Computational Fluid Dynamics (CFD) Simulation of Mixing Tank at Milk Powder Factory to Reduce Material Losses

Agus Surono, Achmad Dwitama Karisma, Muchamad Kurniawan Dwi Febrianto, Fitriah Dwi Mulyani, Daril Ridho Zuchrillah

Abstract


Industrial milk powder production applies the principle of a spray dryer. In the powdered milk industry using a spray dryer, there are still some problems in actual conditions such as fouling in the heat exchanger and losses. Losses are lost material or time so that result in losses for the company. The importance of finding material losses as soon as possible it is possible to make a solution so that initially unknown material is wasted in vain can be used as a finished good. Steps taken to resolve the problem material losses is to identify problems and data by making mapping losses according to actual conditions. After that, a CFD mixing tank simulation can be performed on Ansys with the aim of the simulation is to get the contour of the foaming phenomenon and find out the height the phenomenon of foaming (foam) with the properties set up begins at the beginning of making geometric designs with the size of the tank is 3.5 m and uses a marine propeller type,  then proceeds with meshing In geometry, meshing here uses the automatic meshing method due to the limited analysis students. after that the solving stage is carried out by inputting data such as density, viscosity and input multiphase (mixture), viscous (Large Eddy Simulation), as the boundary conditions of the geometry, after that by making a plane from the results of running to form a plane in geometry, then choose the results of the contour volume fraction to find out the phenomena that occur in mixing  tank so that conclusions and solutions can be drawn. Based on the results of data analysis and the field in the form of mapping and data on quantity losses, there are still some material losses in the form of wet and dry losses that have not been identified, initially the percentage ratio of material losses is 40.57% to 9%. One of the biggest contributors to material wet losses is mixing tanks which simulated until it is known that there is a foaming phenomenon. It interferes with the way it works level sensor which causes less maximum withdrawal of milk liquid by the pump. The best solution right way to reduce losses that occur in the mixing tank is to close the valve mixing tank output when showing 1.8% or can be rounded to 2% for safety pump. The liquid that is used as a product is 270 liters which is equivalent to 113 kg. If the calculation is carried out, the company can store 8,505 kg/month of powder.

Keywords


Mixing tanks; Losses; Powder milk; Spray dryer

Full Text:

PDF

References


U. Sumarwan Megawati Simanjuntak and L. Noor Yuliati, “Meta-Analysis Study: Reading Behavior Of Food Products Label,” 2017. [Online]. Available: http://repository.unair.ac.id/

P. Zhu et al., “Simulating industrial spray-drying operations using a reaction engineering approach and a modified desorption method,” Drying Technology, vol. 29, no. 4, pp. 419–428, Jan. 2011, doi: 10.1080/07373937.2010.501928.

C. Muriana, “A focus on the state of the art of food waste/losses issue and suggestions for future researches,” Waste Management, vol. 68, pp. 557–570, 2017, doi: https://doi.org/10.1016/j.wasman.2017.06.047.

C. Anandharamakrishnan, J. Gimbun, A. G. F. Stapley, and C. D. Rielly, “A Study of Particle Histories during Spray Drying Using Computational Fluid Dynamic Simulations,” Drying Technology, vol. 28, no. 5, pp. 566–576, May 2010, doi: 10.1080/07373931003787918.

J. Butz et al., “Raman spectroscopy for the process analysis of the manufacturing of a suspension metered dose inhaler,” J Pharm Biomed Anal, vol. 54, no. 5, pp. 1013–1019, 2011, doi: https://doi.org/10.1016/j.jpba.2010.12.007.

M. B. Anthony, “Analisis Penerapan Total Productive Maintenance (TPM) Menggunakan Overall Equipment Efectiveness (OEE) Dan Six Big Losses Pada Mesin Cold Leveller PT. KPS,” vol. 2, no. 2, pp. 94–103, 2019.

G. A. Blekas, “Food Additives: Classification, Uses and Regulation,” in Encyclopedia of Food and Health, B. Caballero, P. M. Finglas, and F. Toldrá, Eds., Oxford: Academic Press, 2016, pp. 731–736. doi: https://doi.org/10.1016/B978-0-12-384947-2.00304-4.

C. Sharma, D. Malhotra, and A. S. Rathore, “Review of Computational fluid dynamics applications in biotechnology processes,” Biotechnol Prog, vol. 27, no. 6, pp. 1497–1510, Nov. 2011, doi: https://doi.org/10.1002/btpr.689.

Y. Zhiyin, “Large-eddy simulation: Past, present and the future,” Chinese Journal of Aeronautics, vol. 28, no. 1, pp. 11–24, 2015, doi: https://doi.org/10.1016/j.cja.2014.12.007.

A. Sarkar and H. Singh, “Emulsions and Foams Stabilised by Milk Proteins,” in Advanced Dairy Chemistry: Volume 1B: Proteins: Applied Aspects, P. L. H. McSweeney and J. A. O’Mahony, Eds., New York, NY: Springer New York, 2016, pp. 133–153. doi: 10.1007/978-1-4939-2800-2_5.

R. K. Thakur, Ch. Vial, and G. Djelveh, “Influence of operating conditions and impeller design on the continuous manufacturing of food foams,” J Food Eng, vol. 60, no. 1, pp. 9–20, 2003, doi: https://doi.org/10.1016/S0260-8774(03)00005-0.

T. HUPPERTZ, “Foaming properties of milk: A review of the influence of composition and processing,” Int J Dairy Technol, vol. 63, no. 4, pp. 477–488, Nov. 2010, doi: https://doi.org/10.1111/j.1471-0307.2010.00629.x.

M. Ritota, M. G. Di Costanzo, M. Mattera, and P. Manzi, “New Trends for the Evaluation of Heat Treatments of Milk,” J Anal Methods Chem, vol. 2017, p. 1864832, 2017, doi: 10.1155/2017/1864832.

S. Faisal, A. Bukhari, and W. Yang, “Multi-interface Level Sensors and New Development in Monitoring and Control of Oil Separators,” Sensors, vol. 6, pp. 380–389, 2006, [Online]. Available: http://www.mdpi.org/sensors

A. Afzal, Z. Ansari, A. R. Faizabadi, and M. K. Ramis, “Parallelization Strategies for Computational Fluid Dynamics Software: State of the Art Review,” Archives of Computational Methods in Engineering, vol. 24, no. 2, pp. 337–363, 2017, doi: 10.1007/s11831-016-9165-4.

P. N. Anh, J. S. Bae, and J. H. Hwang, “Computational fluid dynamic analysis of flow rate performance of a small piezoelectric-hydraulic pump,” Applied Sciences (Switzerland), vol. 11, no. 11, Jun. 2021, doi: 10.3390/app11114888.

J. H. Bucklow, R. Fairey, and M. R. Gammon, “An automated workflow for high quality CFD meshing using the 3D medial object,” in 23rd AIAA Computational Fluid Dynamics Conference, in AIAA AVIATION Forum. American Institute of Aeronautics and Astronautics, 2017. doi: doi:10.2514/6.2017-3454.

R. Bois, O. Adriao, G. Delaplace, I. Pezron, A. Nesterenko, and E. van-Hecke, “Influence of process variables on foaming ability of surfactants: Experimental study and dimensional analysis,” Chemical Engineering Research and Design, vol. 165, pp. 40–50, 2021, doi: https://doi.org/10.1016/j.cherd.2020.10.021.

X. Wang, G. M. Evans, and P. Stevenson, “Flooding in a Vertically Rising Gas–Liquid Foam,” Ind Eng Chem Res, vol. 53, no. 14, pp. 6150–6156, Apr. 2014, doi: 10.1021/ie4001844.

J. Sun et al., “A comparison of numerical simulations with experimental and theoretical investigations of highly-viscous oil-aqueous foam horizontal flow,” J Pet Sci Eng, vol. 201, p. 108507, 2021, doi: https://doi.org/10.1016/j.petrol.2021.108507.

L. P. Martínez-Padilla, V. García-Mena, N. B. Casas-Alencáster, and M. G. Sosa-Herrera, “Foaming properties of skim milk powder fortified with milk proteins,” Int Dairy J, vol. 36, no. 1, pp. 21–28, 2014, doi: https://doi.org/10.1016/j.idairyj.2013.11.011.




DOI: http://dx.doi.org/10.12962/j23378557.v9i1.a16323

Refbacks

  • There are currently no refbacks.


Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License. IPTEK The Journal of Engineering published by Pusat Publikasi Ilmiah, Institut Teknologi Sepuluh Nopember. 

 

Please contact us for order or further information at: email: iptek.joe[at]gmail.com Fax/Telp: 031 5992945. Editorial Office Address: Pusat Riset Building 6th floor, ITS Campus, Sukolilo, Surabaya 60111, Indonesia.