food processing waste stream utilization · pdf filefind opportunities to recover waste heat...
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ENHANCING RESOURCE EFFICIENCY AND SUSTAINABILITY IN FOOD PROCESSING:
FOOD PROCESSING WASTE STREAM UTILIZATION
CHRISTOPHER SIMMONS, PHDFOOD SCIENCE & TECHNOLOGY
ENERGY EFFICIENCY CENTERUNIVERSITY OF CALIFORNIA, DAVIS
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GOALFind opportunities to recover waste heat in food processing and develop applications for that recovered heat.
Waste Heat Recovery
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Tomato processing example:Tomato water – hot condensate from evaporation step of paste production.
EVAPORATOR
Condensed water (Tomato water)
(120 – 200 °F)
Waste Heat Recovery
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*California Energy Commission. Industrial Water Energy Nexus Assessment: Campbell Soup California Tomato Processing Facility. Sacramento:California Energy Commission, 2013. Print.
SAVED
WASTE HEAT RECOVERY TO OFFSET STEAM PRODUCTION
How many MMBTU?
ELECTRICITY
236,800 kWh/season$35,520/season
Reusing the cooled tomato provides further energy savings. WELL WATER
PUMPING176,400 kWh/season$22,050/seasonELECTRICITY SAVED
WASTEWATER TREATMENT29,400 kWh/season$4,305/seasonELECTRICITY SAVED
FACILITY SAVINGS = $???/SEASON
Waste Heat Recovery
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CONCEPTUse tomato water waste heat as part of the hot break.
HEAT EXCHANGER
Crushed tomatoes at 200 °F
Chopped tomatoes at 75 °F
Hot steam
Condensate
Waste Heat Recovery
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HEAT EXCHANGER
Chopped tomatoes at 200 °F
Hot steam
Less hot steam/water
EVAPORATOR
Hot tomato water
HEAT EXCHANGER
Chopped tomatoes at 120 °F
Tomato juice Tomato paste
Cooler tomato water
Chopped tomatoes at 75 °F
Waste Heat Recovery
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Modeling heat transfer in first stage of a 2-stage hot break process:
Inputs:1. Tomato temperature2. Tomato flow rate3. Tomato water temperature4. Tomato water flow rate5. Type of heat exchanger6. Heat exchanger heat transfer
coefficient and area
Waste Heat Recovery
Image: Allegheny Bradford
Hot tomato water
Hot chopped tomatoes
Coolchopped tomatoes
Cooltomato water
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OBJECTIVE 2 – MODELING 1ST STAGE OF 2-STAGE HOT BREAK
Effectiveness-NTU method:
Heat transfer rate: q=mcpΔTHeat capacity rate: C=ṁcp
KNOWN𝑁𝑇𝑈 =
𝑈𝐴
𝐶𝑚𝑖𝑛Number of transfer units (NTU):
𝑞𝑚𝑎𝑥 = 𝐶𝑚𝑖𝑛 𝑇𝑇𝑊,𝑖𝑛 − 𝑇𝐶𝑇,𝑖𝑛
Maximum heat transfer rate (W):
Heat capacity rate ratio:=𝐶𝑚𝑖𝑛
𝐶𝑚𝑎𝑥
Calculated from facility data and heat exchanger properties
Effectiveness: 𝜀(𝑁𝑇𝑈,𝐶𝑚𝑖𝑛
𝐶𝑚𝑎𝑥) =
𝑞
𝑞𝑚𝑎𝑥
DETERMINE
OUTPUTHeat transfer rate to tomatoes (energy savings), qTemperature of tomatoes at end of first stage, TCT,out
Time to heat tomatoes in first stage, t
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Waste Heat Recovery
Image: Allegheny Bradford
Hot tomato water32.7 kg/s
74 °C
Cool chopped tomatoes
73.5 kg/s
26.7 °C
Modeling results:
>9 million kWh recovered over 2250 hr season
Offset 10.6 million kWh of natural gas energy in boilers
$217,000 in natural gas savings/season
Cool tomato water
44.6 °C
Hot chopped tomatoes
40.3 °C
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Waste to Energy
GOALEnhance conversion of agricultural and food processing residues into renewable energy.
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Anaerobic Digestion: Converting waste organic matter to biofuel
Digester
Biogas•Methane•Carbon dioxide
Residual biomass and waterFood processing waste
Waste to Energy
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Waste to Energy
Anaerobic digestion is a complex network of microbial activity.
There are many potential points of inhibition.
We can use recent advances in metagenomics to understand and design more robust and functional digester communities.
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Waste to Energy
Xylanase activity Endoglucanase activity
Thermophilic community has more xylanase and
endoglucanase activity than mesophilic community.
thermophilic
mesophilic
Example: finding bacteria and enzymes for high-solids deconstruction of rice straw:
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GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
GTGGTTGCACAAAAAACGTTGCTCCCGATTGTGTGAGACCACATGTGTTGATGGGTGTCGATCCCAACA
Waste to Energy
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Waste to Energy
0
10
20
30
40
50
60
70
80
90
100
Mesophilicenrichment
Thermophilicenrichment
All other phyla
Fungi
Bacteroidetes
Proteobacteria
Firmicutes
Actinobacteria
0
10
20
30
40
50
60
70
80
90
100
Mesophilic
enrichment
Thermophilic
enrichment
Re
lativ
e a
bu
nd
an
ce
(%
)
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Waste to Energy
Thermophilic
community
Mesophilic
community
Cellobiohydrolases with
carbohydrate binding
module 2 are
overrepresented in
thermophilic community
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Waste to Energy
Example: Using microbial communities for wastewater treatment, electricity generation, and desalination:
anode cathodesaline water
+
+
+
-
-
-
wastewater
exoelectrogenicbacteria
cationexchange
membrane
anion exchange
membrane
Simultaneous
-wastewater treatment
-electricity generation
-water desalination
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GOALS
• Develop new applications for agricultural and food processing solids wastes.
• Turn waste streams into co-products.
• Advance sustainable waste management and agriculture.
Solid Waste Management
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Inactivate plant
pathogens and
weed seeds in soil
via passive solar
heating and
microbial activity.
Replaces need for soil fumigants.
Adds nutrients to
soil.
Solid Waste Management
Biosolarization
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Field soilStable green
waste compost
Agricultural or food
processing organic
residues
Induce microbial activity with waste biomass soil amendment:
+ +
Solid Waste Management
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Plastic tarp
Soil
Acid fermentation:-Lactic acid-Butyric acid-Acetic acid
Solid Waste Management
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Solid Waste Management
Inactivation of black mustard seeds:Combination of soil microbial activity and passive solar heating is significantly more effective than heating alone.
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NATIVE SOIL
AMENDED SOIL
S = 100% soil
C = 100% compost
SCW = 90% soil
+ 8% compost
+ 2% wheat bran
n=5
Nonmetric
multidimensional scaling
2D representation of
community similarity.
Similar communities
appear closer together.
NON-SOLARIZED
CONTROLS
Solid Waste Management
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Amended soil shows enrichment of potentially
beneficial bacteria following solarization.
•Azotobacter beijerinckii
enriched in amended soil
(10.5% of total community).
•Azotobacter species can
secrete phytohormones.
•Not detected in native soil
after solarization.
Solid Waste Management