Optimising Demineralisation of whey using Ion exchange and Nanofiltration (ODIN): Part of Downstream ISolation of high-value COmponents (DISCO)

In an era where sustainability takes centre stage, the dairy industry stands at pivotal crossroads. As global demand for dairy products continue to rise, so does the imperative for sustainable practices.
Against this backdrop, Aparna Raghunath, an Engineering Doctorate (EngD) canditate from TU Eindhoven, is collaborating with FrieslandCampina in an effort to make their 90% demineralised whey production process more sustainable. The project is part of a consortium effort led by the Institute of Sustainable Process Technology (ISPT) called Downstream ISolation of high value COmponents (DISCO). DISCO aims at increasing energy efficiency and lowering material usage of downstream processing at FrieslandCampina, Recell Group, Biota, Shell and Corbion. The objective for DISCO at FrielandCampina is to evaluate the current production train and lower the CO2 footprint using innovative technologies like nanofiltration, electrodialysis, ion exchange and CO2 switch.
The production of 90% demineralised whey uses ion exchange for removing the salts in the whey. Ion exchange is a process involving the interchange of ions to remove ash content in the feed. Ions in whey contributing to ash content comprise of cations such as calcium, magnesium, sodium and potassium as well as anions like chloride and phosphate. These ions are exchanged with hydrogen and hydroxide ions using ion exchange resin regenerated using hydrochloric acid and sodium hydroxide respectively. Reduction of chemical and water usage in ion exchange processes is imperative to enhance the overall sustainability profile of the process. This project investigates the use of nanofiltration to remove some of the salts from whey before the ion exchange process to reduce load on the ion exchange and thus lower the chemical and water usage.
As a part of this project, Aparna Raghunath uses her background in Chemical Engineering and fundamental knowledge and skills from process design to understand the nanofiltration and ion exchange processes. This involves experimental study of both processes and making significant strides towards modelling of these processes using gPROMS software. An investigation into the technical and economic feasibility of the proposed change involved a thorough analysis of a base case, providing a foundational estimation for potential implementation. While the current business case may not present an optimistic outlook, Aparna Raghunath identified significant potential for optimisation strategies to enhance the overall feasibility and pave the way for FrieslandCampina in establishing a more viable and efficient operational process for the production of 90% demineralised whey.