1、 Application of Oxidized Potential Water in CIP Process
(1) The selection of equipment is based on the amount of acid and alkali solutions provided by the customer. It is proposed to install a set of oxidation potential water generator system next to the CIP cleaning station. Its characteristics are: 1. Using an oxidation potential water machine type, it will not change the equipment and facilities of the original CIP process in the factory, with simple installation and easy use; 2. Using electrolyzed oxidizing water for CIP can prevent harmful chemicals from entering the factory. Effectively eliminating the risk of harmful substances contaminating beverages and pipeline equipment, as well as causing harm to employees' bodies from the source; 3. The working medium is pure water and salt (NaCl), which can be used safely and confidently; 4. Four hours before CIP, turn on the machine to produce water. Inject the produced electrolyzed oxidizing water and alkaline electrolyzed oxidizing water into the existing acid and alkaline solution storage tanks for later use. (2) Oxidation potential water CIP process flow: 1. Rinse with clean water: 3 minutes; 2. Alkaline oxidation potential water circulation cleaning: 10 minutes; 3. Rinse with clean water: 2 minutes; 4. Oxidation potential water circulation disinfection: 10 minutes. Note: Due to the automatic reduction of acidic oxidation potential water to water, it is not necessary to clean the area with clean water after disinfection with acidic oxidation potential water to avoid secondary pollution.
2、 Cost comparison analysis between using electrolyzed oxidizing water and the original CIP method
(1) Comparison of Time consumption between Two Cleaning and Disinfection Methods: 1. CIP Cleaning and Disinfection Process for Original Production Pipelines (Thermal Disinfection) ① Rinse with Water (5 Minutes); ② Hot alkaline solution circulation (85 ℃, concentration 5%, 30 minutes); ③ Rinse with clean water (5 minutes); ④ Hot acid solution circulation (85 ℃, concentration 3%, 30 minutes); ⑤ Hot water flushing (85 ℃, 5 minutes) Note: Total time consumption: 75 minutes/time. 2. Production pipeline cleaning and disinfection process using electric potential water (cold disinfection): ① Rinse with clean water (3 minutes); ② Alkaline oxidation potential water cycle (10 minutes); ③ Rinse with clean water (2 minutes); ④ Acidic oxidation potential water cycle (10 minutes). Note: Total time consumption: 25 minutes per session. Summary: According to the above process flow, the total time for cleaning and disinfecting production pipelines and storage tanks is only 25 minutes per cycle, while the traditional CIP time is generally over 75 minutes. That is to say, using electrolyzed water as a cleaning disinfectant can save at least 50 minutes of time per cycle. (2) Cost comparison of two cleaning and disinfection methods for the original CIP production pipeline (see Table 1): Table 1
Process | Cost items | Cleaning and disinfection operating costs | |||
Time (minutes) |
Usage(kg)
|
Unit price (yuan/ton) | Cost (yuan) | ||
Rinse with clean water | water consumption |
5
|
2000
|
1.6
|
3.2
|
Hot alkali cycle | water consumption |
30
|
2000
|
1.6
|
3.2
|
Heat consumption |
30
|
286
|
100
|
28.6
|
|
Alkali (NaOH) dosage |
30
|
3.75
|
1元/kg
|
3.75
|
|
Rinse with clean water after hot alkali circulation | water consumption |
5
|
2000
|
1.6
|
3.2
|
Hot acid cycle | water consumption |
30
|
2000
|
1.6
|
3.2
|
Heat consumption |
30
|
286
|
100
|
28.6
|
|
Nitric acid dosage |
30
|
60
|
1.4元/kg
|
84
|
|
Hot water flushing | Heat consumption |
5
|
286
|
100
|
28.6
|
water consumption |
5
|
2000
|
1.6
|
3.2
|
|
Electricity consumption per session | Electricity fees |
75
|
10 degrees | 0.58 yuan/degree |
5.8
|
Time consumption each time | 75 minutes |
|
|||
Total direct costs:
|
195.35
|
The cost of using electrolyzed oxidizing water to clean and disinfect production pipelines per operation (see Table 2): Table 2
Step | Cost items | Cleaning and disinfection operating costs | |||
Time (minutes) | Usage (ton) | Unit price (yuan/ton) | Cost (yuan) | ||
Rinse with clean water |
water consumption
|
3
|
2
|
1.6
|
3.2
|
Alkaline water cycle |
water consumption
|
10
|
2
|
18
|
36
|
Rinse with clean water | water consumption |
2
|
2
|
1.6
|
3.2
|
Rinse with acidic water | water consumption |
10
|
2
|
18
|
36
|
Time consumption each time | 25 Minutes |
|
|||
Total direct costs: |
78.4
|
Summary: In Table 7, the operating cost for cleaning and disinfecting production pipelines using the original CIP method is 195.35 yuan per operation; The operating cost for each use of electrolyzed oxidizing water in Table 8 is 78.4 yuan. The use of electrolyzed oxidizing water for cleaning and disinfecting production pipelines is only 40.14% of the original CIP cost. Both: Each cleaning saves 116.95 costs. Annual savings of 45600 yuan. (3) Comparison of carbon emissions between two cleaning and disinfection methods and the carbon emissions of the original CIP cleaning and disinfection process (thermal disinfection) (see Table 3): Table 3
Carbon emission cleaning methods | Steam (kg/time) |
Standard coal consumption
(Kg)
|
Carbon coefficient |
Carbon emissions
(kg/time)
|
Carbon emissions (ton/year) |
Original CIP hot disinfection |
858
|
807
|
2.493
|
2012
|
785
|
Materials used for carbon emissions | Power consumption (kWh/time) |
Consumption of standard coal
(Kg)
|
Carbon coefficient | Carbon emissions (kg/shift) | Carbon emissions (ton/year) |
Potentiometric water cooling disinfection |
21
|
8.4
|
2.493
|
21
|
8.2
|
Summary: The carbon emissions of using electric potential water cleaning and disinfection process (cold disinfection) are only 1.04% of the carbon emissions of the original CIP cleaning and disinfection process (hot disinfection). Based on the above comparison, it can be seen that using electrolyzed water for CIP cleaning and disinfection each time saves 116.95 yuan in cost compared to the original process, which is only 40% of the cost of the original CIP method. 2. The time for cleaning and disinfecting production pipelines using electric potential water has been reduced by 50 minutes compared to the original CIP method, which is only 33.33% of the original time. If cleaned and disinfected once per shift (8 hours), it will increase production efficiency by 10%. 3. Due to the fact that cold disinfection does not use steam, it saves heat energy and can directly reduce carbon emissions by 776.8 tons per year; The carbon trading price is 46608 yuan. 4. Electric potential water can be reduced to ordinary water after disinfection, and it can also reduce the cost of a large amount of sewage treatment.