DV-d34-p0006-1 03/07 CC The Resource-Optimized Brewery Stephen O‘Sullivan KRONES PROCESS...

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The

Resource-Optimized

Brewery

Stephen O‘SullivanKRONES PROCESS TECHNOLOGY

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CMBAA Rocky Mountain District

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Three pillars of sustainability

- Lowering consumption• More efficient equipment and

technology in beer production- Energy recovery systems- Improved system design

- Utilization of waste materials• Waste water recycling• Utilization of spent grains

- Alternative Energy Sources • Wind or solar energy• Biomass• Hydropower

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Source: ASPO – Association for the study of the Peak Oil & Gas

The demand for fossil fuels is growing with increasing global population and growth in consumption.

In spite of falling new oil discoveries, demand for oil continues to grow all the time.

Since 1985 the volume of oil consumption has outstripped new discoveries.

Oil Production is becoming increasingly difficult, so the price of oil & natural gas will increase even more over the long term.

Extract yield used to be the critical cost factor for a brewery in the past, in future it will be the Cost of Energy.

New discoveries of oil and oil production (1920-2004)

oil production

new discoveries

Second largest oilfield (Kuwait)

World's largest oilfield (Ghawar S.A.)

1. Oil crisis

2. Oil crisis

Deep sea exploration

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Cap

ital

val

ue

[€]

0 2 4 6 8 10 12 14 16 18

Time [a]

Investment reducing consumption

Ca

pit

al

valu

e [

€]

0 2 4 6 8 10 12 14 16 18

Time [a]

Investment increasing yield The Overall brew house yield (OBY) of modern brewhouse systems are already at 98 - 99%.

We’ve practically reached the limit of what is technically possible for increasing OBY.

Capital investment aimed at increasing the yield any further achieves a lower Return on Investment

Investment geared towards cutting energy consumption becomes more the more practical option

Consumers also expect that their brewery utilizes sustainable production systems.

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Energy Recovery and Re-use

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Energy Recovery in the Brewhouse

Typical Recovery Sources

Kettle vapour condenser Condensate cooler Wort cooler

Typical Applications Lauter-wort heating Heat for mashing water Heat for sparging water Heat for cleaning / CIP

Source: Katechismus der Brauereipraxis; J. Dworsky, K. Lense; (1926)

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Energy flow in the traditional brew house (with traditional Wort kettle Energy Recovery)

Hot water

Secondary

Primary

Mash

ing

-in

Mash

ing

Lau

teri

ng

Heati

ng

-up

1

Heati

ng

-up

2

Boilin

g

Coolin

g

CIP

bre

wh

ou

se

Steam Steam SteamCooling/Water

Hot waterHot water

Hot water

Energy storage unit

Steam

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Traditional brew house with wort kettle Energy Recovery

1. Mill

2. Mash Tun

3. Lauter Tun

4. Pre-Run Vessel

5. Energy Storage Tank

6. Vapor Condenser

7. Lauter Wort Heater

8. Wort Kettle

9. Whirlpool

10. Wort Chiller

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Hot water

Mash

ing

-in

Mash

ing

Lau

teri

ng

Heati

ng

-up

1

Heati

ng

-up

2

Boilin

g

Coolin

g 2

CIP

bre

wh

ou

se

Steam Steam SteamCooling/Water

Hot waterHot waterEnergy storage

Steam

C

oolin

g 1

Energy storage

Hot water

Secondary

Primary

Hot water

Energy flow with EQUITHERM

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EquiTherm - Equipment and technology

Using the first stage in the wort chiller to recover hot water at 96°C (200F) and store in an energy storage tank.

This acquired energy is enough for the mashing process depending on temperature of the mash

Usable water temperature is adjusted by mixing water from upper (96°C) and lower (76°C) (205-167F) strata of the energy storage tank.

The return hot water is fed into the energy storage tank in temperature strata.

Radiation losses and start-up energy are regulated and compensated by the CIP heat exchanger.

The first brew house with EquiTherm: Bergquell Brewery Löbau, 2010

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Mash Tun Design – Using Recovered Energy

- The mash is heated up with energy obtained from the first stage of the wort cooler.

- Retrofit Existing Mash Tun - Jacket would require separate hot water and steam sections

- Compared to steam, difference in temperature between heating medium and the mash is relatively low.

- Use of pillow plates enables heat transfer rates of 1 K/min based on appropriate jacket dimensioning.

- Flow of hot water to the heating surfaces. fed from the top to the bottom through the pillow plates, creating the effect of a counter flow heat exchanger.

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WAkQ

Heat transfer coefficient

Temperature difference

Heat flow

(Heating) surface

Mash Tun Design - Equipment and technology of EquiTherm

ShakesBeer EquiTherm- The turbulent flow pattern of the

mash on the heating surface improves the heat transfer coefficient and with this, the heating rate

- This is the only way of ensuring that the heating surface is large enough in spite of the reduced temperature difference

Mash

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Energy Storage Tank Design

- One Storage Tank can be used jointly by both the EquiTherm and lauter wort heater & vapor condenser

- Given the different retuning hot water temperatures a solution is required to avoid mixing zones in the tank

- A stratified charging pipe enables the water to attain a level in the tank according to density/temperature without much mixing

Equipment and technology

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Figures, data and facts

Peak loads for the steam boiler system

- With more than eight brews per day production, the heating up involved in the mashing process and the boiling of the wort inevitably run parallel to each other.

- The steam boiler system must be designed for the maximum possible peak load.

- With the energy required for the mashing process being supplied by EquiTherm, the peak is reduced by this amount.

Steam capacity

Steam capacity

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Standard EquiTherm Savings

Brews per day 10 10 ---

Cast wort, hot 100 hl/brew 100 hl/brew ---

Steam amount 880 kg/brew 595 kg/brew 32 %

Peak load 1280 kg/h 685 kg/h 46 %

Hot water preparation (wort cooler)

11.7 m³/brew 9.0 m³/brew 23 %

Electrical energy (Glycol) *

14.3 kWh/brew 11.0 kWh/brew 23 %

Thermal Energy Requirement (average)

555 kWh/brew 375 kWh/brew 32 %

* Calculated

Figures, data and facts

Savings with EquiTherm

“Standard” brewhouse assumes Energy recovery from Wort Boiling already in place

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Energy & Material Savings using Mashing Technology

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Faster Mash Conversion- Possible additional brew/day

Dimpled Surface Jacket- Improved Heat Transfer

Reduced fouling- Less CIP & Rinse Water Consumption

Optimized deaeration- Quality

Vibration Transponder Technology in Mash Tun

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Saving Energy within the Wort Boiling Process

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Effect of Wort Heating and Boiling on Total Energy Demand

Wort boiling represents one of the greatest individual energy consumers in a brewery.

State of the art brewery - wort boiling can represent up to 30% of the total heat demand.

→ Large savings potential available

42 %27 %

< 20 %

8% Evaporation 4% Evaporation 2% Evaporation

Wort Boiling remaining brewery

State of the Art Brewery(total. heat usage: 19,4 kWh/hl VB without recovery

)

Mashing andCereal cooking

12,5 %

Wort boiling27,0 %

Rest60,5 %

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- During the wort boiling process the free DMS must be expelled to such an extent that the taste threshold value of 100 ppb will not be exceeded during the re-increase in the whirlpool

- High temperatures separate more DMS precursor, but free DMS is no longer reduced because there is no movement / circulation

- The content of free DMS remains constant in the cooled wort.

Time

free D

MS

100 ppb

Energy

Standard

Boiling Whirlpool Cooling

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Equipment and Technology of STROMBOLI

The Stromboli boil system has two circulation circuits: the natural circulation of the boiler and the pump circulation.

The circulation of the wort can be separated from the total evaporation. With the variation in the pump speed and phase duration new parameters are available to control the boiling process.

Natural circulationPump circulation

- Phase 2: Pump circulation with reduced energy supply

- Phase 1: Natural circulation by energy supply and pump circulation

The boiling process is divided into three phases:

- Phase 3: Natural circulation by energy supply and pump circulation

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Stromboli wort boiling process

- Stromboli allows the circulation of the wort to be separated from the evaporation

- In phase 2 of the boiling process the wort is circulated with an external pump and the Venturi nozzle only

- The Stromboli wort boiling process therefore allows a reduction in the free DMS content with reduced energy input

Time

free D

MS

100 ppb

Energy

Standard

Stromboli

Phase 1 Phase 2 Phase 3


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Venturi effect as key to success

The core of the Stromboli internal boiler is a Venturi nozzle installed above the pipe bundle.

Driven by an external pump, the wort is conveyed via the central ascending pipe. This creates a vacuum on the outside of the nozzle which supports the flow of wort in the pipe bundle.

At a circulation rate with the 8-fold amount of wort to be boiled per hour, almost the same circulation rate is also generated by the Venturi nozzle.

System design means 4 m/s is the maximum speed for the wort flow.

Up to 30 Brews between CIPs

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Energy Savings using Wort Stripping Technology

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Wort quality- Wort has valuable substances

but also some undesired components

- If certain levels of these components are exceeded then a loss in quality will result

- Wort stripping offers the abilty to remove undesired flavors from wort in a controlled way

Energy saving- Not only will quality improve,

wort stripping also provides the possibility to reduce total evaporation and energy consumption during wort boiling step

Wort Stripping

Stripping is a technology combining classical quality with modern brewing processes

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DMS - Indicator for the wort quality

timeFre

es

DM

S*

60 minutes boiling time

40 minutes boiling time + stripping

100 µg/l

Stripping enables a reduction of free DMS content below threshold even if boiling time is reduced from 60 to 40 minutes

Wort stripping can be used for:- reducing the boiling time, i.e.

saving energy, with constant wort qualityor

- reducing the percentage of free DMS with constant boiling time

With this, wort stripping allows constant boiling processes with different raw material qualities

Wort stripping allows the reduction of free DMS straight before wort cooling

* Simplified display as linear function


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Equipment and Technology - Boreas Spin injector

- Wort is set into rotation via the spin injector. Using the appropriate speed and angle, the wort is applied continuously already in the cover and a turbulent falling film runs down on the container wall.

- The change of velocity at the outlet of the spin injector leads to a pressure drop in the wort layer, which supports the stripping effect.

- The expelled free DMS is led to atmosphere through the inner space of the spin injector.

The product path can be used for cleaning agents, no further installations are required.

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Partial pressure as key to success

The total pressure in the stripping vessel is based on the partial pressures of the individual phases (shown here in a simplified way as H2O and free DMS)

Depending on the temperature there will be a balance between steam and free DMS in the gas phase. This will be proportional to the percentage of distribution between the individual partial pressures.

Until the point of saturation there will be a constant evaporation of water and free DMS 1000 vessel pressure 95° = 150 mbar DMS + 850

mbar H2OWortH2O

Free DMS

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Partial pressure as key to success

The evaporation of DMS is proportional to the creation of vapor during turbulent wort flow within the stripping vessel

Evaporation enthalpy means the intensity of the generation of water vapour happens proportionally to the temperature difference between the wort inlet and outlet

In the gas “zone” of the stripping vessel a balance point between vapor and free DMS is created. By the injection of strip gas the saturated gas is displaced continuously

Strip gas keeps the driving concentration gradient between wort film and gas zone at a constant level, so that the reproduction of water vapor and with this, the reduction of free DMS can be controlled

Water steam and free DMSStrip gas, water steam and free DMS

Strip gas (CO2, N2, air)

Wort inlet

Wort outlet

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Wort analysis

Depending on the amount of strip gas and the temperature difference between the inlet and the outlet, the DMS reduction can be up to 70 %

In the same way, other unwanted aromatic substances can be removed

The usage of air as strip gas causes no oxidation of the wort

The partial pressure creates a steam layer at the wort surface which avoids contact between wort and oxygen

Reduction of undesired aroma components

0

10

20

30

40

50

60

70

80

90

100

DMS Heptanal 2 Methylbutanal

Red

uct

ion %

Wort color as indicator for oxidation

5

5,5

6

6,5

7

7,5

8

8,5

9

9,5

10

Without stripping CO2 stripping Air stripping

Colo

ur

EB

C

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Energy & Material Savings in the Cold Block Area

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Process concept: High-Gravity Brewing

17°P → 11°P → 11°P → 11°P → 1.42 m hl VB

Conventional brewery (12 brews/d, 500 hl, 11°P)

24°P → 20°P → 17°P → 11°P → 1.42 m hl VB

High-Gravity Brewery (12 brews/d, 275 hl, 20°P)

(Absolute blending factor : 1,0)

First dilution: 1.18) (Second dilution: 1.55) (Absolute blending factor : 1.82)

Brew size 500hl

Brew size 275hl

-45%

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Savings potential by high gravity in the brewhouse

Saving Potentials, running costs per year

0 € 250.000 € 500.000 € 750.000 €

Electrical power

Water usage

Thermal Energy

11°P

20°P

500 hl cast out with 11°P compares with 275 hl with 20°P

→ Total savings potential: up to € 400,000 per year

Calculation basis: Krones standard brewhouse; 8°C cold water temperature; 80° hot water temperature; 0.09 €/kWh (thermal); 0.12 €/kWh (electric); 0.10 €/hl fresh water

Saving Potentials, Investmentcosts

0 € 1.000.000 € 2.000.000 € 3.000.000 € 4.000.000 €

Investment Costs 11°P

20°P

→ Total savings potential in investment costs: up to € 450,000

Additionally large potential in the cold area (tank, line and filter size; cooling energy, compressed air, …)

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before the CIP (contamination marked)

After a CIP time of 10 min.

Reduction in CIP expenditure based on Visual Scanning Technology

Integration of the TopScan in the CIP process - Dynamic cleaning process depending on the

degree of dirt contamination

“As little as possible but as much as necessary”- Reduction in the rinsing water consumption- Reduction in the cleaning agents- Time saving- Increased plant efficiency

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Intelligient Pipe Fence Design in the Cellar

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Pipe system concept

Decentralised piping design- The short connection between the

two valve blocks allows for savings to pipes, valves, cleaning media and displacement water (TWIN-PRO)

Linear piping design- All pipes must be guided past all

tanks. The amount of extra cost and work exponentially increases with each additional tank

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Pipe system concept- One valve block each for the

filling and draining processes in the tank loop

- Connection of up to four tanks to one ring channel which in turn is connected to the main lines via double seat valves

- Required number of pipes and valves reduced by up to 30%

- Required volume of water for displacement and cleaning agents reduced by up to 35% due to minimized pipe lengths

Intelligient Pipe Fence Design in the Cellar – Twin Pro

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Material usage and water demand

MaterialLinear system

TwinPro Saving %

Pipe system [m] 1404 1054 25

Bends 540 352 35

Double seat valves

132 89 32

Push-out amountsLinear system

TwinPro Saving %

Wort line 9.2 hl 6.8 hl

Beer feed pipe 9.2 hl 6.8 hl

Yeast line 3.9 hl 5.4 hl

CIP, product 18.4 hl 9.1 hl

CIP yeast 7.8 hl 5.4 hl

Total 48.5 hl 33.5 hl 31

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•Produce the best quality

•Protect the environment

•Conserve resources

Sustainable thinking

Thanks !

DV-d34-p0006-1 03/07 CC The Resource-Optimized Brewery Stephen O‘Sullivan KRONES PROCESS...

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Transcript of DV-d34-p0006-1 03/07 CC The Resource-Optimized Brewery Stephen O‘Sullivan KRONES PROCESS...