Energy Efficiency in the Brewing Industry National Conference on Thermal Energy Management in the Food & Drink Industries pptx

Past Mann’s Brewery Whitechapel• Brewery on Site from 1808 • Developed in 1880’s with: • Copper Pans, • Copper Vapour Heat Recovery, • Waste Steam from Beam Engine heating Mash Tuns •

Energy Efficiency in the Brewing

Industry

National Conference on Thermal Energy

Management

in the Food & Drink Industries

By Eric Candy

Brewing Industry Energy Efficiency

Areas to be Covered

• Past

• Present

• Future

Drive for Energy Efficiency

Past Mann’s Brewery Whitechapel

• Brewery on Site from 1808

• Developed in 1880’s with:

• Copper Pans,

• Copper Vapour Heat Recovery,

• Waste Steam from Beam Engine

heating Mash Tuns

• By 1930’s Electricity Generation with

District Heating Scheme

Past Copper Pans

Courtesy “A

Treatise on the Art

of Brewing” 1820

Past Copper Pans

Copper with Pans

at Fuller, Smith &

Turner, Chiswick

Mann’s Brewery Whitechapel

Beam Engine

1867

Mann’s Brewery Whitechapel

Beam Engine 1867

Past Papers in Brewing Journals

• 1899 Journal Institute of Brewing

• Patent – self return of condensate to

boiler (J Hall)

• Patent – dry residual products of

distilleries in tubes in furnace flue, use steam to power engines (C Doig)

Past Papers in Brewing Journals

• 1900 Zeit.ges.Brauw

• Need to control excess air in boiler, coal

requirements 25 to 50 kg brown coal

per Hl by decoction (R Madlener)

Past Papers in Brewing Journals

• 1902 Journal Institute of Brewing

• Concern over steam leaks, need for

good lagging, finding uses for waste

products (O Overbeck)

• Brewery Refrigeration – need for

insulation, Carbon Dioxide & Ammonia Primary Refrigerants (G Harrap)

Past Papers in Brewing Journals

(G Harrap)

Past Papers in Brewing Journals

Past Papers in Brewing Journals

• 1902 Zeit.ges.Brauw

• Cheaper to generate electricity from

steam engines rather than gas engines because of both lower fuel cost plus

use of spent steam for other uses (C

Eberle)

Past Papers in Brewing Journals

• 1903 Zeit.ges.Brauw

• Use spent steam to heat water

• Use flue gas to heat boiler feed water &

mash tun sparging water.

• Condensate returned straight to boiler

(C Eberle)

Past Papers in Brewing Journals

• 1908 Journal Institute of Brewing

• Coal use 48 lbs to 90 lbs per barrel

• Need to Control Excess Air in Boiler

• Energy can be saved by Pre Heating

Boiler Feed Water, Use of Economisers in Boiler Flues

• More efficient steam distribution if

superheat the steam

(Maynard)

Past Papers in Brewing Journals

• 1908 Journal Institute of Brewing

• Gas engine more efficient way of

generating electricity than a steam engine (Maynard)

Past Economiser 1910

(Courtesy Coldharbour Mill)

Exit Economiser 1910 Route to Flue

(Courtesy Coldharbour Mill)

Past 1947 Efficient Use of Steam – O Lyle

Copper Vapour Heat Recovery

Past - Benchmarking Results

Past 1947 Efficient Use of Steam – O Lyle

222 to 229 MJ/hl (Low end low Coal GCV, High end high Coal GCV)

Existing Process No Heat Recovery

Past 1947 Efficient Use of Steam – O Lyle

No Process Mod Heat Recovery

• Preheat through Refrigeration condenser

• Wort cooling preheat liquor

• Copper Vapour

Past 1947 Efficient Use of Steam – O Lyle

Process Mod Changes

• Recover from cask washing

• Pressure boil, reduced or even no evap

• Boiler flue gases

• Ozone rather than heat sterilise liquor

• No cask steaming

Past 1947 Efficient Use of Steam – O Lyle

355 to 466 MJ/hl

Existing Brewery Heat Recovery

• Wort cooling preheat liquor

• Copper Vapour

Present - Benchmarking Results

World Lager Brewing

Present - Benchmarking Results

Benchmarking Results

Lager Brewing

Benchmarking Results

Specific Energy Consumption (SEC) kWh/hl

v Implementation Effort

Best Practice Brewery Example

• 1997 Kyoto 12.5% by 2008 – 2012

• Climate Change Bill

– 32% by 2020

– 60% by 2050

Best Practice Brewery Example

• 1997 Kyoto 12.5% by 2008 – 2

• Climate Change Bill

– 32% by 2020

– 60% by 2050 54 MJ/hl 108 MJ/hl

Energy Consumption – As Is

Beer Production 139,000 Btu/US BBL

125,000 kJ/hl

Fridge E 10%

Pumps E 8%

Heating & Other

T 14%

Vigorous Boil

(Courtesy of Steinecker)

Internal Heat Exchanger

Internal Heat Exchanger

(Courtesy of Meura)

External Heat Exchanger Mixing

PDX® Reactor

• Supersonic vapour flow and condensation

shockwave,

• Generated from the injection of high velocity steam

• Steam is introduced into a special annular

"conditioning" chamber that is wrapped around the core of the PDX Reactor unit

• It is injected into the process fluid at supersonic

conditions generating high levels of shear and

turbulence within the process fluid,

PDX® Reactor

• Leads to creation of a controllable cross bore

condensation shockwave

• The combination of these mechanisms provide

unsurpassed homogenous mixing, agitation and heating of the process fluid.

• Claim delivers up to 50% energy savings and

reduced processing time (30 mins from 60

mins) for the intensive wort boiling stage of the brewing process

PDX® Wort Heater Process

(Courtesy of Pursuit Dynamics)

PDX® Reactor

(Courtesy of Pursuit Dynamics)

Continuous Wort Boiling

• wort is in-line heated up to its boiling

temperature.

• Added hop is also homogenized An adapted

agitator is assuring a sufficient mixing for the trub formation Among other

chemical/biochemical reactions, the SMM is turned into DMS An external agitation must

be provided

Continuous Wort Boiling

Wort Preheating with vapour

• Heating wort during transfer between

lauter tun/mash filter and boiling kettle

• Energy recovery by vapour condensing

• Energy stored in a hot water buffer tank

• Heat recovery from condensate possible

for secondary hot water generation

Vapour condenser

(Courtesy of Alpha Laval)

Wort pre-heating with

hot water

(Courtesy of Alpha Laval)

Wort Preheating - Evaluation

• Heat inertia if production interrupted

• Energy losses if number of brews/day < 5

• Wort buffer tank required

External Wortboiling with Vapour

Thermocompression

• Wortboiling with external heat exchanger

(wide gap PHE)

• Energy recovery by thermocompression of

vapour (with high pressure steam)

• Heat recovery from condensate possible

for secondary hot water generation

Ejector of thermocompressor

(Courtesy of Alpha Laval)

(Courtesy of Alpha Laval)

External Wortboiling with Thermocompression

• New PHE or EWB with higher heat transfer

needed (steam max 0.4 bar, 110°C)

• Power requirement for recirculation pump

• The Main Concepts that we use to Improve

Energy Efficiency are Not New

• We are Getting Smarter at Using Them

• We Need to Make the Process Work for Us

• To Do This We Need to Create Beers that

Our Customers Want to Buy Using Low

Energy Processes

• We Need to Understand Our Current

Products e.g Volatile Profile of Wort Pre Pitch to Enable Process Guarantees from Equipment Suppliers

Future Techniques

• Use of enzymes like Novozymes Maturex®

can be used with lager to prevent the

formation of diacetyl reducing the

maturation time from 2 to 14 days

• DSM’s enzyme Brewers Clarex™ removes

the need for a sub-zero temperature

stabilization stage

• Alfa Laval’s Isomix system for effective

mixing in Unitank operation enabling

efficient heat transfer

Future Techniques

• Use of Heat Pumps in Brewing, Packaging &

Trade Outlets

• Efficient Energy from Waste

• Encourage Energy Efficient Small Breweries

Developing Low Energy Brands that

Consumers Want to Buy

Future Techniques

• Even Smarter More Effective & Wider Use of

Existing Techniques

• Use of Energy Use Analysis Tools such as

EINSTEIN II to enable us to Efficiently

Overview Processes to Identify

Opportunities

Best Practice Maltings & Distillery

Ethanol From Cellulose

• 1997 Kyoto 12.5% by 2008 – 2

• Climate Change Bill

– 32% by 2020

– 60% by 2050

Ethanol From Biomass

• 1997 Kyoto 12.5% by 2008 – 2

• Climate Change Bill

– 32% by 2020

– 60% by 2050

Ethanol From Biomass

TMO Process

Heat Pump Application in Dairy 11/12

• Three Compressors in Series

• Heat of Compression at each stage raises refrigerant gas

temperature

• Hot water at 82 C produced from first condensing stage

• Hot water used to Plate Pasteurise Milk rather than use

Steam from Boiler

10°C Boiler 80% efficient

‐2°C +2°C

‐8°C

+15 ‐ 32°C

Compressor

Condenser

Chiller

Milk Intake Chill

Regen  section

Refrigeration in the Dairy

£

GEA Refrigeration

10°C Boiler 80% efficient

‐2°C +2°C

‐8°C

+15 ‐ 32°C

Compressor

Condenser

Chiller

Milk Intake Chill

Regen  section

+69°C +82°C

£

Two stage heat pump ( to deal with limited field of application)

Brewing Industry Energy Efficiency

Possible Lessons Learnt

• Past– Knowledge Helps, Application is Key

• Present – We are Making Progress with variable

performance from site to site, tools like

EINSTEIN II should be useful

- We have many challenges ahead optimising energy from waste

Brewing Industry Energy Efficiency

Future

• Optimise Process – Proviso Customer Acceptable

Beers

• Optimise Utilities Use – Maximise Heat Recovery

• Optimise Energy from Waste

Profit Improvement – Solutions for Industry

Inovate Offer Services to Help Companies IMPROVE their

Profitability focussed on the following areas of Company activity:

Environmental Issues, including Waste Minimisation & Culture Change

Production Processes

Packaging Operations

Product Development & Design

Logistics & Customer Service Development

Safety Issues, including Culture Change

Teambuilding

Training

Profit Improvement – Environment

Inovate Environment Services Include:

• Environmental Audits

• Environmental Impact Assessments

• Environmental Statements

• Environmental Culture Development & Change

• Waste Minimisation Programmes

• Energy Audits

• Energy Efficiency Improvement

• Environmental Training

• PPC, CRC & CCL Support

Profit Improvement – Production Processes

Inovate Production Process Services Include:

• Process Audit – Quality, Efficiency, Cost, Environment, Safety

• Process Development

• Quality System Development & Compliance

• Problem Solving

• Process Operation Support

• Process Capital Project Management & Engineering Support

• Purchasing Support

•Contract Brewing & Packaging Support

Profit Improvement – Packaging Operations

Inovate Packaging Operations Services Include:

• Packaging Audit – Quality, Efficiency, Cost, Materials, Environment, Safety

• Packaging Line Development & Design

• Problem Solving & Performance Improvement

• Quality System Development & Compliance

• Packaging Line Capital Project Management & Engineering Support

• Packaging Line Management Support including relief cover provision

• Performance Improvement through Effective Maintenance

• Waste Minimisation

Profit Improvement – Product Development

& Design

Inovate Product Development & Design Services Include:

• Product Concept Development

• Product Design Support

• Package Concept Development

• Package Design Support

• Product & Package Specification Development & Support

Profit Improvement – Logistics & Customer Service Development

Inovate Logistics & Customer Service Development Services Include:

• Logistics System Analysis & Audit

• Logistics Troubleshooting

• Logistics System Development

• Customer Service Audit & Troubleshooting

• Innovative Customer Service Development

Profit Improvement – Safety

Inovate Safety Services Include:

• Safety Audits

• Risk Assessment Support

• Accident Reduction Programmes

• Safety Culture Development using Behavioural Approach

• Safety Training

Profit Improvement – Teambuilding

Inovate Teambuilding Services Include:

• Enjoyable Yacht Based Teambuilding Courses

• Problem Solving Courses

Profit Improvement – Training

Inovate Training Services Include:

• Production Processes Technical Training

• Packaging Processes Technical Training

• Quality System Development & Compliance Training

• Brewing Technical Training

• Liquid Beverage Packaging Technical Training

• Environmental Training

• Safety Training

• Project Management Training

• Problem Solving Training

• Strategic Planning Training

• Teambuilding

Profit Improvement – Solutions for Industry

Inovate Structure:

• Inovate is able to deliver teams of specialists to achieve

customer requirements

• A key Strength of Inovate is the Depth, Quality and Diversity

of Expertise of the Team

Profit Improvement – Solutions for Industry

Inovate Values:

• Integrity

• Great Customer Service

• High Standards, Quality Service

• Confidentiality

• Openness

• Good Value

Profit Improvement – Solutions for Industry