title: Heat Integrated Milk Powder Production

authors: Walmsley, Timothy Gordon

subjects: Process integration

abstract: Dairy processing is critical to New Zealand’s (NZ) economy producing NZ$13 billion in exports for 2012 while consuming 32 PJ of fossil fuels for process heat. Three quarters of NZ dairy exports are milk powders. This thesis presents methods to reduce process heat use in Milk Powder Plants (MPP) through improved heat integration and addresses key technical challenges preventing industrial implementation. My original contributions to literature include: (1) a novel design method called the Cost Derivate Method (CDM) that cost optimally allocates area in direct heat exchange networks, (2) a new design methodology for integration of semi-continuous process clusters using a Heat Recovery Loop (HRL) with a Variable Temperature Storage (VTS) system for improved heat recovery, (3) an experimentally validated deposition model for predicting critical air conditions that cause milk powder fouling, and (4) a thermo-economic assessment tool for the optimisation of industrial spray dryer exhaust heat recovery projects via a Liquid Coupled Loop Heat Exchanger (LCHE) system.
By applying Pinch Analysis to an industrial MMP, this work confirms that heat must be recovered from the milk spray dryer exhaust air (~75 °C) to achieve maximum heat integration in MPPs. For stand-alone MPPs exhaust heat is best used to indirectly preheat the inlet dryer air reducing steam use by 12.7 % for a 55 °C exhaust outlet. Additional economic heat recovery from condensate and vapour flows decreased steam use by a further 6.9 %. Application of the CDM to the liquid and vapour sections of new MMP maximum energy recovery networks reduced total cost by 5.8 %. For multi-plant dairy factories, a second industrial case study showed the exhaust heat may be integrated with neighbouring plants via a HRL with VTS to increase site heat recovery by 10.8 MW including 5.1 MW of exhaust heat recovery, compared to 7.9 MW using a conventional HRL design method with constant temperature storage. 
A key barrier preventing exhaust heat recovery implementation in NZ MPPs is the possibility of milk powder fouling. Dryer exhaust air contains a low concentration of powder that when exposed to low temperatures at high humidity becomes sticky. For a heat exchanger face air velocity of 4 m/s, experimental data from milk powder fouling tests of flat plates, tubes and fins indicates particulate fouling becomes severe when the exhaust air temperature reaches 55 °C. Higher face velocities are shown to lower this critical exhaust temperature for avoiding severe fouling, which gives potential for increased heat recovery but for increased pressure drop. Lower face velocities show the opposite effect. Designing exhaust heat recovery systems entail an acute trade-off between heat transfer, pressure drop and fouling. Two important design parameters are the number of tube rows in the exhaust heat exchanger and the face velocity. The outputs of a thermo-economic spreadsheet tool suggest LCHE systems for a dryer producing 23.5 t/h is economic. With a face velocity of 4 m/s and 14 rows of finned round tube, the project had an estimated payback of 1.6 years, a net present value of NZ$3 million and internal rate of return of 71 %. This tool will empower industry with greater confidence to uptake exhaust heat recovery technology as a vital method for improving the heat integration of MPPs in NZ.

text: Heat Integrated Milk Powder Production Dairy processing is critical to New Zealand’s (NZ) economy producing NZ$13 billion in exports for 2012 while consuming 32 PJ of fossil fuels for process heat. Three quarters of NZ dairy exports are milk powders. This thesis presents methods to reduce process heat use in Milk Powder Plants (MPP) through improved heat integration and addresses key technical challenges preventing industrial implementation. My original contributions to literature include: (1) a novel design method called the Cost Derivate Method (CDM) that cost optimally allocates area in direct heat exchange networks, (2) a new design methodology for integration of semi-continuous process clusters using a Heat Recovery Loop (HRL) with a Variable Temperature Storage (VTS) system for improved heat recovery, (3) an experimentally validated deposition model for predicting critical air conditions that cause milk powder fouling, and (4) a thermo-economic assessment tool for the optimisation of industrial spray dryer exhaust heat recovery projects via a Liquid Coupled Loop Heat Exchanger (LCHE) system.
By applying Pinch Analysis to an industrial MMP, this work confirms that heat must be recovered from the milk spray dryer exhaust air (~75 °C) to achieve maximum heat integration in MPPs. For stand-alone MPPs exhaust heat is best used to indirectly preheat the inlet dryer air reducing steam use by 12.7 % for a 55 °C exhaust outlet. Additional economic heat recovery from condensate and vapour flows decreased steam use by a further 6.9 %. Application of the CDM to the liquid and vapour sections of new MMP maximum energy recovery networks reduced total cost by 5.8 %. For multi-plant dairy factories, a second industrial case study showed the exhaust heat may be integrated with neighbouring plants via a HRL with VTS to increase site heat recovery by 10.8 MW including 5.1 MW of exhaust heat recovery, compared to 7.9 MW using a conventional HRL design method with constant temperature storage. 
A key barrier preventing exhaust heat recovery implementation in NZ MPPs is the possibility of milk powder fouling. Dryer exhaust air contains a low concentration of powder that when exposed to low temperatures at high humidity becomes sticky. For a heat exchanger face air velocity of 4 m/s, experimental data from milk powder fouling tests of flat plates, tubes and fins indicates particulate fouling becomes severe when the exhaust air temperature reaches 55 °C. Higher face velocities are shown to lower this critical exhaust temperature for avoiding severe fouling, which gives potential for increased heat recovery but for increased pressure drop. Lower face velocities show the opposite effect. Designing exhaust heat recovery systems entail an acute trade-off between heat transfer, pressure drop and fouling. Two important design parameters are the number of tube rows in the exhaust heat exchanger and the face velocity. The outputs of a thermo-economic spreadsheet tool suggest LCHE systems for a dryer producing 23.5 t/h is economic. With a face velocity of 4 m/s and 14 rows of finned round tube, the project had an estimated payback of 1.6 years, a net present value of NZ$3 million and internal rate of return of 71 %. This tool will empower industry with greater confidence to uptake exhaust heat recovery technology as a vital method for improving the heat integration of MPPs in NZ.

year: 2014

title: The development and validation of the Successful Psychopathy Scale [Protocol]

authors: Louise, Wallace

abstract: The personality construct known as ‘Successful Psychopathy’ has attracted the interests of researchers and clinicians alike. The concept suggests an individual who demonstrates the core traits associated with psychopathy but is able to adapt and function within society to prototypical or superior standards. There has yet to be a sound theoretical model of this construct by which to base a psychometric measure. This protocol presents the ethical procedure that will endeavour to create such a measure and validate it within general population samples.

text: The development and validation of the Successful Psychopathy Scale [Protocol] The personality construct known as ‘Successful Psychopathy’ has attracted the interests of researchers and clinicians alike. The concept suggests an individual who demonstrates the core traits associated with psychopathy but is able to adapt and function within society to prototypical or superior standards. There has yet to be a sound theoretical model of this construct by which to base a psychometric measure. This protocol presents the ethical procedure that will endeavour to create such a measure and validate it within general population samples.

year: 2021

title: Different coloured tears: Dual cultural identity and Tangihanga

authors: Edge, Kiri

subjects: bereavement

abstract: Although whānau/family that are configured by both Pākehā and Māori identities number significantly within New Zealand, there has been little or no attention paid to the ways in which these identities influence the bereavement processes that will inevitably impact upon the lives of these whānau/family. The present study explored the experiences of an individual, whose whānau/family included two life ways: Māori and Pākehā. Of specific focus was the ways in which these identities influenced his bereavement subsequent to the death of his beloved wife, who was of Māori descent. One elderly male Pākehā participant was interviewed, using an open ended narrative approach. The interview was semi-structured around five broad themes, but the focus was upon the participant’s experiences and his preference in expressing these. The data analysis utilised a thematic process which allowed the participant’s experiences to determine the emergent themes. The results depicted the diversity of issues that may be raised for dual cultural whānau/family within bereavement processes. Two central themes are discussed in relation to intercultural conflict and the eventual resolution that was created. Decision-making processes, cultural and language differences played significant roles within the conflict and exclusion experienced by the participant. Communication and compromise provided resolution to the prior conflicts experienced. This created positive and unexpected outcomes which resulted in increased understandings and the strengthening of links between the participant, his whānau/family and his wife’s marae.

text: Different coloured tears: Dual cultural identity and Tangihanga Although whānau/family that are configured by both Pākehā and Māori identities number significantly within New Zealand, there has been little or no attention paid to the ways in which these identities influence the bereavement processes that will inevitably impact upon the lives of these whānau/family. The present study explored the experiences of an individual, whose whānau/family included two life ways: Māori and Pākehā. Of specific focus was the ways in which these identities influenced his bereavement subsequent to the death of his beloved wife, who was of Māori descent. One elderly male Pākehā participant was interviewed, using an open ended narrative approach. The interview was semi-structured around five broad themes, but the focus was upon the participant’s experiences and his preference in expressing these. The data analysis utilised a thematic process which allowed the participant’s experiences to determine the emergent themes. The results depicted the diversity of issues that may be raised for dual cultural whānau/family within bereavement processes. Two central themes are discussed in relation to intercultural conflict and the eventual resolution that was created. Decision-making processes, cultural and language differences played significant roles within the conflict and exclusion experienced by the participant. Communication and compromise provided resolution to the prior conflicts experienced. This created positive and unexpected outcomes which resulted in increased understandings and the strengthening of links between the participant, his whānau/family and his wife’s marae.

year: 2011