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. 2020 Apr 7;12(4):847. doi: 10.3390/polym12040847

Table 1.

Information provided on the equipment necessary for processing of whey and production of plastic in the models analyzed.

Steps Equipment Unit Operation Characteristics
A. Pretreatment of Whey P-1/PZ-101 Pasteurization

  • Inlet of 100 t of whey

  • Maximum throughput of 100,000 L/h

  • Pasteurize (61 °C for 15 secs, outlet temp. 30 °C)

  • Heating agent: steam

  • Cooling agent: chilled water
P-2/DC-101 Centrifugation

  • Equipment design based on Solids Removal (Carbs 70%, Fats 60%, Minerals 70%, Proteins 100%)

  • Centrifuge for 30 min to remove solids

  • Sedimentation efficiency: 30%
B. Production of WPC P-3/UF-101
(6 units)		 Ultrafiltration

  • Rejection coefficients:

    Carbohydrates        0.01

    Fats        0.01

    Minerals        0.01

    Proteins        0.95

  • Concentration factor (Feed/Retentate): 20

  • Max. solids conc. in retentate: 600 g/L

  • Solids conc. in retentate: 491 g/L

  • Max. membrane area: 80 m2

  • Membrane area: 76 m2

  • Dft membrane
P-4/DF-101 Diafiltration

  • Rejection coefficient:

    Proteins        0.95

  • Filtrate flux: 20 L/m2hr

  • Max. solids conc. in retentate: 600 g/L

  • Solids conc. in retentate: 340.23 g/L

  • Membrane area: 30.1 m2
P-5/SDR-101 Spray Drying

  • Volatile component evaporation rate: water 93%

  • Outlet gas and product temp: 70 °C

  • Max. diameter: 10 m

  • Height/Diameter ratio: 3
P-6/SL-101 Solids Storage

  • Volume < 1500 L

  • Store WPC powder to partially sell and partially use for following plastic production process
C. Chemical Processing P-7/R-101 Protein Dissolution

  • Stirred reactor Max. volume 40,000 L

  • Transfer in 1 t of WPC

  • Charge 10,000 L of water

  • Agitation Time: 2 h (dissolve protein)

  • Charge 100 L of NaOH

  • Agitation Time: 20 min (raise pH to 10~11)

  • Final temp: 26 °C
P-8/R-102 Methacrylation

  • Stirred reactor

  • Charge methacrylic anhydride 50 L

  • Agitation Time: 7 h

  • Charge NaOH: 125 L (to raise pH to about 9 so proteins don’t precipitate due to presence of methacrylic acid formed from reaction)

  • Temp: 25 °C
P-9/R-103 Polymerization

  • Stirred reactor Max. volume 40,000 L

  • Charge PEGMA 2300 L

  • Charge APS 92 L

  • Charge TEMED 4.6 L

  • Reaction Time: 1 h

  • Temp: 25 °C
D. Production of plastic P-10/WSH-101 (2 units) Washing

  • Wash out excess chemicals

  • Process time: 30 min
P-11/DC-102 Centrifugation

  • Equipment design based on Solids Removal (Polymerized content 90%)

  • Centrifugation time: 4 h

  • Sedimentation efficiency: 30%

  • Limiting solid particle minimum diameter: 1 micron
P-12/DDR-101 Drum Drying

  • Drum area: 12 m2

  • Evaporate 85% of water

  • Heating agent: steam

  • Drying rate: 40 kg/m2hr

  • Drying time: 360 min

  • Final solids temperature: 72 °C