Skip to main content
SpringerLink
Log in

Energetic and exergetic assessment of two- and three-stage spray drying units for milk processing industry

  • Technical Paper
  • Published:
Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

A Correction to this article was published on 09 September 2021

This article has been updated

Abstract

In order to avoid perishable characteristics and secure long shelf life of liquid milk, it is mostly converted into more stable derivatives such as butter, cheese, yogurt and milk powder. Amongst them, milk powder contains highest shelf life at ambient conditions and accounts for 76% of global annual trade of milk and milk derivatives. The milk powder production and its qualitative features are often characterized by huge amount of high- and low-grade energy requirements depending upon the number of stages employed for drying, e.g. single, two or three. In the present work, comparative thermodynamic analysis of two- and three-stage milk drying units has been executed. Both the units have been extensively explored on the grounds of parameters such as exergy efficiency (72.01%/43.67%), drying efficiency (67.50%/65.71%), drying chamber efficiency (57.77%/53.51%), exhaust air temperature (346.15 K/353.15 K), overall specific exergy destruction (3081.64 kJ/kg/5006.28 kJ/kg), overall specific exergy consumption (0.74 kWh/kg/1.34 kWh/kg) and sustainability indices (3.57/1.78) so as to establish the fact that the thermodynamic behaviour of two-stage spray dryer was far better than its three-stage counterpart, at the cost of slightly higher specific steam consumption (3.53 kg/kg/2.77 kg/kg).

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig.1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15

Similar content being viewed by others

Change history

Abbreviations

\(C_{p}\) (J/kg K):

Specific heat at constant pressure

\(C_{pa}\) (J/kg K):

Specific heat of air

\(C_{pv}\) (J/kg K):

Specific heat of vapour

\(e_{a}\) (J/kg):

Specific energy of air

\(E_{f,k}\) (W):

Energetic factor for kth component

\(\dot{E}_{L,k}\) (W):

Energy loss for kth component

\(\dot{E}_{{{\text{in}},k}}\) (W):

Input energy flow rate for kth component

\(\dot{E}_{{{\text{IP}},k}}\) (W):

Energy improvement potential rate for kth component

\(\dot{E}_{{{\text{out}},k}}\) (W):

Output energy flow rate for kth component

\({\dot{\text{E}}\text{x}}\) (W):

Exergy rate

\({\text{ex}}_{{{\text{ch}}}}\) (J/kg):

Chemical specific exergy

\({\text{ex}}_{{{\text{ph}}}}\) (J/kg):

Physical specific exergy

\({\dot{\text{E}}\text{x}}_{D,k}\) (W):

Exergy destruction rate for kth component

\({\dot{\text{E}}\text{x}}_{{{\text{in}},k}}\) (W):

Input exergy flow rate for kth component

\({\dot{\text{E}}\text{x}}_{{{\text{IP}}}}\) (W):

Exergy improvement potential rate for kth component

\({\dot{\text{E}}\text{x}}_{{{\text{out}},k}}\) (W):

Output exergy flow rate for kth component

\({\text{Ex}}_{f,k}\) (W):

Exergetic factor for kth component

\(E_{\beta ,k}\) (W):

Relative irreversibility factor for kth component

\(E_{\beta ,k}\) (W):

Relative energy destruction ratio for kth component

\(h_{fg}\) (J/kg):

Latent heat of vaporization

\(\dot{m}\) (kg/s):

Mass flow rate

\(M_{a}\) (kg/mol):

Molecular mass of air

\(M_{w}\) (kg/mol):

Molecular mass of water

\(n\) :

Number of moles

\(P\) (N/m2):

Pressure

\(P_{0}\) (N/m2):

Ambient pressure

\(R\) (J/mol K):

Universal gas constant

\({\text{SI}}\) :

Sustainability index

\(T\) (K):

Temperature

\(T_{0}\) (K):

Ambient temperature

\(v\)(m3/kg):

Specific volume

\({\text{Vel}}_{a}\) (m/s):

Velocity of air

\(x_{i}\) :

Mole fraction at ith state

\(\omega\) (kg/kg):

Absolute humidity

\(\omega_{s}\) (kg/kg):

Absolute humidity at saturated vapour pressure

\(\eta_{k}\) (%):

Energy efficiency for kth component

\(\eta_{P}\)(%):

Energy efficiency of plant

\(\psi_{P}\)(%):

Exergy efficiency of plant

\(\psi_{k}\)(%):

Exergy efficiency for kth component

\(\varepsilon_{i}\) (kJ/mol):

Standard chemical exergy at ith state

IFB:

Integrated fluidized bed

MT:

Metric tonnes

MF:

Milk fat

MDP:

Madhu Dairy Plant

SSSD:

Single-stage spray dryer

TSSD:

Two-stage spray dryer

THSSD:

Three-stage spray dryer

TPD:

Tons per day

VFB:

Vibro-fluidized bed

References

  1. Focus S, America L (2020) “OECD-FAO Agricultural Outlook 2019-2028”, OECD Publishing, Paris/Food and Agriculture Organization of the United Nations, Rome. https://doi.org/https://doi.org/10.1787/agr_outlook-2019-enwww.fao.org/3/ca4076en/ca4076en.pdf[Accessed : 18, March 2020]

  2. The Statistics Portal, UK, 2018. Available Fromhttps://www.statista.com/statistics/761219/india-milk-powder-production-volume/[Accessed : 18, February 2020]

  3. N. Delhi, A. Aradhey, and M. Wallace. Dairy and Products Annual Report Highlights 2020.https://agriexchange.apeda.gov.in/marketreport/Reports/Dairy_and_Products_Annual_New_Delhi_India_10-15-2019.pdf[Accessed : 18, February 2020]

  4. FAO, “Overview of global dairy market developments in 2018,” Dairy Market Review.https://www.fao.org/3/ca3879en/ca3879en.pdf[Accessed : 18, February 2020]

  5. P. A. T. Scheme, “Widening the coverage of PAT Scheme Indian Dairy Industry 2013. https://shaktifoundation.in/wp-content/uploads/2017/06/widening-of-pat-sectors-dairy.pdf. [Accessed : 18, February 2020]

  6. Zisopoulos FK, Rossier-Miranda FJ, Van der Goot AJ, Boom RM (2017) The use of exergetic indicators in the food industry–a review. Crit Rev Food Sci Nutr 57(1):197–211

    Article  Google Scholar 

  7. Erbay Z, Koca N (2012) Energetic, exergetic, and exergoeconomic analyses of spray-drying process during white cheese powder production. Dry Technol 30(4):435–444

    Article  Google Scholar 

  8. Erbay Z, Koca N (2014) Exergoeconomic performance assessment of a pilot-scale spray dryer using the specific exergy costing method. Biosys Eng 122:127–138

    Article  Google Scholar 

  9. Erbay Z, Koca N (2012) Investigating the effects of operating conditions on the exergetic performance of a pilot–scale spray–drying system. Int J Exergy 11(3):302–321

    Article  Google Scholar 

  10. Saygı G, Erbay Z, Koca N, Pazır F (2015) Energy and exergy analyses of spray drying of a fruit puree (cornelian cherry puree). Int J Exergy 16(3):315–336

    Article  Google Scholar 

  11. Yildirim N, Genc S (2017) Energy and exergy analysis of a milk powder production system. Energy Convers Manag 149:698–705

    Article  Google Scholar 

  12. Bühler F, Nguyen TV, Jensen JK, Holm FM, Elmegaard B (2018) Energy, exergy and advanced exergy analysis of a milk processing factory. Energy 162:576–592

    Article  Google Scholar 

  13. Utlu Z, Hepbaşlı A (2014) Exergoeconomic analysis of energy utilization of drying process in a ceramic production. Appl Therm Eng 70(1):748–762

    Article  Google Scholar 

  14. Khuenpet K, Charoenjarasrerk N, Jaijit S, Arayapoonpong S, Jittanit W (2016) Investigation of suitable spray drying conditions for sugarcane juice powder production with an energy consumption study. Agric Nat Resources 50(2):139–145

    Article  Google Scholar 

  15. Atkins MJ, Walmsley MR, Neale JR (2011) Integrating heat recovery from milk powder spray dryer exhausts in the dairy industry. Appl Therm Eng 31(13):2101–2106

    Article  Google Scholar 

  16. Patel SK, Bade MH (2019) Energy analysis and heat recovery opportunities in spray dryers applied for effluent management. Energy Convers Manag 186:597–609

    Article  Google Scholar 

  17. Aghbashlo M, Mobli H, Rafiee S, Madadlou A (2012) Energy and exergy analyses of the spray drying process of fish oil microencapsulation. Biosys Eng 111(2):229–241

    Article  Google Scholar 

  18. Aghbashlo M, Mobli H, Madadlou A, Rafiee S (2012) Influence of spray dryer parameters on exergetic performance of microencapsulation process. Int J Exergy 10(3):267–289

    Article  Google Scholar 

  19. Soufiyan MM, Dadak A, Hosseini SS, Nasiri F, Dowlati M, Tahmasebi M, Aghbashlo M (2016) Comprehensive exergy analysis of a commercial tomato paste plant with a double-effect evaporator. Energy 111:910–922

    Article  Google Scholar 

  20. Balkan F, Colak N, Hepbasli A (2005) Performance evaluation of a triple-effect evaporator with forward feed using exergy analysis. Int J Energy Res 29(5):455–470

    Article  Google Scholar 

  21. Sogut Z, Ilten N, Oktay ZUHAL (2010) Energetic and exergetic performance evaluation of the quadruple-effect evaporator unit in tomato paste production. Energy 35(9):3821–3826

    Article  Google Scholar 

  22. Singh G, Singh PJ, Tyagi VV, Barnwal P, Pandey AK (2019) Energy, exergy and exergoeconomic analysis of high temperature short time milk pasteurisation plant. Int J Exergy 30(1):26–62

    Article  Google Scholar 

  23. Singh G, Singh PJ, Tyagi VV, Barnwal P, Pandey AK (2019) Exergy and thermoeconomic analysis of cream pasteurisation plant. J Therm Anal Calorim 137(4):1381–1400

    Article  Google Scholar 

  24. Singh G, Singh PJ, Tyagi VV, Barnwal P, Pandey AK (2019) Exergy and thermo-economic analysis of ghee production plant in dairy industry. Energy 167:602–618

    Article  Google Scholar 

  25. Singh G, Singh PJ, Tyagi VV, Pandey AK (2019) Thermal and exergoeconomic analysis of a dairy food processing plant. J Therm Anal Calorim 136(3):1365–1382

    Article  Google Scholar 

  26. Soufiyan MM, Aghbashlo M (2017) Application of exergy analysis to the dairy industry: a case study of yogurt drink production plant. Food Bioprod Process 101:118–131

    Article  Google Scholar 

  27. Soufiyan MM, Aghbashlo M, Mobli H (2017) Exergetic performance assessment of a long-life milk processing plant: a comprehensive survey. J Clean Prod 140:590–607

    Article  Google Scholar 

  28. Jokandan MJ, Aghbashlo M, Mohtasebi SS (2015) Comprehensive exergy analysis of an industrial-scale yogurt production plant. Energy 93:1832–1851

    Article  Google Scholar 

  29. Nasiri F, Aghbashlo M, Rafiee S (2017) Exergy analysis of an industrial-scale ultrafiltrated (UF) cheese production plant: a detailed survey. Heat Mass Transf 53(2):407–424

    Article  Google Scholar 

  30. Dowlati M, Aghbashlo M, Soufiyan MM (2017) Exergetic performance analysis of an ice-cream manufacturing plant: a comprehensive survey. Energy 123:445–459

    Article  Google Scholar 

  31. Garg A, Sharma MP, Sharma V (2016) Exergy and energy analyses of a sugarcane juice production and clarification unit. Int J Exergy 19(1):78–90

    Article  Google Scholar 

  32. van der Goot AJ, Pelgrom PJ, Berghout JA, Geerts ME, Jankowiak L, Hardt NA, Keijer J, Schutyser MA, Nikiforidis CV, Boom RM (2016) Concepts for further sustainable production of foods. J Food Eng 168:42–51

    Article  Google Scholar 

  33. Friso D, Bortolini L, Tono F (2020) Exergetic analysis and exergy loss reduction in the milk pasteurization for Italian cheese production. Energies 13(3):750

    Article  Google Scholar 

  34. Samarin GN, Vasilyev AN, Normov DA, Eventeva EA, Mamahay AK (2020, March) Energy efficiency increase of the initial milk processing. In: IOP Conference Series: Materials Science and Engineering (Vol. 791, No. 1, p. 012072). IOP Publishing

  35. Feil AA, Schreiber D, Haetinger C, Haberkamp ÂM, Kist JI, Rempel C, Maehler AE, Gomes MC, da Silva GR (2020) Sustainability in the dairy industry: a systematic literature review. Environ Sci Pollut Res 27:33527–33542

    Article  Google Scholar 

  36. Reichler SJ, Murphy SI, Erickson AW, Martin NH, Snyder AB, Wiedmann M (2020) Interventions designed to control postpasteurization contamination in high-temperature, short-time-pasteurized fluid milk processing facilities: a case study on the effect of employee training, clean-in-place chemical modification, and preventive maintenance programs. J Dairy Sci 103(8):7569–7584

    Article  Google Scholar 

  37. Camci M (2020) Thermodynamic analysis of a novel integration of a spray dryer and solar collectors: a case study of a milk powder drying system. Dry Technol 38(3):350–360

    Article  MathSciNet  Google Scholar 

  38. Wincy WB, Edwin M, Sekhar SJ (2020) Energy and exergy evaluation of rice processing mills working with biomass gasifier in parboiling process. Fuel 259:116255

    Article  Google Scholar 

  39. Srinivasan B, Pal J, Srinivasan R (2018) Enhancement of energy efficiency at an Indian milk processing plant using exergy analysis. In: Sustainable energy technology and policies. Springer, Singapore, pp 425–450

  40. Johnson P (2020)  Energy and exergy analysis in spray drying systems. PhD Thesis, The University of Sydney, Australia

  41. Dincer I, Rosen MA (1999) Energy, environment and sustainable development. Appl Energy 64(1–4):427–440

    Article  Google Scholar 

  42. Dinçer İ, Zamfirescu C (2016) Drying phenomena: theory and applications. John Wiley & Sons

    Google Scholar 

  43. Ren CQ, Tang GF, Li NP, Zhang GF, Yang J (2001) Analysis of exergy of moist air and energy saving potential in HVAC by evaporative cooling energy recovery. Int J Archit Sci 2(4):113–117

    Google Scholar 

  44. Atmaca A, Yumrutaş R (2014) Thermodynamic and exergoeconomic analysis of a cement plant: part I-Methodology. Energy Convers Manag 79:790–798

    Article  Google Scholar 

  45. Holman JP (2001) Analysis of experimental data. In: Holman JP (ed) Experimental methods for engineers. McGraw-Hill, Singapore, pp 48–143

    Google Scholar 

  46. Singh G, Chopra K, Tyagi VV, Pandey AK, Ma Z, Ren H (2021) A comprehensive energy, exergy and enviroeconomic (3-E) analysis with carbon mitigation for multistage evaporation assisted milk powder production unit. Sustain Energy Technol Assess 43:100925

    Google Scholar 

  47. G. E. A. P. Engineering, “Milk Powder Technology Evaporation and Spray Drying”, GEA Niro, Copenhagen, 2010. https://www.gea.com/en/binaries/Milk%20Powder%20Technology%20%20 Evaporation%20and%20Spray%20Drying_tcm11–33784.pdf[Accessed : 18, March 2020]

  48. Woo MW, Majumdar AS, Daud WRW (2016) Spray drying technology. National University of Singapore, Singapore

    Google Scholar 

Download references

Acknowledgements

The authors would like appreciate the technical-cum-non-technical assistance extended to us by the authorities of National Dairy Research Institute (NDRI, Karnal) and Madhu Dairy Plant (MDP, Pehowa), Haryana (India), throughout the assessment phase in order to accomplish the titled objectives.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Punjab Engineering College, Chandigarh, 160012, India

    Gurjeet Singh

  2. School of Energy Management, Shri Mata Vaishno Devi University, Katra, Jammu and Kashmir, 182320, India

    V. V. Tyagi & K. Chopra

  3. School of Mechanical Engineering, Shri Mata Vaishno Devi University, Katra, Jammu and Kashmir, 182320, India

    K. Chopra

  4. Research Centre for Nano-Materials and Energy Technology (RCNMET), School of Engineering and Technology, Sunway University, No. 5, Jalan Universiti, Bandar Sunway, 47500, Petaling Jaya, Selangor Darul Ehsan, Malaysia

    A. K. Pandey

  5. Department of Mechanical Engineering, Manipal University Jaipur, Jaipur, 303007, India

    R. K. Sharma

  6. Department of Metallurgical and Material Engineering, Karadeniz Technical University, 61080, Trabzon, Turkey

    Ahmet Sari

  7. Center of Research Excellence in Renewable Energy, King Fahd University of Petroleum & Minerals (KFUPM), Dhahran, 31261, Saudi Arabia

    Ahmet Sari

Authors
  1. Gurjeet Singh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. V. V. Tyagi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. K. Chopra
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. A. K. Pandey
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. R. K. Sharma
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Ahmet Sari
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to V. V. Tyagi.

Additional information

Technical Editor: Monica Carvalho.

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

The online version of this article was revised as the affiliations of authors in the author group are mismatched.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Singh, G., Tyagi, V.V., Chopra, K. et al. Energetic and exergetic assessment of two- and three-stage spray drying units for milk processing industry. J Braz. Soc. Mech. Sci. Eng. 43, 359 (2021). https://doi.org/10.1007/s40430-021-03015-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40430-021-03015-3

Keywords

Search

Navigation