RWR presentation to Retort Manufacturers updated Eco Innovation … · 2015-05-28 · History &...

RECOWATER PROJECTRetort Water Recycling

Dissemination via retorts manufacturers

24242424thththth & 30& 30& 30& 30thththth of July 2013of July 2013of July 2013of July 2013

ParticipantsParticipantsParticipantsParticipants

Christophe Crouzet : Composite project leader

Gebhard Kregel : Global R&D, responsible for dissemination

Philippe Frickert : ERN chief Engineer, local project leader

Christophe Mathey : ERN maintenance manager

2

Christophe Mathey : ERN maintenance manager

Yann Weissgerber : Steriflow

Jean Patrick Roumagnac : Steriflow

Gerd Werner : Scholz (Separate meeting 30/07/2013)

Frank Funke : Scholz (Separate meeting 30/07/2013)

12:00 – 12:30 Welcome on Site and a first introduction Philippe Frickert

12:30 – 13:30 Lunch in the cafeteria All

13:30 - 14:00 Retort Process Steam Air and the special requirements Gebhard Kregel

14:00 – 14:45 Detail technical presentation of the RWR Christophe Crouzet

14:45 – 15:00 Break

Agenda of the dayAgenda of the dayAgenda of the dayAgenda of the day

3

15:00 – 16:30 intensive and detailed factory tour All

16:30 – 17:00 Quality requirements for a successful operation Philippe Bernard

17:00 – 17:30 Question & Answer Session Gebhard, Christophe and Philippe

17;30 Return to the Hotel Petite France in Strasbourg

Content of this presentationContent of this presentationContent of this presentationContent of this presentation

1) History

2) Dissemination

3) Technical description

4) Results & challenges

4

4) Results & challenges

History & contextHistory & contextHistory & contextHistory & context

- 2009 : We commissioned in VDN a innovative Retort cooling Water Recycling System based on

fine filtration, UV light, ozone, saving 95% water and keeping water quality on potable level

-Early 2010 : Based on this success, we decided to roll out to European factories equipped with

steam air retorts : ERN & GAR with the support of European Union (MEL & BRK stepped out for strategic & economical reasons)

5

- October 2010 : Contract with EU was signed to get subsidies from them to help us

implementing the replications, as far as will disseminate this project outside.

DisseminationDisseminationDisseminationDissemination

-> From the initial contract, we were asked to disseminate via the following channels :

European

food

industry/

public

MARS Commercial → Subcontractor

6

-> Due to time & resources constraints we downscaled the scope to retorts manufacturers only

-> Therefore we would need your help to fulfil the contract terms :

(We have)...”also approached the major European retort and filter producers and currently discusses the option of including information on the project e.g. in their newsletters. That way, approximately 60% of all food producing companies within Europe could be reached”

Principle of the RWRPrinciple of the RWRPrinciple of the RWRPrinciple of the RWR

• Coarse filter to remove solids, avoid debris build up & reduce COD level

Here is the principle :Retort Coarse

FilterWater check & rejectstation

Raw WaterTank

FineFilter

UV Treatment

Weekend cleaning system

Police disinfection

Clean Water Tank

7

• Online checking station for incoming water, with rejection of water > 10 NTU

• Raw-water buffer tank and pumps

• Self cleaning filter (size 20-30µm) to prevent that any debris or build-up of substances in the system becomes nutrients for bacterial growth.

• UV light for water disinfection, as it will not impact the water chemistry nor require special safety protections/training of operators deal with hazardous substances.

• Ozone police disinfection via ozone injection to keep the system clean after the UV treatment and provide verification of chemical sanitation

• Clean water buffer tank and pumps

• Automatic CiP system to provide weekly cleaning and sanitation of the whole recycling system

Cold

water

PT100

Heat-

V2

Pouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortStart

empty retort

8

T

Control

valve

Condensat

Pump 2x

Heat-

exchanger

2x

P2A

P2B

V3

VD1

V7

Pouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortCondensate

(C.U.T and Sterilisation)

CP2

CP1

Venting

Cold

waterPT100

PS1

Heat-

V2

Flow direction away from the van

Flow direction to the van

9

T

Condensat

Steam

Pressure

air

Pump 2x

Heat-

exchanger

2x

P2A

P2B

V3

Condensate(300 - 350 ltr.)

100 mmVD1

V7

N0∑300 - 350 ltr.

N3

N1

Pouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retort

Cold

water

Pre-Cooling

valve

Heat-

V2 V1

Flow direction away from the van

Flow direction to the van

Pre-Cooling water

from 125°C to ~95°C

10

N0

Condensat

Pump 2x

Heat-

exchanger

2x

P2A

P2B

V3

Cold water

injection

VD1

V7

250 mm∑1.300 ltr

Pre-Cooling water

(1.000 ltr.)

N3

N1


Cold

water

Heat-

V2 V1

Additional water to reach the

correct level for circulation pump

11

Condensat

Pump 2x

Heat-

exchanger

2x

P2A

P2B

V3

Cold

water

VD1

V7

Additional water

(few hundred ltr.)

∑1.500 ltr

N3

N1

N0


Cold

water

Heat-

V2 V1

Start cooling over heat exchanger

from 95°C to 35°C

12

Condensat

Pump 2x

Heat-

exchanger

2x

P2A

P2B

V3

VD1

V7

Condensate

recyclingN3

N1

N0


Cold

water

PT100

Heat-

V2

Empty the retort

(Drain the water)

to the drain water and waste it

A)

send the water to the RWR system for reuse

B)

or

13

Condensat

Pump 2x

Heat-

exchanger

2x

P2A

P2B

V3

VD1

V7

Drain

N3

N1

N0

Retort Recirculation Cooling Water Retort Recirculation Cooling Water Retort Recirculation Cooling Water Retort Recirculation Cooling Water Treatment System Treatment System Treatment System Treatment System

TI

P

roM

aq

ua

®

Pro

Min

en

t®

Coarse Filter > 1 mm

Pro

Min

en

t®

From the Retorts

45 m3/h

QIS FI

P

PD

2

Potable water conn.

Failure Indication

Berkefeld-Filter

Stö

rungsm

eld

ung

UV

Ca

taly

tic

rem

ain

ing

ozo

n a

nnih

ilato

r

34

5

67

21

P

CIP- Pipe

P

P

DN 100

DN 40

DN 40DN 40

DN 65

DN 50

P

23

min. 1 m infeed lenght

1

Ozon-Injection25

01

02 04

11

LIC

05

LIC

06

2726

Pro

Min

en

t®

Pro

Min

en

t®

Pro

Min

en

t®

Failure Indication

Ozon

DN

100

DN 40

TI

03

optional

Lf

00

Pro

Min

en

t®P

roM

ine

nt®

Conductivity Turbidity

TemperatureFlow

Redox

Flow

Ozone

pH

LevelLevel

Temperature

14

UV-Lamp

QIS

FT

FIC

FU

P

P

Ozon rH QIS-

Ra

w w

ate

r-ta

nk

Pro

ce

ss w

ate

r-ta

nk

SAC pH

P Fine filtration10 µm

P

8

9 10

1112

13

14

21

18

19

22

CIP-Base 50 %

P2

P3

P1

P

treated coolingwater

Emptying pipes

20

P

to the Retorts56 m3/h

DN

50

DN

40

DN 40DN 40

DN 50DN 65

DN 50

15

23

24

DN 100

FT

FIC

P4

08 09 10

12 13 14

Zirculation pipe to

avoid switch off the UV-lamps

LSA-

15

LSA-

16

Flu

shin

g A

ir

DN 50

16

PP

DN

50

P

Flushing tank

PPP

PP

PP

P

P

P

LSA-

16

P

to Waste Water

d P

FlowFlow Level

SpectralAbsorption

Coefficient

pH

Agenda of the dayAgenda of the dayAgenda of the dayAgenda of the day





14:45 – 15:00 Break


15





ContentContentContentContent

1 - General project overview

2 – From idea to pilot

3 – Technical overview & deep dive on key elements

16

4- Reco summary

5- Achieved results

1111---- Project CharterProject CharterProject CharterProject Charter

• OBJECTIVE : Recycle retort cooling water (steam air retorts) to reduce dramatically

potable/softened water usage, and keep water quality on Q&FS standards

• SCOPE :

• 11 retorts in ERN (300m3 water/day) , 21 retorts in GAR (500m3 water/day)• Conversion to “water through process” in ERN, and full emptying in GAR

• PROJECT KEY DATA :

• 1 turnkey supplier for the core treatment system• Local suppliers for environing systems/interfaces

17

• Local suppliers for environing systems/interfaces• ERN : 0,8 M€ project, actual commissioning July 2011• GAR : 1,6 M€ project, actual commissioning October 2011

• KEY SUCCESS FACTORS :

KPI Measure

Retort fresh water consumption reduction -90% on basis of equivalent portofio/volume

CFU at system outlet <100 bacts/ml

Coliforms & enterococci at system outlet 0

Impact on retort cycle time 0

Workload to operate & maintain the system Max 4h/weekStandalone for 1 week

2 2 2 2 ---- Why such a system ?Why such a system ?Why such a system ?Why such a system ?

The project started from blank sheet and different options were studied for water treatment :

1) Physical treatment : RO/Ultra filtration Filtration CapabilitiesReverse Osmose (RO)Reverse Osmose (RO)Reverse Osmose (RO)Reverse Osmose (RO) Flow DirectionNanofiltrationNanofiltrationNanofiltrationNanofiltration (NF)(NF)(NF)(NF) Ultrafiltration (UF)Ultrafiltration (UF)Ultrafiltration (UF)Ultrafiltration (UF) Mikrofiltration (MF)Mikrofiltration (MF)Mikrofiltration (MF)Mikrofiltration (MF)No No No No poresporesporespores

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+ : bacteria avoidance, chemical-free, no impact on material/product

- : Low efficiency (less savings), prefiltration needed to cope with pollution, possible re-infection after system

Viruses

Bacteria, parasitesanorganic substances

Highly molecular org.substances

Org. Substances with medium size

Low molecular org. Substances

Polyvalent ions

Univalent ions

2222---- Why such a system ?Why such a system ?Why such a system ?Why such a system ?

2) Thermal treatment

+ : No add-ons or chemicals required, Sterile water after cycle , no impact on material

- : Energy usage, Pre-filtration for particles necessary

3) Chemical treatment (Chlorine, Bromine, Hydrogen peroxide)

+ : Strong disinfection agent, easy to operate

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+ : Strong disinfection agent, easy to operate

-: Possible creation of by products, risks on material / product if not correctly handled

For these reasons we had to design a fit-for-purpose specific water treatment system

3333---- PrinciplePrinciplePrinciplePrinciple

• Coarse filter to remove solids, avoid debris build up & reduce COD level

• Online checking station for incoming water, with rejection inappropriate of water

Here is the principle :

20

• Online checking station for incoming water, with rejection inappropriate of water

• Raw-water buffer tank and pumps to “transform” a batch process to a continuous process

• Self cleaning filter (size 20-30µm) to prevent that any debris or build-up of substances in the system becomes nutrients for bacterial growth.

• UV light for water disinfection, as it will not impact the water chemistry nor require special safety protections/training of operators deal with hazardous substances.

• Ozone police disinfection via ozone injection to keep the system clean after the UV treatment and provide verification of chemical sanitation

• Clean water buffer tank and pumps

• Automatic CiP system to provide weekly cleaning and sanitation of the whole recycling system

3333---- Deep dive : Checking stationDeep dive : Checking stationDeep dive : Checking stationDeep dive : Checking station

1) Theory : role of the checking station

Photo Cell

LampLens

Aperture

90°scattered Light

Glas Cuvette

21

-> Temperature control : filters out water >45°C (damage to turbidity/UV light devices)

-> Conductivity control : water quality (condensate vs softened)

-> Turbidity control : filters out polluted water

2) Lessons learned on turbidity

-> VDN : On line measurement -> Not working because of air bubbles from emptying pumps

-> ERN/GAR : Measurement in bypass and bubble removal with ultrasonic bath -> Working better, but too long time between measurement & rejection (too late), bacteria buid-up in bath

3 3 3 3 ----Deep dive : Checking stationDeep dive : Checking stationDeep dive : Checking stationDeep dive : Checking station

3) Recommendation for future project

• By pass solution

• Need to reduce the time between taking the water and measuring as much as possible

• Turbidity meter to be placed far enough from tank1 to allow possibility to reject batches

22

• Commissioning with involvement of manufacturer

• Rejection limit =4 NTU

3333---- Deep dive : FiltersDeep dive : FiltersDeep dive : FiltersDeep dive : Filters

1) Theory : role of the filter

Basics of Filtration Molecular weight 200 20.000 100.000

0,1 1 10 100 1000 10.000

Particle Colloids Macro-

molecules Pharma-ceuticals pesticides

Ions Microfiltration (MF)

Ultrafiltration (UF)

Nanofiltration (MF)

Reverse Osmose (RO)

0,1B – 2 bar

0,1 – 5 bar

3 – 10 bar

5 – 100 bar

B

P

V

B P

V

23

Here the goal is not to filter out all particles/bacts, but just to remove “big” particles (>10-30 microns) which could prevent the UV light to work properly (shadow effect) or create a nest for bact growth.

To fulfil its role the filter must be as well :

- Automatic self washable (backwash) and able to remove bacts/ biofilm

- Withstand CIP conditions

- Several units in parallel to allow continuous operation

0,1 1 10 100 1000 10.000

Particle size (nm)


2) Results from VDN pilot

Techno : Disk filter 20 µm Beckerfeld

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WorkingWorks fine for ½ week (biofilm)Low water usage

ChallengesSuitable only up to 50°C (plastic)Not able to work continuously 1 week


3) Implementation ERN/GAR

-> Stainless filter 30 micron (hot CIP 85°C) from Wolftechnik

-> Problems we faced :

•Mesh destruction : solved after changing design to 3 layer & setting proper operational conditions

•Blockages by biofilm : solved by manual cleaning 3/week and local CIP by mid-week

25

Working Filters water @ 30 microns

ChallengesLong time to find the solutionManual cleaning 3/week and mici CIP mid weekStill blockages in GARgzdai


4) Recommendation for future projects

• Ability to clean automatically the pollution including bio film for 1 full week

• Withstand CIP conditions 85°C with caustic

• Hygienic design

• Mesh size as small as possible (20 µm max)

• Water usage limited as much as possible

26

• Water usage limited as much as possible

3333---- Deep dive : UV lightDeep dive : UV lightDeep dive : UV lightDeep dive : UV light

1) Theory : role of the UV light

Ultraviolet radiation causes damage to organic cells by modifying their vital enzymes and the DNS. Because of that, the metabolic process and cell replication will be stopped. The microorganisms will then die shortly

27

- The disinfection effect of the light is in a range of 240 to 290 nm wave length with a maximum at 254 nm. - Water has to be clear water with low absorption within the UV range-2 types of lamps : low pressure and the medium pressure lamps

Medium pressure discharge lamps have a higher specific electric power in W/cm, produce a lower percentage of UV at 254 nm , but emit a wider spectral range of microbial effective radiation



1 medium pressure lamp from Prominent

-> 2kW power

-> over designed power (3000J/m2 whereas 450J/m2 are enough in theory)

28

WorkingKilling bacteria0 bacts after UV and ozone

ChallengesStill some bacts after UVEnergy usage


3) Results from ERN/GAR

On supplier recommendation, we decided to go for low pressure lamps from Wedeco (more homogeneous energy flow due to higher number of lamps, better efficiency at 254 nm, lower consumption…)

-> 10 -16 lamps in 1 housing 3-5 kW

-> Over designed power (3000J/m2 instead 450J/m2 )

29

Working Killing bacteria, efficiently as in VDN (medium pressure)

Challenges

Still some bacts after UVKilling rate around 1:100 to 1000 (vs 1:100.000 promised by supplier)Measured power is only 80W/m2 (Design=220W/m2) due to water qualityIssues on commissioning



• No bacteria after UV

• Overdesigned

• Involve supplier for commissioning

• Automatic emitter tube wiping system (based on time/ actual power)

• Withstand CIP conditions when Off

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• Withstand CIP conditions when Off

• Withstand up to 45°C in normal operations

• Equipped with a intensity sensor (W/m2 or %)

3333---- Deep dive : Ozone systemDeep dive : Ozone systemDeep dive : Ozone systemDeep dive : Ozone system

1) Theory : role of the Ozone

Role :

-> Keeps the water sustainably clean (avoid re-infection after UV)

->Traceability (presence of ozone in water = no bacteria)

-> Target 0,3-0,7 ppm in water after tank 2 (clean water)

31

It is composed of different equipments :

-> Ozone generator

-> Ozone dosing & mixing devices

-> Online concentration measurement

-> Gas warning system (safety)



• From Prominent

• Designed on 1,5g/m3/hour

• Compressed air inlet -> ozone/air outlet

• Online dosing in main water pipe before tank 2

• Static mixer

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• Static mixer

Working Ozone is injected and measured on line

Challenges -



On supplier recommendation, we used a different technology :

• From BWT

• Designed 1,5-2 g/m3/h

• Water by pass 6m3/h from the main water flow to tank 2

• Ejector sucking air by venturi effect

33

Working Ozone in fresh water concentration after injection at target

ChallengesLong investigations to find out the dilution problem (mixers)Still not enough ozone in water to cope with pollution

• Ejector sucking air by venturi effect

• After analyse of gaps between dosed and measured quantities, we implemented 2 additional static mixers



• Recommendation for the VDN solution with compressed air and no bypass(more simple)

• Cruise dosing 2g/m3/h

• 2 Ozone mixers

• Connexion to both tanks to avoid bacteria growth in tanks

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• Ozone measurement online based on VDN solution but after tank 2

• Involvement of manufacturer for commissioning

• Gas detector as in ERN/GAR

3333---- Deep dive : CIP systemDeep dive : CIP systemDeep dive : CIP systemDeep dive : CIP system

1) Theory : role of the CIP system

•Bring the overall system 100% clean once a week

• Cleaning via caustic soda solution (0,5-2%)

• Disinfection with Chlorine

• Must include as well the inlets/outlets from/to retorts

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• Only local CIP (Treatment system)

• Cold CIP

Working Core system is clean after CIP

ChallengesDirtiest point of the system (pipe from retorts) not cleanedLimited efficiency (cold)Need manual mechanical / chemical cleaning several times/year



• Hot CIP 85°C

• Includes pipes from / to retorts including individual & main pipes

• Reutilisation of the caustic mix (tank)

• Possibility to make local CIP wihin the week, without stopping production

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Working System fully cleaned

Challenges Long commissioning phase



• Based on ERN/GAR overall –> RWR + retort main + retort pipes

• Hot CIP, but with bypass if disk filters

• For automated factory, based on ERN solution

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• For semi automated based on GAR solution (CIP needs manual validation before starting, problem on retort during CIP handled differently, light management)

4444---- RecoRecoRecoReco basisbasisbasisbasis

Item Top line Spec Base

Coarse filter 0,2mm ERN/GAR

Check station Turbidity by pass ERN/GAR + relocation

Tanks & pumps Hygienic design, 1h ERN/GAR

As a summary, here is the lessons learned recap from VDN/ERN/GAR installations which could be used to setup a reco. However, future investigations may be needed

38

Fine filtration Disks 20µm VDN stainless steel

UV Medium or low Test needed

Ozone 2g/h, compressed air VDN

CIP system Including full piping ERN/GAR

ControlsJust fit for purpose &

interfaceFunctions ERN/GAR

Techno VDN

5 5 5 5 ---- What have we achieved initiallyWhat have we achieved initiallyWhat have we achieved initiallyWhat have we achieved initially

From the beginning (commissioning summer 2011) we achieved

-> Water savings >90%

-> No impact on the rest of the factory

-> Good hygienic design & very efficiency CIP system

But :

-> Quick build up of biofilm

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-> Quick build up of biofilm

-> generating bacteria over limit after 3 days in ERN and 1 day in GAR (higher pollution)

-> and blockage of the filter generating installation stop.

5555---- What have we achieved finallyWhat have we achieved finallyWhat have we achieved finallyWhat have we achieved finally

After months of optimisation on :

-> Filters (3 layers design, operating conditions)

-> Ozone dilution (adding mixers)

-> Controls (filter cleaning, rejection dirty batches...)

-> Implementation of mid week local CIP

-> Setting up proper supervision procedures

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-> Setting up proper supervision procedures

We managed to reach the required quality of water and signed the HO2 in July 2012 for ERN and in June 2013 for GAR





14:45 – 15:00 Break


Quality requirementsQuality requirementsQuality requirementsQuality requirements

41





ERN Achieved quality todayERN Achieved quality todayERN Achieved quality todayERN Achieved quality today

42

Conclusion : ERN meets expectations on KPIs as far as a good maintenance & supervision is carried out

1) Preventive maintenance

-> Systematic CIP &system emptying at weekend & verification of effectiveness (CIP report)

-> Systematic mini CIP on Wednesdays/Thursdays

-> Filter cleaning systematically 3 times/ week

2) Supervision & corrective actions

-> Control of key parameters daily (Ozone, UV, pollution ultrasonic bath...) by key user

-> Automatic alarm if problem with the system (filter blockages, water rejection too high, UV transmission too

ERN operational procedure to fit R&D requirementsERN operational procedure to fit R&D requirementsERN operational procedure to fit R&D requirementsERN operational procedure to fit R&D requirements

43

-> Automatic alarm if problem with the system (filter blockages, water rejection too high, UV transmission too low, stopped ozone generator....)

In case of deviation the key user put the system back in good function. If pollution is suspected, the system will be emptied, a mini CIP will be run and 1 ATP control will occur within 24h. As emergency solution, the system is switched to softened water until the root cause is found. Further punctual treatment with biocide is possible in addition

-> Supervision of production defects (which could pollute the system) by sterilisation operator

In case of production defect, the system will be stopped immediately

-> Systematic water analyse (system outlet) on Friday

In case of deviation, the following procedure will take place :

3) Escalation procedure in case of excessive bacteria count

From the Friday analyse, the results are available

4.1 If total bacteria count is between 100 and 10000 UFC/ml :

� System is switched off

� Analyse root causes and implement corrective actions

� mini CIP and ATP control every day until the results of bacteria count. Biocide treatment possible

4.2 If total bacteria count is above 10000 UFC/ml or another parameter is above 1 :

ERN operational procedure to fit R&D requirementsERN operational procedure to fit R&D requirementsERN operational procedure to fit R&D requirementsERN operational procedure to fit R&D requirements

44

4.2 If total bacteria count is above 10000 UFC/ml or another parameter is above 1 :

� System is switched off

� PRIMP process is started

� Analyse root causes and implement corrective actions (System cleaning with biocide is possible/required)

� restart only after a validation with microbiological analysis

� ATP controls every day during 2 weeks

RWR presentation to Retort Manufacturers updated Eco Innovation … · 2015-05-28 · History &...

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Transcript of RWR presentation to Retort Manufacturers updated Eco Innovation … · 2015-05-28 · History &...