilizes” them.

– Multi lamp reactors for both high and low flows

– In low turbidity and low absorbance situations flows can be increased.

Features Stainless Steel, Food Grade materials Lamp status indicators Wash down stainless steel NEMA 4 enclosures PPC containment (glass breakage) No flat surfaces No tool disassembly CIP capable Small Foot Print Integrated leak detectors (with relay contact) Can integrate with optional flow sensors and

temperature sensors

UV Fluid Treatment Products

– FLUV-20 unit is for flow rates up to 20 GPM

– FLUV-60 unit is for flow rates up to 60 GPM

– FLUV-200 (aka. HVUV) is for flow rates up to 200 GPM

FLUV-20SPECIFICATIONS: Model FLUV-20Material Stainless SteelElectrical 120 volt 8 ampsWeight 45 lbs.Flow rate 20 gpm (per unit)Max operating pressure 50 psiConnections 1 1/2” Sanitary (Tri clover style)Tube Diameter 4”UV Lamps 5

FLUV-60SPECIFICATIONS: Model FLUV-60Material Stainless SteelElectrical 120 volt 30 ampsWeight 90 lbs.Flow rate 60 gpm (per unit)Max operating pressure 50 psiConnections 2” Sanitary (Tri clover style)Diameter of tube 6”UV Lamps 14

FLUV-200 (aka HVUV)SPECIFICATIONS: Model FLUV-200Material Stainless SteelElectrical 120 volt 30 ampsWeight 375 lbs.Flow rate 200 gpm (per unit)Max operating pressure 50 psiConnections 3” Sanitary (Tri clover style)Tube Diameter 10”UV Lamps 31

Example Performance Data– Pork Chill Brine UV system– Chub Chill Glycol UV system– Marinate injection UV system

Typical Reductions

Turkey Marinate

Examples of before and after UV sample testing

Typical Reductions Turkey Marinate

UV Treated Mid-Run

UV Treated End-Run

Control Mid-Run

Control End-Run

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

13

7

10

00

0

605371

228

18600

11650

14500

TPC's

Turkey Marinate TPC Growth Study #1 (WB)

34°F Control Turkey Fluid WB- 1st BreakTPC's per Sample Dilution TPC's per Sample Dilution

Elapsed Time (days)

Energy Measurement through fluid

(uW)

Single Pass 1:1 1:10 1:100 1:1000

1 200 GPM TNC TNC 172 203 N/A 200 GPM TNC TNC 123 117 200 GPM TNC TNC 140 15

34°F Control Turkey Fluid WB- End of ShiftTPC's per Sample Dilutions TPC's per Sample Dilutions

Elapsed Time (days)


(uW)

Single Pass 1:1 1:10 1:100 1:1000

1 200 GPM TNC 71 5 ND3 N/A 200 GPM 392 42 3 ND7 200 GPM 273 31 1 ND

34°F UV Treated Turkey Fluid WB - 1st BreakTPC's per Sample Dilution TPC's per Sample Dilution

Elapsed Time (days)


(uW)

Single Pass 1:1 1:10 1:100 1:1000

1 200 GPM ND 1 ND ND3 4000.00 200 GPM ND ND ND ND7 200 GPM ND ND ND ND

34°F UV Treated Turkey Fluid WB- End of ShiftTPC's per Sample Dilutions TPC's per Sample Dilutions

Elapsed Time (days)


(uW)

Single Pass 1:1 1:10 1:100 1:1000

1 200 GPM ND ND ND ND3 5000.00 200 GPM ND ND ND ND7 200 GPM ND ND ND ND

NOTE: Control samples from the WB line had a very high percentage of mold growth.

UV System Validation

0

200

400

600

800

1000

1200

1400

1600

1800

0 2 4 6 8 10 12 14

TP

C

Sample Number

Baseline vs. Validation Brine Chill Application

With UV System

Without UV System

VALIDATION

BASELINE

0

100

200

300

400

500

600

1/5 1/6 1/7 1/8 1/9 1/10 1/11 1/12 1/13 1/14 1/15 1/16 1/17 1/18 1/19 1/20 1/21 1/22 1/23 1/24 1/25 1/26 1/27 1/28 1/29 1/30 1/31 2/1 2/2 2/3 2/4 2/5 2/6

CFU

's

Sample Date

Chub Chiller Glycol CFU History

UV Activation

520 CFU

UV System Validation

0

200

400

600

800

1000

1200

cfu

/ml

Hours of Production

No UV

UV Day 1

UV Day 2

UV Day 3

UV Day 4

UV System ValidationBrine Marinate Injection System

Typical Brine Injection Install

BRINE MAKE-UP TANK

FS54 UV FLUID STERILIZER

3/4 HP CENTRIFUGAL PUMP

UNTREATE BRINE

TREATED BRINE

FLOAT VALVE

WOLFTEC INJ ECTOR

1/32" STRAINER

DRUM FILTER

3" UNISOURCE

SERIES 2710

SANITARY HOSE

150 PSI

4" WIDE SS RETURN SLIDE

NOTE: ALL PIPING IS 1.5" OD SS UNLESS SPECIFICALLY MARKED.

PRODUCT INFEED

15hp Centrifical Pump

SAMPLE POINT #2Open Sump

(before UV system )

15hp Centrifical Pump

UV System BypassValve Set

Incoming Brinefrom outside brine mixing unit

(sytem refilled daily)

System Drain(open to floor drain)

Flow Meter

4" to 3" Tube diameter reduction

4" OD SS Tube

High Volume UV Fluid Sterilizer Unit

3" to 4" Tube diameter increase

SAMPLE POINT #11" sample valve

(after UV system)Chiller Sump

4" OD SS Tube

Chilling Cabinet

Set of (2) Triple Strainer Filters

Exit Flow

Dual Chamber Brine Chilling Unit

4" OD SS Tube

Brine Spayers

Product Racks

Typical Chiller Loop Install

What to ask? Speak with the customer and complete and SOC. Visit if feasible. Review micro data (if available).

– Pre processing.– During operation.– Post processing.– What are the target reductions (log or percentage).

Determine the water quality.– What does the water contain? Brine, Glycol, flavorings….– Flow rates, maximum and average flow.– Line Pressure.– Temperature.– Pre and post processing differences

OZONE CONTACT SYSTEMS POOR QUALITY WATER FOR WASHING

PRODUCE POOR QUALITY CONTROL MEASURES HUMAN ERROR FACTORS POOR PROCESSING METHODS CHLORINE IS HAZARDOUS TO STORE CHLORINE CAUSES HEALTH PROBLEMS

IN PLANTS FROM EMISSIONS

OZONE CONTACT SYSTEMS CHLORINE EMISSIONS CAUSE

OXIDATION OF PLANT MACHINERY AND OTHER EQUIPMENT

SOME BACTERIA ARE RESISTANT TO IT

Competitive Technologies Chemicals; Sanova, peracetic acid

(Inspexx), chlorine and chlorine dioxide, quatenary ammonia– Except for chlorine they are expensive– Can create taste and color changes– Surface treatment only– No labeling requirements– Elevated COD levels in plant effluent– Storage and handling problems – Chlorine and caustic foaming agents,

corrosive to plant equipment– Difficult to maintain accurate method of

application

Assumptive Questions Do you use chlorine in your plant for sanitation or product washing? Are you interested in reducing chlorine consumption? Do you experience corrosion that you attribute to chlorine use? How much do you spend on chlorine per year? Are you required to document chlorine use? Do you swab product or equipment for pathogens during production? Do you experience spikes or ramping of bacteria on equipment or

product? Do you have shelf life issues? Do you have product returns as result of shelf life? What are the advantages for an anti-microbial, which does not require

storage or result in chemical residue on plant equipment or foodstuff? What are your concerns about cross contamination points such as

cutting surfaces, conveying surfaces or other product/equipment contact points?

Ozone System SizingWhy so many ?’s

System Sizing Factors

1. Applied Ozone Dosage

2. Total Ozone Demand

3. Flow Rate

4. Desired Residual

Applied Ozone Dosage(AOD Value)

Applied Ozone Dosage (ppm) = (CN x OR)

Where:CN = ppm of contaminant in

the waterOR = ppm of O3 required

to neutralize contaminant

Ozone Required(OR Value)

Contaminant O3 Practical

(ppm) (ppm)Iron(Fe++) 0.43 0.14-0.5Manganese (Mn++) 0.88 0.6-1.5Hydrogen Sulfide (H2S) 1.0 0.5-

1.5Unknown 0.5-1.5 0.5-1.5

Total Ozone Demand(TOD Value)

Total Ozone Demand (ppm) = AOD + MTF

Where:AOD = Applied Ozone DosageMTF = Mass Transfer Factor

Mass Transfer Factor (MTF Value)

MTF Value is based on Factors Affecting Transfer of Ozone into a liquid:

1 - Pressure2 - Temperature*3 - Bubble Size4 - Concentration of Ozone (% by

weight)*5 - Unknown Demand

* - Ozone Solubility Chart

Contact Time

- Flow Rate- Tank size (Contact Tank)- Delivery distance- Targeted reduction- Delivered Dosage required

4. CT Value

CT Value =C x T

Where:C = O3 Residual Concentration

T = Contact Time (time in contact with ozone prior to

measurement)

Measuring Ozone Residuals

DPD Colorimetric Test– Measures free oxidants

ORP Measurement– mV Readings unstable past 950

mV

Ozone Monitor– Expensive, high maintenance, – very accurate

Sizing Example

Question: What size ozone generator is required to eliminate iron and hydrogen sulfide?

Given: Flow = 10 gpmIron = 1.1 ppmHydrogen Sulfide = 0.44 ppm

Sizing Example

Applied Ozone Dosage Calculations: AOD = CN x OR

Iron: AOD = 1.1 x 0.43 = 0.473

ppm

Sulfide: AOD = 0.44 x 1.0 = 0.44 ppm

AOD Total = 0.913

ppm

Sizing Example

Total Ozone Demand Calculation:

TOD = AOD + MTF

AOD: AOD = 0.913 ppm

MTF: MTF = AOD For AOD <1

TOD: TOD = 0.913 + 1 = 1.913 ppm

Sizing Example

Ozone Generator Size Calculation:

OGS = TOD x FR x .012 x 19

TOD: TOD = 1.913 ppm

FR: FR = 10 gpm

OGS = 1.913 x 10 x .012 x 19

OGS = 4.36 gm/hr

Sizing Example(Cooling Tower)

Question: What size ozone generator is required for a Cooling Tower to provide disinfection?

Given: Flow = 150 gpmTonnage = 200 Ton


General Rules: Disinfection = 0.2 - 0.6 ppm = 4 - 10 gm / ton

Total Ozone Demand Calculation:

TOD = 0.6 ppm


Ozone Generator Size Calculation:

OGS = TOD x FR x .012 x 19

TOD: TOD = 0.6 ppm

FR: FR = 150 gpm

OGS = 0.6 x 150 x .012 x 19

OGS = 20.52 gm/hr

Ozone Contacting System

THE END

AOP Food Systems

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