Integrierte Vermeidung und Verminderung der Umweltverschmutzung
Integrierte Vermeidung und Verminderung der Umweltverschmutzung Integrierte Vermeidung und Verminderung der Umweltverschmutzung
Chapter 3 Total energy consumption from electricity and fuel oil (kWh/l processed milk) Products Sweden Denmark Finland Norway Market milk and 0.11 – 0.34 0.07 – 0.09 0.16 – 0.28 0.45 cultured products (8)* (3) (8) (1) Cheese and whey 0.15 – 0.34 0.12 – 0.18 0.27 – 0.82 0.21 (4) (4) (3) (1) Milk powder, cheese 0.18 – 0.65 0.3 – 0.71 0.28 – 0.92 0.29 – 0.34 and/or liquid products (7) (3) (2) (2) * Figures in brackets show the number of dairy installations in each category Table 3.60: Total energy consumption for some Nordic dairies [42, Nordic Council of Ministers, et al., 2001] More energy is used in dairies where butter, as well as drinking milk, is produced and where the production of powdered milk is greater. Four installations of the ice-cream industry in Nordic countries have reported to have a total energy consumption in the range 0.75 - 1.6 kWh/kg of ice-cream produced [42, Nordic Council of Ministers, et al., 2001]. Other reports show an energy consumption of 2 – 10 GJ/t ice-cream produced [118, CIAA-EDA, 2002]. 3.3.5.5 Consumption of chemicals Most of the chemicals are used for the cleaning and disinfection of process machinery and pipelines. Fresh product dairies mainly use caustic and nitric acid and some disinfectants, such as hydrogen peroxide, peracetic acid and sodium hypochlorite. Disinfection agents are also used in a range of 0.01 – 0.34 kg/t processed milk [160, European Dairy Association, 2002]. Table 3.61 shows the consumption of cleaning agents used in European dairies. Of the total chemical consumption in Nordic dairies, 55 % is caustic and 30 % nitric acid. Table 3.62 shows the consumption of cleaning chemicals used in some Nordic dairies. Consumption of cleaning agents (kg/t processed milk) Products NaOH, 100 % HNO3, 100 % Detergents Market milk and yoghurt 0.2 – 10 0.2 – 5.0 * Cheese 0.4 – 5.4 0.6 – 3.8 0.1 – 1.5 Milk and whey powder 0.4 – 5.4 0.8 – 2.5 * Values vary with the length and capacity of production runs *Not applicable Table 3.61 Consumption of cleaning agents used in European dairies [160, European Dairy Association, 2002] Caustic Nitric acid Product as NaOH, 100 % as HNO3, 100 % kg/m 3 of processed milk or tonne of ice Market milk and yoghurt 0.2 – 0.9 0.1 – 1.0 (13) (13) Cheese/milk and whey powder 0.4 – 5.4 0.6 – 3.8 (14) (14) Ice-cream 0.5 – 4.5 0.2 – 2.5 (7) (7) Figures in brackets show the number of dairy installations in a category Table 3.62: Consumption of cleaning chemicals used in some Nordic dairies [42, Nordic Council of Ministers, et al., 2001] 194 January 2006 RHC/EIPPCB/FDM_BREF_FINAL
Chapter 3 Whey processing involving electrodialysis, ion exchange, ultra and nanofiltration, requires large amounts of phosphoric, sulphuric and hydrochloride acid as well as potassium hydroxide and sodium hypochlorite. Chelating agents are widely used in dairy cleaning operations and are discussed in Sections 4.3.8.2 to 4.3.8.2.5. 3.3.5.6 Noise Noise is caused by the movement of milk tankers and distribution lorries; evaporators, spray driers, and cooling condensers [42, Nordic Council of Ministers, et al., 2001]. Bag filters use significantly less energy than cyclones and produce less noise. If filtering installations suitable for CIP are used for outgoing air, it is not necessary to use cyclones allowing huge energy savings and noise reductions to be achieved. 3.3.6 Dry pasta The basic raw material for the production of high quality pasta products is semolina from durum wheat. 1.04 – 1.05 tonnes semolina are used to produce 1 tonne of pasta. Water and other ingredients are added to make a stiff dough containing approximately 31 % water. The dough is forced under pressure through dies of an extrusion auger. The major environmental issue in this sector is energy consumption as all pasta manufacturing processes involve drying. 3.3.6.1 Water Water consumption is between 22 – 30 m 3 /t product. Water is mainly used as an ingredient. The production of process related polluted waste water is reported to be insignificant [117, CIAA- UNAFPA, 2002]. 3.3.6.2 Emissions to air Thermal energy is obtained in boilers generally using natural gas. Superheated water, of 130 - 160 ºC and 4 – 7 bar as measured in a hydraulic air vessel, is used to dry pasta. Typical air emission values are shown in Table 3.63. Parameter Range Carbon dioxide Carbon monoxide 130 – 160 kg CO2/t product Lower than 100 mg/Nm 3* NOx Lower than 350 mg/Nm 3* * At 3 % O2 concentration Table 3.63: Air emissions from pasta manufacturing [117, CIAA-UNAFPA, 2002, 150, Unione Industriali Pastai Italiani, 2002] 3.3.6.3 Energy The drying step utilises about 85 – 90 % of the thermal energy and 50 – 60 % of the electricity consumption of the installation. These figures may even be higher for lines producing special products such as nests or lasagne. Air conditioning of the workspace needs 35 – 50 kWh/t energy. In evaluating energy consumption in the sector, the results of a study on pasta factories with a production capacity of over 75 t/d led to the estimated consumption of electricity, expressed in kWh/t of product, and of thermal energy, expressed in kWh/t and MJ/t shown in Table 3.64. RHC/EIPPCB/FDM_BREF_FINAL January 2006 195
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Chapter 3<br />
Total energy consumption from electricity and fuel oil<br />
(kWh/l processed milk)<br />
Products Sweden Denmark Finland Norway<br />
Market milk and 0.11 – 0.34 0.07 – 0.09 0.16 – 0.28 0.45<br />
cultured products<br />
(8)* (3) (8)<br />
(1)<br />
Cheese and whey 0.15 – 0.34 0.12 – 0.18 0.27 – 0.82 0.21<br />
(4) (4) (3)<br />
(1)<br />
Milk pow<strong>der</strong>, cheese 0.18 – 0.65 0.3 – 0.71 0.28 – 0.92 0.29 – 0.34<br />
and/or liquid products (7) (3) (2)<br />
(2)<br />
* Figures in brackets show the number of dairy installations in each category<br />
Table 3.60: Total energy consumption for some Nordic dairies<br />
[42, Nordic Council of Ministers, et al., 2001]<br />
More energy is used in dairies where butter, as well as drinking milk, is produced and where the<br />
production of pow<strong>der</strong>ed milk is greater. Four installations of the ice-cream industry in Nordic<br />
countries have reported to have a total energy consumption in the range 0.75 - 1.6 kWh/kg of<br />
ice-cream produced [42, Nordic Council of Ministers, et al., 2001]. Other reports show an<br />
energy consumption of 2 – 10 GJ/t ice-cream produced [118, CIAA-EDA, 2002].<br />
3.3.5.5 Consumption of chemicals<br />
Most of the chemicals are used for the cleaning and disinfection of process machinery and<br />
pipelines. Fresh product dairies mainly use caustic and nitric acid and some disinfectants, such<br />
as hydrogen peroxide, peracetic acid and sodium hypochlorite. Disinfection agents are also used<br />
in a range of 0.01 – 0.34 kg/t processed milk [160, European Dairy Association, 2002]. Table<br />
3.61 shows the consumption of cleaning agents used in European dairies. Of the total chemical<br />
consumption in Nordic dairies, 55 % is caustic and 30 % nitric acid. Table 3.62 shows the<br />
consumption of cleaning chemicals used in some Nordic dairies.<br />
Consumption of cleaning agents<br />
(kg/t processed milk)<br />
Products NaOH, 100 % HNO3, 100 % Detergents<br />
Market milk and yoghurt 0.2 – 10 0.2 – 5.0 *<br />
Cheese 0.4 – 5.4 0.6 – 3.8 0.1 – 1.5<br />
Milk and whey pow<strong>der</strong> 0.4 – 5.4 0.8 – 2.5 *<br />
Values vary with the length and capacity of production runs<br />
*Not applicable<br />
Table 3.61 Consumption of cleaning agents used in European dairies<br />
[160, European Dairy Association, 2002]<br />
Caustic<br />
Nitric acid<br />
Product<br />
as NaOH, 100 % as HNO3, 100 %<br />
kg/m 3 of processed milk or tonne of ice<br />
Market milk and yoghurt 0.2 – 0.9<br />
0.1 – 1.0<br />
(13)<br />
(13)<br />
Cheese/milk and whey pow<strong>der</strong> 0.4 – 5.4<br />
0.6 – 3.8<br />
(14)<br />
(14)<br />
Ice-cream 0.5 – 4.5<br />
0.2 – 2.5<br />
(7)<br />
(7)<br />
Figures in brackets show the number of dairy installations in a category<br />
Table 3.62: Consumption of cleaning chemicals used in some Nordic dairies<br />
[42, Nordic Council of Ministers, et al., 2001]<br />
194 January 2006 RHC/EIPPCB/FDM_BREF_FINAL