Nile Brewery Ltd. In-plant Water CP-assesment

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Nile Brewery Ltd. In-plant Water CP-assesment

• January 19th, 2007
• Richard Harrow 6 Steffen Wissing
• Danbrew

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Agenda

• The assignment
• Methodology
• Overall Material Balance
• Process flow chart for water
• Evaluate inputs and outputs and select audit
  focus
• Waste generation causes and potential solutions
• Conclusion

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The assignment of Danbrew

• UN Environmental Programme have asked Danbrew to
  perform In-Plant CP-assessments with a focus on
  water saving and waste water.
• This is part of the a UN water saving initiative
  within the African brewery sector (The Abrew
  project). This project will
• Identify the potential for water savings in the
  African brewery sector and suggest solutions.
• Develop a UN project for external funding for
  implementing water conservation measures in the
  brewing sector and subsequently in the entire
  beverage sector in Africa.
• The preliminary assumption of the project is that
  water usage is 32 hl water per 1 hl beer. If so
  the water saving potential is 1.7 billion hl. l
• Cleaner Production methods are assumed to
  generate savings of 20 to 50.

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Agenda

• The assignment
• Methodology
• Overall Material Balance
• Process flow chart for water
• Evaluate inputs and outputs and select audit
  focus
• Waste generation causes and potential solutions
• Conclusion

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Solutions within the CP concept
Engineering
Training
Plant equipment

• No part of the solution must be seen isolated

UN Technical Report N 33 p. 40
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What will we be looking after ?
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UN CP assesmentUNEP Technical report N 33 p.
101Environmental Management in the Brewing
Industry
Recognized need for CP
Is there a large potential of water sawing ?
Planning and Organisation Task 1 Obtain
management commitment Task 2 Identify barriers
and solutions Task 3 Set plant-wide CP
goals Task 4 Organize project team
Planning and Organisation Task 1 Obtain
management commitment Task 4 Organize project
team
Assesment organisation established
Assesment organisation established
Pre-Assesment Task 5 Develop process flow
chart Task 6 Evaluate inputs and outputs Task 7
Select audit focus
Pre-Assesment Task 5 Develop process flow
chart Task 6 Evaluate inputs and outputs Task 7
Select audit focus
Audit focus selected
Audit focus selected
Assesment Task 8 Derive materials balance Task
9 Assess waste generation causes Task 10
Generate CP options Task 11 Screen CP options
Assesment Task 8 Derive water balance Task 9
Assess waste generation causes Task 10 Generate
CP options Task 11 Screen CP options

• Abrew water assesment

Comprehensive set of CP options
Comprehensive set of CP options
Feasibility Studies Task 12 Preliminary
evaluation Task 13 Technical evaluation Task 14
Economic evaluation Task 15 Environmental
evaluation Task 16 Selection of feasible options
Feasibility Studies Task 12 Preliminary
evaluation Task 13 Technical evaluation Task 14
Economic evaluation Task 15 Environmental
evaluation Task 16 Selection of feasible options
List of feasible options
List of feasible options
Implementation and Continuation Task 17 Prepare
CP plan Task 18 Implement feasible options Task
19 Monitor CP progress Task 20 Sustain CP
On going CP successes
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Project organisation for Nile Brewery CP water
assesment

• Nile Brewery
• Technical Director Trevor Gray
• Utility Manager Joseph Lubuulwa
• Brewing Manager Moses Musisi
• Packaging Manager Isaac Ongora
• Danbrew
• Senior Consultant Richard Harrow
• Senior Consultant Steffen Wissing
• UN
• Programme Manager Niclas Svenningsen
• UCPC
• Technical Officer Edgar Mugisha

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Sources of information

• Interviews
• Org. Chart
• Meter readings
• ISO 14000 plan from 2004.
• Water balances for each area (Brewhouse,
  Packaging, Cellars, Filtration)
• Observations

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Agenda

• The assignment
• Methodology
• Overall Material Balance
• Process flow chart for water
• Evaluate inputs and outputs and select audit
  focus
• Waste generation causes and potential solutions
• Conclusion

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Material Balance for a Typical Brewery High
Consumption
Brewhouse Fermentation / Beer
Processing Packaging Ancillary Operations
Malt/Adjunct, 18 kg. Energy, 350
MJ Electricity, 20 kWh Water, 20 hl
1 hl Beer
Waste Water 18,5 hl 1,2 kg BOD
By-products Spent Grains, 17 kg Yeast, 3 kg
UN Technical Report N 33 p. 19
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Material Balance for a Typical Brewery Low
Consumption
Brewhouse Fermentation / Beer
Processing Packaging Ancillary Operations
Malt/Adjunct, 15 kg. Energy, 150
MJ Electricity, 8-12 kWh Water, 5 hl
1 hl Beer
Waste Water 3,5 hl 0,8 kg BOD
By-products Spent Grains, 14 kg Yeast, 3 kg
UN Technical Report N 33 p. 19
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Water balance for Nile Brewery Medium Water
Consumption
Brewhouse Fermentation / Beer
Processing Packaging Ancillary Operations
Malt/Adjunct, 15 kg. Energy, 150
MJ Electricity, 8-12 kWh Water, 7,4 hl
1 hl Beer
Waste Water 3,5 hl 0,8 kg BOD
By-products Spent Grains, 14 kg Yeast, 3 kg
UN Technical Report N 33 p. 19
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Agenda

• The assignment
• Methodology
• Overall Material Balance
• Process flow chart for water
• Evaluate inputs and outputs and select audit
  focus
• Waste generation causes and potential solutions
• Conclusion

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Schematic Layout of a brewery
Malting Plant
Barley Hops Adjunct Spent grains Spent
Yeast Packaging Material
Malt
Brewhouse
Ancillary Operations Boiler Plant Cooling
Plant Water Treatment Plant CO2 Recovery
Plant Compressed Air plant Electricity
Supply Waste Water Treatment Laboratory Workshops
Waste Storage
Water Fuel Electricity
Wort
Fermentation / Beer Processing
Bright Beer
Packaging
Packaged Beer
Warehouse
UN Technical Report N 33 p. 19
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Schematic Layout of Nile Brewery
Malting Plant
Barley Hops Adjunct Spent grains Spent
Yeast Packaging Material
Malt
Brewhouse
Ancillary Operations Boiler Plant Cooling
Plant Water Treatment Plant CO2 Recovery
Plant Compressed Air plant Electricity
Supply Waste Water Treatment Laboratory Workshops
Waste Storage
Water Fuel Electricity
Wort
Fermentation / Beer Processing
Bright Beer
Packaging
Packaged Beer
Warehouse
Domestic, Office, Canteen, Gardens
UN Technical Report N 33 p. 19
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Water flow of Nile Brewery
Malting Plant
Barley Hops Adjunct Spent grains Spent
Yeast Packaging Material
Malt
Brewhouse
Ancillary Operations Boiler Plant Cooling
Plant Water Treatment Plant CO2 Recovery
Plant Compressed Air plant Electricity
Supply Waste Water Treatment Laboratory Workshops
Waste Storage
Water Fuel Electricity
Wort
Fermentation / Beer Processing
Bright Beer
Packaging
Packaged Beer
Warehouse
Domestic, Office, Canteen, Gardens
UN Technical Report N 33 p. 19
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Water flow of Nile brewery in UN CP Brewery model
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Agenda

• The assignment
• Methodology
• Overall Material Balance
• Process flow chart for water
• Evaluate inputs and outputs and select audit
  focus
• Waste generation causes and potential solutions
• Planed Nile Breweries Initiatives
• Conclusion

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Water usage from 2004 until 2006
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Detailed Water Balance of Nile Brewery
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Focus areas

• There is potential of sawing water in all areas,
  but the potential is more in the Brewhouse and
  Beer Process than in Packaging.
• Beer losses are higher than perhaps they should
  be. This loss is especially in the Brewhouse and
  in the Cellars.
• High water loss in the Cellars could well be due
  to the current CIP.
• (Is there also a high beer loss during transfer
  to filtration) To reduce this can one accept a
  small dilution factor before the high gravity
  brewing dilution point. I.e. chasing with
  deaerated water.
• Packaging. What to do with the vacumpump water.
• Whith water is used for domestic an garding
  purpuses, which is upto a 100.000 hl a year.
• Discussion

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Water cost

• If Nile brewery was paying same price for water
  as others in Jinja the prices would be one
  shilling per litre or 320.000 a year and the
  attached waste water fee would be 75 of this
  amount The total water fee would be 560.000 USD
  a year.
• Nile Brewery has a free concession to pump water
  from the Nile. So the only cost associated to
  water supply is chemicals, electricity and
  maintenance which is estimated to be less than
  40.000 USD a year or less that 0,01 USD per hl.

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Agenda

• The assignment
• Methodology
• Overall Material Balance
• Process flow chart for water
• Evaluate inputs and outputs and select audit
  focus
• Waste generation causes and potential solutions
• Conclusion

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Brewhouse and Cellars

• Maybee the disposal af yeast to the drain is the
  root cause of the higher beer losses.

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Agenda

• The assignment
• Methodology
• Overall Material Balance
• Process flow chart for water
• Evaluate inputs and outputs and select audit
  focus
• Waste generation causes and potential solutions
• Conclusion

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• Theoretical potential saving is just under that 2
  m hl/year or 40 for Nile Brewery
• UN assumption of Afican breweries using 32 hl
  water per hl Beer can not be confirmed
• UN assumption of savings 20 to 50 can be
  confirmed

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