Retrofitting of Process Cooling Plant · Existing system APB’s facility has a centralised process...

© Asia Pacific Breweries, Singapore

Retrofitting of Process Cooling Plant

Asia Pacific Breweries (Singapore)Pte Ltd

EENP Awards 2016 Best Practices


• Background :

Asia Pacific Breweries Singapore, Pte Ltd, established in 1932, is wholly owned of Heineken. APB Singapore, Tuas factory started its operation since 1988, and Sprawling across nine hectares in Tuas, it is the largest commercial brewery in Singapore.

From milling to fermentation and filtration, the brewery adopts the most technologically advanced brewing process that is fully automated.

APBS –Introduction

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Milling

Mashing

Lautering

Wort boiling

Whirlpool

Wort cooling

Fermentation

Yeast treatment

Filtration

BBT

Dilution water Packaging

Brewing- Process Flow Thermal energy influence

Cooling influence


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Background

In energy point of view , cooling plant consume 35% of the total energy consumption of the plant. For the cooling requirement in APBS brewery, we are currently having a cooling utility plant which is operating 25 years old technology and equipment. Although the present equipment is able to generate the require cooling, the required electricity to generate the cooling is 4.095 kwh/hl of beer produced which is above the benchmark figure of other breweries with new equipment and technologies. (about 3.4 kwh/hl)


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Existing system

APB’s facility has a centralised process cooling plant with 5 nos. of ammonia screw compressors Gaseous ammonia from the compressors is condensed by cooling towers into liquid, which cools alcohol water in evaporators. The cold alcohol water at -4 to -5 oC is used for process cooling at APB’s facility. A schematic of the current system is shown in Diagram Based on one-year data on product output and electricity consumption of the process cooling plant, the specific energy consumption of the process cooling plant was 4.1 kWh/ hl of beer (1 hectolitre equals to 100 litres ) .


Existing system


Alcohol Water Return Temperature measurement point

Alcohol Water Flow measurement point at return pipe.

Ammonia Liquid temperature measurement point

Power measurement at LT room

System study : To evaluate the performance of the cooling plant , study been carried out with the existing system - it to calculate the COP of the system , and keep the number of brew for the before and after the improvement as constant


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Study on improvement : Total Ammonia Plant Power Consumption

127,738.97 + 26,272.97 + 26,843.05 = 180,854.99 kWh for 2 weeks


180,854.99 kWh ÷ 44,160.33hl = 4.095 kWh/hl

= 359,533.94 kWh / 180,854.99 kWh

= 1.988


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Study On improvement

Process analysis : * An alcohol water supply temperature of 3oC is sufficient to cool the wort (wort cooling process) to 8oC for fermentation, thus the current supply temperature of -4oC is not required and can be increased;, adding additional heat exchanger plate allow better cooling rate , * The alcohol water return temperature for Dilution water line is currently at 6oC, which can be increased to 27oC , to improve the efficiency of the process cooling plant.

The highest energy consumption process widely took place in wort cooling (15.3Mwh/day) follow by Dilution water and Fermentation Process (8.3Mwh/day )


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Study On improvement : Equipment Analysis

To improve the efficiency of the process cooling plant, APB has to install two cascade ammonia compressors with higher efficiency for wort cooling process and blending water line. Two ammonia compressors and two evaporators or heat exchangers, one produces ammonia to cool alcohol water from 27 oC to 12.6oC through an evaporator (heat exchanger), and the second to cool alcohol water from 12.6 oC to 3oC through a second heat exchanger/evaporator.


Modified Plant :


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After modification Total Ammonia Plant Power Consumption

= 79,787.63 + 24,645.14 + 27,567.04 + 23,419.45 = 155,419.26 kWh for 2 Weeks


155,419.26 kWh ÷ 43,496.92hl 3.57 kWh/hl

(145,997.32 + 230,928.76) kWh / 155,419.26 kWh

= 2.425


Old Compressor New Cascade Compressor


Result : With the Equipment upgrade bring down the energy consumption from 4.1kwh / hl to 3.5Kwh/ hl. and the Process optimization allowed further reduction to 3.27kwh/hl.

Saving : ROI :

Electrical consumption : around 1.25Gwh / Annum

Simple Payback of around 5.5 years

Retrofitting of Process Cooling Plant · Existing system APB’s facility has a centralised process...

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