Steam Requirements and Troubleshooting in The Manufacture of Process Cheese

Troubleshooting, Proper Sizing and Application of Steam Boiler for Cheese Processing
Steven J. Haberli Green Bay, Wisconsin 54311
2004, 2010, 2011 Steve Haberli
Abstract
This is a basic guide for addressing steam supply issues with the production of process cheese. This publication describe not only the operative side of process, it deals with a very important issue. Troubleshooting, backed by practical operative empirical data gathered throughout my career in designing OEM and custom process equipment for the food and dairy industry. It is written for the use of cheese processing Plant Engineers, however, it is encourage to share this with other departments such as Maintenance that may find this helpful.
Steam Loads and Issues for the Processing of Cheese

Introduction
This publication was developed to be used as a tool for establishing a benchmark for processing. Of which to save time of trial and error which without it would increase significantly. To establish this, one needs to be introduce to what is happening within the process, and to keep consistency the use of technical terms with an explanation to the layman. Now with this being said, visualize this, you are processing your product (for example in this case, cooking cheese) by using steam as a conduit of energy, with this energy being heat. You want to transfer this energy as efficiently as possible with minimal losses. Losses comes in many forms, time, energy or quality. Along with this other efficiency or problematic issues may occur. And not understanding the process, when a problem occurs, what may seem quite evident to the cause, the actual origin of the problem may be a number of layers upstream or downstream of the process or a combination of the two. And to solve the problem one has to address the origin of the problem which may not be relative to where the difficulty actually reveals itself. This publication focuses on the issues of using steam as an energy conduit, by addressing the properties of steam, using it, and to deliver it in a most efficient and an understandable way. It also includes a basic transition introduction to the actual cooking process. One of the most important factors in process that is often overlooked is control. When control is taken lightly, chaos and anarchy is soon to follow. Bottom line, costs are dear. This will also be addressed in this publication.
Conditioning and Controlling of Steam Properties

When people talk about steam in an informal manner, It is pictured as a gaseous hot state. In other words in a pure and quite simplified manner. When talked about in process, doing this is not only incorrect, but can be quite lethal.
(continued) Conditioning and Controlling of Steam Properties

Look at steam as an container, a container that holds energy. This steam exists in multi-phased states. What this is, its in a vapor state and also a liquid state (condensate) simultaneously. When using it in a process, the preferred state is in a vapor state, otherwise known as dry steam. How Steam transfers energy (heat) the most efficient, is when it changes from a vapor state to a liquid state, the energy is released. Energy in this case, heat, travels hot to cold. There are a number of ways to conserve or prevent these inefficiencies, which I prefer to call conditioning of the steam. The most efficient way is to keep removing the condensate to supply a dry product and that product is steam. The meaning of dry is having the lease amount of liquid as possible. To accomplish this, there are a number of ways or combination of ways to do this. In the delivery system (the piping) one can install drip legs to remove the condensate, these require more maintenance, but is relatively cheap, or the use of steam traps installed at the lower places in the line or where impingement1 may occur. When steam is impinged, it has a tendency to knock the moisture out of the vapor state. And just prior to the process, a steam separator can be install to separate the moisture from the steam. This process is based on the steam is in a vapor state and is suspended, while the liquid collects and flows down to be collected. An example of a culinary steam hookup is shown in Figure 1. (Haberli, 2004)
STEAM SEPARATOR STEAM FILTER
STEAM IN
OPTIONAL MANUAL VALVE
TO STEAM INJECTORS
Fig. 1 Typical Culinary Steam Hook-up

(Courtesy of Haberli Industries, Inc..)
STEAM INJECTOR MANIFOLD STEAM TRAP CONDENSATE (TYPICAL)
Steam Properties for Process

Steam has different properties when put into different environments. Understanding these properties and processes one will better utilize your resources. When steam is delivered in various environments its assorted characteristics are revealed. An example comparison is shown in Fig. 2, Fig. 3, and Fig. 4. (Katmar SoftwareWASP, 2004) Now in the next few paragraphs I will try to delivery it in a understandable way, because if you can pick up on this, you can better understand and know how to extrapolate2 this data to bring in efficiencies to the process. Looking at Figure 2 you are delivering steam at 15 psi the saturated temperature is 213 F, Figure 3 you are delivering steam at 60 psi the saturated temperature is 293 F, while Figure 4 you are delivering steam at 70 psi the saturated temperature is 303 F. The most common mistake done in process, is that people look at is the temperature being delivered. To increase efficiency, in this case reduce time, look at it as units of energy being delivered. And the unit is BTUs3.
Pressure Sat. Temp. Enthalpy (h) h h h s s s s Spec. Volume v v v Density
f g fg f g fg f g fg
15.00 213.03 181.21 181.21 1150.86 969.65 0.31 0.31 1.76 1.44 0.0167 0.02 26.29 26.27 59.79
psia Pressure F Sat. Temp. Btu/lbm Enthalpy (h) Btu/lbm h Btu/lbm h Btu/lbm h s Btu/lbm-F s Btu/lbm-F s Btu/lbm-F s Btu/lbm-F ft3/lbm Spec. Volume v ft3/lbm v ft3/lbm v ft3/lbm Density ft3/lbm
60.00 292.71 262.21 262.21 1177.61 915.40 0.43 0.43 1.64 1.22 0.0174 0.02 7.17 7.16 57.53
psia Pressure 70.00 psia F Sat. Temp. 302.93 F Btu/lbm Enthalpy (h) 272.74 Btu/lbm Btu/lbm 272.74 Btu/lbm h Btu/lbm 1180.56 Btu/lbm h Btu/lbm 907.82 Btu/lbm h Btu/lbm-F 0.44 Btu/lbm-F s Btu/lbm-F 0.44 Btu/lbm-F s Btu/lbm-F 1.63 Btu/lbm-F s Btu/lbm-F 1.19 Btu/lbm-F s ft3/lbm ft3/lbm Spec. Volume 0.0175 ft3/lbm 0.02 ft3/lbm v ft3/lbm 6.21 ft3/lbm v ft3/lbm 6.19 ft3/lbm v ft3/lbm 57.20 ft3/lbm Density
Fig. 2
PROPERTY DIAGRAMS AND STEAM TABLES
Fig. 3
3
Fig. 4
= specific entropy (Btu/lbm-R) = specific entropy of saturated liquid (Btu/lbm-R) = specific entropy of saturated vapor (Btu/lbm-R) = specific entropy change of vaporization (Btu/lbm-
fg h h h h
f g fg
= specific volume change of vaporization (ft /lbm) = specific enthalpy (Btu/lbm) = specific enthalpy of saturated liquid (Btu/lbm) = specific enthalpy of saturated vapor (Btu/lbm) = specific enthalpy change of vaporization (Btu/lbm)
s s S s
f
fg
(continued) Steam Properties for Process

Now establishing this, one also has to realize that you do have an operating envelope that is determined by the process and product. By understanding this, one can process a batch of cheese for example in less time by introducing units with a greater potential amount of energy. In other words, reduce cycle time by increasing temperature. Keep in mind that you only have a window to do this, and it is not unlimited. Now the gage of measurement is called enthalpy4. As you see the difference between Figure 2 and Figure 3 the heat content is 181 btu/ lbm and 262 btu/lbm respectively. An application example is given in the next segment, this can be more efficiently accomplished by how the steam is delivered. The saturated steam tables give the energy transfer properties of saturated water and saturated steam for temperatures from the critical temperature and for the corresponding pressures. Normally, the saturated steam tables are divided into two parts: temperature tables, which list the properties according to saturation temperature (Tsat); and pressure tables, which list them according to saturation pressure(Psat). The values of enthalpy and entropy5 given in steam tables are measured relative to the properties of saturated liquid at 32F. Hence, the enthalpy (hf) of saturated liquid and the entropy (sf) of saturated liquid have values of approximately zero at 32F. Most practical applications using the saturated steam tables involve steam-water mixtures. The key property of such mixtures is steam quality (x), defined as the mass of steam present per unit mass of steam-water mixture, or steam moisture content (y), defined as the mass of water present per unit mass of steam-water mixture. The following relationships exist between the quality of a liquid-vapor mixture and the specific volumes, enthalpies, or entropies of both phases and of the mixture itself. These relationships are used with the saturated steam tables. Now what was just said here, basically when transporting steam at higher pressure, one is also transporting a corresponding higher temperature, and at a high temperature you raise the corresponding critical temperature when steam turns into a liquid (condensate). When steam turns into a liquid, because it was a higher temperature, more energy was released when it changed phases, (vapor to a liquid).
Application and Delivery of Steam

After the steam is conditioned, and by conditioned means it is controlled with a steady constant pressure, dry as possible, and with adequate and constant supply available. The adequate supply is addressed later with an example. By doing this, one creates quality controls, by being able to produce repeatability. Figure 5 shows a typical steam hook-up for a steam injection process. (Haberli, 2004)
Fig. 5 Typical Culinary Steam Hook-up

(Courtesy of Haberli Industries, Inc.)
Now a common mistake that not only processors make but also consultants that give the processor recommendations, is that they will use a schematic similar to this, but do not address issues not only downstream but upstream in the process as well. Will it work, possible, if other criteria is met. If other criteria is not met, problems will develop and reveal themselves in the system, but not at where the cause originated. And allot of time and expense will be exhausted by the processor, the equipment supplier/ manufacturer or both trying to correct the problem, because the origin is not fully revealed. In the following, an example is given. 2004, 2010, 2011 Steve Haberli
(continued) Application and Delivery of Steam

An excellent example is explained below where a problem reveals itself, is not where the problem originated, and where the problem originated is where it then can be corrected. And to explain this, one has to be familiarize with the process. A company was establishing itself into a niche market for cooking cheese. The company hired a consultant to determine its process system requirements. Which would include a cooker, grinding, emulsifying, surge hopper as well as a boiler and its requirements for processing. The customer was processing 800 lbs of cheese in a lay down batch style cooker. Now first one must start determining utility requirements. What has been established to start with is it requires approximately 5 lbs of steam to cook 100 lbs of cheese to bring the cheese from an ambient temperature to 150 F. (Zerhen et al., 1992) Since they were processing 800 lb batches, the required steam that would be used is 40 lbs.6, 7 After that, one would take in consideration of process and ambient losses. Such as line impingement, and atmospheric loses. The total steam requirement would be 40 lbs. to deliver the required energy. The process cook cycle is shown in Figures 6a, 6b and 6c. (Haberli, 2004)
PRODUCT COOKER DIRECTION
STEAM MANIFOLD
Fig. 6a Process Loading
STEAM INJECTOR CLOSED
DIRECTION
DIRECTION
Fig. 6b Process Steam Inject
STEAM INJECTOR OPEN
Fig. 6c Process Unloading

STEAM INJECTOR CLOSED

Here lies the problem and it started at the beginning. The required steam would be approx. 310 pounds/hour, so the boiler was size to 1200 lbs/hour may seem logical and the reasons are many, budgetary, space, or even a lack of practical process knowledge of what is actually happening in the overall process. What was occurring is when it was processing, the steam traps would release an abnormal amount of steam along with the condensate, which caused the boiler reserve to drop until it would trip the boiler, after which it would have to be reset. This caused problems, such as inconstant product quality with various moisture content, body texture, and taste due to these interruptions. So what they did to improve the process was reduce the steam pressure which reduced the load capabilities of the boiler, which helped slightly. An issue occurred is how the steam is supplied. Which is not constant, but surges, as Figure 7 shows it leaves the process with very little reserves from the boiler capacity. (Haberli, 2004) This was the fist clue.
TOTAL 40 LBS OF STEAM INJECTED PER BATCH ACTUAL MARGIN OF SIZING DIFFERENTIAL TOO SMALL TO ALLOW FOR PROCESS INEFFICIENCIES FOR THE SYSTEM TO ABSORB LEGEND FILL/BLEND STEAM INJECT COOK/UNLOAD 1200 #/HOUR TOTAL BOILER CAPACITY 1120 # MAXIMUM PROCESS NEEDS
INITIAL PERCEIVED SIZE DIFFERENTIAL (INCORRECT) APPROXIMATELY 310 LBS/HOUR OF STEAM REQUIRE
20 DELIVERY STEAM PRESSURE (psi)
10
0 0 10 BATCH 20 30 TIME/MINUTES 40 50 60
Fig. 7 Steam Load Usage Requirements
The processor had the manufacture of the equipment in because the cooker was not performing, and the manufacturer made quite a investment in trying to correct the problem by putting in more controls to the steam, but since it was not addressing the root of the problem, the problem still existed. The processor had contacted me, and because they already spent quite a large amount of capital, they asked if I could help them over the phone. I told them I would like to look over the process as a whole, and see what I could do, the company instead sent pictures of the process. 2004, 2010, 2011 Steve Haberli
10

After examining the pictures, what I saw that could be the problem had to do with the steam condensate on the traps, I told them without seeing the process and the information they supplied there may be a steam trap failure. Without seeing the system in person, as a whole, I could only give them a possibility. They asked what type of trap I would recommend, I told them I prefer the F&T (float and thermostat) style trap, however, due to the lack of information I would contact a prominent steam trap manufacture and asked for their recommendations to the issues that they were having. The manufacturer concurred that the steam trap failure looks to be the cause of the boiler trip, they recommended a inverted bucket trap. Currently the processor had a disc style trap. Now each trap has their own pros and cons for operations, and they all can work. I did not want to confuse the customer and went with the Inverted Bucket Trap. I used this because the valve and the seat are above the trap, and away from the contaminants. (Armstrong, 2010) This worked for a number of shifts but the problem with the boiler returned. They called back, and reported this to me, I told them that there is more to this and to get to the bottom of it, I need to see the system as a whole. I inquired who services their boiler, and when is his next appointment, and scheduled my visit with that time frame. When I arrive I notice quickly that all the condensate is being returned to the boiler. I was surprised by this. For a number of reasons. For quite some time the industry has been pushed to reclaim the condensate, which does have its value. What I was surprised about is for the small size of this company that they were doing it. The savings would be nominal. And with the small size of the boiler, and other information I acquired, that this may be the root of the problem. I asked the boiler technician if he could take a sample of the condensate, he ask what he would be sampling for and told him proteins. He said no problem and tested it. And the results showed a high amount of proteins. Now the processor maintains their boiler regularly but no one put the issues together. I explained the situation to the technician and asked if that could be the problem. He replied most diffidently, and went farther to explain the proteins would cause a slip and fouling in the system such as the valves. (Thomsen, 1959) With a larger boiler capacity the boiler would be able to absorb this, except with the size of the boiler barely having the capacity, any issue like this would magnify significantly. Refer back to Figure 7.
11

What I did was, sketch up a schematic with the modifications that would resolve the issue. Refer to Figure 8. (Haberli, 2004) Basically what was required, was to disconnect the condensate return from the injector manifold, to the boiler and send it to the drain. The amount of condensate was nominal (barely a quarter to a half cup of condensate per batch), and to let the boiler make up for it.
STEAM IN
STEAM
NOTE 1). REMOVE CONDENSATE RETURN TO BOILER AND DRAIN TO FLOOR TO Fig. 8 Revised Steam Supply Schematic
Doing this made the process satisfactory. What had happen, is not too terribly uncommon. And how do you address the problem, basically quite directly. Who is accountable for it, its a combination of everyone, yet its a fault of no one. The processor has to keep within budget, The consultant may not have full control of the process as a whole, the manufacturer should at least have a basic understanding of the requirements of its equipment to perform, in this case it was a combination of all. And unfortunately ones worst experience is usually the best, though it may not seem that way at the time. 2004, 2010, 2011 Steve Haberli
12
Summary and Conclusion

There are a number of lesson points to this publication some of which is listed below.
The Cheapest system is not always the best, The Best system is not always the solution, but the system that is satisfactory, is usually located in the middle, and determining that is the issue. A problem may not reveal itself at the origin, do not try to study where the problem occurs, but look at the process as a whole. The Consultant, The Processor, or The Manufacturer, no one has all the answers. And to get the answers, each one may have to have to ask quite direct questions and assume nothing. Are all systems like this, no. But the risk still remains.
I have attempted to present this in an interesting way, which is quite hard to do with steam. Doing it this way, I tried to deliver knowledge that was acquired through practical applications, and try to share this without having to have the companies involved learn it through the school of hard knocks. Is it complete, no. No process never is, and realizing that, one can avoid some of the issues that exist.
13
References Haberli, Steven J., (2004) - Intellectual Properties of Steve Haberli Steve Haberli, President Haberli Industries, Inc , Stainless Process Systems 2004 Green Bay, WI Parker, Sybil P., (Ed.) (1994) Dictionary of Scientific and Technical Terms, (5th Ed.) McGraw-Hill, New York, NY Parker, Sybil P., (Ed.) (1994) Dictionary of Engineering, McGraw-Hill, New York, NY Katmar Software, (2004), Water And Steam Properties Program (WASP) Retrieved From Website Link: http://www.katmarsoftware.com/wasp.htm Westville 3630, South Africa Woodruff, Everett B., Lammers, Herbert B. and Lammers, F. Thomas (1998) Steam Plant Operation, (7th ed) Retrieved from: http://site.ebrary.com/lib/itttechlibrary/docDetail.action?docID=10152834 McGraw-Hill, NY, New York p. 783 - 795 Zehren, Vincent L. and Nusbaum, D.D. (Dave) (1992) Process Cheese, Cheese Reporter Publishing Company, Madison, WI p. 250 Armstrong International, Inc., (2010) Retrieved from Website Link: http://www.armstronginternational.com/steam-traps-inverted-bucket Three Rivers, MI Thomsen, L.C. (1959) Production of Quality Process Steam - Journal of Dairy Science Department of Dairy and Foods Industries, University of Wisconsin - Madison, Retrieved from: http://jds.fass.org/cgi/reprint/42/7/1241.pdf Madison, WI, p. 1241 - 1245
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Footnotes
1
Impingement; Removal of liquid droplets from flowing gas or vapor stream by causing it to collide with a baffle plate at high velocity, so that droplets fall away from the stream. [ im pinj-ment]
Extrapolate; To formulate or to estimate the final result with a limited information available.
3
BTU; (British Thermal Unit) is the quantity of heat required to change the temperature of water with a mass of one standard pound through one Fahrenheit degree Enthalpy; the sum of internal energy of a system plus the product of the systems volume multiplied by the pressure exerted on the system by its surroundings. Also known as, heat content; sensible heat; total heat.
Entropy; function of the state of a thermodynamic system whose change in any differential reversible process is equal to the heat absorbed by the system from its surroundings divided by the absolute temperature of the system. Also known as thermal charge. Amount of steam may vary due to the quality, availability and the condition of the steam. 40 lbs of steam is 40 lbs of water after the steam transfers its energy

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Troubleshooting, Proper Sizing and Application of Steam Boiler for Cheese Processing

2004, 2010, 2011 Steve Haberli

2004, 2010, 2011 Steve Haberli

Steam Loads and Issues for the Processing of Cheese

Conditioning and Controlling of Steam Properties

2004, 2010, 2011 Steve Haberli

(continued) Conditioning and Controlling of Steam Properties

STEAM SEPARATOR STEAM FILTER

OPTIONAL MANUAL VALVE

Fig. 1 Typical Culinary Steam Hook-up

STEAM INJECTOR MANIFOLD STEAM TRAP CONDENSATE (TYPICAL)

2004, 2010, 2011 Steve Haberli

Steam Properties for Process

2004, 2010, 2011 Steve Haberli

(continued) Steam Properties for Process

2004, 2010, 2011 Steve Haberli

Application and Delivery of Steam

Fig. 5 Typical Culinary Steam Hook-up

(continued) Application and Delivery of Steam

Fig. 6a Process Loading

STEAM INJECTOR CLOSED

(Courtesy of Haberli Industries, Inc.)

Fig. 6b Process Steam Inject

STEAM INJECTOR OPEN

Fig. 6c Process Unloading

STEAM INJECTOR CLOSED

2004, 2010, 2011 Steve Haberli

(continued) Application and Delivery of Steam

20 DELIVERY STEAM PRESSURE (psi)

Fig. 7 Steam Load Usage Requirements

(continued) Application and Delivery of Steam

2004, 2010, 2011 Steve Haberli

(continued) Application and Delivery of Steam

Summary and Conclusion

2004, 2010, 2011 Steve Haberli

2004, 2010, 2011 Steve Haberli

2004, 2010, 2011 Steve Haberli

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