ShakesBeer

1
The Resource-Optimized Brewery
Stephen OSullivan KRONES PROCESS TECHNOLOGY
2
(No Transcript)
3
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

4

• 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)
Second largest oilfield (Kuwait)
World's largest oilfield (Ghawar S.A.)
1. Oil crisis
new discoveries
2. Oil crisis
oil production
Deep sea exploration
Source ASPO Association for the study of the
Peak Oil Gas
5

• The Overall brew house yield (OBY) of modern
  brewhouse systems are already at 98 - 99.
• Weve 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.

6
Energy Recovery and Re-use
7
Source Katechismus der Brauereipraxis
J. Dworsky, K. Lense (1926)
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

8
Energy flow in the traditional brew house (with
traditional Wort kettle Energy Recovery)
9
Traditional brew house with wort kettle Energy
Recovery

• Mill
• Mash Tun
• Lauter Tun
• Pre-Run Vessel
• Energy Storage Tank
• Vapor Condenser
• Lauter Wort Heater
• Wort Kettle
• Whirlpool
• Wort Chiller

10
Energy flow with EQUITHERM
11
EquiTherm - Equipment and technology

• Using the first stage in the wort chiller to
  recover hot water at 96C (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 (96C) and lower (76C)
  (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
12
(No Transcript)
13
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.

14
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

15
Equipment and technology

• 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

16
Figures, data and facts
Steam capacity

• 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
17
Figures, data and facts

• Savings with EquiTherm

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 Calculated Calculated Calculated
Standard brewhouse assumes Energy recovery from
Wort Boiling already in place
18
Energy Material Savings using Mashing Technology
19
Vibration Transponder Technology in Mash Tun

• Faster Mash Conversion
• Possible additional brew/day
• Dimpled Surface Jacket
• Improved Heat Transfer
• Reduced fouling
• Less CIP Rinse Water Consumption
• Optimized deaeration
• Quality

20
Saving Energy within the Wort Boiling Process
21
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
22
free DMS

• 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.

Boiling
Whirlpool
Cooling
100 ppb
Standard
Time
Energy
23
Equipment and Technology of STROMBOLI

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

• Phase 2 Pump circulation with reduced energy
  supply

• Phase 3 Natural circulation by energy supply and
  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.

24

• 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

free DMS
Boiling
Whirlpool
Cooling
100 ppb
Phase 1
Phase 2
Phase 3
Stromboli
Standard
Time
Energy
25
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
26
Energy Savings using Wort Stripping Technology
27
Wort Stripping

• 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

• Stripping is a technology combining classical
  quality with modern brewing processes

28
DMS - Indicator for the wort quality

• 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 quality
• or
• reducing the percentage of free DMS with constant
  boiling time
• With this, wort stripping allows constant boiling
  processes with different raw material qualities

Frees DMS
60 minutes boiling time
40 minutes boiling time stripping
100 µg/l
Whirlpool
Boiling
Cooling
time
Simplified display as linear function

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

29
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.

30
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 H2O
Wort
H2O
Free DMS
31
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

Wort inlet
Wort outlet
Strip gas (CO2, N2, air)
Water steam and free DMS
Strip gas, water steam and free DMS
32
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

33
Energy Material Savings in the Cold Block Area
34
Process concept High-Gravity Brewing

• Brew size 500hl

(Absolute blending factor 1,0)
High-Gravity Brewery (12 brews/d, 275 hl, 20P)
Brew size 275hl
-45
24P ? 20P ? 17P ? 11P ? 1.42 m hl VB
First dilution 1.18)
(Second dilution 1.55)
(Absolute blending factor 1.82)
35
Savings potential by high gravity in the brewhouse
500 hl cast out with 11P compares with 275 hl
with 20P
Calculation basis Krones standard brewhouse 8C
cold water temperature 80 hot water
temperature 0.09 /kWh (thermal) 0.12 /kWh
(electric) 0.10 /hl fresh water
? Total savings potential up to 400,000 per
year
? 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, )
36
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

before the CIP (contamination marked)
After a CIP time of 10 min.
37
Intelligient Pipe Fence Design in the Cellar
38
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

39
Intelligient Pipe Fence Design in the Cellar
Twin Pro

• 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

40
Material usage and water demand
Material Linear system TwinPro Saving
Pipe system m 1404 1054 25
Bends 540 352 35
Double seat valves 132 89 32
Push-out amounts Linear 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
41

• Produce the best quality
• Protect the environment
• Conserve resources

Sustainable thinking Thanks !