Advances in and the Economics of High Pressure Reverse Osmosis
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The Advances in and the Economics of High Pressure Reverse Osmosis for Product Concentration Applications in the Food Industry
Complete Process Essentials
Overview of Presentation
- Osmotic Pressure
- Standard Pressure Reverse Osmosis
- High Pressure Reverse Osmosis
- Case Study: Concentration of Sweet Whey
- Applications
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Osmotic Pressure
- The pressure exerted by the flow of water through a semi-permeable membrane separating two solutions with different solute concentrations
- P = MRT for dilution solutions
- M = concentration
- R = gas constant
- T = absolute temperature
| Component |
MW |
2% |
5% |
10% |
15% |
20% |
| Lactose |
342 |
24 |
63 |
134 |
215 |
320 |
| Glucose |
180 |
48 |
127 |
264 |
405 |
588 |
| NaCl |
58.5 |
250 |
620 |
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| MgSO4 |
120.4 |
65 |
168 |
352 |
615 |
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Standard Pressure Reverse Osmosis: Operating Parameters and Capabilities
- Membranes: spiral-wound TFC
- Systems: continuous w/ recirculation loops
- Operating Parameters
- Pressure < 600 psig
- Temperature < 50 C (standard)
- Capabilities
- Concentrate products to < 20% solids (typical)
- Commercial Applications
- Widely used in food, dairy, beverage industries
High Pressure Reverse Osmosis: Operating Parameters and Capabilities
- Membranes: spiral-wound TFC
- Systems: continuous w/ recirculation loops
- Operating Parameters
- Pressure 600 - 1000 psig
- Temperature 0-50 C (standard)
- Capabilities
- Concentrate products up to 25% - 35% solids (typical)
- Hot water sanitizable (some elements)
- Equipment Requirements
- More limited selection of components
- Process
- Achieve commercially viable solids concentrations
- Improved product quality
- No thermal degradation of product quality
- Economic
- Reduced transportation costs
- Better capital and operating costs than other technologies
Case Study: Sweet Whey Concentration
Overview
- Client interested in concentrating sweet whey with high pressure RO to reduce transportation costs
- Feed is sweet whey pre-concentrated with RO
- Innovation = USDA and 3A approval
- Alternative technologies include:
- use of standard pressure RO and NF
- NF generates a salt laden permeate
- Lower total solids concentrate
Case Study: Sweet Whey Concentration
Flux Data
Sweet Whey Process Stream Compositions
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Feed |
Concentrate |
Permeate |
| True Protein, % |
1.90 |
2.81 |
0.00 |
| NPN, % |
0.63 |
0.85 |
0.18 |
| Lactose, % |
14.25 |
21.08 |
0.00 |
| Acid, % |
0.48 |
0.71 |
0.00 |
| Ash, % |
1.58 |
2.32 |
0.04 |
| Fat, % |
0.16 |
0.24 |
0.00 |
| T.S., % |
19.00 |
28.00 |
0.22 |
Application Information
- Operating Specifications
- Feed Solids 19% Total Solids
- Water Removal Rate 12 gpm (>5M Gal/Yr)
- Concentrate Solids 28% Total Solids
- Operating Basis
- Days per Year 365
- Production Mode 20 hours / day
- CIP Mode 4 hours / day
- System - GEA's Scope of Supply
- All components, including PLC and MCC
- All engineering and fabrication services
- Excludes installation services
Project Costs and ROI
- Capital Costs (including install) ~ $500,000
- Operating Costs ~ $200,000 / year
- Includes costs for: labor, membrane replacement, CIP chemicals, power, steam, CIP water, cooling water
- Operating Cost ≤ $0.04 / gallon of water removed
- Transportation requires >1,000 fewer tank trucks
- Basis is 5,000 gallons / tanker
- Shipping costs per tanker ~ $1,000
- Cost Savings per year > $1,000,000
- ROI breakeven point - 9 months
High Pressure Reverse Osmosis
Applications (spiral-wound membranes)
- Concentration of whey products
- Sweet whey
- Sweet whey UF permeate
- Concentration of clarified fruit juices
- Concentration of clarified vegetable juices
- Concentration of clarified polysaccharide, sugar and sweetener products
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