Documente Academic
Documente Profesional
Documente Cultură
National Conference on Thermal Energy Management in the Food & Drink Industries
By Eric Candy
Drive for Energy Efficiency Not New In short, I expect almost totally to prevent waste of steam James Watt letter to Dr Lind 1765
Past Manns Brewery Whitechapel Brewery on Site from 1808 Developed in 1880s with: Copper Pans, Copper Vapour Heat Recovery, Waste Steam from Beam Engine heating Mash Tuns By 1930s Electricity Generation with District Heating Scheme
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)
(G Harrap)
(G Harrap)
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)
(Basis for Benchmarking Fuel Ranges Not Known, probably excludes lighting) (Low end low Coal GCV, High end high Coal GCV)
(Low end low Coal GCV, High end high Coal GCV)
124 to 163 MJ/hl (Low end low Coal GCV, High end high Coal GCV)
No Process Mod Heat Recovery Preheat through Refrigeration condenser Wort cooling preheat liquor Copper Vapour
(Low end low Coal GCV, High end high Coal GCV)
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
Existing Brewery Heat Recovery Wort cooling preheat liquor Copper Vapour
Present - Benchmarking Results UK Brewing Year 1976 1999 2009 SECMJ/hl 303 232 171
(Courtesy BLRA)
Benchmarking Results
Specific Energy Consumption (SEC) kWh/hl v Implementation Effort
Vigorous Boil
(Courtesy of Steinecker)
(Courtesy of Meura)
(Courtesy of Meura)
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 Reactor
(Courtesy of Meura)
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
Pros: Energy recovery up to 25% Shorter time to reach boiling Wort heating up to 96 C Environmental impact (lower emissions) Cons: Heat inertia if production interrupted Energy losses if number of brews/day < 5 Wort buffer tank required
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
Thermocompressor
Pros: Energy recovery up to 40% Intensive but gentle boiling (max steam temp 110C) Environmental Impact (lower emissions) Cons: Losses of condensate water used for thermocompressor New PHE or EWB with higher heat transfer needed (steam max 0.4 bar, 110C) Power requirement for recirculation pump
Future 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
Future 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. DSMs enzyme Brewers Clarex removes the need for a sub-zero temperature stabilization stage. Alfa Lavals 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
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
RefrigerationintheDairy
+2C 3C +2C Regen section +74C +2C Heater +65C +11C Past. +74C +65C +69C 10C Chiller +11C 3C +2C +2C Chiller Power Compressor 2C +2C Condenser Water + Power 8C Gas Boiler80%efficient +15 32C +76C IntakeChill +5C Milk
GEA Refrigeration
RefrigerationintheDairy withheatpump
+2C 3C +2C Regen section +74C +2C +80C Heater +65C +11C Past. +74C +65C +69C 10C Chiller +11C 3C +2C +2C Chiller Power Compressor Water + Power 8C Gas Boiler80%efficient +15 32C Condenser +76C +80C Power HPCompressor +69C IntakeChill +5C Milk
+82C
2C
+2C
GEA Refrigeration
GEA Refrigeration
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
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 Carbon Footprinting
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
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 Packaging Technical Training
Inovate Product Development & Design Services Include: Product Concept Development Product Design Support Package Concept Development Package Design Support Product & Package Specification Development & Support
Inovate Logistics & Customer Service Development Services Include: Logistics System Analysis & Audit Logistics Troubleshooting Logistics System Development Customer Service Audit & Troubleshooting Innovative Customer Service Development
Inovate Safety Services Include: Safety Audits Risk Assessment Support Accident Reduction Programmes Safety Culture Development using Behavioural Approach Safety Training
Inovate Teambuilding Services Include: Enjoyable Yacht Based Teambuilding Courses Problem Solving Courses Corporate Entertainment Pampered Cruises RYA Recognised Sailing School teaching RYA Shorebased and Practical Courses
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
Inovate Values: Integrity Great Customer Service High Standards, Quality Service Confidentiality Openness Good Value
Contact Details: Eric Candy MSc, BSc(Hons), CEng, CSci, CEnv, CMIOSH, FIChemE, DMS, MBrew St Johns Innovation Centre, Cowley Road, Cambridge CB4 0WS Mobile: +44 (0)7812 333143 Telephone: +44 (0)1223 420252 Fax: +44 (0)1223 420844 E mail: ericcandy@inovate.co.uk