|
Ae = 488731.7 kWh/month | S/W | Ae = 38530 + 21.93Zm | 0.917 | |
We = 104.9 kWh/1000L | We = 178.6 - 0.019Zm | −0.982 | |||
P = 5400 kW |
Ae = 1842461 kWh/month | S/W | Ae = 80.184 - 74908Zm | 0.63 |
Zm: 21749 – 25541 Mg/month Z15: 2184 – 3023 Mg/month |
Ae = 155.75·Z11+84.68·Z12 - 573.45·Z13–11.36·Z14+232.33·Z15 + 139383.53 | 0.72 | ||||
We = 77.0 kWh/1000 L | We = 0.0002 Zm + 72.558 | Weak correlation | |||
We = 3∙10−3 Z11 + 7∙10−3·Z12 - 0.017·Z13 - 0.025·Z14 + 3∙10−3·Z16 + 36.5 | 0.31 | ||||
Ac = 17060.39 GJ/month | Ac = 0.0946Zm + 14799 | Weak correlation | |||
Ac= −1.49·Z11 - 1.33·Z12 + 3.46·Z13 + 5.84·Z14 + 3.93·Z15 + 16572.40 | 0.65 | ||||
Wc = 0.71 GJ/1000 L | Wc= −3E-05Zm + 1.3441 | 0.47 | |||
Wc = −1∙105·Z11 - 3∙105·Z12 + 2∙104·Z13 + 7∙10−6 ·Z14 + 1∙10−5 ·Z15 + 0.99 | 0.83 | ||||
P = 420 kW Z = 132,765 L/24h |
Ae = 101,516 kWh/month | S/W | 0.741 |
Z20: 3,962 – 35,914 kg/month Z22: 37,806 –187,223 kg/month Z23: 281 – 3079 kg/month |
|
Ae = 0.17·Z16 + 3.38·Z17 + 0.32·Z18 - 0.70·Z19 + 1.62·Z20 + 0.48·Z21 + 0.08·Z22 - 0.84·Z23 - 15048.70 | 0.984 | ||||
We = 25.94 kWh/1000 L | 0.526 | ||||
0.905 | |||||
P = 300 kW Z4d = 181,300 L/96 h |
Ae = 10,681 kWh/4d | S/W | Ae = 84.71Z4d - 4676.82 | 0.675 | Z4d: 173,430 – 192,500 L/4d |
We = 58.87 kWh/m3 | We = 0.1479Z4d + 31.75 | 0.285 | |||
Ac = 56.93 GJ/4d | Ac = 0.6966Z4d - 69.36 | 0.719 | |||
Wc = 313.56 MJ/m3 | Wc = 2.00 Z4d - 48.81 | 0.482 |
S | 50.0 – 2,385.0 (34) | 2,374.1 | 59.305 | 32.13 | 1.0882 | Ae = 559.42 + 29.374Z1 | 0.834 | Z1: 2.5 – 80.6 |
Ae =345.63 + 4.420P1 + 18.787P2 | 0.950 |
P1: 0.0 –1785.0 P2: 7.5 –170.0 |
||||||
Ac = 18.658 + 0.460 Z1 + 1.766Z2 | 0.849 |
Z1: 2.5 – 80.6 Z2: 3.1 – 39.6 |
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W | 63.0 – 646.0 (24) | 1,081.4 | 52.366 | 30.70 | 1.7502 | Ae = 358.08 + 35.352Z1 | 0.672 | Z1: 1.0 – 59.1 |
Ae = 463.75 + 6.235P3 | 0.429 | P3: 6.0 – 250.0 | ||||||
Ac = −0.121 + 0.531P1 − 1.899P7 | 0.811 |
P1: 17.4 – 273.7 P7: 0.0 – 41.2 |
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Ac = 30.777 + 1.054Z1 | 0.441 | Z1: 1.0 – 59.1 |
Milk, dairy beverages, cream, tvorog, cheese, butter, casein, milk powder | |
Identical to |
|
Identical to |
|
Milk, dairy beverages, cream, and tvorog only |
Energy consumption (direct) and energy conservation | |
Heat recovery | |
Energy consumption in wastewater treatment | |
Renewable energy | |
Cleaner production standards | |
Best available techniques | |
Environmental performance | |
Energy efficiency and optimization of selected production processes | Alves et al. [2014], |
Financial and environmental implications of energy management | |
Process integration | |
Pulsed electric field processing | |
Solar energy | |
Electric power substitution/electrification | |
Life cycle assessment ( |
|
Cleaner production and the environmental impact of dairy production | |
Cleaning of production equipment |
0.59 – 3.10 | 0.36 – 5.66 | 0.54 – 3.10 | 0.62 – 2.42 | 0.32 – 2.90 | 0.22 – 2.99 | 0.25 – 2.90 | 0.40 – 1.16 | |
0.35 – 1.33 | 0.23 – 3.54 | 0.30 – 2.13 | 0.14 – 0.82 | 0.19 – 1.18 | 0.13 – 2.46 | 0.13 – 1.35 | 0.18 – 0.90 | |
3.52 – 17.74 | 3.93 – 40.46 | 5.30 – 31.67 | 1.13 – 21.40 | 4.13 – 17.74 | 1.16 – 39.55 | 1.17 – 17.74 | 2.26 – 13.53 | |
2.43 – 12.91 | 1.26 – 23.75 | 3.06 – 23.75 | 0.49 – 8.93 | 0.70 – 13.16 | 1.02 – 32.41 | 1.08 – 11.92 | 1.31 – 8.77 | |
3.74 – 13.69 | 2.63 – 28.79 | 4.02 – 28.79 | 0.99 – 24.66 | 1.76 – 24.66 | 1.99 – 34.33 | 1.99 – 32.26 | 3.38 – 24.64 |
S | 83.0 – 1,923.0 (22) | 3,079.5 | 148.151 | 37.83 | 1.5542 | Ae = 953.19 + 29.707Z4 + 430.898Z6 | 0.932 |
Z4: 10.0 – 335.8 Z6: 0 – 22.5 |
We = 42.633 - 0.481Z5 | 0.346 | Z5: 0 – 80.3 | ||||||
Ac = −36.781 + 0.607P1 - 0.523P3 + 1.037P4 + 0.968P6 + 5.555P10 | 0.990 |
P1: 30.3 – 574.0 P3: 0.0 – 320.0 P4: 0.0 – 592.0 P6: 0.0 – 58.6 P10: 0.0 – 101.0 |
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Wc = 1.476 + 0.001P4 - 0.012P6+0.013P10 | 0.662 | |||||||
Ac = 41.899 - 0.964Z3 + 2.204Z4 + 15.219Z6 | 0.971 |
Z3: 0 – 164.2 Z4: 10.0 – 335.8 Z5: 0– 80.3 Z6: 0 – 22.5 |
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Wc = 1.6316-0.006Z3 + 0.003Z4 - 0.013Z5 | 0.608 | |||||||
W | 30.3 – 1,938.0 (20) | 3,548.8 | 230.243 | 42.82 | 2.9086 |
Ae = 2133.00 - 85.291Z4 We = 32.375 + 5.757Z6 |
0.660 0.770 |
Z4: 0 – 53.0 Z6: 0 – 7.9 |
Ac = 1.145 + 0.444P1 + 0.936P4 + 1.275P7 | 0.985 |
P1: 30.3 – 470.0 P4: 0.0 – 592.0 P7: 0.0 – 87.0 |
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Wc = 2.2652 + 0.028P7 | 0.627 | |||||||
Ac = 117.423 + 62.187Z6 | 0.399 | Z6: 0 – 7.9 | ||||||
Wc = 2,3795 + 0.291Z6 | 0.563 |
Basic operating parameters and process automation | ||
Production profile |
||
Technical equipment |
S | 454.0 – 2,421.7 (21) | 7,682.1 | 432.650 | 41.73 | 2.3207 | Ae = 3944.70 + 37.110 Z4 | 0.568 | Z4:19.0 – 335.8 |
Ac = 134.293 + 0.546P2 + 0.760P4 | 0.789 |
P2: 31.0 – 777.0 P4: 100.0 – 964.0 |
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Ac = 140.56 + 2.433Z4 + 1.977Z5 + 0.815 Z8 | 0.834 |
Z4: 19.0 – 335.8 Z5: 0 – 81.8 Z8: 0 – 335.8 |
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W | 318.0–2,548.0 (19) | 6,246.0 | 396.632 | 52.70 | 3.4125 | Ae = 4289.00 + 41.401Z4 for Wc R2 < 0.20 | 0.502 | Z4: 10.4 –282.7 |
Ac = 83.369 + 0.530P2 + 0.644P4 + 0.857P10 for Wc R2 < 0.34 | 0.846 |
P2: 31.0 – 777.0 P4: 100.0 – 964.0 P10: 0.0 – 358.3 |
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Ac = 246.86 + 3.168 Z4 | 0.546 | Z4: 10.4 – 282.7 |
Electric energy consumption | kWh/m3 of raw milk | Total production | WZ | 90 | 10 – 680 | |
kWh/m3 of milk | Milk powder, cheese, butter, yogurt, dairy desserts | 27 | - | |||
Cheese, tvorog, yogurt, dairy desserts | 32 | - | ||||
Cheese, butter, yogurt, dairy desserts | - | 34 – 52 | ||||
Butter, milk powder, yogurt, dairy desserts | - | 53 – 57 | ||||
Cheese, milk powder, butter | 64 | |||||
Cheese, butter | 65 | |||||
Yogurt, dairy desserts, tvorog, butter | 66 | |||||
kWh/m3 of milk | Cheese | WT | - | 2.9 – 6.6 | ||
kWh/Mg of butter | Butter (continuous method) | - | 12.9 – 17.0 | |||
kWh/Mg of milk | Milk processing output (based a study of three dairy plants) | WZ | - | 30 – 80 | ||
kWh/Mg of end product | Milk powder | WZ | 429.9 | 377.0 – 482.9 | ||
Heat consumption | GJ/m3 of raw milk | Total production | WZ | 2.01 | 0.12 – 14 | |
MJ/m3 of processed milk | Milk powder, cheese, butter, yogurt, dairy desserts | 1348 | - | |||
Cheese, tvorog, yogurt, dairy desserts | 1439 | - | ||||
Cheese, butter, yogurt, dairy desserts | - | 1583 – 2380 | ||||
Butter, milk powder, yogurt, dairy desserts | - | 2733 – 3171 | ||||
Cheese, milk powder, butter | 2882 | - | ||||
Cheese, butter | 1884 | - | ||||
Yogurt, dairy desserts, tvorog, butter | 2698 | - | ||||
GJ/Mg of evaporated water | Spray-drying | WA | 4.87 | 3 – 20 | ||
GJ/Mg of processed milk | Modern dairy plants with heat recovery systems | WZ | 0.34 | - | Bosworth et al. [2001] | |
Modern plants where hot water is used as an energy carrier | 0.50 | - | ||||
Older plants where steam is used as an energy carrier | 2.00 | - | ||||
Total energy consumption | MWh/Mg of milk powder | Milk powder (mechanical vapor recompression, MVR) | WP | 3.08 | - | |
GJ/Mg of product | Milk powder | WZ | 29.95 | 26.41–33.49 | ||
MWh/Mg of dry product | Spray-drying of cheese whey | WA | 2.049 | - | ||
Fuel gas | kWh/Mg of milk | Total production (based on a study of three production plants) | WZ | - | 100 – 220 | |
Total energy consumption | GJ/m3 of processed milk |
Milk, tvorog (based on a study of a selected dairy plant) | - | 3.04 | 1.93 – 2.47 Summer | |
3.63 – 4.19 Winter | ||||||
GJ/m3 of processed milk |
WZ | 2.46 | 1.40 –1.96 Summer | |||
3.04 – 3.55 Winter | ||||||
Total energy consumption | kWh/kg of evaporated water | Three-phase evaporator | WA | 0.14 | - | |
Five-phase evaporator | 0.085 | - | ||||
Total energy consumption expressed in fuel equivalents | kg of fuel equivalent/m3 of processed milk |
Milk, tvorog (based on a study of a selected dairy plant) | WZ | 104 | 66 – 84 Summer | |
124 –143 Winter | ||||||
kg of fuel equivalent/m3 of processed milk |
84 | 48 – 67 Summer | ||||
103–121 Winter | ||||||
Energy consumption in wastewater treatment | kWh/kg BOD5 | Total production | WT | - | 0.89 – 3.22 | |
kWh/m3 of wastewater | - | 1.94 – 6.32 | ||||
SO2 emissions | kg/m3 of raw milk | Total production | WZ | 1.65 | 0.05 – 22.4 | |
kg/m3 of processed milk | - | 0.83 | - | |||
NOx emissions | kg/m3 of raw milk | Total production | WZ | 0.49 | 0.03 – 6.4 | |
kg/m3 of processed milk | - | 0.60 | - | |||
CO2 emissions | kg/m3 of raw milk | Total production | WZ | 1.97 | 0.01 – 9.23 | |
kg/m3 of processed milk | 1.25 | - | ||||
Carbon footprint of end products | kg CO2eq/kg of butter | Butter | WZ | 8.1 | - | |
kg CO2eq/kg of milk powder | Milk powder | 7.4 | - | |||
kg CO2eq/kg of cheese | Cheese | 6.5 | - | |||
kg CO2eq/kg of dairy beverage | Dairy beverages | 1.2 | - | |||
Particulate-matter emissions | kg/m3 of raw milk | Total production | 1.3 | 0.01 –14.4 | ||
kg/m3 of processed milk | Total production | WZ | 1.15 | - | ||
Black carbon emissions | kg/m3 of raw milk | Total production | WZ | 19 | 0.01 – 193 | |
kg/m3 of processed milk | Total production | - | 0.04 | - |
End product storage | - | - | 41,868 | - | 41,868 | 9.46 |
Packing | - | 3,489 | - | - | 3,489 | 0.71 |
Storage before packing | - | - | 20,934 | - | 20,934 | 4.73 |
Deodorissation | 5,815 | - | - | - | 5,815 | 1.32 |
Cooling | - | - | 19,771 | - | 19,771 | 4.47 |
Homogenisation | - | - | - | 2,326 | 2,326 | 0.53 |
Pasteurisation | 213,992 | - | - | - | 213,992 | 48.30 |
Separation | - | - | - | 41,868 | 41,868 | 9.46 |
Clarification/Standardisation | - | - | - | 20,934 | 20,934 | 4.73 |
Reception and Storage | - | 30,238 | 41,868 | - | 72,106 | 16.29 |
Total | 219,807 | 33,727 | 124,441 | 65,128 | 443,103 | 100 |
S | 83.0 – 2,935.0 (37) | 3,289.9 | 118.909 | 39.52 | 1.3607 | Ae= 748.34 + 60.1453Z1 + 39.4929Z3 + 22.079Z5 + 75.286Z8 for We R2 < 0.32 | 0.442 |
Z1: 0 – 211 Z3: 0 – 164 Z5: 0 – 141 Z8: 0 – 157.5 |
Ac= 1.152 + 0.310P1 + 1.266P2 + 1.082P6 for Wc R2 < 0.37 | 0.860 |
P1: 24.4 – 1155.1 P2: 0.0 – 434.0 P6: 250.0 – 956.0 |
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Ac= 18.295 + 1.501Z1 + 1.748Z2 + 0.990Z3 +1.006 Z5 −5.385 Z7 + 5.265 Z8 | 0.830 |
Z1: 0 – 211 Z2: 0 – 73 Z3: 0 – 164 Z5: 0 – 141 Z7: 0 – 44.4 Z8: 0 – 157.5 |
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W | 30.3 – 1,938.0 (24) | 2129.3 | 120.581 | 39.92 | 2.4672 | Ae = 864.92 + 94.4138Z2 + 104.032Z8 for We R2 < 0.20 | 0.603 |
Z2: 0 – 63.6 Z8: 0 – 75.6 |
Ac = −4.109+0.364P1 +0.989P2+ 1.080P7 + 0.191P10 for Wc R2 < 0.33 | 0.896 |
P1: 30.3 – 708.0 P2: 0.0– 312.0 P7: 0.0 – 68.0 P10: 0.0 – 377.0 |
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Ac = 26.259+2.981Z1 +2.492Z3 + 15.157Z7 + 6.733Z8 | 0.693 |
Z1: 0 – 111.6 Z3: 0 – 64.2 Z7: 0 – 9.9 Z8: 0 – 75.6 |