Documente Academic
Documente Profesional
Documente Cultură
WP2
Technical Potential for Polygeneration
in the
Food Processing Industry
Contents
1
Introduction........................................................................................................... 4
1.1 Definition of Polygeneration ...................................................................4
1.2 Definition of Food Sectors ......................................................................4
Current On-Site Energy Production in the Food and drink Industry .................... 7
APPENDIX:
I
II
III
IV
V
VI
VII
Abbreviations
CHP
CIP
Cleaning in Place
COP
Coefficient of Performance
COD
MW
Megawatt
kW
Kilowatt
VS
ORC
Introduction
The overall aim with WP2 of the OPTIPOLYGEN project is to investigate and
perform a first estimation of the general potential for polygeneration in the food
industry in the EU-15 countries of Europe.
1.1
Definition of polygeneration
Polygeneration is the use of multiple primary energy inputs to create multiple energy
outputs.
The term primary energy includes fossil fuels, biofuels, renewable energy sources,
etc. Energy output means the different forms of energy which are useful in an activity.
In the case of the food industry this could mean electricity, and heat in various
temperature levels i.e. steam, hot water, chilling mediums etc. Other useful products,
which might come out from a polygeneration process like e.g. compost fibers will be,
treated as secondary by-products of polygeneration.
1.2
In order to facilitate these estimations for the whole food industry, investigations of
the general processes utilised in the food processing and the energy requirements
(thermal and electrical) for these industries were undertaken.
In order to make this investigation possible the food processing industry was divided
into 7 main sectors covering different kinds of food products and each industry sector
was investigated separately.
The seven food sectors are:
I.
II.
III.
IV.
V.
VI.
VII.
In this report general results and findings of the whole WP2 are described and
discussed. The details on the processes and in detailed results as well as estimations
done for the evaluations are described in the APPENDIX I VII for each food sector
respectively.
Process descriptions
In general, almost all food processing requires both electric power as well as heat for
some kind of thermal processing. Electric power is required for mechanical
processing such as pumping, ventilating, mixing and conveying etc., but a great part is
also used for cooling by mechanical compression coolers.
The required thermal processing comprises both high temperatures processing such as
pasteurisation, cooking and evaporation as well as low temperature processing such as
freezing and cooling. In Table 1 the most common thermal processes are listed and
indicated in which food sector they are predominating.
The detailed descriptions of processes and products are further described and
explained in the APPENDIX I VII for each food sector.
Table 1: Summary of some of the most common thermal processes used in the food
processing industry, indicated for each food sector
Thermal
Process
Cooling,
chilling
Freezing
Blanching
Cooking,
boiling, frying
Degumming
Roasting
Pasteurisation
Bleaching
Deodorization
CIP
Baking
Distillation,
Evaporation
Proofing
Defrosting
Freeze storage
Cooled storage
Air condition
Temp
Food Sector
I
II III
IV
VI
VII
4 to 8C
-15 to -40C
80 C
90 to 150C or
100 to 300C
100 C
X
X
X
X
X
X
150 C
180 270 C
> 50C
300 to 400 C
> 100 C
40C
20 to 40 C
-18 to -40C
4 to 8 C
10 to 20 C
X
X
X
X
X
X
X
X
X
X
X
X
X
In order to be able to estimate the total potential for polygeneration, the amount and
type of energy required for the food processing has to be known or qualitatively
approximated. Therefore, a significant part of the work within WP2 has been to
determine and identify the specific energy requirements for the most common
products in each food sector. By determine the specific energy requirements i.e.
thermal and electric energy required per tonne food produced or processed, the energy
requirements for the whole EU-15 can be calculated from available statistical data of
food produced.
The specific electric power and thermal energy required for producing or processing
one tonne of food product in respective food sector are listed in Table 2.
The results from the collections of the data showed that even for the same food
product, great variations in the specific energy requirements can be expected (see
Table 2). The reason is that the energy demand of each process depends on the design,
technology and also scale of the plants investigated. In some cases several products
are produced in the same plant and thereby the specific energy for one product will
also depend on the amount of the other products processed or produced in the plant.
Therefore, to keep the number of possible variations on a reasonable level, average
values were derived from these data and used for the subsequent estimations of the
polygeneration potentials.
The calculations and origin of the data in Table 2 are descried in detail in the
APPENDIX I-VII for respective food sector.
Table 2: Summary of specific energy needs per tone food produced or processed in
each food sector
Food
Sector
Product
Electricity / tonne
product
Fish
Meet1
II
III
VI
VII
IV
Beer
Spirits
Juice, etc
0 0.97
0 1.52
0 - 0.80
0.60 0.97
MWh/ tonne food product
0.3 0.9
0.3 0.9
1.22
0.69
0.64
1.02
0.73
0.71
1.51
0.87
0.12
0.14
0.2 - 0.87
5.05
0.26
0.055
0.2 0.6
0.14 0.2
0.3 0.4
0.45 0.6
0.0552
0.16
0.09
0.09
0.13
0.10
0.11
0.16
0.29
0.90
0.43
0.14
0.5 - 1.9
0.56
0.41
0.128
1.3 - 1.2
0.98 1.9
2 5.7
0.5 - 0.9
0.1282
kWh/ hl
53.6
13.4
302 kWh/hl pure alcohol 2 kWh/hl pure alcohol
36.4
7.3
Several factors are important the most suitable energy solution has to be chosen for a
food processing plant. Not only is the nature of the processes but also the operating
environment of a food factory a major factor. These local factors could be local price
of fuel, energy taxes, distance to grids, possibility to sell and buy waste energy or
excess electricity to the grid or neighbour industries, etc.
The performed investigation reveals that already several food industries have
implemented combined heat and power (CHP) generation. Some of these are
described in the database at the webpage of the OPTIPOLYGEN project.
Commonly these CHP plants are based on natural gas combusted a in a gas turbine
and the exhaust heat is used for hot water and steam production.
Moreover, where the natural gas network is not available, heating needs are covered
with onsite oil or solid fuel burners, and electricity is bought from the electricity grid.
District heat, where available, is also used, especially in the Scandinavian countries.
More details on specific energy production in each food sector are described in the
Appendixs.
The current installations of CHP units in the food, beverage and tobacco industry
are discussed in more detail in section 8.4.
I
II
III
IV
V
VI
VII
kg solids
COD
100 450 kg
ton carcase
250 kg / ton
product
1000-5000
kg/ton product
23 kg /hl beer
40 kg / ton
carcase
80 130 mg /
kg cheese
The processes of each food sector were analysed and possible co- tri- and
polygeneration technologies were derived for the subsequent estimations. From this
investigation three general technologies were extracted as plausible for all the food
sectors and subsequently used as cases for calculating the theoretical technical
potential for polygeneration in the food industry in EU-15.
These chosen cases used as a comparison for all food sectors were:
1. co-generation of heat and electricity in a natural gas fired gas turbine,
2. tri-generation by using heat from the gas turbine as a source for absorption
cooling and,
3. usage of biodegradable waste streams for production of biogas which in turn is
used in the gas turbine
The following sections (see section 6.1- 6.3) explain the chosen technologies and
there limitations in terms of size and operation. These limitations were subsequently
utilised for the estimations of potentials of the whole food industry.
6.1
Cogeneration - CHP
Combined heat and power production is a standard technology in large central energy
producing plants. During recent years, new smaller scale CHP technologies has been
developed for use onsite, reducing electricity transmission losses and costs, and
giving more reliability to the electricity supply, both onsite and in the neighbourhood.
Also, environmentally harmful fuels, such as oil, have been replaced by less harmful
ones, such as natural gas or even biogas.
The feasibility of implementing onsite CHP, e.g. in food factories, depends on several
things, but often on that a sufficient heat demand can be guaranteed from the process.
Moreover, assuming that electricity can be bought from or sold to the grid with
reasonable prices, the remaining question concerning the applicability of CHP is the
durability of heat loads. Many food factories, even big ones, operate only in one, or at
most, in two shifts which results in significant fluctuation of the loads. The same
problem applies for factories using batch processing which causes short time
fluctuations in the energy demand.
However, strong daily fluctuation of loads does not necessarily have to be an obstacle
to the application of onsite CHP. Combining heat storage of suitable size with a CHP
unit makes it quite easy to cope with daily load fluctuations, even if the fluctuations
are strong and the difference between minimum and maximum load high.
The same principle can be applied in the production of cold i.e., storage of cold as
ice baths in order to deal with the daily variations in the cooling demand.
There are several CHP technologies available for onsite energy production, some of
which are standard technology (gas engines, gas turbines, steam turbines), others
more or less mature (Organic Rankine Cycle (ORC), Stirling engines, fuel cell
technologies). In most food industries, steam is used for the heat transfer and thus
9
thermal energy at more than 100 C is needed. Because of this gas turbine technology
is selected as the most feasible CHP technology in almost all the estimations
performed for the different food sectors investigated in this work.
6.2
Tri-generation is based on the use of absorption cycles to produce cool using the
exhaust heat energy from a CHP unit. The set-up of an absorption cycle depends on
the temperatures where this cycle is operating. Absorption cycles are usually based
on LiBr /water or on Ammonia/water binary mixtures. Details of these processes and
there function can be found elsewhere1 and is out of the scope of this report.
Absorption chilling and freezing equipment is commercially available in different
sizes and operational temperatures suitable for food industry applications2. Absorption
coolers have typically lower coefficient of performance (COP) compared to
compressor driven coolers (see Table 4 in section 8.2) requires more space and also
higher investment costs. On the other hand absorption coolers need much lower
maintenance and can be combined with almost any source of heat for their operation.
This fact makes this technology ideal to combine with a CHP unit producing waste
heat. The minimum commercial available absorption coolers are about 150 kW and
their COP (Coefficient of Performance) ranges from 0.6 - 1 depending on the freezing
cycle served and on the heat available.
The polygeneration benefit from applying tri-generation, is that electricity
consumption from the grid for freezing or chilling ceases and at the same time
additional electricity is efficiently co-generated by the CHP unit. Because of this a
double positive energy saving effect occurs.
6.3
Almost all food processing industries produces some kind of organic waste- or byproducts. Instead of disposal many of these materials can be used to generate thermal
energy and power at the plant by direct combustion, thermal gasification or
anaerobically treated to produce biogas.
Among these technologies anaerobic digestion of biodegradable waste from the food
industry, is the most flexible option of utilising food industry process wastes or low
value by-products. The resulting biogas, rich with methane, can be combusted in gas
burners and utilised as for hot water or steam production, or it can be used to run a gas
engine or turbine in a CHP applications.
1
2
10
In order to estimate the potential for polygeneration in different food sectors, the total
energy used in each food sector had to be estimated. This was mainly performed by
combining the specific energy requirements defined in section 3 with best available
statistical data for the production or processing of the each specific product. Typically
the used data for these estimations are the amounts of food products produced in the
EU-15 in combination with size and number of enterprises in each food sector.
Most of the data of produced amounts of food products were extracted from the
EUROSTAT database PRODCOM3, but also other sources have been used when
more resent and detailed data has been available elsewhere. The different data
sources and total amounts of products considered are described in detail in the
APPENDIX of respective food sector.
In order to calculate the total energy consumption in the food and drink industry in the
OPTIPOLYGEN project a number of estimations, extrapolations and averring of data
was necessary. Thus the results can only be indicative and not seen as exact figures.
Currently, there is no statistic data for exactly the same industries which are covered
by the OPTIPOLYGEN to compare to. However, the EUROSTAT database does
contain statistic data for the energy consumption in the Food, drink and tobacco
industry in each country of the EU-15. These values were thus compared with the
energy consumption calculated in the OPTIPOLYGEN project and are shown in
Figure 1 to Figure 3.
According to the EUROSTAT, the total energy consumption for the Food, drink and
tobacco industry for the EU-15 countries was 316 TWh in 2004. The calculation in
the OPTIPOLYGEN project revealed a figure of 211 TWh (Figure 1) which is lower
but in the same size range. Investigating the different countries, the correlation for
some countries such as Denmark, Finland and Germany are quite good while e.g. Italy
and the Netherlands are not so close.
EUROSTAT, http://epp.eurostat.ec.europa.eu
11
TWh
200
150
100
50
-
EU15 Swe
EUROSTAT 2004
OPTIPOLYGEN
316
211
6
4
Fin
Den
Ger
Bel
Neth
UK
Ir
Aus
Ita
Fra
Spa
Por
3
3
8
7
53
49
12
10
26
10
42
22
6
6
7
5
44
25
59
36
36
28
6
3
The energy was further compared in terms of consumption of electric power (Figure
2) and energy demand in form of heat (Figure 3). The general result is that the
calculation of the electricity consumption is closer and sometime slightly
overestimated compare to the EURSOSTAT data. The total consumption of electricity
in the food, drink and tobacco industry and the EU-15 countries is 94 TWh and
according to the OPTIPOLYGEN calculations 88 TWh.
Figure 2: Consumption of electricity in the food, drink and tobacco industry
compared to OPTIPOLYGEN calculations
100
90
TWh electricty
80
70
60
50
40
30
20
10
EUROSTAT 2004
OPTIPOLYGEN
EU15
Swe
Fin
Den
Ger
94
88
2,52
1,60
1,55
1,12
2,34
3,73
14,97 4,08
18,12 4,65
Bel
Neth
6,54
4,16
UK
Ir
12,36 1,67
7,86 3,11
Aus
1,54
2,23
Ita
Fra
Spa
Por
Gre
1,90
1,10
12
TWh
160
120
80
40
-
EU15
Swe
Fin
Den
Ger
Bel
Neth
UK
Ir
Aus
Ita
Fra
Spa
Por
EUROSTAT 2004
222
3,1
1,4
5,6
38
8,2
19
29
4,8
5,5
31
40
26
4,3
Gre
5,6
OPTIPOLYGEN
123
2,1
1,8
3,7
31
5,4
14
2,7
3,0
13
20
17
1,7
1,6
Moreover, taking into account the great number of estimations necessary for being
able to carry out the calculation of the energy demand within the OPTIPOLYGEN
project, the correlations with the EUROSTAT database has to be seen as plausible and
absolutely within the correct size range. Due to this fact the calculated values of the
polygeneration potential revealed in the following sections should be within a
plausible size range to.
The technical potential for co-, tri- and poly-generation was estimated for each of the
food sectors specified in section 1.2. The investigation comprises the technical
potential based upon estimated energy demands of the processes. No concerns were
taken to economical constrains making the implementation of polygeneration less
beneficial. Economical restrictions are by far much more complex than the technical
and do also vary considerably by regional and political differences which considering
the resources needed not possible to take into account for in this project.
Attempts were made to account for already implemented CHP and polygeneration in
the food industry when calculating the potentials for new implementation. However,
no statistical data was found covering this type of information from the food industry
and the collection of own data would be a work far beyond the resources available for
this project. The calculated potentials are thus the maximum technical potential
including already implemented CHP and polygeneration in the food processing
industry.
13
8.1
Due to the lack of detailed data for energy use, size and number of food processing
plants in whole Europe, two basic types of methodologies were developed for the
estimations.
The first of the methodologies is based on the assumption that a certain production
volume per employee can be estimated and thereby the number of plants (enterprises)
having production capacities above a certain threshold value is used in the
calculations of the total polygeneration potential. The number of employees was
collected from EUROSTAT using the NACE code separation.
The second methodology is based upon detailed data from at least one country where
the number and production distribution between existing food processing plants is
known. By using this detailed information from one country, the production
distribution in other EU-15 countries is estimated.
In some food sectors a hybrid methodology between the two methodologies described
above had to be developed in order to get useful results. For more detailed
descriptions please see APPENDIX I to VII.
Based on these data, estimations of the total energy requirements (electrical and
thermal) can be calculated. However, due to the fact that some of the food producing
industry consist of very small units there certain technological limitation to the
amount of the used that can be replaced or enhanced by polygeneration at the plants.
Thus threshold values had to be determined for each food product and technology in
order to get a estimations closer to the true value.
The determination of these thresholds values as well as the potentials for
polygeneration is explained in next section.
8.2
Calculation of threshold values used for the estimations of co-, tri- and
poly-generation
14
These values result in the minimum onsite heat load requirement of 450 MWh/year,
rounded up to 500 MWh/year in the calculations. The same heat to electricity ratio
(2.5) is used regardless of CHP technology or unit size.
Threshold estimation for tri-generation:
The smallest commercially available absorption cooler has presently 100 kW cooling
capacity . This means about 125 kW thermal driving force in the deep freezing
applications (COP 0.8) and about 85 kW in the refrigeration applications (around +4
C; COP 1.2).
These are both higher than the thermal output of the smallest available micro turbine,
which means that the minimum capacity of the absorption cooler is the technical
threshold in the combination of CHP and absorption cooling. This can be used
directly if the capacity of the cooling equipment, or the overall cooling load, at a site
is known. In the polygeneration potential calculations it is assumed, however, that
only the overall electricity load of a food factory is known and the threshold load is
calculated using the following assumptions:
Table 4 : Typical technical data used for the calculating cooling energy
Cooling temperature
+ 4 C
- 30 C
2.5
1.2
1.2
0.8
15
Table 5 : Used threshold values for the potential evaluation in the different food
sectors
Sect. Food Product
Fish1
Meet1
III
Cotton seed
Ground nut
Rape-seed
Safflower
Sesame
Sunflower
Soybean
Corn
Bakery
Cereals
Coffee
Sugar
Chocolate3
Milk
Cheese
Butter
Milk powder
Ice Cream
Cultured products
VI
VII
IV
Beer
Spirits
Juice
II
CoTriBiogas
generation
generation production
Tonnes processed /year
4 000
989
10 417
1 875
1 552
35 519
Tonnes product/year
3 000
1 700
n.a.
Solid
3 000
n.a.
Biomass
2 500
n.a.
2 500
n.a.
17 000
3 000
n.a.
Biogas
2 500
n.a.
1 100
n.a.
1 640
1 640
283 843
8 857
3 490
577 778
n.a.
n.a.
19 923
2 708
7882
n.a.
400 000
n.a.
6 410
82 286
18 581
n.a.
11 719
32 727
n.a.
1 250
6 000
32 581
1 531
14 619
n.a
429
10 286
n.a.
1 875
3 333
n,a
11 538
32 727
n.a.
hl product / year
22 721
27 975
217 391
n.a.
71 429
4 972
hl pure
hl pure
alcohol
alcohol
15 790
n.v.
400 000
Number of employees in the factory
17
20
96
16
In this work it is therefore used an average value of 400 Nm3/ton of volatile solids
(VS) or 0.35 Nm3/ton per kg COD for the calculations which in turn give threshold
values of 190 ton VS/year or 215 kg COD/year respectively.
The amount of solid waste or COD per kg of produced food product depends on
which food product that is investigated (see also Table 3) and thereby the threshold
values for biogas production for each food product.
In Table 5 the threshold values used for the estimations of co- ,tri- or poly-generation
(biogas production) for each food sector and food product are listed in values of
produced amounts.
8.3
By using the methodologies and technologies described above the technical potentials
for co- tri- and poly-generation were calculated and the results summarised in Table 6
and the figures 1 to 5.
The results of the calculations are shown in total electrical energy per year, which can
be generated if the existing methodologies separated by co- or tri- generation or
energy production of waste streams (biogas or solid biomass waste CHP combustion)
take place in the EU-15 countries, split by food sector.
In the food sector III, large quantities of solid biomass residues occurs which are not
suitable for biogas production but could instead be used as a solid biomass fuel in
CHP unit (steam turbine). Thus for this food sector a fourth methodology is added.
By summing up the calculated values for all four methodologies (co-, tri- and waste
stream utilisation) the total polygeneration potentials are revealed.
The main part of the total polygeneration potential is made up from co-generation
(56%). The possibility for co-generation is also the basic for the other methods and
technologies are more or less add-ons to this type of technology.
Moreover, the results in Table 6 and Figure 5 show that the single largest technical
potential for polygeneration is found in the meat industry (food sector I). About half
of this potential is by co-generation and the other half from tri-generation by
absorption cooling. The beer and the sugar industry do also show quite high potentials
for especially co-generation. In the cereal industry a remarkable potential for
utilisation of waste streams for biogas production is revealed.
By instead looking at the technical potentials divided by each country in the EU-15
(Figure 6), the largest potentials for polygeneration in the food sector are found in the
highly populated countries Germany, France, Spain , UK and Italy.
Digging further down in detail the distribution of the technical potential for each food
product per methodology (co-,tri- or waste product utilisation) are shown in Figure 7
to Figure 9. The results show that the potential for co-generation is dominated from
meat and beer industry (Figure 7), the potential for tri-generation is to a large part
made by the meat industry (Figure 8) and the utilisation of waste streams for biogas
production by the cereal industry (Figure 9).
17
Furthermore, by further looking at Figure 5- Figure 9 the interested reader can get an
idea which industry and food products has the highest potential for either cogeneration, tri-generation or waste product utilisation in a specific EU-15 country.
Table 6 : Technical polygeneration potential in food industry of the EU-15
CoTrigeneration generation
Waste stream
utilisation
(gas
turbine)
Waste
stream for
biogas prod
(gas turbine)
(gas turbine +
abs
cooler/freezer)
Tot
Waste
stream as
solid
biomass
fuel (CHP)
GWhel
I
II
III
IV
VI
Fish
Meet
Cooked food &
vegetables
Cotton seed
Ground nut
Rape-seed
Saf & Sun
flower
Sesame
Soya been
Olive oil
Beer
Spirits
Juice
744
9 701
974
638
8 327
1 635
207
1 029
111
n.a.
n.a.
n.a.
1 588
19 057
2 720
0
7
620
354
n.a.
n.a.
n.a.
n.a.
0
0
23
15
0
2
193
97
0
9
836
466
0
688
584
6 311
3 135
1 743
n.a.
n.a.
n.a.
1 545
n.a.
n.v.
0
18
0
1 485
1 064
41
0
185
183
n.a.
n.a.
n.a.
891
766
9 341
4 199
1 784
Corn
Bakery
Cereals
Coffee
Tea
Sugar
Chocolate
2 900
727
0
376
n.a.
3 463
115
0
1 117
0
95
n.a.
47
681
0
9 206
0
n.a.
2 473
37
n.v.
n.v.
n.v.
n.v.
n.v.
n.a.
n.a.
3 580
1 844
9 206
471
5 936
199
VII
Consumers
1 434
514
0
n.a.
1 948
milk
Cheese
3 047
635
11
n.a.
3 692
Butter
614
64
0
n.a.
678
Milk powder &
2 405
100
0
n.a.
2 505
Cond milk
Ice Cream
611
478
0
n.a.
1 089
Cultivated
230
81
0
n.a.
311
products
Sum EU-15
40 784
15 276
16 399
660 73 119
Explanations: n.a. not applicable according to estimation calculations, n.v.no
values available
18
The detailed data of all calculations and background analyses in the different food
sectors are revealed in the APENDIX I-VII. It should be noticed that in some of these
reports the values for tri-generation potentials also includes co-generation. However,
in this summary report the values for these two technologies are reported separated.
Figure 4 : Technical polygeneration potential by food sector
Total polygeneration potential in EU 15: 73,1 TWhel
25.000
Solid biomass combustion
Biogas production
20.000
GWhel
Tri-generation
Co-generation
15.000
10.000
5.000
Fish
Meat
Cooked f &
Cotton
GroundRape-seed
Saf & sunSesame
Soyabean
Olive oil
Beer
Spirits
Juice
Corn
Bakery
Cereals
Coffee
Tea
Sugar
Chocolate
Consumers
Cheese
Butter
Powder &
IceCream
Yoghurt
II
III
IV
VI
VII
16.000
Biogas production
14.000
Trigeneration
GWhel
12.000
Cogeneration
10.000
8.000
6.000
4.000
2.000
Swe Fin Den Ger
UK
Ir
Aus
Ita
19
100
90
70
80%
60
50
40
40%
30
% coverage
TWh electricty
80
20
10
-
EU1
Swe Fin
5
0%
Den Ger Bel Neth Lux
UK
Ir
Aus
Ita
Fra Spa
Por
Gre
Estimated consum.
88
1,6 1,1
3,7
18,1 4,6
4,2
0,1
7,9
1,1
Pot. Polygeneration
73
1,3 0,9
2,7
15,3 3,4
3,6
0,0
8,4
1,6 1,7
0,9
% covered by poly
1,1
83% 82% 82% 72% 84% 73% 87% 41% 106 50% 74% 70% 94% 84% 76% 79%
20
Meat
Fish
Cooked food &vegetables
Consumer milk
Cheese
Butter
Milk powder & Cond Milk
Ice Cream
Cultured Products
Cereals
Bakery
Coffee
Corn
Beer
Spirits
Juice
Cotton seed
Ground-nut
Rape-seed
Saf- & Sun-flower
Sesame
Soyabean
Virgin olive oil and refined oilve oil
Sugar
Chokolat
Meat
24%
Spirits
8%
Beer
15%
Cheese
7%
Corn
7%
100%
80%
60%
40%
20%
0%
Swe
Fin
Den Ger
UK
Ir
Aus
Ita
Fra
Spa Por
Gre
21
Bakery
7%
Beer
10%
Cheese
4%
Meat
55%
Cooked food
&vegetables
Fish
11%
4%
100%
80%
60%
40%
20%
0%
Swe
Fin
Den Ger
UK
Ir
Aus
Ita
Fra
Spa Por
Gre
22
Meat
Fish
Cooked food &vegetables
Consumer milk
Cheese
Butter
Milk powder & Cond Milk
Ice Cream
Cultured Products
Cereals
Bakery
Coffee
Corn
Beer
Spirits
Juice
Cotton seed
Ground-nut
Rape-seed
Saf- & Sun-flower
Sesame
Soyabean
Virgin olive oil and refined oilve oil
Sugar
Chokolat
Meat
6%
Spirits
6%
Beer
9%
Corn
4%
Cereals
56%
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
Swe
8.4
Fin
Den Ger
UK
Ir
Aus
Ita
Fra
Spa
Por
Gre
According to data collected by COGEN Europe for the year 2003, there are 595 CHP
units installed in the food, beverage and tobacco industry in EU-15 5. Together they
have a total production capacity of 3048 MWel, when running in CHP mode. The
distribution of these plants among the EU-15 countries is shown in Table 7.
The countries with the currently highest implementation and utilisation of CHP within
this industry are Spain, UK, Germany, France and the Netherlands. It is also
5
CHP Statistics in European Member States 2003 data, COGEN EUROPE 2005
23
noticeable that some countries such as Finland, Greece and Luxembourg are supposed
to have no CHP units installed. This is probably due to incomplete data as the
OPTIPOLYGEN project has identified at least one Finnish CHP unit of 4.2 MWel (see
database at www.optipolygen.org).
Table 7 : Installed CHP capacity and number of installed CHP units in the food,
beverage and tobacco industry in EU-15
Sweden
Finland
Denmark
Germany
Belgium
Netherlands
Lux
UK
Irland
Austria
Italy
France
Spain
Portugal
Greece
EU 15
Installed CHP
capacity
Number of installed
units 2003
[Mwel]
#
27
131
723
n.v.
2
24
151
n.v.
316
378
78
72
265
503
543
12
3.048
61
41
13
6
107
43
143
5
596
The data collected in the COGEN statistics is collected for the Food products,
beverages and tobacco industry and is thus not 100% comparable to the technical
potential calculated for food and drink industry in the OPTIPOLYGEN project.
However they are a good indication and thereby the total amount of produced
electricity from CHP units (running in CHP mode) are used as comparison to the
OPTIPOLYGEN values in Figure 10.
The result reveals that in 2003, 10.76 TWhel was produced from CHP-units in the
Food products, beverages and tobacco industry in EU-15. This is about of the
technical potential for co-generation estimated for the food and drink industry in the
OPTIPOLYGEN project.
24
Figure 10: Produced electric power by CHP units in the food, beverage and tobacco
industry in EU-15 (2003) compared to technical potential for CHP in the food and
drink estimated by OPTIPOLYGEN
Tot (EU-15) produced by CHP in food, drink and tobacco industry 10,76 Twhel
Tot estimated CHP potential (EU15) in food, drink industry 40,78 Twhel
(COGEN 2003)
(OPTIPOLYGEN 2004)
10,0
9,0
8,0
TWh
7,0
6,0
5,0
4,0
3,0
2,0
1,0
-
8.5
Swe
Fin
Den
Ger
Bel
Neth
UK
Ir
Aus
Ita
Fra
Spa
Por
COGEN 2003
0,0
0,5
1,7
1,5
1,9
0,4
0,3
0,6
1,4
2,4
0,03
Gre
OPTIPOLYGEN
0,7
0,5
1,4
8,9
2,2
2,3
4,7
0,9
1,0
4,5
7,5
5,1
0,7
0,4
By using these figures the total results for the potential CO2 savings by
polygeneration in the food industry in the EU-15 amounts to 20 839 ktonnes CO2/
year.
The allocation of these savings among the different polygeneration technologies
methodologies is shown in Figure 6 and on the EU-15 countries in Figure 7.
25
Co-generation
132
3.443
Tri-generation
Waste stream utilisation
(biogas)
10.604
5.000.000
4.500.000
ktonnes CO2/year
4.000.000
3.500.000
3.000.000
Biogas production
Trigeneration
Cogeneration
2.500.000
2.000.000
1.500.000
1.000.000
500.000
-
The revealed figures for saving CO2 emissions by the technical potential in the food
industry are calculated without withdrawing the current installed CHP discussed in
section 8.4. This due to that the data for current installed CHP also contain the
tobacco industry while the estimated technical potentials in the OPTIPOLYGEN
project only consider the food processing industry.
However, if these values should be used, about of the technical potential from cogeneration is already implemented. Applying this assumption the total actual potential
should be reduced to about 18 188 ktonnes CO2/year instead.
26
The technical polygeneration potential for the food industry has been calculated for
the EU-15 countries. The performed calculations were based on data for energy
consumption, existing in the literature as well as on information collected via energy
audits performed by the partners of the project. Data from EUROSTAT, PRODCOM ,
as well as food sector specific data bases were used as sources to gather data on the
size distribution of food processing plants as well as produced amounts of food
products in each EU 15 country. Despite these public available data, several
assumptions and estimations have been necessary in order to get useful results.
The plausibility of the data has been tested by comparing energy demands calculated
in the OPTIPOLYGEN project with EUROSTAT data on the actual consumption of
heat and electricity in the industry sector food, beverage and tobacco. The results
revealed that the despite the insecurity in all the estimations that had to performed the
OPTIPOLYGEN values for the energy demand in the food processing industry are
feasible and in the correct size range. Thereby the calculated technical potentials for
polygeneration based upon the calculated energy demands of each food sector should
also be feasible.
The calculated results reveal a total technical polygeneration potential (co- + trigeneration and full utilisation of biomass waste stream) for all EU-15 countries to
amount to about 73 TWhel/year, subsequently resulting in a potential CO2 emission
saving of about 20 millions tonnes CO2/ year.
More than half of the technical potential for polygeneration in the food industry is
identified to be co-generation. By comparing with available data of installed
capacities of CHP in the food, beverage and tobacco industry it can be assumed that
up to of the calculated technical potential is already installed. However due to the
different bases for the data calculated in the OPTIPOLYGEN project and the
available data in the literature, this comparison should only be used indicative.
Though, if used as valid values for the food processing industry it would reduce the
additional total technical polygeneration potential to about 63 TWhel and
subsequently the additional potential CO2 emission savings by polygeneration to
about 18 million tonnes CO2/year.
The high potential of co-generation is followed by tri-generation and the technical
potential for converting waste streams into biogas which is subsequently used in a
onsite CHP application. Both these technologies revealed technical potentials of about
16 TWhel each.
No data for the actual total usage of these technologies in the food industry was found
in the literature, although examples of both technologies implemented can be found.
The fourth technology investigated was the utilisation of solid waste used as solid
biomass fuel in a CHP plant using a steam turbine cycle. This technology was
however only found feasible for the food sector III and was estimated to be around 0,6
TWhel for the whole EU-15.
The differences between the different food sectors in terms of applicable
polygeneration technologies is further shown by that e.g. in the food sector III trigeneration is not at all technically plausible while in food sector I and II, which both
27
28
OPTIPOLYGEN
OPTIPOLYGEN
OPTimum Integration of POLYGENeration in the food industry
WP2
Potential for Polygeneration in the
Fish & meat Industry
Author:
Dr Ing Athanasios Katsanevakis
OPTIPOLYGEN
Table of contents
TABLE OF CONTENTS ..................................................................................................2
1
INTRODUCTION.....................................................................................................4
2.1
2.2
GENERAL .................................................................................................................................................... 4
TERMS AND DEFINITIONS ........................................................................................................................... 4
INTRODUCTION ......................................................................................................................................... 11
CHARACTERISTICS OF ON-SITE POWER GENERATION PLANTS.................................................................... 11
CHP.......................................................................................................................................................... 14
TRIGENERATION ....................................................................................................................................... 14
SOLID WASTES AND BY-PRODUCTS USE. ................................................................................................... 15
METHODOLOGY. ....................................................................................................................................... 17
FISH AND MEAT/POULTRY PRODUCTION IN EUROPE .................................................................................. 20
RESULTS ................................................................................................................................................... 24
CONCLUSIONS....................................................................................................29
REFERENCES......................................................................................................30
OPTIPOLYGEN
1 Executive Summary
On-site power generation in conjunction with the processes involved in the food industry
may form an efficient alternative and a step towards sustainability. It is however important to estimate the real potential of on-site power generation methods which are currently available in the European Food industry sector.
A part of this sector is the Fish and meat poultry processing industry.
Polygeneration potential in the fish and meat processing industry has been calculated
for the Eur-15 countries.
Calculations were based on data for energy consumption, which exist in the open literature and collected via energy audits performed by the authors. The data from Eurostat
for fish and meat/poultry production all over Europe were also used together with estimations for the size of the processing plants located in every country.
Results show that polygeneration potential for all Eur-15 countries for this specific
industry sector reach the 25.000 GWh el /year resulting in CO2 emission savings of
over 11 million tones CO2 /year.
The higher potential about 19000 GWh/year- comes from combination of cogeneration+trigeneration using absorption freezing or chilling cycles followed by cogeneration
and biogas generation using anaerobic digestion of the solid residues of the processes.
The reason for this is that a significant amount of thermal energy consumed in the fish
and meat-processing industry concerns freezing and chilling loads at temperatures
down to 20C. These loads operate more smoothly over the day and the year creating
opportunities for base load efficient use of the heat co-generated by the CHP units.
Biogas generation potential is limited mainly because of the size of the food plants
there is a need for significant amount of wastes for a biogas installation to be viableand the limited generation of by-products as most of them is used as lower value products for non-human consumption purposes in the animal by-products industry. Depending on the legislation and the current industrial practice in this sector biogas potential
generation can be doubled in the future i.e. the electricity, which can come from biogas,
may increase by 100%.
OPTIPOLYGEN
2 Introduction
2.1 General
The aim of this report is to describe the general processes in the fish and meat processing industry, focusing on energy usage (thermal and electrical) and the type of processes using this energy, with the goal to estimate the total polygeneration potential in
the fish and meat processing industry in Europe.
OPTIPOLYGEN
3 Process description
3.1 The fish industry
3.1.1 Process flow chart in the fish industry
Fish industry processes can be generally represented in the following simple process
chart.
The raw material for the fish industry is fish or other seafood coming from open sea fishing or fish farming. Raw fish is either send directly to the sales or to the fish processing
plants. Big fish is sometimes pre-processed and fish portions are then send to the
processing plants. There raw fish is usually frozen and stored. Freezing usually takes
place at around20oC and refrigeration cycles driven by compressors are mainly used.
Part of this frozen fish is directly sold as frozen fish and part is being defrost and then
processed. Defrosting is usually take place in water tanks at about 20oC.
The defrost fish is usually processed (slicing, de-heading, de-skinning, etc) and during
this processing some solid residues come out tails, heads etc-. As already mentioned
this process step can take place before the initial freezing of the fish.
Resulting fish is either frozen again and send to the sales or is being further processed,
usually cooked and canned before send to the sales. Cooking may take place at temperatures varying up to 120oC while an important part of packaging or canning is the
sterilisation process, which follows different heating and cooling curves up to 120oC.
Part of the cooked fish is frozen and stored before sold as frozen cooked food while the
rest is send to the sales.
Detailed description of the processes which take place in the whole spectrum of the fish
industry activities can be found in specialised reports e.g. [1, 2]. It has to be mentioned
that several differences exist between plants; the main processes however remain the
same. Moreover it should be mentioned that not all the processes take place in a single
plant. There are plants where all the processes operate under a single roof while others
where frozen raw fish is stored and only part of the described processes take place e.g.
canning only.
OPTIPOLYGEN
sales
freezing
Fish processing
industry
Defrosting/
de-icing
solid
residues
Preprocessing
(de-heading,
slicing etc)
BIOGAS
packaging
-freezing storage
waste
water+
solids
cookingcanning
storage selling
OPTIPOLYGEN
Table 1. Energy demand and by-product ranges in the fish industry processes.
In the table the potential for biogas produced via anaerobic digestion of the process
solid by-products is also shown. Biogas is the main renewable energy source, which
can come out from the fish processing industry. Utilisation of fish processing byproducts for biogas production might be of importance for potential polygeneration
schemes in the fish industry. Values used in the table come out from own data recovered from gasability tests [3], while the range came from oral communication with biogas plant manufacturers. In every case where an application is sought there is a need
for analysis of the solid residues. The above-mentioned values can however be used
for the planning purposes of this work.
OPTIPOLYGEN
OPTIPOLYGEN
cover the freezing/chilling/cooling loads. It has been reported that about 50% of the
electricity demand is devoted to freezing /chilling needs, [6].
Living animals
or poultry from
animal farms
or poultries
meat processing
industry
Slaughtering
solid
residue
sales
Freezing
BIOGAS/incineration
preproces
sing
waste
water+
solids
cookingcanning
defrosting
packaging
-freezing storage
storage selling
OPTIPOLYGEN
The energy consumed in each process varies considerably depending on the equipment and the details of the process used, on the specific nature of the product and on
several other parameters. It is not the purpose of this report to describe the details of
the various specific processes which can be met in the meat and poultry industry. For
every process however there is some energy demand. The following table shows the
typical ranges of these energy needs.
Table 2. Typical ranges of energy demand and wastes in the meat processing industry.
In the table the potential for biogas produced via anaerobic digestion of the process
solid wastes and water effluent is also shown. Biogas is the main renewable energy
source which can result from the meat and poultry processing industry. Because of
this it is important to be incorporated into the potential polygeneration schemes.
Values used in the table resulted from oral communication with biogas plant manufacturers. In every case there is a need for analysis of the solid residues, if an application
is sought. The above-mentioned values can however be used for the planning purposes
of this work.
10
OPTIPOLYGEN
11
OPTIPOLYGEN
Table 3. Parameter ranges for on-site power units used in this report.
Electric efficiency is the ratio of the electrical energy-or power- produced over the total
fuel power input to the CHP unit i.e
nel
= Pel/Pfuel
(1)
Total efficiency of the CHP unit is the ratio of the summary of the electrical energy-or
power- and useful thermal energy or power- produced over the total fuel power input
to the CHP unit i.e.
ntotal = (Pel+Ptherm)/Pfuel
(2)
Thermal efficiency of a CHP unit is derived from eq. (1) and (2) and is
ntherm = ntotal nel
(3)
It is obvious that electrical efficiency depends most of the times solely on the CHP
equipment characteristics while thermal efficiency depends strongly and in all cases on
the way the heat generated by the CHP unit is used in the plant. From this point of view
the whole plant is a part of the CHP unit and participates in the calculation of the thermal efficiency of the CHP unit.
CHP size is usually ranged according to its electrical generation capacity. The typical
applications in the fish and meat industry sector can reach several MWs of installed
power capacity. Although there are now days equipment available at the mini and micro
range they are hardly used in industrial applications; most of the plants where on-site
power has been applied concern much bigger units at the range of MWs. This can be
partially assigned to the relative size of the expected profits compared to the size of the
plants and the IRR achieved by this kind of investments.
12
OPTIPOLYGEN
13
OPTIPOLYGEN
6.1 CHP
As already mentioned applicability of CHP depends among other parameters on the capability to use efficiently the heat cogenerated with the power. This is not a straightforward task especially in cases where various temperature levels of heat are needed by
the process. The optimum CHP fit to the process needs becomes more difficult when
batch operation is used this being quite often in the fish and meat processing industry.
For the purposes of this report the following parameters shown in table 4 have been
considered to be valid for CHP to be viable in a plant.
In several steps of the fish and meat processing industry significant amount of heat is
needed. Heat is normally needed at temperatures ranging from 40oC up to 150oC. For
simplicity CHP units generating heat at high temperatures have been considered for potential capacity calculations. These are turbine based CHP sets.
Other important parameter affecting the applicability of CHP is the total yearly operating
hours. Usually these should exceed 4000 hours/year for a CHP plant to be viable.
It has been already mentioned that efficient use of the heat co generated in a CHP unit
defines the applicability of CHP. If micro CHP is used then the total plant requirements
should exceed 1,5 GWh /year based on the minimum yearly operating hours of the
CHP unit and the minimum size of unit available in the market.
6.2 Trigeneration
Trigeneration is based on the use of absorption cycles to produce cool. The set-up of
an absorption cycle depends on the temperatures where this cycle is operating. Absorption cycles are usually based on LiBr /water or on Ammonia/water binary mixtures.
Details of these processes can be found elsewhere, e.g. [9]. At this stage it is of interest
that there is available in the market absorption chilling equipment suitable for food industry applications i.e. suitable to generate cool down to 40oC, e.g. [10].
14
OPTIPOLYGEN
The minimum size of this equipment is about 150 kW and their COP ranges from 0,6-1
depending on the freezing cycle served and on the local conditions. The important fact
when trigeneration is applied efficiently is that electricity consumption virtually ceases as
far as freezing or chilling concerns. Moreover additional electricity is efficiently cogenerated by the CHP unit. Because of this a double positive effect exists:
Not only grid electricity consumption produced with low efficiency (40-50%) stops, but
also electricity generated with efficiencies up to 85% is produced. In contrast with a
typical CHP only efficient electricity is generated and sent to the grid.
15
OPTIPOLYGEN
16
OPTIPOLYGEN
7 Technical Potential of on site power generation & emission savings by polygeneration in the fish and
meat/poultry industry in Europe
7.1 Methodology.
7.1.1 General
The goal of this report is to determine within accuracy needed for strategic planning the
technical potential of polygeneration CHP, trigeneration, RES- in the meat and fish
processing industry within the wider frame of the European food industry. Studies for
the other food sectors are undertaken by the other partners of the OPTIPOLYGEN project.
The results of the calculations will be the total electrical energy per year, which can be
generated if fully use of the existing methodologies for cogeneration, trigeneration and
polygeneration take place in the European food industry split by country.
This part of the work is focused in the fish and meat food products sector i.e. the industrial plants whose products fall within NACE 15.11, 15.12, 15.13, 15.20 codes.
The countries where the calculations are focused include the 15 member states of the
EU until summer 2004.
On top of the total potential for electricity generation, the environmental impact of polygeneration potential will be quantified in terms of annual CO2 savings.
7.1.2 Model development.
To achieve the goal i.e. to estimate the polygeneration potential several assumptions
should be made and data should be used. Then by performing suitable calculations the
goal can be achieved. The whole set of assumptions; data and calculations are the
parts of the calculation model. These parts are described below.
7.1.3 Assumptions
The assumptions, which were used, include:
1. Electricity generation potential in the case of cogeneration or trigeneration application depends on the amount of useful heat,
which can be absorbed in the process served by the CHP unit.
This means that dumping or spoiling the heat co-generated is not
accepted and electricity can be co-generated only as a byproduct when useful heat is demanded.
2. It has been assumed that as far as the total yearly operating
hours of the CHP or trigeneration unit exceed 4000 hours per
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OPTIPOLYGEN
[ kWhel]
(4)
(5)
(6)
Biogas = Msolids*%DS%VS*580*6
[kWh]
Msolids = Total tones of product *specific solid waste generated by the process
(7)
(8)
The data used in the calculations are summarised in the following table.
18
OPTIPOLYGEN
Data in the above table show a significant improvement of the CO2 emission savings
when electricity is trigenerated. This comes out from the fact that when electricity is trigenerated a double benefit comes out. Electricity spent for compressors ceases i.e.
there is reduction of the electricity demand from the grid and additional efficient electricity is trigenerated and sent into the grid i.e. additional grid electricity from the grid is replaced. By using the values shown in the table for grid transmission losses and for CHP
total cycle efficiencies etc, the values of CO2 savings can be calculated.
The specific energy demand and solid waste generation of the processes in the fish and
meat processing industry, which have been used, for the calculations are shown in the
next tables.
Table 6 Specific process energy need and solid generation used in the calculations fish industry-
19
OPTIPOLYGEN
Table 7 Specific process energy need and solid generation used in the calculations meat industry-.
20
OPTIPOLYGEN
Fish and meat-poultry production and processing concern the NACE codes 15.11,
15.12, 15.13, 15.20. The investigation of the sector data needed for the purposes of
this report were done using the Eurostat database for the year 2003, [11].
7.2.1 Fisheries production data
The following fig.3 shows the total fisheries production for all the Eur-15 countries in
2003. Numeric data can be found in the Appendix.
fisheries production in Europe
tonnes/year -2003-
1.400.000
1.200.000
1.000.000
800.000
600.000
400.000
200.000
0
be
dk
Ger
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Based on Eurostat data for Spain, [11], and from other sources, [1], the total fisheries
production was split into 4 main categories in conjunction with the processes presented
in fig.1.
These categories include
-raw fish used for human food without processing fresh fish -,
-raw fish used for human food processed via processes 1, 3 and 5 frozen fish-raw fish used for human food are processed via processes 1,2,3, 4-cooked or canned
fish-raw fish used for human food processed via processes 1,2,3,4,5 cooked or canned
fish frozen ater cookingAlthough different portions of fisheries production follow one of the above routes in each
European country, because of lack of data the following percentages were used for
every eur-15 country. In case that data would be available for each country it is easy to
repeat the analysis. The figures used for the analysis are:
-35% of the raw fish is consumed without processing as fresh fish.
-25% of the raw fish is consumed as frozen
-30% of the raw fish is consumed as cooked/canned
-10% of the raw fish is consumed as frozen cooked fish.
Based on these figures the total production of each country belonging to every one of
the above routes was calculated.
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OPTIPOLYGEN
One more parameter which would affect the polygeneration potential is the part of each
country production that comes from plants whose capacity is above the determined
thresholds shown in the next table.
Table 8. Plant capacity threshold for polygeneration applications for the fish industry
In this way the plant size and the applicability of polygeneration technologies in the
specific plant are taken into account.
The data used for each country are shown in the calculation table in the appendix and
were estimated based on the relative size of each countrys total production.
7.2.2 Meat and poultry production data.
The following figure 4 shows the total meat and poultry production data for the Eur-15
countries.
Based on Eurostat data for Germany, [11], the total meat production was split into 3
main categories in conjunction with the processes presented in fig.2.
These categories include
-raw meat products used for human food coming out of the slaughteries,
-raw meat products that have been processed via processes 2 & 4
products-raw meat products that have been cooked or canned
frozen meat
Although different portions of meat production follow one of the above routes in each
European country the following percentages were used for every eur-15 country.
-100% of the meat products are coming out of the slaughter houses carcasses-.
-15% of the carcasses are processed and consumed as frozen meat products.
-30% of the carcasses is processed and consumed as cooked/canned meat products.
Based on these figures the total production of each country belonging to every one of
the above routes were calculated.
One more parameter which would affect the polygeneration potential is the part of each
country production that comes from plants whose capacity is above the determined
thresholds shown in the next table.
22
OPTIPOLYGEN
Table 9. Plant capacity thresholds for polygeneration applications used for the meat industry.
In this way the plant size and the applicability of polygeneration technologies in the
specific plant are taken into account.
The data used for each country are shown in the calculation table A.4 in the appendix
and were determined based on the relative size of each countrys total production.
meat and poultry production in Europe -200310.000.000
9.000.000
8.000.000
tonnes/year
7.000.000
6.000.000
5.000.000
4.000.000
3.000.000
2.000.000
1.000.000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
23
OPTIPOLYGEN
7.3 Results
7.3.1 Fish processing industry.
The following figure 5 shows the polygeneration potential in the fish processing industry
in Europe split by country. Model set-up and calculations have been described in
par.6.1.
Polygeneration potential in Europe-15
300000
250000
MWh el/year
200000
cogeneration
trigeneration
150000
biogas
100000
50000
0
be
dk Ger gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
206504
743868
Cogeneration
Trigeneration
Biogas production
1381625
Outcome of figures 5 & 6 is that the higher potential comes for trigeneration applications
devoted to cover chilling and freezing loads. Their potential for energy savings are far
higher than the other technologies examined.
24
OPTIPOLYGEN
tonnes CO2/year
70000
60000
cogeneration
50000
trigeneration
biogas
40000
30000
20000
10000
0
be
dk ger
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Figure 7. CO2 savings potential from polygeneration applications in the European fish industry.
Emission savings from Polygeneration in the fish industry in
Europe-15 in tonnes CO2/year
43366
193406
Cogeneration
Trigeneration
Biogas production
471468
Figure 8. Total CO2 savings potential in the European fish industry when polygeneration is applied.
25
OPTIPOLYGEN
3500000
3000000
MWhel /year
2500000
cogeneration
trigeneration
2000000
biogas
1500000
1000000
500000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
1,028,558
9,701,206
Cogeneration
Trigeneration
Biogas production
18,028,601
Figure 10. Total Polygeneration potential in the European meat & poultry processing industry split
by technology.
26
OPTIPOLYGEN
It should be noted that the calculation of the polygeneration potential concerning biogas
applications did not take into account the solids and by-products generation in the
slaughterhouses. This because it is not at the moment clear which use of these byproducts would be preferable based on the existing legislation. If total by products of
slaughterhouses would be anaerobically treated the total biogas potential would be
double.
Figures 11 & 12 show the potential CO2 savings if polygeneration potential shown in
figures 9 & 10 are to be installed in the European meat and poultry industry.
CO2 savings from polygeneration potential applications
1400000
1200000
tonnes CO2/year
1000000
800000
cogeneration
trigeneration
biogas
600000
400000
200000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Figure 11. CO2 savings due to polygeneration application in meat processing industry.
27
OPTIPOLYGEN
215,997
2,522,313
Cogeneration
Trigeneration
Biogas production
6,153,058
Figure12. Total CO2 savings potential in tones/year in the European meat processing industry
split by technology.
28
OPTIPOLYGEN
8 Conclusions
Polygeneration potential in the fish and meat processing industry has been calculated
for the Eur-15 countries.
Calculations were based on data for energy consumption, which exist in the open literature and collected via energy audits performed by the authors. The data from Eurostat
for fish and meat/poultry production all over Europe were also used together with estimations for the size of the processing plants located in every country.
Results show that polygeneration potential for all Eur-15 countries for this specific
industry sector reach the 25.000 GWh el /year resulting in CO2 emission savings of
over 11 million tones CO2 /year.
The higher potential about 19000 GWh/year- comes from cogeneration combined with
trigeneration using absorption freezing or chilling cycles followed by cogeneration and
biogas generation using anaerobic digestion of the solid residues of the processes.
The reason for this is that a significant amount of thermal energy consumed in the fish
and meat-processing industry concerns freezing and chilling loads at temperatures
down to 20C. These loads operate more smoothly over the day and the year creating
opportunities for base load efficient use of the heat co-generated by the CHP units.
Biogas generation potential is limited mainly because of the size of the food plants
there is a need of significant wastes for a biogas installation to be viable- and the limited
generation of by-products as most of them is used as lower value products for nonhuman consumption purposes in the animal by-products industry. Depending on the
legislation and the current industrial practice in this sector biogas potential generation
can be doubled in the future i.e. the electricity, which can come from biogas, may increase by 100%.
Acknoweledgments
I would like to thank all the colleagues of the Optipolygen consortium and especially
Jonas Dahl and Markku Hagstrom for useful discussions on the structure of this report.
29
OPTIPOLYGEN
9 References
[1]
United Nations Environment Programme -UNEP-Division of Technology,
Industry and Economics, Danish Environmental Protection Agency, Cleaner Production
Assessment in Fish Processing, COWI AS, Denmark.
[2]
Draft reference document on BAT in the Food, drink and Milk industries,
JRC, Seville, Spain, 2005.
[3]
Energy and Water audit in North Aegean Fish canneries, ESTIA consulting S.A. Internal report, 2003.
[4]
port, 2004.
Energy audit in AMASA Hellas S.A., ESTIA consulting S.A. Internal re-
[5]
Prefeasibility study on energy saving interventions for XIFIAS S.A., ESTIA
consulting internal report, 1999.
[6]
Reference document on BAT in the Slaughterhouses and animal byproducts industries, JRC, Sevilla, Spain, 2005.
[7]
EC 2004/8, 2004
[8]
[9]
ASHRAE handbook
[10]
www.colibri-bv.com
[11]
http://europa.eu.int/com/eurostat
30
OPTIPOLYGEN
APPENDIX
31
OPTIPOLYGEN
32
OPTIPOLYGEN
33
OPTIPOLYGEN
34
OPTIPOLYGEN
Table A.4 Meat and poultry industry data used for the calculations
ESTIA consulting & engineering S.A.
\\Pc09\c\Documents and Settings\Administrator\Desktop\ok wp2\APPENDIX I ESTIA-WP2-Fish and meat Industry.doc
35
OPTIPOLYGEN
Polygeneration and RES potential in the
Cooked food and vegetables industry
WP2-report
Markku Hagstrm
Jari Hiltunen
Juha Vanhanen
CONTENTS:
1 INTRODUCTION .............................................................................................................3
1.1 WHAT IS COOKED FOOD AND VEGETABLES?....................................................................3
1.2 INCOMPATIBLE STATISTICAL CLASSIFICATIONS .............................................................3
1.3 OVERLAPPING SECTORS IN OPTIPOLYGEN ......................................................................4
1.4 OTHER PROBLEMS IN THE ESTIMATION OF POLYGENERATION POTENTIAL ......................4
2 PROCESS DESCRIPTION ..............................................................................................5
3 ENERGY NEEDS AND PRESENT SOLUTIONS.........................................................7
4 ON-SITE ENERGY PRODUCTION IN THE COOKED FOOD AND
VEGETABLES INDUSTRY ...............................................................................................9
5 PROCESS WASTE AND BY-PRODUCTS ..................................................................10
6 POTENTIAL TECHNOLOGIES FOR ON-SITE ENERGY PRODUCTION IN
THE COOKED FOOD AND VEGETABLES INDUSTRY ...........................................12
6.1 CHP.............................................................................................................................12
6.2 BIOGAS FROM PROCESS WASTE & CHP .......................................................................13
6.3 CHP DRIVEN ABSORPTION COOLING ............................................................................14
7 COOKED FOOD AND VEGETABLES PRODUCTION IN EUROPE....................16
7.1 PRODUCTION STATISTICS .............................................................................................16
7.2 NUMBER OF ENTERPRISES ............................................................................................17
8 TECHNICAL POTENTIAL OF ON-SITE ENERGY PRODUCTION IN THE
COOKED FOOD AND VEGETABLES INDUSTRY ....................................................21
8.1 ESTIMATION METHOD ..................................................................................................21
8.2 RESULTS ......................................................................................................................22
8.3 CONCLUSIONS ..............................................................................................................25
1 Introduction
1.1 What is Cooked food and vegetables?
Food industry sector Cooked food and vegetables is a very general, large and diverse group of food
manufacturing processes. It can be considered to include production of e.g. frozen vegetable
dishes, jams and marmalades, all kind of sausages, cooked and frozen potatoes and other
vegetables, potato chips and crisps, cooked pasta products stuffed with anything edible, frozen
pasta dishes and pizzas, dishes of couscous, food preparations for infants, prepared dishes and
salads of sea food, home meal replacements (HMR-products), etc. Due to this multitude of
different production lines, a more general description and analysis is aimed at in this report.
In spite of missing data in many cases (countries and statistical food items), relatively
comprehensive overall picture of the large volume production lines could be formed. On the
other hand, many of the listed statistic items include both cooked and uncooked food. This
makes it very difficult to give well-grounded estimates on the polygeneration potential in the
Cooked food and vegetables industry as even the total production volumes in the sector are
unknown.
Another complication in the estimation of polygeneration potential is the seemingly total lack
of classification of food factories according to the size of the factory, and in particular, broken
down by the production volume size classes. This information is essential if one is to estimate
well the number of factories in which a particular technology would be feasible. However,
statistics on the number of enterprises in the whole food and drink industry broken down by
employment size classes do exist, as well as statistics on the number of enterprises in several
sub sectors. Unfortunately, sub sector Cooked food and vegetables does not exist - only sub sectors
that include appropriate products for Cooked food and vegetables, but also others.
2 Process description
Manufacturing Cooked food and vegetables involves so many different processes with different
energy needs, processing techniques and temperatures, and storage requirements that it is
virtually impossible to describe each of them in sufficient detail to allow polygeneration
potential to be estimated in the whole sector based on process details. Figure 2.1, however,
gives a simplified overall view of what happens in a food factory.
The raw materials may be received fresh, cooled, in freeze, or pre-processed and preserved. In
big food factories, producing (also) meat-containing products, animals may even be received
alive and butchered in onsite butchery. Most of the raw materials are stored for some time
before being fed into the process, each material at a suitable temperature.
Depending on the condition as-received, the raw materials need more or less pre-processing.
When in freeze, the first step is thawing which requires thermal energy to happen sufficiently
fast. Some raw materials are washed with hot water. Most other pre-processing operations cutting, slicing, grinding, mixing, etc. - are carried out with electricity driven machines. Major
portion of biodegradable wastes are produced in the pre-processing phases. According to
EUROSTAT statistics, Animal disposal unfit for human consumption, was 4,1 million tons in 2004
(18 countries of 30 giving non-zero inputs) and Vegetable by-products and waste for animal
consumption 0,8 million tons (6 countries of 30) in the whole Food and drink industry. Eleven
countries (of 30) gave zero as input to the latter category, which implies a potentially large
source of vegetable waste that could be converted into biogas and energy.
Thermal energy in the form of boiling water, steam, hot vegetable oil, radiation (heat &
microwave), etc. is used to cook the food, fully or partly food meaning here anything from
single vegetable ingredient, such as potatoes or peas, to ready-to-eat dishes, such as pizzas,
meat pies or casserole dishes.
After cooking, the products must be cooled down rapidly, to avoid microbial growth. Some
products are cooled down close to 0 C, others are frozen, mostly to 18 C. There are some
cooked food products that can be stored at room temperature after being cooked - meaning
heat processed, cooled and ready to eat - sometimes with added preservatives. These include
potato and maize crisps, jams and marmalades, canned soups, etc. Thus, the cooling and
storage needs depend heavily on the produced items. In addition, the ambient temperature
requirements at the production line depend on the materials being processed: meat-processing
takes place at about +5 C (minced meat at +2 C), while most vegetables can be processed at
about +15 C.
In addition to the actual food processing, and ambient conditions, there are several necessary
supporting processes and operations, directly coupled to the overall energy system of the food
factory, see Figure 2.1.
Biowaste
Packing waste
Materials pre-processing
Effluents
Heating processes
- melting, blanching, boiling & cooking, frying, roasting,
tempering, evaporation, drying, etc.
Cooling Processes
- cooling, chilling & freezing
Products post-processing
-packing, filling, storage under gas, etc.
Other energy
consuming
operations:
-moving
materials
-cleaning
-vacuum
generation
-compressed
air generation
-space heating
& cooling
-lighting,
ventilation,etc.
Storage
Delivery
Transportation
- wholesale
- retail
- industry
Figure 2.1 Simplified process chain of a food factory manufacturing Cooked food and vegetables.
100
Cooking,
boiling,
frying
Thermal
Cooling,
chilling
Thermal
Freezing
Thermal
Storage
Thermal
Much more constant and illustrative figures can be found, when looking at the overall energy
and electricity consumption per product ton and per employee in large, multi-line food
factories. Based on data from the environmental reports of major Finnish food factories and
interviews with representatives of those factories specific consumption figures were found or
calculated, see Table 3.2.
Table 3.2 Specific energy consumption and production volumes in Finnish food factories.
MWh/product ton
MWh/employee, year Tons/employee, year
Electricity
0,3 0,9
30 60
Total energy
0,6 1,5
70 - 100
Production
50 70
The higher end energy consumption values given in Table 3.2 may not be representative of
entire Europe: in southern countries the role of electricity is likely to be more dominant due to
less space heating loads and higher cooling loads in general. But the yearly production tons per
employee were remarkably constant in Finnish cases. This fact shall be utilized in the
estimation of polygeneration potential in Chapter 8.
10
was sold to another user. In most cases, however, the biowastes are composted or further
processed to cattle feed, etc. That is, converting biowastes into energy is not common in
Finland.
In Denmark, biowaste from food industry is in many cases transported to central biogas plants
digesting different biodegradable wastes in the same reactor.6
Teodorita Al Seadi: Danish Centralised Biogas Plants Plant Descriptions, Bioenergy Department, University of
Southern Denmark, 2000.
6
11
6.1 CHP
Combined heat and power (CHP) production is standard technology in central energy
production. During recent years, it has been applied more and more onsite and in smaller scale,
reducing electricity transmission losses and costs, and giving more reliability to the electricity
supply, both onsite and in the neighbourhood. Also, environmentally harmful fuels, such as oil,
have been replaced by less harmful ones, such as natural gas or still better, biogas. However, it
must be remembered that onsite CHP as such does not represent sustainable development,
unless overall energy consumption is reduced or CO2 emission reductions are achieved.
Feasibility of onsite CHP, for example in food factories, depends among other things - on
sufficient heat loads. Assuming that electricity can be bought from and sold into the grid with
reasonable contracts, the remaining question concerning CHP applicability is the durability of
heat loads. Many food factories, even big ones, operate only in one, or at most, in two shifts
which results in significant fluctuation of the loads. The same applies with batch processes,
both in heating and cooling ones, which are also common in the cooked food industry.
The strong daily fluctuation of loads does not necessarily have to be an obstacle to the
application of onsite CHP. Combining heat storage of suitable size with a CHP unit makes it
quite easy to cope with daily load fluctuations, even if the fluctuations are sharp and the
difference between minimum and maximum load high.
12
The same principle could be applied in the production of cold i.e., storage of cold in order to
deal with the daily variations in the need - but suitable case examples were not found. This is
the case probably because other, more convenient technologies rule the cooling technology
market.
There are several CHP technologies available for onsite energy production, some of which are
standard technology (gas engines, gas turbines, steam turbines), others more or less mature
(ORC7, Stirling engines, fuel cell technologies). In the case of cooked food industry, thermal
energy is often needed at more than 100 C. Because of this gas turbine technology is selected
as the representative of CHP technologies. Due to the development of small turbine units
(micro turbines), CHP technology has become available in smaller and smaller size class
applications, even with high temperature thermal loads. In this report, the smallest
commercially available micro turbine, 30 kWel 8, has been taken as the technical threshold.
Naturally, this threshold technology choice does not limit the technologies applied in bigger
industrial plants: standard gas and steam turbines can be applied, and even gas engines find
their application, where the high temperature thermal loads (above about 80 C) are smaller
than the lower temperature thermal loads (below 80 C). In addition, it should be emphasised
that the CHP potential estimated in this report is generally not technology dependent, except
for the vicinity of the lower limit technical threshold. Also, turbine technology has to be
assumed in cases where thermal loads require exclusively high temperatures and preheating
(with gas engines lower temperature output) cannot be applied.
Minimum peak-load hours of operation is taken to be 4000 h/year. In addition, 50 %
additional thermal load is required, due to the seasonal load variations. The ratio of thermal
energy output to the electrical energy output is approximately 2.5 for micro turbines. These
values result in the minimum onsite heat load requirement of 450 MWh/year, rounded up to
500 MWh/year in the calculations. The same heat to electricity ratio (2.5) is used regardless of
CHP technology or unit size.
7
8
13
The biogas reactor must produce as much biogas (methane) as is needed to feed the CHP unit.
The biogas yield from different waste fractions varies quite a lot, and depends also on the
anaerobic digestion process details, such as temperature, pressure, pH management, etc.
Generally, slaughter waste as well as fish waste gives higher specific biogas yields than
vegetable waste. In the polygeneration potential calculations, however, only vegetable waste is
assumed, with the following characteristics:
Biogas reactor input
Vegetable waste/product ton
Share of input that is volatile solids (VS)
Biogas yield
Biogas energy content
Vegetable waste
25 %
30 %
400 Nm3/ton of VS
6 kWh/Nm3
The amount of (vegetable) waste per product ton depends on the raw materials processed and
the applied processes. So, the actual value is very much case dependent, but the value used (25
%) serves as an approximation of the average in the cooked food industry. Demanding that a
30 kWel micro turbine can be adequately fed with the biogas results in the threshold of 1200
tons of biowaste per year and 4800 product tons per year.
14
minimum capacity of the absorption cooler is the technical threshold in the combination of
CHP and absorption cooling. This can be used directly if the capacity of the cooling
equipment, or the overall cooling load, at a site is known. In the polygeneration potential
calculations it is assumed, however, that only the overall electricity load of a food factory is
known and the threshold load is calculated using the following assumptions:
compressor cooling COP
absorption cooling COP
electricity for conventional cooling/total electricity
+ 4 C
2.5
1.2
30 %
- 30 C
1.2
0.8
50 %
On average, assuming both refrigeration and freezing loads, the threshold electricity load of a
food factory turns out to be about 600 MWhel/year (conventional electricity load before
installation of absorption cooling).
15
16
in any proportion
Dried; undried and frozen pasta and pasta products (including prepared
dishes) (excluding uncooked pasta, stuffed pasta)
INCL
Cooked or otherwise prepared couscous (including put up with meat;
vegetables and other ingredients as a complete dish of couscous)
V/EXCL
Homogenised vegetables (excluding frozen, preserved by vinegar or acetic
acid)
EXCL
Homogenised preparations of jams; fruit jellies; marmalades; fruit or nut puree
and fruit or nut pastes
INCL/EXCL Homogenised composite food preparations for infant food or dietetic
purposes p.r.s. in containers <= 250 g
INCL
Food preparations for infants; p.r.s. (excluding homogenised composite food
preparations)
INCL
Milk-based food preparations for infants
INCL
Flour-based food preparations for infants
INCL
From Table 7.1 it becomes quite clear that it is not possible to determine the amount of Cooked
food and vegetables produced in Europe on the basis of EUROSTAT data. This fact necessitates a
new perspective in the estimation of polygeneration potential in the sector Cooked food and
vegetables.
da1531
da1533
da1588
da1589
17
2200
2000
1800
number of enterprises
1600
1400
1200
1000
800
600
400
200
0
be
cz
dk
de
ee
gr
es
fr
ie
it
cy
lv
lt
lu
hu
mt
nl
at
pl
pt
si
sk
fi
se
uk
bg
ro
no
ch
al
Figure 7.1. Total number of enterprises producing items under NACE codes da1531, da1533,
da1588 and da1589, country by country; EUROSTAT data.
Also EUROSTAT data on number of enterprises broken down by employment size classes
were used in the polygeneration potential calculations, in order to make use of the technical
thresholds in different polygeneration scenarios. Figures 7.2 and 7.3 show the number of
enterprises in the applicable sub classes of da153 (=da1531+da1533) and da158
(=da1588+da1589), and in the size classes 20 employees and more. The size distribution of the
enterprises in the applicable sub classes (e.g. 1531 +1533) is assumed to be the same as that in
the mother class (153) for which statistical data exists.
18
50-249 employees
250 or more
180
160
Number of enterprises
140
120
100
80
60
40
20
0
cz
dk
de
ee
es
fr
it
cy
lv
lt
nl
at
pt
sk
bg
ro
Figure 7.2. Estimated number of enterprises in given size classes; NACE codes da1531 and
da1533; EUROSTAT data 2003.
Manufacture of other food products, incl. homogenised & dietetic food
20-49 employees
50-249 employees
250 or more
80
70
Number of enterprises
60
50
40
30
20
10
0
cz
dk
de
ee
es
fr
it
cy
lv
lt
nl
at
pt
sk
bg
ro
Figure 7.3. Estimated number of enterprises in given size classes; NACE codes da1588 and
da1589; EUROSTAT data 2003.
Knowing the approximate amount of energy used per employee and product tons per
employee (Chapter 3), these estimated numbers of enterprises in the employment size classes
were then used in the polygeneration potential calculations (Chapter 8).
19
20
Czech Republic
Denmark
Germany
Estonia
Spain
fr
it
cy
lv
lt
France
Italy
Cyprus
Latvia
Lithuania
nl Netherlands
at Austria
pt Portugal
sk Slovakia
bg Bulgaria
ro Romania
da1531
da1533
da1588
da1589
2. The number of enterprises in each European country producing these items was collected
using EUROSTAT Annual detailed enterprise statistics on manufacturing, subsections DADE and total manufacturing (NACE D)'. Data from some countries is missing and these
countries were simply excluded from the basic calculations. Given the data, they could be
easily included. Sixteen European countries (see Fig. 7.2) are thus included in the basic
estimation.
3. Typical amount of production per employee (tons/employee) and energy consumption per
employee (electricity and heat) (MWh/employee) in the cooked food factories were calculated,
using the home pages, environmental reports and representative interviews of as many
enterprises as reasonably available. The share of electricity used for cooling purposes (including
refrigeration and freezing) compared to the total electricity consumption was estimated on the
basis of similar data.
21
4. Threshold size (in number of employees) of a cooked food factory that allows a specific
technology to be applied was determined. The specific technologies, or polygeneration
scenarios, considered were:
-
case 1: CHP
case 2: biogas production through anaerobic digestion of biowastes + CHP
case 3: CHP driven absorption cooling
The specific indicators needed in each case and the values used were:
-
In addition to these key indicators, the other important assumptions have been explained and
their numerical values given in Chapter 6.
5. The polygeneration potential of each case (1-3) in installed capacity (MW) was calculated
using the EUROSTAT data 'Manufacturing subsections DA-DE and total manufacturing
(NACE D) broken down by employment size classes' (see Chapter 7) and the previously
mentioned indicator values and assumptions. The average size of each size class was taken as
the representative of the class, except for the biggest class (250 or more), for which the lower
limit (250) was taken, to be conservative. Three additional assumptions were made:
1) the enterprise size distribution within a size class is uniform
2) each enterprise has only one factory or production plant
3) natural gas is available or can be easily arranged at every food factory (i.e., oil is not
considered a fuel option for the CHP units)
The second assumption surely leads to underestimation of the polygeneration potential, but
just as surely, the third assumption leads to overestimation since the natural gas network does
not cover the entire Europe and there are food factories in Europe that are far away from the
gas network. Thus, in essence it is assumed that the distorting effect of assumptions 2 and 3
are opposite and equal in magnitude, and cancel each other.
The detailed calculations can be found in the attached excel-file, including comments on minor
assumptions and approximations.
8.2 Results
The estimated polygeneration potential in 16 European countries is shown in Figures 8.1, 8.2
and 8.3.
22
706
Capacity (MW)
700
600
500
400
300
263
200
100
29
0
CHP (MWel)
Figure 8.1. Estimated technical polygeneration potential in installed megawatts (MW); last
column presented in installed absorption cooling capacity (includes refrigeration & freezing).
282
263
Capacity (MW)
250
200
150
100
29
50
0
CHP (MWel)
Biogas+CHP (MWel)
CHP+abs.cool
(MWel inst. CHP)
Figure 8.2. Estimated technical polygeneration potential in installed megawatts (MW); last
column presented in installed CHP electrical capacity.
23
biogas+CHP (MWel)
80
70
60
Capacity (MW)
50
40
30
20
10
0
cz
dk
de
ee
es
fr
it
cy
lv
lt
nl
at
pt
sk
bg
ro
Greece
Hungary
Luxembourg
Malta
Norway
Poland
Slovenia
Sweden
Switzerland
United Kingdom
These countries represent about 30 % of the total European GDP (EUROSTAT 2002-2004).
If we assume that the polygeneration potential is proportional to the GDP, a rough estimate of
the total European polygeneration potential in the cooked food and vegetables industry can be
obtained:
CHP
Biogas + CHP
CHP driven absorption cooling
370 MWel
40 MWel
400 MWel (inst. CHP)
24
8.3 Conclusions
With the assumptions and approximations made, the calculation results indicate that there is
significant technical potential in Europe both for CHP and CHP driven absorption cooling, as
far as the cooked food and vegetables industry is concerned. On the contrary, it seems that the
potential for biogas production from process waste is quite limited. It should also be noticed
that the CHP and the CHP driven absorption cooling potentials are not overlapping i.e., their
potentials can be summed up. The same applies with biogas production and CHP driven
absorption cooling. The only case in which overlapping occurs is CHP versus biogas
production & CHP.
From the results in Chapter 8.2 one might draw the conclusion that the potential for CHP and
CHP driven absorption cooling are about the same. It must be kept in mind, however, that the
estimation method includes several very general indicators, the values of which are based on
fairly few cases. Varying the key indicator values as for sensitivity analysis, showed that the
potentials change accordingly and it cannot be concluded at this point which of the two
polygeneration scenarios has higher potential. This calculation exercise should therefore be
repeated when wider database on the key indicators of food factories is available.
The size class of the overall technical polygeneration potential in the European cooked food
and vegetables industry is most probably hundreds of megawatts (CHP electrical), not tens or
thousands of megawatts. Although most approximations and simplifications made were
conservative, there are surely case dependent technical limitations that decrease the actual,
technically realizable potential.
25
Work Package 2
POTENTIAL FOR POLYGENERATION IN THE OIL, FATS AND OLIVE OIL
INDUSTRIES
February, 2006
Table of Contents
Table of Contents ....................................................................................................................... 2
1. Introduction ............................................................................................................................ 3
2. Process Description ................................................................................................................ 4
2.1 Vegetable Oils .................................................................................................................. 4
2.1.1 Cleaning/Storage ....................................................................................................... 4
2.1.2 Hulling ....................................................................................................................... 4
2.1.3 Crushing .................................................................................................................... 5
2.1.4 Cooking ..................................................................................................................... 5
2.1.5 Pressing...................................................................................................................... 5
2.1.6 Solvent Extraction ..................................................................................................... 5
2.1.7 Degumming ............................................................................................................... 5
2.1.8 Neutralisation ............................................................................................................ 5
2.1.9 Bleaching ................................................................................................................... 6
2.1.10 Deodorization .......................................................................................................... 6
2.2 Fats ................................................................................................................................... 6
2.3 Olive Oil ........................................................................................................................... 7
2.3.1 Preparation and Extraction of Virgin Olive Oil ........................................................ 7
2.3.2 Solvent Extraction ..................................................................................................... 7
2.3.4 Refining of Crude Olive Oil ...................................................................................... 8
3. Utilities and Energy Use......................................................................................................... 9
4. CHP in Oil, Fats and Olive Oil Industry .............................................................................. 11
5. Rest Products ........................................................................................................................ 12
5.1 Solid Output.................................................................................................................... 12
5.2 Waste Water ................................................................................................................... 12
6. Potential New Technology for CHP Production in Oil, Fats and Olive Oil Industry ..........14
7. Oil Production in Europe...................................................................................................... 15
8. Potential Energy Savings by Polygeneration in Oil, Fats and Olive Oil Industry ............... 17
9. References ............................................................................................................................ 24
Pg. 2 of 24
1. Introduction
This report is part of the OPTIPOLYGEN Project whose main goal at this phase is to
calculate the electrical nominal power that can be efficiently produced by polygeneration
applications, using existing technologies in the European Food industry split by sectors.
IST is responsible for the analysis of the Food Industry sub-sector of Oils, Fats and Olive Oil
and in this report it is described the analysis made on the general industrial transforming
processes in the oils, fats and olive oil products industry estimated according to the wastes of
each seed used in each process.
Pg. 3 of 24
2. Process Description
Oil industry processes use different kinds of oleaginous seeds, beans, fruits and nuts for the
production of vegetable oils, mainly for human consumption but also for animal feeding.
Usually crushing plants have integrated refining facilities that produce fatty products, which
are intended for food, feed or technical usages.
The flow chart displayed in Figure 1 illustrates the various steps of the oilseeds processing for
the production of meals, crude, refined oils and olive oils.
2.1.2 Hulling
The preparation of the seeds before an extraction step depends on the kind of seed/bean and
the required quality of the meal. Some oilseeds, like soybeans and sunflower seed, may be
dehulled after the cleaning step. After dehulling the meal will have a lower crude fibre
content, and a higher protein content. The hulls can also be used for feeding purposes [3].
Pg. 4 of 24
2.1.3 Crushing
In the past, factories where crushing was done between millstones, were known as oil mills
and the process as oil milling later crushing became made by steel rolls and the process
known as oil crushing [3].
2.1.4 Cooking
Soybeans, with relatively low oil content, are thermally treated, mechanically crushed and
used as raw material/flakes for further extraction. Sometimes the raw material is pressed
without heating; such oils are known as cold-pressed oils. Since cold pressing does not extract
all the oil, it is applied only in the production of a few special edible oils, i.e., olive oil [3].
2.1.5 Pressing
Seeds with high oil content, like rapeseed and sunflower seeds, are usually pressed in
expellers after a preheating step in indirectly heated conditioners. The expeller cake (or
pressed cake) will then be further treated in the extractor since it might have still a content of
oil from 4 to 8 or even 10 per cent. In some cases, the expeller cake is not further extracted
but after deep expelling, sold as such for feed purposes [3].
2.1.7 Degumming
The first step of refining is degumming. Its purpose is to remove seed particles, impurities,
and most of the phosphatides, carbohydrates, proteins and traces of metals. crude oil is treated
oodgrade processing aids and/or water at a temperature around 100 C, which leads to
hydration of most of the phosphatides, proteins, carbohydrates and traces of metals. The
hydrated material precipitates from the oil and is removed [3].
2.1.8 Neutralisation
Alkali neutralisation reduces the content of the following components: free fatty acids,
oxidation products of free fatty acids, residual proteins, phosphatides, carbohydrates, traces of
metals and a part of the pigments.
In this phase, the oil treated with an alkali solution (caustic soda) that reacts with the free fatty
acids present and converts them into soap stock. The mixture allows then to separate the oil
Pg. 5 of 24
phase freed from fatty acid that floats on top from a layer phase of soap, alkali solution and
other impurities, which are drawn off. The oil is then washed with water to remove the soap,
the alkali solution and other impurities, when it is ready for the decolorizing or deodorising
process.
The under layer of soap and other impurities, which is drawn from the oil, it is a solid material
mixed with some water. A large proportion of it is soap stock, which may be sold to soap
manufacturers or it may be treated with an acid treatment (sulphuric acid) to set free the fatty
acids contained in it. These are used for feed purposes and for soap or candle manufacturing
[3].
2.1.9 Bleaching
The purpose of bleaching (or decolorizing) is to reduce the levels of pigments such as
carotenoids and chlorophyll, and residues of phosphatides, traces of metals and oxidation
products. These compounds can have a deleterious effect on the course of further processing
and on the quality of the final product. These substances are removed by adsorption with
activated clay and silica. If also heavy polycyclic aromatic hydrocarbons are present,
activated carbon shall be used for their removal. Dosage of these adsorption agents should be
adapted to ensure the removal of the specific substances. The bleaching clay containing all
these substances is separated by filtration. Those processes are partly done under vacuum and
at temperatures below 150 C [3].
2.1.10 Deodorization
The purpose of deodorization is to reduce the level of free fatty acids and to remove odours,
off-flavours and other volatile components such as pesticides and light polycyclic aromatic
hydrocarbons by a stripping media. Careful execution of this process will also improve the
stability and the colour of the oil, while preserving the nutritional value.
The deodorization process is carried out under vacuum (0.5 8 mbar) with temperatures
between 180 270 C, and using a stripping media.
Conditions should be adapted within these ranges as appropriate to ensure the removal of the
specific substances [3].
2.2 Fats
The main products manufactured from edible oils and fats are margarine, edible fats, edible
oils and mayonnaise. In view of its major outstanding importance, only margarine production
is described here.
Most installations carry out hydrogenation to produce fats with superior retention qualities
and higher melting points. Hydrogenation, or hardening of edible oils, is the process of
saturating mono or poly-unsaturated fatty acids by adding hydrogen gas for hydrogenation
and nickel as catalyst. Neutral or bleached oil is heated to a temperature of 150 to 205 C in
the presence of nickel catalyst, maximum 10 kg/ton of product. H2 is the added to the mixing
reactor to achieve the hardening, i.e., the transformation of oil to fat.
Pg. 6 of 24
Pg. 7 of 24
of the olive cake, e.g., by reducing the content of glucosinolates or trypsin inhibitors; and,
thirdly, to minimise the risk of biological contamination.
Pg. 8 of 24
Seed
Cotton-seed
Ground-nut
Rape-seed
Safflower
Sesame
Sunflower
Soya bean
Oil in kernel
(%)
30
49
43
35
47
42
19
Meal in kernel
(%)
70
51
57
65
53
58
81
Table 1: Standard percentage of hull, oil and meal present in each seed [4].
For the olives, about 20% (mass basis) results in virgin olive oil and 80% in pomace. The
final products of this pomace are refined olive oil and olive cake. The balance is 55% and
45%, respectively.
The industry of oils & fats uses heat and electricity, although cold could be necessary if some
additional steps were made in the refining process, such as winterisation. These processes
where not considered in the present study.
Table 2 shows the electric and heat demands by process per ton, as well as the temperature of
the heat necessary and the type of product that they are referring too, for example, crude oil,
seed, olives or final product).
The first steps of the process (cleaning, hulling, breaking and pressing) are not shown because
there were no values for each separately they are included in the solvent extraction data.
These processes are the major consumers of energy, in the extraction and preparation
processes (refining not included) representing near 75% of the energy consumption.
For Groundnut, Sesame, Cottonseed and Safflower the data was obtained from [1, 4, 7], for
Soya bean, sunflower and Rape-seed the data was obtained from a Portuguese oil company
[2], and for olives the data was obtained from [1, 10].
Pg. 9 of 24
Seed
Ground-nut
Sesame
Cotton seed
Safflower
Olives
Soya bean
Sunflower
Rape-seed
Olive
Process
Solvent extraction
Solvent recovery
Deguming
Neutralisation
Bleaching
Deodorisation
Extraction
Refining
Extraction
Refining
Extraction
Refining
Preparation and
extraction of virgin
olive oil
Referred
too
Seed
Meal
Crude
Crude
Crude
Crude
Seed
Oil
Seed
Oil
Seed
Oil
Heat
(kWh/ton)
280
108.8
75
53
20
45
300
132
320
187
323,8
132
Electric
(kWh)
45
3.5
7.7
9
6
3.5
29,5
24
36.5
46
36.5
26
Max. Temp.
(C)
90
80
85
110
225
90
225
90
225
90
225
Olives
30
75
Pg. 10 of 24
Company Name
City
FEXOL FBRICA DE
Montemor
EXTRAO DE LEOS DE
Novo
MONTEMOR, LDA
CENTROLIVA INDUSTRIA E
Vila Velha
ENERGIA, SA
de Rdo
COMPANHIA TRMICA LUSOL,
Barreiro
ACE
COMPANHIA TRMICA TAGOL,
Almada
ACE
Inst. Power
[kVA]
Production
[kWh]
630
4 170
5 499 450
8 140
30 299 803
9 345
52 812 000
Pg. 11 of 24
5. Rest Products
5.1 Solid Output
Depending on the type of oilseed, the raw materials for vegetable oil production can almost be
converted completely into products, e.g., vegetable oil, protein rich meal, fatty acids and
lecithin, or by-products, e.g., human food, animal feed and pharmaceutical products.
Solid wastes, e.g., leaves, wood and stones, are generated in the raw materials first step
(cleaning). In oilseeds, this fraction is less than 1%, in the decortications of the seed the
percentage of solid output depends on the percentage off hull in the whole seed (see Table 1).
The hull either can join the meal or be incinerated.
The solid wastes of olive oil production consist of two major parts, i.e., the stones and the
olive cake. The stones accumulate in installations and can be used for building materials or
for activated charcoal. The olive cake is often used as a fuel for heating, for animal feed
supplement or returned to the olive grove as mulch to the soil. In this case, all the olive cake is
used as fuel for heating (biomass). The olive cake represents around 45% of the pomace.
In the pressing and solvent extraction, the crude oil is produced among the meal the
percentage of oil and meal can be approximated to the values presented before (see Table 1).
Those values can obviously change due to weather conditions, origin of the seed, etc.
Meal is normally used for animal feed, but it is possible to be incinerated among with the
hulls to produce energy. This aspect was considered in this study.
In the case of neutralisation, there is production of soap. Usually, it is further processed in the
refinery by splitting the soaps and regaining the fatty acids (acid oil). In some countries, it is
possible to mix the soap stock from the chemical refining of vegetable oil with other
ingredients for the production of low quality soaps or for use in meal for animal feed.
In the bleaching operations, spent bleaching earth containing 20-40% fat is produced. This
makes the waste prone to spontaneous combustion. In production plants, which exclusively
refine and modify edible oil, the earth is utilised by third parties for energy production by cofermentation to produce biogas or to make bricks. In mixed production plants, that produce
and refine oils, the earth is mixed with the meal and both are used as animal feed.
Pg. 12 of 24
Process/unit operation
Crude oil production (seed
processing)
Neutralisation
Parameter
COD load
Waste water volume
COD load
Deodorisation
Level
0.1-1.0 kg/ton seed
processed
1-1.5 m3/ton refined
product
5 kg/ton refined product
10-30 m3/ ton refined
product
7 kg/ton refined product
Pg. 13 of 24
Pg. 14 of 24
ground-nut
1,25%
rape-seed
33,25%
soyabean
16,78%
sesame
0,02%
Pg. 15 of 24
3.000.000
2.500.000
Ton/year
2.000.000
1.500.000
1.000.000
500.000
0
be
dk
ger
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
900
800
number of enterprises
700
600
500
400
300
200
100
0
be
dk
ger
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Figure 4 Number of enterprises in Eu-15 that produces refined and crude oil.
Pg. 16 of 24
Seed
Cleaning
Leaves
Stones
Hulling
Hulls
Breaking
Water
Solvent
Pressing
Waste water
Solvent-extraction
miscella
Crude oil
Water
Biomass
Cooking
Biogas
Solvent recovery
degumming
Waste water
neutralisation
Bleaching earth
Water
Bleaching
Deodorization
Spent earth
Waste water
Figure 5: Flow diagram considered for biogas and biomass production from oilseed.
Pg. 17 of 24
For the production of olive oil, the diagram is slightly different; Figure 6 shows this diagram.
Olive
Preparation
and
extraction of
olive oil
Virgin
olive oil
Pomace
Biomass
Solvent
Solvent-extraction
Pomace Crude olive oil
Water
miscella
Olive
cake
Solvent recovery
degumming
Waste water
neutralisation
Bleaching earth
Water
Bleaching
Deodorization
Biogas
Spent earth
Waste water
Figure 6: Flow diagram considered for biogas and biomass production for olive oil.
Note that in the diagrams the steps in red are the ones that are included in extraction, and the
ones in blue are included in the refining.
Figure 7 presents the total energy spent to produce a ton of refined oil for each seed.
Pg. 18 of 24
1600,0
1400,0
electricity
heat
1200,0
1000,0
800,0
600,0
400,0
200,0
0,0
cotton seed ground-nut
rape-seed
safflower
sesame
sunflower
soyabean
virgin olive
oil and
refined oilve
oil
Electric power
Heat/electricity ratio
Minimum yearly operating hours
Fuel/electricity ratio
100 kWe
2.5
5000 hours/year
3
5000-ton solids/year
450000 Nm3/year
For the polygeneration with biomass, it was considered a small steam turbine/engine CHP
systems with the following values:
Electric power
Heat/electricity ratio
Yearly operating hours
Fuel/electricity ratio
150 kWe
8
8700 hours
6
Pg. 19 of 24
In addition, it was also considered a boiler burning biomass and producing only heat, with the
following characteristics:
Thermal power
Efficiency
200 kWth
85%
By applying the units described above, the results included in Table 5 were obtained for the
minimum oil plant production per year that justifies the use of cogeneration or
polygeneration.
Seed
Cogeneration
(ton/year)
Cottonseed
Groundnut
Rape-seed
Safflower
Sesame
Sunflower
Soya bean
Olive oil
1700
3000
2500
2500
3000
2500
1100
2500
Polygeneration
with biogas
(ton/year)
17000
17000
17000
17000
17000
17000
17000
18000
Polygeneration
with Biomass
(ton/year)
3000
3000
3000
3000
3000
3000
3000
3000
Polygeneration
only Heat
(ton/year)
520
520
520
520
520
520
520
520
Table 5: Minimum production of the plants per year that are suitable for CHP.
From Table 5 it was obtained the data displayed in Figure 8.
900.000
800.000
700.000
cogeneration
polygeneration with biogas
polygeneration with Biomass
Mhe/year
600.000
500.000
400.000
300.000
200.000
100.000
0
be
dk
ger
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Pg. 20 of 24
As can be seen, the cogeneration has a bigger potential as compared with the polygeneration.
This is because the annual production needed to implement cogeneration is smaller when
compared with the others; other reason is linked with the fact that a gas turbine CHP system is
more efficient than a steam turbine system.
Figure 8 reveals that Germany and Spain are the countries with the biggest potential owing to
the larger number of facilities and the production of oils.
Figure 9 shows the mean power installed by seed.
250.000
200.000
cogeneration
Polygeneration ( Biomass )
Polygeneration ( Biogas )
150.000
100.000
50.000
0
cotton seed
ground-nut
rape-seed
safflower and
sunflower
sesame
soyabean
Pg. 21 of 24
25.000.000
Mhth/year
20.000.000
15.000.000
10.000.000
5.000.000
0
be
dk
ger
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Pg. 22 of 24
5.000.000
4.500.000
4.000.000
cogeneration
Polygenaration (biogas)
Polygeneration (Biomass)
only heat
Tones CO2/year
3.500.000
3.000.000
2.500.000
2.000.000
1.500.000
1.000.000
500.000
0
be
dk
ger
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Pg. 23 of 24
9. References
[1] European Commission (2005). Draft Reference Document on Best Available Techniques
in Food, Drink and Milk Industry. European Commission, Sevilha.
[2] Tagol, Companhia Oleagenosas do Tejo (2005). Personal Comunications.
[3] FEDIOL: www.fediol.be.
[4] Norris, F. A. (1982). Extraction of Fats and Oils in Bailey's Industrial Oil and Fat
Products, Swern, D. (ed.). John Wiley, Nova Iorque.
[5] Santos, P (2000). Guia Tcnico do Biogs (in portuguese). Centro para a Conservao
de Energia, Direco Geral de Energia, Lisboa.
[6] Eurostat: http://epp.eurostat.cec.eu.int.
[7] UNIDO United Nations Industrial Development Organization (1977). Guidelines for
the Establishment and Operation of Vegetable Oil Factories. ONU, Nova Iorque.
[8] www.naturalandtasty.co.uk/margarine_process.htm.
[9] Civantos, L. (1998). El Olivo, el Aceite, la Aceituna. COI, Madrid.
[10] www.ucm.es/info/improliv/allgem.htm.
Pg. 24 of 24
OPTIPOLYGEN
OPTIPOLYGEN
OPTimum Integration of POLYGENeration in the food industry
WP2
Potential for Polygeneration in the
Drink and Beverages Industry
Author:
Christian Steinreiber
Peter Lucny
OPTIPOLYGEN
Executive Summary
On-site power generation in conjunction with the processes involved in the food industry may
form an efficient alternative and a step towards sustainability. It is however important to estimate
the real potential of on-site power generation methods which are currently available in the European food industry sector. A part of this sector is the Drink and Beverage Industry and the technical polygeneration potential for its most promising sectors breweries, distilleries and juice
producers has been calculated for all EU15 countries.
Calculations were based on data for energy consumption, which exist in the open literature or
were collected via oral communication with companies of the Drink and Beverages Industry.
The data from Eurostat for the different Drink and Beverages sectors and EU15 countries were
used together with figures from sector associations (e.g. The Brewers of Europe) and/or own
estimations of the size of the plants located in every country.
Results show that the polygeneration potential for technical application (without explicit financial
aspects) in all EU15 countries reach 7,900 GWh el /year with trigeneration (only analyzed for
breweries), 11,200 GWh el/year with cogeneration and 2,600 GWh el with biogas application. If
this potential is realized, CO2 emission savings of 2.7 million tones with trigeneration, 3.3 million
tones with cogeneration and with biogas more than 0.5 million. tones CO2 /year are achieved.
The highest potential of a drink sector 7,900 GWh comes from using trigeneration (cogeneration with absorption chilling cycles) in breweries. This can be explained with the significant
amount of thermal energy consumed for heat and also for chilling loads at temperatures down
to 10C. In the other two analyzed sectors distilleries and juice producers no trigeneration
could be estimated because of the lack of detailed information on existing plants.
Biogas generation potential is limited mainly because of the size of the plants there is a need
for significant amount of biogenic wastes for a biogas installation to be viable and because of
the limited generation of by-products as most of them is sold as cattle food (e.g. spent grains
from breweries and distillers wash). Nevertheless, the technical biogas potential for energy use
has been analyzed.
For wine producers, trigeneration and biogas can be a good option. Because of the very different production processes for different wines in the different wine regions all over Europe, no estimation was done. An analysis of energy benchmarks in the biggest wine regions (e.g. in Spain,
Italy and France) would be the pre-condition for such a calculation of the polygeneration potential.
OPTIPOLYGEN
CHP........................................................................................................................................... 18
TRIGENERATION .......................................................................................................................... 19
SOLID WASTES AND BY-PRODUCTS USE. ....................................................................................... 19
CONCLUSIONS................................................................................................................ 34
REFERENCES ................................................................................................................. 34
OPTIPOLYGEN
Introduction
1.1 General
The aim of this report is to describe the general processes in the Drink and Beverages Industry,
focusing on energy usage (thermal and electrical) and the type of processes using this energy,
with the goal to estimate the total polygeneration potential in this sector in EU15 and the corresponding CO2 emission savings, which may arise.
Polygeneration
Polygeneration is the use of multiple primary energy inputs to create multiple energy outputs.
The term primary energy includes conventional fossil fuels and renewable energy sources which
arise from the production process (e.g. solid biomass or biogas). External renewable energy
sources (e.g. wind or solar energy) are not taken into account.
Energy output means the different forms of energy which are useful in an activity. In the Drink
and Beverages Industry this can be electricity and heat in various temperature levels i.e. steam,
hot water, chilling mediums etc.
1.2.2
The Drink and Beverages Sector includes all drinks, excluding coffee and tea which are dealt by
the OPTIPOLYGEN partner Chalex (UK). More specifically the following NACE codes have
been taken into account.
NACE
15.32
15.91-92
15.93-95
15.96
15.98
Code description
Manufacture of fruit and vegetable juice
Distilled potable alcoholic drinks
Ethyl alcohol from fermented materials
Wines
Other fermented drinks, e.g. cider, perry and
mead, an mixed drinks containing alcohol
Vermouth and other flavoured wine of fresh
grapes
Beer made from malt
Mineral waters and soft drinks
Table 1. NACE codes of the Drink Industry Sectors dealt in this report.
1.2.3
Geographical coverage.
This report covers the Drink and Beverages Industry in the European Union of the 15 countries
forming the European Union until May 2004. The methodology however is easy to be used in
the 10 new EU member countries.
OPTIPOLYGEN
2 Process description
2.1 Breweries (NACE 15.96)
2.1.1
The raw materials for beer generally include barley malt, adjuncts, hops, water and yeast. The
main processes are:
Wort production
Fermentation / Beer processing
Packaging
Wort production
Malt is delivered to the brewery, weighed, conveyed, cleaned, stored and made available for
wort production. After milling of the malt and preliminary treatment of the adjuncts to facilitate
the extraction, the malt and adjuncts are mixed with brewing water to form a mash. Adjuncts are
a supplementary carbohydrate supply added either to the mash kettle as starch (e.g. maize grits
or rice) or alternatively to the wort kettle as sucrose or glucose / maltose syrup. The mash is
heated following a pre-set time - temperature programme, in order to convert and dissolve substances from the malt and the adjuncts in the brewing water. Extraction is accomplished through
a combination of simple dissolution and the influence of the natural enzymes formed during the
malting. The substances dissolved in the water are collectively called the extract. The solution
of extract and water is called the wort.
When the mashing is completed the insoluble solids, called the brewers grains, are separated
from the wort by straining. The brewers grains can be used as cattle feed. The wort is boiled
with hops and hop extracts releasing bitter substances and oils, which are dissolved in the wort.
During boiling a precipitate consisting mainly of proteins is obtained (the trub) and the bitter
substances are isomerised which increases their solubility. After separation of the trub, the finished wort is cooled to approx. 8-20C depending on the yeast strain in question and the fermentation process chosen. The cooled wort is hereafter transferred to the fermentation area.
Fermentation / Beer Processing Area
The cold wort is aerated and pitched, i.e. yeast is added. Oxygen is necessary to support development of the yeast to a state and amount capable of fermenting wort efficiently. Fermentation is an anaerobic process; the yeast metabolises the fermentable carbohydrates in the wort
forming alcohol and carbon dioxide. A large number of different compounds, such as higher alcohols, esters, aldehydes, etc., influencing the aroma and taste of the beer, are also produced.
When the main fermentation is completed and the yeast has been harvested, the green beer
matures at lower temperatures. At this stage, the yeast decomposes certain undesirable constituents of the green beer, the beer is enriched with carbon dioxide, the residual extract is fermented and yeast and other precipitates settle.
The fine clarity is achieved by filtering the beer, mostly with Kieselguhr as filtration aid. During
filtering, the rest of yeast cells are removed as well as other substances causing turbidity and
any bacteria that might cause the beer to spoil,. The filtered beer is pumped to the so-called
bright beer tanks.
OPTIPOLYGEN
Packaging
From the bright beer tanks the beer is pumped to the packaging area where it is bottled, canned
or kegged. During this final operation it is important that the beer is prevented from getting into
contact with oxygen and that no CO2 is lost.
Packaging lines may be equipped quite differently, not only with respect to packaging material
but also with respect to the level of automation and inspection. Returnable bottles require thorough cleaning. The bottle washer consumes large quantities of energy, water and caustic. Furthermore, substantial quantities of wastewater are discharged. The use of non-returnable packaging material reduces the consumption of energy, water and caustic, therefore reducing
wastewater generation.
In packaging lines using non-returnable bottles and cans, the bottles / cans are only flushed
with water before filling. Alternatively, compressed air is used to blow out any dust particles. If
kegs are used, they are cleaned and sterilised with steam before filling.
For a general ovierview of all these processes and flows in a brewery see Figure 1.
Further details on the processes involved in breweries can be found in BREF (2006) and Brewers of Europe (2002).
2.1.2
Energy is usually supplied to breweries in the form of oil, gas, coal, steam, high temperature hot
water and electricity. To run a brewery following energy utility installations are the most important:
Boiler Plant: The processes are supplied with heat from a boiler plant. The heat is available to the various consumers as steam or high temperature hot water. Oil, natural gas,
biogas or coal may be used as fuel for the boilers.
Cooling Plant: Process cooling is supplied from a cooling plant using reciprocating,
screw or centrifugal compressors. The cooling at the consumers may take place directly
by expansion of a primary refrigerant mostly ammonia or indirectly by use a secondary coolant such as propylene glycol.
Electricity Supply: Most breweries are supplied with electricity from the public grid. Some
have their own co-generation plant producing both electricity and heat / steam. For the
OPTIPOLYGEN
USA it is reported that 22% of total beer production is produced in breweries with CHP.
For Europe it is estimated that this figure is lower.
A brewery utilises energy both in the form of heat and electricity. A brewery without a sophisticated heat recovery system consumes about 27.78-55.55 kWh/hl beer. Ranges of heat consumption for some departments is given in Table 2.
Department/
process
Brewhouse
Bottling installation
Kegging installation
Process water
Service water
Miscellaneous
Total
Min
24.17
16.11
2.22
0.83
43.33
Mean
Max
Figure
kWh/hl beer
25.56
33.61
23.89
26.11
3.06
3.61
1.11
2.22
53.62
65.55
Literature
Measured
Range
kWh/hl beer
23.33-31.39
13.89-22.22
6.94-12.78
10.56-16.11
2.22-3.61
1.11-2.22
2.22-4.72
9.17-12.78
26.39
44.99-67.50
24-64.72
Table 2 Ranges of heat demand in different processes in a brewery, Source: BREF (2006)
The actual heat consumption for a brewery depends on process and production characteristics
such as packaging method, pasteurising technique, type of equipment, and by-product treatment. The main heat consuming processes in a brewery are:
Mashing
Wort boiling
Generation of hot liquor
CIP / Sterilising
Bottle washing
Keg washing
Pasteurising
Room heating (in cold climate)
The largest single heat consumer will normally be the wort kettle in the Brewhouse.
Analyzing data from literature and via oral communication with Austrian breweries the ratio between heat and electricity consumption is estimated to be 75% (heat) to 25% (electricity). Depending on process and production characteristics an efficient brewery consumes between 8
and 12 kWh/hl beer, but some breweries still have an electricity consumption 2 times higher.
The main single consumers of electricity with its share of total electricity consumption in a brewery in parenthesis are:
Cooling plant (40%)
Packaging area (18%)
Brewhouse (13%)
Air conditioning (6%)
Wastewater treatment plant and others (23%)
There are also many small consumers of electricity counting for a large part of the electricity
consumption, e.g. pumps, ventilators, drives and electric lighting.
The following activities can also take place at a brewery:
Malt production. Malt is the most important raw material for the production of beer.
Nowadays it is usually produced by external malthouses. Thus it is excluded in the following analysis.
Production of non-alcoholic beverages / soft drinks in addition to beer. This production
process is dealt in chapter 2.4.
OPTIPOLYGEN
Solid Biomass by-products in breweries consist mainly from spent grains in the brewing process
(23 kg per hl beer), most of which are sold as cattle feed. A downturn in the sales of animal
feed, new regulations for the disposal of organic waste and continuously rising transport and
energy costs are forcing the industry to search for alternative ways of sensibly utilising organic
waste. Along with the utilisation of water pressed from the spent grains and accumulated ashes,
the spent grains themselves are also directly used to produce heat (two plants are reported in
Austria and Nigeria). This promising technology with a potential of 45 kWhtherm per hl beer
produced is mentioned, but does not enter in our polygeneration definition where multiple usage
of output energy is required. So this technology is not integrated in the following polygeneration
potential.
Spent grains can also be used via anaerobic digestion for biogas production. Additionally, biogas can also be gained from an anaerobic Waste Water Treatment Plants (WWTP). Values in
the table below were calculated by EKV, using data from Austrian breweries with biogas from
WWTP. In every case where an application is sought there is a need for analysis of the solid
residues. The mentioned values can however be used for the planning purposes of this work.
The energy consumed in each process varies considerably between plants depending on the
equipment and the details of the process used, on the specific nature of the product and on
several other parameters. It is not the purpose of this report to describe the details of the various specific processes, which can be met in the brewery industry. For every process however
there is some energy demand. The following table shows the figures which where used for the
calculation of the polygeneration potential
Process description
Electricity
kWhel/hl
beer
Brewhouse
Bottling
Kegging
installation
Process water
Service water
air-conditioning
elelctrical
thermal
cooling
electrical
thermal
other
TOTAL conventional cooling
with absorption
cooling
1,74
2,41
heat
kWhtherm/h
l beer
oC
25,56
23,89
3,06
147
125
128
1,11
80
60
10
0,80
1,68
-1 to 8
5,36
10,72
3,08
13,41
53,62
7,24
66,02
The estimated energy benchmark of 67 kWh/hl beer is proved as very realistic in the second
worldwide Energy Efficiency Benchnmark study 2003 for breweries with more than 0.5 million hl
beer/year, initiated by the Dutch Brewery Association. With the responsing breweries 26% of total worldwide beer production was covered, the European responses covered even 43% of totla
European beer production. The calculated average energy benchmark in this study was 66
kWh/hl beer. No detailed energy demand for the different production processes was published,
so this report only proved the size of the energy figures estimated in Table 3.
OPTIPOLYGEN
Further details on the processes involved in breweries can be found in BREF (2006), Brewers of
Europe (2002) Austrian Chamber of Commerce (2000), Wouda and Pennartz (2002) and
Wouda (2004).
Fruit juices are produced throughout temperate and tropical areas of the world. Orange juice
predominates in temperate climates and pineapple juice in tropical climates. The bulk of the
world fruit juice production is from citrus fruits, mostly oranges, pomes; from apple and pear
type fruits and from vine fruits. Some stone fruit juices are manufactured but in much smaller
quantities.
The steps of the manufacturing process of these juices can be very different. A simplified process flow chart for the juice production is shown in Figure 2.
Figure 2. Simplified process chart for the juice production, Source: BREF 2006
OPTIPOLYGEN
Thanks to its low pH (about 4), orange juice has some natural protection from bacteria, yeast,
and mold growth. However, pasteurization is still required to further retard spoilage. Flash pasteurization minimizes flavor changes from heat treatment and is recommended for premium
quality products. Several pasteurization methods are commercially used. One common method
passes juice through a tube next to a plate heat exchanger, so the juice is heated without direct
contact with the heating surface. Another method uses hot, pasteurized juice to preheat incoming unpasteurized juice (reported in an Austrian juice company). The preheated juice is further
heated with steam or hot water to the pasteurization temperature. Typically, reaching a
temperature of 85-94C for about 30 seconds is adequate and prepare the juice for filling. Batch
wise pasteurisation uses a temperature of 62 to 65C for up to 30 minutes. High temperature
short time (HTST) pasteurisation uses a temperature of 72 to 75C for 15 to 240 seconds. High
heat short time pasteurisation (HHST) applies a temperature of 85 to 90 C for 1 to 25 seconds.
Batch wise pasteurisation is carried out in agitated vessels. Sometimes the product, i.e. fruit
juices, is pasteurised after bottling or canning. Here the products in their containers are immersed in hot water or fed through a steam tunnel. For continuous pasteurisation, flowthrough
heat-exchangers, e.g. tubular, plate and frame, are applied. These have heating, holding and
cooling sections.
To ensure sterility, the pasteurized juice should be filled while still hot. Where possible, metal or
glass bottles and cans can be preheated. Packaging which can not withstand high temperatures
(e.g., aseptic, multilayer plastic juice boxes which don't require refrigeration) must be filled in a
sterile environment. Instead of heat, hydrogen peroxide or another approved sterilizing agent
may be used prior to filling.
Juice made into bulk frozen concentrated orange juice (FCOJ) is sent to an evaporator where
vacuum and heat are used to remove excess water in order to obtain a base concentrate of 65
brix, which is a seven-to-one strength ratio to normal juice. Steam, vapour, or exhaust gases
from other drying operations, are usually used as the heating medium. The latent heat of condensation is transferred to the liquid food to raise its temperature to boiling point, to evaporate
the water. The vapour is then removed from the surface of the boiling liquid. For low temperatures the boiling of the liquid is partly under vacuum. Evaporation normally occurs in the range
of 50 to 100C. In its simplest form, evaporation is carried out by boiling off water to the air, using immersed electric heaters. However, in practice the most commonly used equipment is multistage shell and tube evaporators, or plate evaporators. Shell and tube evaporators may be
natural or forced circulation, climbing or falling film types. Concentrated juice is discharged to a
vacuum flash cooler, which reduces the product temperature to about 13C. A newer concentration process requires minimal heat treatment and is used commercially in Japan. The pulp is
separated from the juice by ultra-filtration and pasteurized. The clarified juice containing the volatile flavorings is concentrated at 10C by reverse osmosis and the concentrate and the pulp
are recombined to produce the appropriate juice concentration.
Many juice producers just buy the juice concentration. When the juice processor is ready to prepare a commercial package for retail sale, concentrate is pulled from several storage batches
and blended with water to achieve the desired sugar to acid ratio, color, and flavor. Proper
blending of juice concentrate and other flavor fractions is necessary to ensure the final juice
product achieves a high quality flavor.
Other juices
A typical pome juice process includes similar processes but without an oil extraction step. The
fresh fruits are washed, sorted and then crushed after eventual coring or pitting, e.g. for
peaches and apricots. The white fruits are heated to avoid enzymatic browning. The crushed
fruits are then strained and refined to extract the juice. For apple juice, the juice is sometimes
clarified with an enzymatic treatment and filtration.
More about the juice production can be found in BREF (2006) and Heiss (1996).
10
OPTIPOLYGEN
2.2.2
Energy is usually supplied to juice producers in the form of oil, gas, coal, steam, high temperature hot water and electricity. To run a juice production following energy utility installations are
the most important:
Boiler Plant: The processes are supplied with heat from a boiler plant. The heat is available
to the various consumers as steam or high temperature hot water. Oil, natural gas, biogas or
coal may be used as fuel for the boilers.
Cooling: After the pasteurisation the liquid has to be cooled from 80 down down to 10oC, for
end-products a cooling down to 30oC is reported in an Austrian juice company. This cooling
is often done by cooling towers and no compressors are used. If the juice or concentrate is
stored, temperatures down to 18oC are reported.
Electricity Supply: Most juice producers are supplied with electricity from the public grid.
There are very few which have their own co-generation plant producing both electricity and
heat / steam.
The main heat consuming process step is the heating and pasteurisation step with process
temperatures commonly range from 60 to 95C. The highest electricity consumption is reported
for the cooling/storage (down to 18C, if it is not pasteurized and bottled/packed immediately
after the juice production) and the final packing and bottling.
By-products from juice production come from the rind and pulp that is created as waste. The
weight of the waste ranges from 20 to 60% of the raw material. Products made with this waste
include dehydrated feed for livestock, pectin (e.g. from apple), citric acid, essential oils, molasses, and candied peel. Some fractions of orange oil are sold for use in industrial cleaners. The
organic waste and wastewater can also be used for biogas via anaerobic digestion.
In comparison to breweries, very few data on energy consumption in the juice industry is available. So the base for our calculations were drawn from oral communication with two Austrian
juice companies. The energy consumed in each process can vary considerably between plants
depending on equipment and the details of the process used, on the specific nature of the product (see chapter 2.2.1 about the different processes for different fruits) and on several other parameters. It is not the purpose of this report to describe the details of the various specific processes, which can be met in the juice industry. For every process however there is some energy
demand. The following table shows the figures which where used for the calculation of the polygeneration potential
Process description
Electricity
kWhel/hl
juice
Sorting/Washing
Extraction/Pressing
Heating
Leaning
Clarification/Enzymatic treatment
De-aeration
Filtration
Concentration
Cooling/Storage
Pasteurising
Cooling
Concentration
Packaging
TOTAL
heat
kWhtherm/
hl juice
3,00
16,00
4,29
20,43
7,29
36,43
biogas
Nm3/hl kWhbiogas/h
juice
l juice
1,125
6,75
Table 4. Typical ranges of energy demand and wastes in the juice industry
EKV Austrian Energy Consumers Association
11
OPTIPOLYGEN
There are many subtleties involved in the creation of different spirits drinks. Here the main steps
for cereal-based spirits are mentioned.
Step 1: Milling. The raw material is ground into a coarse meal. The process breaks down the
protective hull covering the raw material and frees starch.
Step 2: Mashing. The starch is converted to sugar, which is mixed with pure water and cooked.
This produces a mash.
Step 3: Fermentation. The sugar is converted to alcohol and CO2 by the addition of yeast.
Step 4: Distillation. The alcohol, grain particles, water and congeners are heated. The alcohol
vaporises first, leaving the water, the grain particles and some of the congeners in the boiling
vessel. The vaporised alcohol is then cooled or condensed, to form clear drops of distilled
spirits.
Two additional steps are often taken in making some distilled spirits:
Step 5: Ageing. Certain distilled spirits (e.g. rum, brandy, whisk(e)y) are matured in wooden
casks where they gradually develop a distinctive taste, aroma and colour.
Step 6: Blending. Some spirits go through a blending process whereby two or more spirits of
the same category are combined. This process is distinctive from mixing since the blended spirit
remains of the same specific category as its components.
Many spirits producers buy the distilled alcohol from specialized distilleries and produce their final product by mixing it with other ingredients. A simplified process flow chart can be found in
Figure 4. The main steps are the mixing of the ingredients, filtration and the filling process.
12
OPTIPOLYGEN
More about the spirits production can be found in BREF (2006), Heiss (1996) and European
Spirits.
2.3.2
Energy is usually supplied to distilleries and spirit producers in the form of oil, gas, coal, steam,
high temperature hot water and electricity. To run a distillery following energy utility installations
are the most important:
Boiler Plant: The processes are supplied with heat from a boiler plant. The heat is available to the various consumers as steam or high temperature hot water. Oil, natural gas,
biogas or coal may be used as fuel for the boilers.
Cooling: After the different distillation steps the liquid has to be cooled down to condensate.
Electricity Supply: Most distilleries are supplied with electricity from the public grid. There
are very few (e.g. one reported in the UK) which have their own co-generation plant producing both electricity and heat / steam.
The main heat consuming process step is the distillation process. The main electricity consumers are he bottling process and the pumping devices. In comparison to breweries, very few data
on energy consumption is available. So the base for our calculations were drawn from Heiss
(2006), BREF (2006) and additionally from oral communication with an Austrian distillery.
The biogenic waste, called distillers wash or vinasse, which is a dark brown syrup containing all
the inorganic substances from the wort and slops, is mainly used as a high nutritive animal feed.
In an Austrian distillery a protein share of 35% is achieved via vacuum dehydration. The salts
are used as a potassium fertiliser. This waste can also be used via anaerobic digestion for biogas production.
The energy consumed in each process varies considerably between plants depending on
equipment and the details of the process used, on the specific nature of the product (see chapter 2.3.1 about the different processes for different spirits) and on several other parameters. The
EKV Austrian Energy Consumers Association
13
OPTIPOLYGEN
following ranges in the table resulted from oral communication with an Austrian distillery and
were also taken from the above mentioned literature.
Distillation
Mixing and
Bottling*
Electricity
kWhel/l pure
alcohol
0.02
heat
kWhtherm/l
pure alcohol
1 to 4
0.017
biogas
Nm3/l pure
kWhbiogas/l
alcohol
pure alcohol
0.18 to 0.46
1.1 to 2.8
* This figure is originally given for a spirits installation in kWh/0.7 l standard bottle of final product. For our calculation a share of 40% for pure alcohol is used.
Table 5. Ranges of heat demand in the two main processes of a spirits production
It is not the purpose of this report to describe the details of the various specific processes which
can be met in the juice industry. For every process however there is some energy demand. In
every case there is a need for analysis of the solid residues, if an application is sought. The following values were used for the calculation of the polygeneration potential.
Process description
Distillation
Mixing and Bottling
installation*
TOTAL
Electricity
kWhel/l pure
alcohol
heat
biogas
kWhtherm/l Nm3/l pure kWhbiogas/l
pure alcohol
alcohol
pure alcohol
3
0,28
1,67
0,02
0,017
0,02
3,02
Table 6. Energy demand and wastes in distilleries and spirits producers used for the potential calculation
14
OPTIPOLYGEN
tion. These methods, in combination with low pH, prevent microbiological spoilage. The basic
processes for the manufacture of soft drinks involve the mixing of ingredients in the syrup room,
followed by the addition of water that has been subjected to various water treatments. The mixture may be heat processed or chemically preserved at this stage. The product is carbonated if
required. Alternatively, after the syrup and water are combined, the product may be filled into
packaging and in-pack heat processed. Syrup may require filtration or homogenisation and may
be pasteurised. Most packaging is cleaned prior to filling, either by rinsing water, possibly containing rinsing aids, or by air blasting.
The energy demand in the soft and mineral water production is similar to the mixing and bottling
installation described in chapter 2.3. With a heat and electricity demand of each 2 kWh/hl final
product and almost no cooling demand it has a much smaller CHP and trigeneration potential
than e.g. breweries (40 times more heat needed/hl beer). For the soft drink production mostly
pre-prepared juices or chemical additives are mixed together with water. Thus no high biogenic
waste is expected which causes almost no biogas potential. Therefore, no further calculation of
the polygeneration potential was made.
More information about the production of soft drinks can be found in BREF (2006).
15
OPTIPOLYGEN
16
OPTIPOLYGEN
Energy demand
Wine producers have a high electricity demand which is mainly used for refrigeration in the
processes fermentation, cold stabilization and cold storage. The rest goes into compressed air,
in the pumping and bottling line motors and other installations (e.g. lighting). Hot water is
needed for cleaning barrels and equipment and for heating red wine ferments and yeast
generator tanks. Specific energy use varies highly for each winery, as will the distribution of
energy use, depending on the region (hot-temperate climate), the type of product made,
process choices and efficiency of the operation. Therefore, typical energy demand ranges were
not found in the literature and also not given by winery experts.
Meanwhile the low heat demand limits cogeneration applications, trigeneration can be a option.
Also biogas via digestion of the biogenic waste in the grape presses can be a energy source.
Because of the very different production processes for different wines in the different wine regions all over Europe, no estimation was done. An analysis of energy benchmarks in the biggest wine regions (e.g. in Spain, Italy and France) would be the pre-condition for such a calculation of the polygeneration potential.
More information on the wine production can be found in: BREF (2006), EEBP (2003) and PIER
(2005)
17
OPTIPOLYGEN
4.1 CHP
Within Work Package 1 of OPTIPOLYGEN some CHP plants in breweries and distilleries were
identified. See Figure 6 for a flow chart of a CHP in a brewery.
The applicability of CHP depends among other parameters on the capability to use efficiently
the heat cogenerated with the power. This is not a straightforward task especially in cases
where various temperature levels of heat are needed by the process. The optimum CHP fits to
the process needs becomes more difficult when batch operation is used (e.g. in breweries). For
the purposes of this report the following parameters shown in Table 7 have been considered to
be valid for CHP to be viable in a plant.
In several steps of the analyzed drink sectors breweries, juice producers and distilleries significant amount of heat is needed. Heat is normally needed at temperatures ranging from 40oC
up to 150oC. For simplicity CHP units generating heat at high temperatures have been considered for potential capacity calculations. These are turbine based CHP sets.
Other important parameter affecting the applicability of CHP is the total yearly operating hours.
Usually these should exceed 4000 hours/year for a CHP plant to be viable.
It has been already mentioned that efficient use of the heat cogenerated in a CHP unit defines
the applicability of CHP. If micro CHP is used then the total plant requirements should exceed
1.5 GWh /year based on the minimum yearly operating hours of the CHP unit and the minimum
size of unit available in the market.
18
OPTIPOLYGEN
4.2 Trigeneration
Trigeneration is based on the use of absorption cycles to produce low temperatures. The set-up
of an absorption cycle depends on the temperatures where this cycle is operating. Absorption
cycles are usually based on LiBr /water or on ammonia/water binary mixtures. The minimum
size of this equipment is about 100 kW. The important fact when trigeneration is applied efficiently is that electricity consumption virtually ceases as far as freezing or chilling concerns.
Moreover additional electricity is efficiently cogenerated by the CHP unit. Because of this a
double positive effect exists. Not only grid electricity consumption produced with low efficiency
(40-50%) stops, but also electricity generated with efficiencies up to 85% is produced. In contrast with a typical CHP only efficient electricity is generated and sent to the grid.
19
OPTIPOLYGEN
20
OPTIPOLYGEN
5 Technical Potential of on site power generation & emission savings by polygeneration in the Drink and Beverages Industry in EU15
5.1 Methodology.
The goal of this report is to determine within accuracy needed for strategic planning the technical potential of polygeneration CHP, trigeneration, RES in the Drink and Beverages Industry
(NACE 15.32 and the NACE family 15.9x except 15.97 malt production) in the EU15 countries.
Studies for the other food sectors are undertaken by the other partners of the OPTIPOLYGEN
project.
The results of the calculations are the total electrical energy per year, which can be generated if
fully use of the existing methodologies for cogeneration, trigeneration and polygeneration takes
place in the EU15 food industry split by country. On top of the total potential for electricity generation, the environmental impact of polygeneration potential will be quantified in terms of annual CO2 savings.
The model created by the OPTIPOLYGEN leader ESTIA for the estimation of the polygeneration potential in the fish and meat industry was modified and used for the calculation in the Drink
and Beverages Industry (see chapter 7.1 of the ESTIA report).
The same assumptions and calculations were used:
5.1.1
Assumptions
Calculations.
(1)
21
OPTIPOLYGEN
(2)
(3)
The biogas values were taken from experts in the different drink sectors and/or calculated via
the Volatile Solid Share of the biogenic waste multiplied by Nm3 biogas/kg of that solid waste
and the kWh per Nm3 biogas [kWh]
(4)
The data used in the calculations are summarised in the following table.
GENERAL DATA
COP of conventional freezing cycle 10oC.
COP of freezing for ammonia absorption cycle -10oC.
COP of conventional chilling cycle +4oC.
COP of chilling for ammonia absorption cycle +4oC.
heat /electricity ratio for CHP units
fuel/electricity ratio for biogas CHP units
mean CHP total cycle efficiency
mean Grid efficiency+ trans losses
CO2 savings /kWh el. cogenerated
CO2 savings /kWh el. trigenerated
CO2 savings /kWh of biogas produced
2
1
2,5
1,2
2,5
3
80
40
0,26
0,436
0,21
%
%
kgCO2/kWhel
kgCO2/kWhel
kgCO2/kWhbiogas
Data in the above table show a significant improvement of the CO2 emission savings when
electricity is trigenerated. This comes out from the fact that when electricity is trigenerated a
double benefit comes out. Electricity spend for compressors ceases i.e. there is reduction of the
electricity demand from the grid and additional efficient electricity is trigenerated and send to the
grid i.e. additional grid electricity from the grid is replaced. By using the values shown in the table for grid transmission losses and for CHP total cycle efficiencies etc, the values of CO2 savings were calculated by ESTIA.
The specific energy demand and solid waste generation of the different drinks sectors which
have been used for the calculations are shown in the tables in chapter 2.
22
OPTIPOLYGEN
products) and 15.96 (breweries) were estimated. The needed sector data came mainly from the
Eurostat database for the year 2004 or if not available for 2003. Additionally other information has been collected from different sources mentioned in the following chapters.
5.2.1
Figure 7 shows the total beer production in hectolitres (hl) for all EU15 countries in 2004 (NACE
code 15.96).
100.000
1.000 hl beer/year
90.000
80.000
70.000
60.000
50.000
40.000
30.000
20.000
10.000
0
be
dk
ger
gr
es
fr
ie*
it
lu*
nl
at
pt
fi
se
uk*
* Data 2003
Figure 7. Total beer production in the EU15 countries in 2004, Sources: EUROSTAT, Brewers of
Europe
One parameter which affects the polygeneration potential is the part of each countrys production that comes from plants whose capacity is above the determined thresholds shown in the
next table.
PRODUCTION CAPACITY THRESHOLDS FOR
POLYGENERATION TECHNOLOGIES
trigeneration
22.721 hl beer/year
cogeneration
27.975 hl beer/year
biogas
217.391 hl beer/year
In this way the plant size and the applicability of polygeneration technologies in the specific
plant are taken into account. Data for an estimation of the production size of the breweries in
each country were taken from the Brewers of Europe online database (number of breweries for
different production ranges available for 8 of analyzed 15 EU countries). The production size for
the breweries in the other 7 countries were estimated using this data and EUROSTAT data
about the total national beer production. In Figure 8 you find the share of this total national beer
production which is produced in breweries which fulfil the technology threshold for each technology.
23
OPTIPOLYGEN
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
be
dk
ger
gr
es
trigeneration
fr
ie
it
lu
cogeneration
nl
at
pt
fi
se
uk
biogas
Figure 8. Estimated share of national beer production beer which is produced in breweries which
fulfil the technology threshold
5.2.2
The following Figure 9 shows the total juice production data for the EU15 countries (NACE code
15.32x). Table 10 shows the production of the different sub-categories of NACE code 15.32.
Juice Production 2003 in EU15
(EUROSTAT, NACE 15.32x)
25.000.000
hl juice/year
20.000.000
15.000.000
10.000.000
5.000.000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
15321013 Frozen
unconcentrated
orange juice (Kg)
15321022 Unconcentrated
juice of any single citrus
fruit (excl. orange and
grapefruit) (liters)
TOTAL per
country
96.043.368
2.107.960
18.382.458
dk Denmark
537
47.712.258
545.154
3.373
927.107
1.223.622
56.766
34.093.003
de Germany
27.479.000
1.045.922.382
47.448.872
36.341.797
24.702.449
43.213.337
114.168.775
1.080.997.189
79.646.994
6.389.102
6.914.373
4.887.448
1.485.469
2.881.068
1.748.463
371.273.040
8.318.131
20.343.361
79.851.611
10.914.679
319.046.171
36.574.250
fr France
396.466.348
60.681.975
2.972.850
37.342.737
8.975.227
29.702.617
65.557.585
ie Ireland
18.676.671
68.573.000
38.340.556
7.404.870
109.738.399
27.394.148
24.527.625
201.169.337
24.147.304
116.533.786
84.561.283
2.392.794.801
102.204.454
846.321.243
601.699.339
18.676.671
432.722.239
0
4.652.000
167.598.944
17.713.597
127.596.971
0
be Belgium
gr Greece
es Spain
it Italy
lu Luxembourg
nl Netherlands
at Austria
4.652.000
60.730.284
6.325.148
1.082.865
17.921.078
81.539.569
pt Portugal
17.713.597
fi Finland
77.695.399
1.431.978
43.800
5.053.908
674.124
819.893
41.877.869
se Sweden
42.503.010
17.512.263
uk United
Kingdom
eu15
554.211.361
35.163.091
97.801.000
2.804.432.258
173.708.321
177.440.818
240.583.496 115.286.306
:
161.416.666
810.806.391
664.963.559 1.547.466.961 5.723.881.719
Table 10. Production of different juices in the EU15 countries, Source: EUROSTAT
* The NACE category frozen unconcentrate orange juice is given in kg, but was transferred for the total juice production into litre (1 kg=1l).
24
OPTIPOLYGEN
No differentiation between the different juices was made, as the main energy demanding processes (e.g. pasteurisation) forms part of every juice production. As there was no data available
about the production size of the companies, EUROSTAT data on number of enterprises broken
down by employment size classes was used for the polygeneration potential calculation. In order to make use of the technical thresholds in different polygeneration scenarios the technical
thresholds were calculated in minimum number of employees. Therefore, the average juice production per employee (7,000 hl/employee) was estimated via oral communication with Austrian
juice companies. For the analyzed technologies the following thresholds exist:
PRODUCTION CAPACITY THRESHOLDS FOR
POLYGENERATION TECHNOLOGIES
cogeneration
2 employees
biogas
57 employees
Table 11. Plant capacity threshold for polygeneration applications at juice producers
The statistical data on number of enterprises broken down by employment size classes only exists for the NACE family class 15.3x which also includes 15.31 (Processing and preserving of
potatoes) and 15.33 (Processing and preserving of fruit and vegetables). The share of the juice
companies (NACE 15.32) of the total number of NACE 15.3x family companies in the different
size categories has been estimated in the following way:
1) The total number of juice companies in many EU15 countries is known as well as the total
number of companies of the NACE 15.3x family. So the national share of juice companies within
the NACE 15.3x family has been calculated (see Figure 10).
2) Over the available nine countries the average production per company (in litre) was calculated. For the missing countries total production per year is known, but no number of companies. So the total production of these countries was divided by the calculated average production per company to estimate the number of companies in these six countries.
3) For the nine countries, where this data is available, this share has been multiplied with the
number of NACE 15.3x family companies in the different size categories. So the size distribution
of the juice companies is assumed to be the same as the NACE 15.3x family.
4) The estimation of the number of companies in each size category in the remaining six EU15
countries were made via the average share of the known 9 countries.
The final estimated number of companies in the different size categories in all EU15 countries
can be found in Figure 11.
25
OPTIPOLYGEN
60%
50%
40%
30%
20%
10%
uk
se*
fi*
pt
at
nl
lu*
it
ie*
fr
es
gr*
de
dk
be*
average
0%
* no data available
Figure 10. Ratio between number of juice companies and total NACE 15.3x family companies,
Source: EUROSTAT
140
number of enterprises
120
100
80
1_9
10_19
60
20_49
50_249
40
ge_250
20
uk
se
fi
pt
at
nl
lu
it
ie
fr
es
gr
de
dk
be
Figure 11. Estimated number of enterprises in given size classes; NACE codes 15.32, Source:
EUROSTAT
With this methodology the plant size and the applicability of polygeneration technologies in the
specific plant are taken into account.
5.2.3
The following Figure 12 shows the total spirits and alcohol production for the EU15 countries
(NACE code 15.91x-92x). Table 12 shows the production of the different sub-categories of
these NACE codes (in l pure alcohol).
26
OPTIPOLYGEN
8.000.000
7.000.000
6.000.000
5.000.000
4.000.000
3.000.000
2.000.000
1.000.000
0
be
dk
ger
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Figure 12. Total spirits and alcohol production (in hl pure alcohol), split by EU15 countries,
Source: EUROSTAT
NACE 15.91x
15911020 Spirit
obtained from
distilled grape
wine or grape
marc
15911040 R
um and tafia
15911030
Whisky
NACE 15.92x
15911063
15921100
15921200
15921203 Ethyl
15921205 Ethyl
15911080
Vodka of an 15911065 S
Spirits, liqueurs Undenatured ethyl Denatured ethyl alcohol and other
alcohol and
alcoholic
pirits
15911070 Pu
and other
alcohol of an
alcohol and other denatured spirits: other denatured
strength by
distilled
re alcohols
spirituous
alcoholic strength denatured spirits; agric. production
spirits:
volume of <=
from fruit
beverages
by volume >= 80% of any strength
(fermented mat.)
synthetic
45.4%
15911050
Gin and
Geneva
Sum country
be Belgium
221.877
2.177.207
307.820
2.741.523
5.448.427
dk Denmark
1.930
3.854
5.415
1.731.006
17.207
4.184.117
3.912.409
14.184.878
24.040.816
181.952.404
de Germany
165.762.366
16.190.038
gr Greece
2.192.253
41.610
286.560
16.764.451
12.519.898
3.381.310
35.186.082
es Spain
79.475.800
9.003.800
6.018.700
9.578.100
1.771.800
1.144.500
11.815.300
44.608.500
161.739.400
231.814.300
556.970.200
fr France
42.244.200
1.349.538
44.622.087
1.564.728
6.840.079
3.605.780
916.115
76.612.006
651.839.189
133.200.995
962.794.717
24.047.905
350.182
2.237.666
1.419.300
7.721.077
964.341
6.269.344
89.221.594
115.892.239
25.761.761
273.885.409
lu Luxembourg
nl Netherlands
290.000
1.098.000
828.000
9.900.000
7.795.000
99.000
10.653.000
30.663.000
at Austria
101.146
41.196
555.660
23.139
531.095
339.503
3.868.526
5.460.265
43.008
138.314
34.027.116
ie Ireland
it Italy
151.148
27.536
1.208.041
3.629.902
5.645.960
fi Finland
3.441.468
9.616.893
14.609.405
se Sweden
986.600
30491500
31.478.100
uk United Kingdom
510.785.000
3.685.366 38.460.775
11.925.392
564.856.533
171.534.511
523.838.123
58.102.481 63.197.810
69.444.337
6.308.645
20.208.800
255.725.087
1.126.928.354
439.142.687
2.734.430.835
pt Portugal
eu15
23.183.207
27.667.766
Table 12. Production of different spirits and alcohols (in l pure alcohol) in the EU15 countries,
Source: EUROSTAT
One parameter which affects the polygeneration potential is the part of each countrys production that comes from plants whose capacity is above the determined thresholds shown in the
next table.
PRODUCTION CAPACITY THRESHOLDS FOR
POLYGENERATION TECHNOLOGIES
cogeneration
4.972 hl pure alcohol/year
biogas
71.429 hl pure alcohol/year
In this way the plant size and the applicability of polygeneration technologies in the specific
plant are taken into account. Data for an estimation of the production size of distilleries were not
found in the literature. A similar approach as used for the juice industry using EUROSTAT data
broken down by employment size was also not possible. Meanwhile juice being one of in total
only three sub-categories the NACE code family 15.3x, the NACE code damily 15.9x (drinks ad
beverages) with 8 diferent sub-categories is too big to draw conclusions from the employment
size distribution of the whole 15.9x family to the spirits sub-categories. Via oral communication
with the Austrian Association of spirits producers and distilleries the following estimation was
made:
Over all EU15 countries a share of 95% of their national spirits production (in l pure alcohol) was estimated to fulfil the above mentioned technology threshold for cogeneration
application,
meanwhile the share for biogas applications was calculated with 70%.
EKV Austrian Energy Consumers Association
27
OPTIPOLYGEN
5.3 Results
5.3.1
Brewery.
The following figure shows the polygeneration potential in breweries in EU15 split by country.
Model set-up and calculations have been described in chapter 4.
Polygeneration potential in breweries in EU15
2.500
GWh el/year
2.000
1.500
1.000
500
0
be
dk
ger
gr
es
fr
ie*
cogeneration
it
lu*
trigeneration
nl
at
pt
fi
se
uk*
biogas
As expected polygeneration potential is proportional to the capacity of each countrys production. The highest potential comes for trigeneration applications (EU15: 7,900 GWhel/year) devoted to cover chilling and freezing loads. Their potential for energy savings are far higher than
CHP (6,300 GWhel) or biogas (1,500 GWhel). The exact figures can be taken from the following
table.
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
eu15
Trigeneration
439.953
220.654
2.258.752
103.222
827.197
460.381
218.583
359.945
7.894
622.959
223.329
203.524
127.700
99.266
1.682.638
7.855.996
MWhel
CHP
355.401
178.248
1.773.935
83.747
671.126
373.699
177.342
292.032
6.244
505.422
180.499
165.170
103.158
80.189
1.365.167
6.311.380
Biogas
94.014
47.152
213.409
23.561
188.814
107.624
50.646
82.160
967
144.339
45.396
46.864
28.147
21.880
389.866
1.484.838
Table 14. Total EU15 potential for polygeneration in breweries, in MWh el/year
28
OPTIPOLYGEN
Polygeneration potential is also very important if the EU Kyoto target of CO2 reduction is examined. Results are shown in Figure 14 and Table 15.
900.000
800.000
tones CO2/year
700.000
600.000
500.000
400.000
300.000
200.000
100.000
0
be
dk
ger
gr
es
fr
cogeneration
ie*
it
lu*
nl
at
trigeneration
pt
fi
se
uk*
biogas
Figure 14. CO2 savings potential from polygeneration applications in breweries in EU15
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
eu15
Tones CO2/year
Trigeneration
CHP
151.252
114.388
75.859
57.370
798.655
587.275
35.329
26.838
283.118
215.071
157.492
119.699
74.813
56.832
123.195
93.586
2.772
2.052
213.215
161.969
76.739
58.065
69.639
52.916
43.902
33.202
34.127
25.809
575.903
437.486
2.716.011
2.042.559
Biogas
19.743
9.902
44.816
4.948
39.651
22.601
10.636
17.254
203
30.311
9.533
9.842
5.911
4.595
81.872
311.816
Table 15. Total CO2 savings potential in breweries in EU15 when polygeneration is applied.
29
OPTIPOLYGEN
5.3.2
Juice
The polygeneration potential in the juice industry is the lowest of the three analyzed drink sectors, but it is still quite high with 1,740 Gwhel/year with cogeneration and 41 Gwhel/year with
biogas. As mentioned in chapter 2 no trigeneration potential could be estimated, mainly because of lack of information.
The total polygeneration potential of this industry sector in each EU15 country is shown in
Figure 15. The total numbers are shown in Table 16.
1.000
900
GWh el./year
800
700
600
500
400
300
200
100
0
be dk
de
gr
es
fr
CHP
ie
it
lu
nl
at
pt
fi
se uk
Biogas
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
eu15
Mwhel
CHP
Biogas
24.181
574
18.562
516
956.496
23.558
21.207
503
159.195
3.708
174.182
3.879
3.875
92
141.665
2.474
0
0
39.315
1.057
95.808
2.411
37.394
827
26.476
628
0
0
44.205
1.049
1.742.562
41.277
Table 16. Total EU15 potential for polygeneration in the Juice Industry, in MWh el/year
Figure 16 and Table 17 show the potential CO2 savings if polygeneration potential would be installed at all EU15 juice companies which produce more than the technology threshold calculated in chapter 4.
30
OPTIPOLYGEN
t CO2 savings/year
250.000
200.000
150.000
100.000
50.000
0
be dk de
gr es
fr
ie
it
CHP
lu
nl
at
pt
fi
se uk
Biogas
Figure 16. CO2 savings due to polygeneration application in the EU15 Juice Industry, in Tones
CO2/year
Tones CO2/year
CHP
Biogas
be
6.287
120
dk
4.826
108
de
248.689
4.947
gr
5.514
106
es
41.391
779
fr
45.287
815
ie
1.008
19
it
36.833
520
lu
0
0
nl
10.222
222
at
24.910
506
pt
9.722
174
fi
6.884
132
se
0
0
uk
11.493
220
eu15
453.066
8.668
Table 17. Total CO2 saving potential in the EU15 Juice Industry split by technology, in Tones
CO2/year.
5.3.3
Distilleries
The polygeneration potential in distilleries is less than for breweries, but still very high with 3,130
Gwhel/year with cogeneration and 1,060 Gwhel/year with biogas. As mentioned in chapter 2 no
trigeneration potential could be estimated, mainly because of lack of information.
The polygeneration potential from cogeneration and biogas in distilleries are shown in Figure 17
(for all EU15 countries) and in Table 18 the total numbers can be found. Figure 18 and Table 19
show the potential CO2 savings if this polygeneration potential is to be installed in the EU15 distilleries.
31
OPTIPOLYGEN
1.200
GWh el/year
1.000
800
600
400
200
0
be
dk
ger
gr
es
fr
ie
it
lu
cogeneration
nl
at
pt
fi
se
uk
biogas
6.246
27.559
208.580
40.335
638.481
1.103.696
0
313.967
0
35.150
6.259
39.007
31.717
36.085
647.521
3.134.604
Biogas
2.121
9.357
70.816
13.694
216.773
374.720
0
106.596
0
11.934
2.125
13.243
10.768
12.251
219.842
1.064.240
Table 18. Total EU15 potential for polygeneration in distilleries and in the spirits industry, in MWh
el/year
350.000
300.000
tones CO2/year
250.000
200.000
150.000
100.000
50.000
0
be
dk
ger
gr
es
fr
ie
cogeneration
it
lu
nl
at
pt
fi
se
uk
biogas
Figure 18. CO2 savings due to polygeneration application in distilleries in the EU15 countries
32
OPTIPOLYGEN
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
eu15
Tones CO2/year
CHP
Biogas
1.624
445
7.165
1.965
54.231
14.871
10.487
2.876
166.005
45.522
286.961
78.691
0
0
81.632
22.385
0
0
9.139
2.506
1.627
446
10.142
2.781
8.246
2.261
9.382
2.573
168.355
46.167
814.997
223.491
Table 19. Total CO2 savings potential in tones/year in the EU15 distilleries split by technology
33
OPTIPOLYGEN
6 Conclusions
Polygeneration potential for the most promising drink industries breweries, distilleries and
juice producers - has been calculated for the EU15 countries. Calculations were based on data
for energy consumption, which exist in the open literature or were collected via oral communication with companies of the Drink and Beverages Industry. The relevant data from EUROSTAT
for this industry sector were also used together with figures from sector associations (e.g. The
Brewers of Europe) and/or own estimations of the size of the plants located in every country.
Results show that the polygeneration potential for technical application (without explicit financial
aspects) in all EU15 countries reach 7,900 GWh el /year with trigeneration (only analyzed for
breweries), 11,200 GWh el/year with cogeneration and 2,600 GWh el with biogas application. If
this potential is realized, CO2 emission savings of 2.7 million tones with trigeneration, 3.3 million
tones with cogeneration and with biogas more than 0.5 million. tones CO2 /year are achieved.
The highest potential of a drink sector 7,900 GWh comes from using trigeneration (cogeneration with absorption chilling cycles) in breweries. This can be explained with the significant
amount of thermal energy consumed for heat and also for chilling loads at temperatures down
to 10C. In the other two analyzed sectors distilleries and juice producers no trigeneration
could be estimated because of the lack of detailed information on existing plants.
Biogas generation potential is limited mainly because of the size of the plants there is a need
for significant amount of biogenic wastes for a biogas installation to be viable and because of
the limited generation of by-products as most of them is sold as cattle food (e.g. spent grains
from breweries and distillers wash). Nevertheless, the technical biogas potential for energy use
has been analyzed.
7 References
Austrian Chamber of Commerce (2000), Branchenenergiekonzept fr Brauereien
BREF (2006), Reference document on BAT in the Food, Drink and Milk Industries, JRC, Seville,
Spain, January 2006
Brewers of Europe (2002), Guidance Note for establishing BAT in the brewing industry, 2002
Brewers of Europe, http://stats.brewersofeurope.org/stats_pages/plants_by_prod.asp.
EEBP (2003) Energy Efficiency Best Practice Program, A guide to energy efficiency innovation
in Australian wineries, Australian Department of Industry, Tourism and Resources,
http://www.isr.gov.au/assets/documents/itrinternet/WineGuide20040206170704.pdf
European Spirits, http://www.europeanspirits.org/OurIndustry/TheDistillationProcess.asp
EUROSTAT, http://europa.eu.int/com/eurostat
Heiss (Ed.), Lebensmitteltechnologie, 5th Edition, Springer, 1996
PIER (2005), Best Winery Guidebook: Benchmarking and Energy and Water Savings Tool for
the Wine Industry, Lawrence Berkeley National Laboratory, California, November 2005
Wouda and Pennartz (2002), Worldwide benchmark for energy efficiency in the brewing industry, Brauwelt International 2002/II, pages 106-110
Wouda (2004), Benchmarking Energy Efficiency World-wide in the Beer Industry 2003, Feedback report to the participating breweries, KWA Business Consultants
34
OPTIPOLYGEN
WP2
Contents
Contents .........................................................................................................................2
Abreviations...................................................................................................................4
1 Introduction.................................................................................................................5
1.1
Terms and Definitions....................................................................................5
1.1.1
Polygeneration .......................................................................................5
1.1.2
Cereals Industry .....................................................................................5
1.1.3
Corn Industry .........................................................................................5
1.1.4
Bakery Industry......................................................................................5
1.1.5
Tea Industry ...........................................................................................6
1.1.6
Coffee Industry ......................................................................................6
1.1.7
Geographical Coverage..........................................................................6
2 Process Descriptions ...................................................................................................7
2.1 Baking Industry....................................................................................................7
2.2 Cereals Industry ...................................................................................................9
2.2.1 Milling of Wheat to Produce Flour.............................................................11
2.3 Corn Industry .....................................................................................................15
2.4 Coffee Industry ..................................................................................................17
2.5 Tea Industry .......................................................................................................19
3 Energy Needs and Present Solutions ........................................................................21
3.1 Baking Industry..................................................................................................21
3.1.1 Proofing Process .........................................................................................21
3.1.2 Baking Process............................................................................................21
3.2 Cereals Industry .................................................................................................21
3.3 Corn Industry .....................................................................................................22
3.4 Coffee Industry ..................................................................................................22
3.4.1 Roasting ......................................................................................................22
3.5 Tea Industry .......................................................................................................22
4 Current On-Site Energy Production in the Industry Sectors.....................................24
4.1 Baking Industry..................................................................................................24
4.2 Cereals Industry .................................................................................................24
4.3 Corn Industry .....................................................................................................24
4.4 Coffee Industry ..................................................................................................24
4.5 Tea Industry .......................................................................................................24
5 Process Waste and By-Products ...............................................................................26
5.1 Baking Industry..................................................................................................26
5.2 Cereals Industry .................................................................................................27
5.3 Corn Industry .....................................................................................................28
5.4 Coffee Industry ..................................................................................................29
5.5 Tea Industry .......................................................................................................29
6 Potential New Technologies for On-Site Energy Production...................................30
6.1 Baking Industry..................................................................................................30
6.2 Cereals Industry .................................................................................................30
6.3 Corn Industry .....................................................................................................30
6.4 Coffee Industry ..................................................................................................30
6.5 Tea Industry .......................................................................................................31
7 Technical Potential of on Site Power Generation and Emission Savings by
Polygeneration in Europe.............................................................................................32
7.1 Methodology ......................................................................................................32
7.1.1 General........................................................................................................32
7.1.2 Assumptions................................................................................................32
7.1.3 Calculations.................................................................................................32
7.2 Baking Industry..................................................................................................34
7.2.1 Baking Industry Production Data................................................................34
7.2.2 Results.........................................................................................................36
7.3 Cereals Industry .................................................................................................39
7.3.1 Cereal Industry Production Data.................................................................39
7.3.2 Results.........................................................................................................40
7.4 Corn Industry .....................................................................................................42
7.4.1 Corn Industry Production Data ...................................................................42
7.4.2 Results.........................................................................................................44
7.5 Coffee Industry ..................................................................................................46
7.5.1 Coffee Industry Production Data ................................................................46
7.5.2 Results.........................................................................................................47
9 Conclusions...............................................................................................................50
10 Appendix.................................................................................................................51
11 References...............................................................................................................53
Abreviations
BTU
CHP
CIP
COD
CTC
HHV
LHV
MC
MW
TBTU
VOC
1 Introduction
This report is concerned with describing the general processes involved in the Baking,
Cereals, Corn, Coffee and Tea industry. It will specifically focus on the energy
requirements (thermal and electrical) for these industries, allowing an estimate of the
total European energy usage for the various industries to be made and the potential for
polygeneration to be assessed.
Due to the diverse spread of areas within this report each industry sector will be
tackled separately.
Polygeneration
Polygeneration is the use of multiple primary energy inputs to create multiple energy
outputs. The term primary energy includes fossil fuels, biofuels, renewable energy
sources etc. Energy output means the different forms of energy, which are useful in
an activity. In the case of the Food industry this could mean electricity, and heat at
various temerpeture levels i.e. steam, hot water, chilling mediums etc. Other useful
products, which might come out from a polygeneration process e.g. compost, will be
treated as secondary by-products of polygeneration.
This work aims to calculate the potential of polygeneration application in European
Cereals, Corn, Bakery, Tea and Coffee Industries and the corresponding emission
savings, which may arise.
1.1.2
Cereals Industry
The cereal industry includes all processes whose production incorporate, as a main
component wheat, rice, maize/corn (although this is also treated separately), millets,
sorghums, rye, oats, barley or other cereal products. Specifically this refers to
products identified by the NACE code 15.61.
1.1.3 Corn Industry
The corn industry refers specifically to industry whose production incorporates
corn/maize as a main component. Specifically this refers to products identified by the
NACE codes 15.60 and 15.62.
1.1.4
Bakery Industry
The bakery industry includes all processes whose products include bread, pastry
goods, cakes and biscuits. Specifically this refers to products identified by the NACE
codes 15.81 and 15.82.
1.1.5
Tea Industry
The tea industry includes all processes whose production incorporate tea as a main
component. Specifically this refers to products identified by the NACE code 15.86.
1.1.6
Coffee Industry
The coffee industry includes all processes whose production incorporate coffee as a
main component. Specifically this refers to products identified by the NACE code
15.86.
1.1.7
Geographical Coverage
This report covers the food processing industries outlined above in the EU-15 until
2004. However, the methodology could easily be extended to the other 10 countries
which joined in 2004.
2 Process Descriptions
2.1 Baking Industry
Bakeries vary widely in terms of scale and product range. Typically, they cover three
categories of products - bread and bread roll products, pastry products (pies, pasties
etc.) and specialty products (cake, biscuits, donuts and specialty breads etc.). The
baking industry uses a wide range of raw materials including prepared and partially
prepared products.1 For example:
Milk/Cream/Ice cream
Flour
Sugar
Fats/Emulsified bread fats, specialised bun fats
Oils
Stabilisers
Enzymes
Flavours
Yeasts
Improvers
Meat/Savoury fillings
Fruit/Dried and prepared fruit fillings
These are delivered and stored appropriately at the bakeries pending their use. This
may require refrigeration depending on the products. The flow-chart below outlines
the processes involved in the production of a typical product (i.e. bread) of the bakery
industry (Scheme 2.1).
All ingredients are pumped from large storage bins or silos into the dough
mixers automatically. The equipment is controlled by computer. The dough is
mixed intensely for about three minutes in a high-speed mixer in batches of
around 300 Kg. The temperature of the dough has to be carefully controlled at
28 C so that the yeast can grow and the dough become elastic.
When mixing is complete the large mass of dough is tipped into a divider. It is
then separated into individual pieces and shaped into a ball. The weight of
each piece of dough is very important to ensure that the finished product
complies with Weights and Measures Regulations.
The dough pieces are allowed to `recover` for about eight minutes in a
conveyor prover. Each piece of dough is then shaped and moulded and placed
in a tin, four pieces to a tin for a loaf of bread. The texture and size of the
dough piece is automatically controlled. The dough then travels through the
final prover, which allows the dough to rise gently for about one hour in
strictly controlled temperature and humidity conditions. This is typically 40
C with a relative humidity of 70-80%. The heat for this part of the process is
usually generated by steam generated from gas fired boilers.2 It is then ready
for baking.
The bread is baked for about 20 minutes at between 200 C and 400 C . The
loaves then go into a cooler. Cooling is usually done under carefully
controlled conditions to ensure correct temperature, humidity and time. This is
very important for quality. The cooling stage lasts for about two hours, which
enables the loaves to be sliced easily. The bread is then wrapped and ready for
despatch. 3
After havesting grains are transported to a separate area for further drying and
storage. Depending on the climate and the level of investment, drying may be
carried out in dryers or in the sun on a large flat surface such as a concrete or
hardened earth slab, on mats or plastic sheets or on roofs. It is important that
the grain is dried quickly to prevent mould growth, germination,
discolouration and insect infestation, but not too quickly as this can result in
cracking or case hardening. There are considerable quality advantages in
using one of the many designs of forced air dryer in which the temperature,
humidity and airflow are controlled. The grain is dried quickly and uniformly.
The grain is also stored in different types of silo dryers and therefore requires
less handling.
Depending on the outcome of the raw material inspection and the level of
contamination that is found, it may be necessary to clean the grain before it is
milled. This is necessary for two reasons: to prevent contamination of the
finished product and to protect the mill or dehuller from excessive wear or
damage by sand or stones. The cleaning method to be used depends to some
extent on the contaminants that are present, but it is usually sufficient to sieve
the grain to remove dust, sand, insects, small stones, weed seeds, etc. through
a fine mesh and retain chaff, leaves and larger stones on a coarse mesh.
The grain supplied to rural millers is in most cases, milled to a single flour
which is then sold. However, if millers are supplying bakers or other
secondary processors, there may be a demand for flours that have specific
properties or for composite flours. It is then necessary to blend different
grains before milling.
The most appropriate types of mill for different cereal products depend on a
number of factors, including the type of cereal being milled, the degree of
10
Jute or hessian sacks are commonly used to package flour or dehulled grain
but multi-layer paper and woven polypropylene sacks are increasingly being
used.
Sacks of flour or dehulled cereals are stored on pallets to keep them off the
floor of the store-room. The store-room is kept cool and dark with a good
ventilation to maintain a flow of air.
2.2.1 Milling of Wheat to Produce Flour
The flow diagram shown in Scheme 2.2 outlines the processes involved in the milling
of wheat to make flour.
11
Wheat arrives at the mill by truck, ship, barge, or train. Before the wheat is
unloaded, samples are taken to ensure it passes inspection. X-rays may be used
to detect any signs of insect infestation. Meanwhile, product control chemists
begin their tests to classify the grain by milling and baking a small amount to
determine end-use qualities. The results from these tests determine how the
wheat will be handled and stored. Millers may blend different wheats to
achieve the desired end product. The wheat will then be stored at the mill in
large bins.
The first milling steps involve equipment that separates wheat from seeds and
other grains, eliminates foreign materials such as metal, sticks, stones and
straw; and scours each kernel of wheat. It can take as many as six steps.
o Magnetic Separator. Removes iron and steel particles.
12
An impact scourer uses centrifugal force to break apart any unsound kernels
and rejects them from the mill flow. From the entoleter, the wheat flows to
grinding bins, large hoppers that will measure or feed wheat to the actual
milling process.
The wheat kernels, or berries, are now in far better condition than when they
arrived at the mill and are ready to be milled into flour. Wheat kernels are
measured or fed from the bins to the "rolls," or corrugated rollers made from
chilled cast iron.
From the rolls, the grist is sent way upstairs to drop through sifters. The grist
is moved via pneumatic systems that mix air with the particles so they flow,
almost like water, through tubes.
The broken particles of wheat are introduced into huge, rotating, box-like
sifters where they are shaken through a series of bolting cloths or screens to
separate the larger from the smaller particles. Inside the sifter, there may be as
many as 27 frames, each covered with either a nylon or stainless steel screen,
with square openings that get smaller and smaller the farther down they go.
The "scaled" fractions are sent to other roll passages and particles of
endosperm are graded by size and carried to separate purifiers.
In a purifier, a controlled flow of air lifts off bran particles while at the same
time a bolting cloth separates and grades coarser fractions by size and quality.
Four or five additional "break" rolls, each with successively finer corrugations
and each followed by a sifter, are usually used to rework the coarse stocks
from the sifters and reduce the wheat particles to granular "middlings" that are
as free from bran as possible. Germ particles will be flattened by later passage
13
through the smooth reduction rolls and can be easily separated. The reduction
rolls reduce the purified, granular middlings, or farina, to flour. The process is
repeated over and over again, sifters to purifiers to reducing rolls, until the
maximum amount of flour is separated, consisting of close to 75 percent of the
wheat.
Toward the end of the line in the millstream, if the flour is to be "bleached,"
the finished flour flows through a device, which releases a bleaching-maturing
agent in measured amounts.
The flour stream passes through a device that measures out specified
quantities of enrichment. The enrichment of flour with four B vitamins
(thiamin, niacin and riboflavin) and iron, begun in the 1930s. In 1998 folate,
or folic acid, was added to the mix of vitamin B. If the flour is self-rising, a
leavening agent, salt and calcium are also added in exact amounts.
Finally, the flour millstream flows through pneumatic tubes to the packing
room or into hoppers for bulk storage.7
14
The corn shipments arrive and are inspected and cleaned twice to remove cob,
dust, chaff and foreign materials before steeping, the first processing step,
begins.
The corn is placed in stainless steel steep tanks, which hold about 3,000
bushels of corn for 30 to 40 hours of soaking in 50 degree water. During
steeping, the kernels absorb water, increasing their moisture levels from 15
percent to 45 percent and more than doubling in size. The addition of 0.1
percent sulfur dioxide to the water prevents excessive bacterial growth in the
warm environment. As the corn swells and softens, the mild acidity of the
steepwater begins to loosen the gluten bonds within the corn and release the
starch. After steeping, the corn is coarsely ground to break the germ loose
from other components. Steepwater is condensed to capture nutrients in the
water for use in animal feeds and for a nutrient for later fermentation
processes. The ground corn, in a water slurry, flows to the germ separators.
15
Cyclone separators spin the low density corn germ out of the slurry. The
germs, containing about 85% of corn's oil, are pumped onto screens and
washed repeatedly to remove any starch left in the mixture. A combination of
mechanical and solvent processes extracts the oil from the germ. The oil is
then refined and filtered into finished corn oil. The germ residue is saved as
another useful component of animal feeds.
The corn and water slurry leaves the germ separator for a second, more
thorough, grinding in an impact or attrition-impact mill to release the starch
and gluten from the fibre in the kernel. The suspension of starch, gluten and
fibre flows over fixed concave screens, which catch fibre but allow starch and
gluten to pass through. The fibre is collected, converted to slurry and screened
again to reclaim any residual starch or protein, then piped to the feed house as
a major ingredient of animal feeds. The starch-gluten suspension, called mill
starch, is piped to the starch separators.
Gluten has a low density compared to starch. By passing mill starch through a
centrifuge, the gluten is readily spun out for use in animal feeds. The starch,
with just one or two percent protein remaining, is diluted, washed 8 to 14
times, re-diluted and washed again in hydroclones to remove the last trace of
protein and produce high quality starch, typically more than 99.5% pure.
Some of the starch is dried and marketed as unmodified cornstarch, some is
modified into specialty starches, but most is converted into corn syrups and
dextrose.
16
17
After screening to remove dirt and other debris, green coffee beans are
transferred to feed hoppers, which charge beans to the roaster, which may
operate on a batch or continuous basis. Roasting temperature typically ranges
from 370 oC to 540 oC with roasting times ranging from 5 to 20 minutes
depending on the desired coffee bean colour and flavour.
When the beans reach the desired colour, they are immediately quenched with
a water spray to halt the roasting process. Due to the elevated temperature of
the roaster, the water applied is emitted as steam.
The beans are then transferred to an enclosed cooler, where ambient air is
blown over and/or through the beans as they are stirred or agitated to facilitate
the cooling process. In the case of small, batch type roasters, this step is
carried out in an open bin (referred to as a cooler car) equipped with a rotating
stirring arm and blower to facilitate the cooling process.
The cooled beans are then transferred to a destoner, which is essentially an air
classifier which separates the beans from heavier material such as stones,
metal fragments, and other waste materials that were not removed during the
initial cleaning process. In the case of small, batch-type roasting operations,
operators typically rely on the initial cleaning process and do not mechanically
destone the beans after roasting.
Ground coffee and whole coffee beans are packaged into various sizes for consumer
and commercial distribution.
18
Scheme 2.5 Flow Diagram of the Tea Processing Industry, CTC Method10
Lorries bring tea from the garden to the factory. The process of making the
dried tea leaf starts with the fresh leaves being emptied into troughs where
they are allowed to go flaccid and dry a little before being moved on by
human labour. This starts the process of breaking down the cells after which
there is a 6-14 hour withering period using a rolling table or rotor wain.
Oxidisation occurs when the cells are disturbed so the process is to literally
break down the leaf.
The rollers used are based on those used in flour mills and consist of a series
of cutting edges that have to be kept sharp. Cutting and tearing gives a higher
concentration of tea by volume. Both orthodox (rolled tea) and Darjeeling
have less processing as the leaf is not cut so much and makes a weaker tea.
The CTC process takes 25-40 minutes and after that the marl, as it is now
called, is allowed to cool so that the oxidisation process can continue.
Temperature is crucial here for if it exceeds 35 C then the marl will be spoilt.
So cold air is blown onto the marl while it moves along a conveyer belt. Marl
used to be left on the floor to oxidise but it was difficult to check the speed of
oxidization when in heaps. There is no machine that can tell when
19
fermentation has finished. It is left to the skill and experience of the manager
and his staff to halt the process at the right time before drying.
This can take 45 minutes to 2.5 hours. The dryers are used to arrest the
oxidisation process. In the dryers, hot air blows through the marl and the chaff
is separated from it by suction. Then it is run through rollers that are covered
in plastic that creates static electricity to attract finer dust particles.
20
21
Table 3.1 above shows a breakdown of energy usage for each process involved in the
milling of wheat.
22
drying. Every Kg of made tea requires 3.5-6 kWh of thermal energy, 0.21 - 0.5 kWh
of electrical energy and 0.11 kWh of manpower.15
However, within Europe the tea industry is confined to blending and packaging of tea
imported from outside of Europe. These processes require electrical energy but little
heat or cooling energy.
23
24
However, this has no impact on the European tea processing industry as this is
confined to blending and packaging of pre-processed teas.
25
Waste Source
receival
and
damage,
spills.
deterioration,
Ingredient make-up
Mixing
Fermentation
Forming
Release agents
overspray, washdowns.
misforming, contamination /
staining.
overproduction, damage in
transport
Washing
equipment
plant
and
wastewater,
organic
material, oil and grease.
26
remaining 50% is used for cleaning and other ancillary activities and is ultimately
discharged as wastewater. Water consumption and wastewater generation rates
fluctuate considerably throughout a production day dependent on when cleaning
activities occur.
More than 90% of the waste load contained in bakery wastewaters comes from
ingredients that are lost and flow into floor drains during processing and cleaning.
Flour, sugar, yeast, shortening and oil are the major components. A waste assessment
undertaken for an Australian bakery found that over one tonne of ingredients can be
lost to wastewater over a week of production. Measurements of wastewater generated
from this plant indicated that for every tonne of dough produced, 0.5 kL of
wastewater, 1.9 Kg COD and 1.0 Kg suspended solids were generated.
By comparison, pastry, cake and specialty bread lines are often characterised as
generating large volumes of wastewater with relatively low concentrations of COD,
due to smaller scales of production and generally less efficient manual cleaning
practices. Cleaner Production strategies in these areas therefore should focus on
reducing the volumes of water used for cleaning. However, the production of sweet
goods such as doughnuts, cream buns, fruit pies can also generate high loads of COD
due to the high grease, sugar and fruit content of ingredients used. Bakery
wastewaters are also characterised as having high loads of oil and grease. Food grade
oils are used to grease baking trays prior to each baking and are usually applied using
automatic spray systems. The oil content in bakery wastewaters can generally be
attributed to over-spray from these systems. Other sources of oil and grease originate
from lubricants used on conveyor systems.
Solid wastes generated from bakeries are principally waste dough and out-ofspecification products. These wastes can represent a substantial cost to the company,
since costs include not only the cost of ingredients, but also the production, cleaning
and maintenance costs for producing the waste materials. Some benefit can be
recovered from these wastes by cooking waste dough to produce breadcrumbs and by
passing cooked product onto pig farmers for fodder.
27
28
29
The lack of any chilling or freezing requirements means that the trigeneration
potential within this industry is limited.
6.4 Coffee Industry
The following processes could be employed for polygeneration within the coffee
industry:
30
31
[kWhel]
(1)
When trigeneration is examined the calculation of the heat needed for potential
absorpton cycle, Heatabs, was calculated as:
Heatabs = [electricity need for chilling/COPel]/COPabs
(2)
[kWh]
(3)
[kWh]
(4)
Msolids = Total tonnes of product x specific solid waste generated by the process
(5)
The data used in the calculations are summarised in the following table:
COP of conventional freezing cycle
COP of freezing for ammonia absorption cycle
COP of freezing for ammonia absorption cycle
COP of freezing for ammonia absorption cycle
total dry solids content of the solid wastes
Part of the TDS which is VS -volatile solidsBiogas generated by 1 ton of VS
LCV of biogas
heat /electricity ratio for turbine based CHP units
mean CHP total cycle efficiency
mean Grid efficiency+trans losses
CO2 savings /kwh of el. Cogenerated
CO2 savings /kwh of el. Trigenerated
CO2 savings /kwh of biogas produced
Biogas generated by 1 kg of COD
1.2
0.8
2.5
1.2
30 %
50 %
580 Nm3
6 kWh/Nm3
2.5
80 %
40 %
0.26 kgCO2/kWhel
0.436 kgCO2/kWhel
0.21 kgCO2/kWhbiogas
0.35 Nm3/kg COD
33
Process
code
kWhel/ton kWhtherm/ton
bread
bread
oC
14.46
0
1 Dough Mixing
2 Proving
3 Baking
4 Cooling
Total
21.37
148 200 - 400
125
260.42
139.46
429.79
kgs COD
or
solids/ton
bread
28 COD
1.9
40
Solids
1
26
Potential
Biogas
produced kWhbioga
Nm3/ton s/ton
bread
bread
0.67
0.087
0.5
and 16% for semi-industrial bread, including frozen part-baked products and in-store
bakery production. Even now, in France, Italy and Germany craft bakers have by far
the largest market share although the situation is changing rapidly. Throughout
Western Europe the plant sector is taking market share away from the master bakers.
In Germany there are 18, 000 craft bakers but the number is expected to half in the
next five years. In the UK and Denmark, plant bakeries currently hold between 75
80% of the market.
7,000,000
6,000,000
tonnes/year
5,000,000
4,000,000
3,000,000
2,000,000
1,000,000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
35
uk
biogas production
tonnes/year
process heat
requirements/ton bread
kWh/ton -for cogeneration
169.37
429.79
577778
Table 7.3 Plant Capacity Threshold for Polygeneration Applications for the Baking
Industry
7.2.2 Results
Graph 7.2 show the polygeneration potential in the European bakery industry split by
country as calculated based on the model described in Section 7.1.1.
Polygeneration potential in Europe-15
350000
300000
MWhel /year
250000
cogeneration
trigeneration
200000
biogas
150000
100000
50000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
36
se
uk
726,795
Cogeneration
Trigeneration
Biogas production
1,844,288
37
tonnes CO2/year
100000
cogeneration
80000
trigeneration
60000
biogas
40000
20000
0
be
dk de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Graph 7.4 CO2 Savings Potential from Polygeneration Applications in the European
Bakery Industry
0
188,967
Cogeneration
Trigeneration
Biogas production
676,193
Graph 7.5 Total Co2 Savings Potential in the European Bakery Industry When
Polygeneration is Applied
38
Electri
city
Need Heat Need
Process code
Farming to produce raw
materials
Potential
Total solid Biogas
Wastes
produced
Temperature of Heat
Mass balance
relationship
expressed in
1tonne of cereal kWhel/to kWhtherm/ton
produced
n cereal cereal
oC
not included in
this study
Cleaning
2.1
0 RT
Milling
57.2
0 RT
kgs COD or
solids/ton
cereal
kWhbio
gas/ton
cereal
Nm3/ton
cereal
250
21.8
130.5
Solid
0.75
3.2
0 RT
Millfeed
Conveying
N/A
2.7
0 RT
28.1
0 RT
Table 7.4 Specfic Process Energy Need and Solid Generation Used in the
Calculations on the Cereal Industry
As can be seen the main energy requirements in cereal milling industry are electrical
with no requirement for eating or cooling. This means that the potential for
cogeneration or trigeneration of energy is very limited. However, significant amounts
of solid waste products are produced during the process and this presents an
opportunity for biogas production.
7.3.1 Cereal Industry Production Data
Cereal Production in EU-15 2002
80,000
70,000
60,000
50,000
40,000
30,000
20,000
10,000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
39
fi
se
uk
7.3.2 Results
Graph 7.7 shows the estimated polygeneration potential in the European cereal
industry. It can be clearly seen that the lack of heat or cooling requirements within
the milling process means that there is no real cogneration or trigeneration potential.
There is however the potential for the production of biogas.
Polygeneration Potential in EU-15 Cereal Industry
3500000
3000000
2500000
Cogeneration
2000000
Trigeneration
1500000
Biogas
1000000
500000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Cogeneration
Trigeneration
Biogas production
9,206,301
40
The potential emissions saving from the use of the biogas generated by the European
cereal industry is shown in Graph 7.9 below.
400000
Trigeneration
300000
Biogas
200000
100000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Graph 7.9 CO2 Savings Potential from Polygeneration Applications in the European
Cereal Industry
Graph 7.10 shows the total potential emission savings for the whole of Europe.
Total EU-15 CO2 Savings Potential from Polygeneration
0
0
Cogeneration
Trigeneration
Biogas production
1,933,323
Graph 7.10 Total CO2 Savings Potential in the European Cereal Industry
41
temperatu
heat need re of heat total solid wastes
Mass balance
relationship
kWhtherm
expressed in
kWhel/tonne /tonne
bushels of corn corn
corn
oC
not included in
this study
Process
code
Crop Growing
1 Steeping + Steep water eveporation
8.6
17.3
29.3
225.2
Potential
Biogas
produced
Nm3/ton kWhbioga
corn
s/ton corn
50
78.2 100-427
0 N/A
17.4
41 100-427
36.3
311.5 100-427
11.2
258.7 100-427
2.61
0.91
5.48
1.75
0.61
3.68
Total
Table 7.5 Specific Process Energy requirements and Solid Generation Used in
Calcualtions
Table 7.5 shows the energy requirements in a typical wet mill. Again the exact
values of these will vary from mill to mill depending on size, age, type of equipment
etc. These values were taken from a number of different sources25, 26
tonnes/year
tonnes/year
50,000
2000000
40,000
1500000
30,000
1000000
20,000
10,000
500000
0
0
be
be
dk
dk
de
de
gr
gr
es
es
fr
fr
ie
ie
it
it
lu
lu
nl
nl
at
at
pt
pt
fi
fi
42
se
se
uk
uk
2500000
tonnes/year
2000000
1500000
1000000
500000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
tonnes/year
biogas production
Corn Processing 1 + 2 + 3 + 4 + 5 + 6
process heat
requirements/ton corn
kWh/ton -for
cogeneration
1640.06
283843
Table 7.6 Plant Capacity Threshold for Polygeneration Applications for the Corn
Milling Industry
Table 7.6 shows the production threshold in order for polygeneration to be applicable
in the corn industry. This data was used to take into account plant size in each of the
EU-15 countries. The data used for each country was estimated based on the relative
size of each countries total production and are shown in the appendix.
43
uk
7.4.2 Results
Graph 7.13 below shows the estimated polygeneration potential in the European corn
milling industry as produced by the model described earlier.
Polygeneration potential in Europe-15
900000
800000
700000
MWhel /year
600000
cogeneration
500000
trigeneration
400000
biogas
300000
200000
100000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
There is no significant trigeneration potential within the corn milling industry as there
is no requirement for cooling/freezing within the production process. However, there
is the possibility of biogas production.
680,666
Cogeneration
Biogas production
2,899,738
44
There is a large potential for cogeneration within this food industry sector and this is
already being exploited. There is also a significant potential for the use of biogas
generated from solid waste from the industry.
The true impact of polygeneration potential is seen much more clearly when CO2
reduction is examined. Graphs 7.15 and 7.16 show the results of this analysis.
CO2 savings from polygeneration potential applications
250000
tonnes CO2/year
200000
150000
cogeneration
trigeneration
biogas
100000
50000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Graph 7.15 CO2 Savings Potential from Polygeneration Applications in the European
Corn Industry
296,771
Cogeneration
Biogas production
753,932
Graph 7.16 Total CO2 Savings Potential in the European Corn Industry When
Polygeneration is Applied.
45
Process
code
1 Roasting
kgs COD
or
solids/ton
coffee
0
2 Cooling
3 Destoning
0
0
4 Grinding
225
5 Freeze drying
648
1350
-40
155
873
Potential
Biogas
produced kWhbioga
Nm3/ton s/ton
coffee
coffee
0
0
1904
Table 7.7 Specific Energy Requirements in the Green Coffee Processing Industry
Table 7.7 shows the energy requirements in a typical green coffee processing factory.
Again the exact values of these will vary depending on size, age, type of equipment
etc. The values used were taken from a number of different sources. 28,29
tonnes/year
350,000
300,000
250,000
Roasted Coffee
Instant Coffee
200,000
150,000
100,000
50,000
0
be dk de
gr
es
fr
ie
it
lu
nl
at
pt
46
fi
se uk
biogas production
Graph 7.17 shows the production statistics for roasted and instant coffee in the EU15 in 2002. Table 7.8 shows the production threshold in order for polygeneration to
be applicable in the coffee industry. This data was used to take into account plant size
in each of the EU-15 countries. As the threshold values are so low it was assumed
that all of the coffee plants would have significant output to make polygeneration
viable (N.B. typical plant output aprox. 34 794 ton/year)
2708
2708
2708
788
Table 7.8 Plant Capacity Threshold for Polygeneration Applications for the Green
Coffee Processing Industry
7.5.2 Results
Graph 7.18 below shows the estimated polygeneration potential in the European
green coffee processing industry as produced by the model described earlier.
As can be seen there is a good potential for cogeneration and trigeneration. In
countries where significant amounts of freeze dried coffee are produced (i.e. de, es, nl,
uk) the potential for trigeneration is increased with respect to the cogeneration
potential due to the significant requirements for low temperatures in the freeze drying
process.
There is no potential for the generation of biogas as most of the wastes from the
coffee industry are generated in the early stages of processing which occur directly
after harvesting of the coffee cherries. These processes occur before the green coffee
beans are transferred to the roasting and blending factories. The wastes from the later
processing stages are minimal and therefore not suitable for use in biogas generation.
47
MWhel /year
120000
cogeneration
100000
trigeneration
80000
biogas
60000
40000
20000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
376,239
Cogeneration
Trigeneration
Biogas production
471,083
Graph 7.19 Total European Polygeneration Potential in the Green Coffee Processing
Industry
Graph 7.19 shows the total polygeneration potential for the EU-15 countries within
the green coffee processing industry.
48
60000
tonnes CO2/year
50000
40000
cogeneration
30000
trigeneration
biogas
20000
10000
0
be
dk
de
gr
es
fr
ie
it
lu
nl
at
pt
fi
se
uk
Graph 7.20 CO2 Savings Potential from Polygeneration Applications in the European
Coffee Industry
97,822
Cogeneration
Trigeneration
Biogas production
139,174
Graph 7.21 Total CO2 Savings Potential from Polygeneration Applications in the
European Coffee Industry
Graphs 7.20 and 7.21 show the results of translating the potential energy savings into
CO2 emissions savings. As can be seen the use of polygeneration in the coffee
processing industry would provide significant CO2 emissions reductions.
49
9 Conclusions
Based on the methodology outlined in Section 7.1 significant potential for
polygeneration has been identified in a number of food industry sectors within the
EU-15. These can be summarised as follows:
The baking industry shows a good potential for the use of cogeneration
and trigeneration.
The corn industry shows promise for the use of cogeneration and also
biogas production.
The European coffee industry shows significant potential for the use of
cogeneration and polygeneration but no potential for biogas production.
50
10 Appendix
Bakery Industry
Total bread production -2002 data- in tonnes/year
eu15
be
dk
My estimate =
gr
es
Germany (incGreece
fr
Spain
ie
France
it
Ireland
lu
Italy
nl
at
Luxembourg Netherlands
pt
Austria
fi
se
Portugal Finland
uk
Sweden
United Kingdo
365,000
6,400,000
326,425
2,362,000
3,394,450
399,625
3,960,000
48,175
960,000
44,325
73,375
235,312
769,975
1,812,000
56,081
34,408
112,430
13,057
19,496
135,778
15,985
30,993
1,927
37,307
1,773
2,935
10,301
30,799
86,486
% of production exported
EU Bread production =
de
Denmark
1,402,025
% of production coming ou
48
85
30
48
48
48
80
48
48
61
48
48
85
48
80
Trigeneration
% of production coming ou
48
85
30
48
48
48
80
48
48
61
48
48
85
48
80
Biogas production
% of production coming ou
726795
45593
21019
130076
10615
76810
110384
21659
128775
1567
39673
1441
2386
13551
25039
98208
Trigeneration
1844288
115694
53337
330076
26936
194910
280107
54961
326775
3975
100673
3658
6055
34386
63538
249208
Biogas production
726,795
45593
21019
130076
10615
76810
110384
21659
128775
1567
39673
1441
2386
13551
25039
98208
Trigeneration
1,844,288
115694
53337
330076
26936
194910
280107
54961
326775
3975
100673
3658
6055
34386
63538
249208
Biogas production
188,967
11854
5465
33820
2760
19971
28700
5631
33482
407
10315
375
620
3523
6510
25534
Trigeneration
676,193
42418
19555
121020
9876
71462
102699
20151
119810
1458
36911
1341
2220
12607
23296
91370
Biogas production
9916311.76
1481600 -
633384
100
75
1477896 -
2E+06 -
100
75
100
75
100
75
231717
54392
40652 223587
9542 52483
540673
126914
823883
193393
40652 223587
9542 52483
540673
126914
0 823883
0 193393
0 214210
0 84319
100
75
111120 611160
51
pt
fi
se
uk
Portugal Finland SwedenUnited Kingdo
2,900 19,400
100
75
718576
100
75
100
75
100
75
94855 100160
22266
23511
39297
9224
262884
61708
0
0
94855 100160
22266
23511
39297
9224
0
0
0
0
262884
61708
0
0
24662
9708
10217
4022
0
0
0
0
68350
26905
26042
10251
0
0
100
0
0
100
0
0
100
0
0
100
0
0
100
0
0
100
0
0
100
0
0
100
0
0
100
0
0
100
0
0
100
0
0
100
0
0
100
0
0
100
0
0
100
0
0
0
0
1887522 177258
0
0
0
0
907575 3025673
0
0
0
0
85504 864664
0
0
7342
0
0
79337
0
0
206943
0
0
58761
0
0
0
0
171364 237593
0
0
998994
0
0
0
0
907575 3025673
0
0
0
0
85504 864664
0
0
7342
0
0
79337
0
0
206943
0
0
58761
0
0
0
0
171364 237593
0
0
998994
0
0
1542
0
0
16661
0
0
43458
0
0
12340
0
0
35986
0
0
49894
0
0
209789
R oasted C
F reeze D r
1,522,191,185
71,954,270
27,579,732
408,778,355
9,627,041
105,857,000
214,629,572
391,939,000
90,018,000
27,096,602
33,269,973
53,347,440
71,898,200
175,637,886
102,830
87,998,094
786,935
26,482,000
263,000
12,237,000
16,027
13,000
16,196 ,000
47,739 ,000
100
100
0
100
100
0
100
100
0
100
100
0
10 0
10 0
0
1 00
1 00
0
1 00 ##
1 00 ##
0 0
100
100
0
100
100
0
100
100
0
100
100
0
10 0
10 0
0
100
100
0
9 0585
9 0585
0
2133
2133
0
23458
23458
0
4756 2
4756 2
0
0
0
0
0
0
0
19948
19948
0
6005
6005
0
7373
7373
0
11822
11822
0
1593 3
1593 3
0
3589
3589
0
100
100
0
100
100
0
100
100
0
100
100
0
10 0
10 0
0
1 00
1 00
0
1 00 ##
1 00 ##
0 0
100
100
0
100
100
0
100
100
0
100
100
0
10 0
10 0
0
100
100
0
1 9500
6 7019
0
174
599
0
5868
20169
0
0
0
0
0
0
0
58
2 00
0
0
0
0
2712
9320
0
0
0
0
0
0
0
4
12
0
3
10
0
10579
36358
0
T O TA L E U R O P E A N P O L Y G E N E R A T IO N P O T E N T IA L in M W h el.
C ogenera
376,2 39
1 5945
6134
11 0086
2308
T rigenerat
471,0 83
1 5945
6190
15 7605
2733
B iogas pro
0
0
0
0
0
29326
43627
0
4756 2
4756 2
0
0
0
0
869 12
870 54
0
0
0
0
22660
29268
0
6005
6005
0
7373
7373
0
11825
11834
0
1593 6
1594 3
0
14168
39947
0
225 97
226 59
0
0
0
0
5892
8773
0
1561
1561
0
1917
1917
0
3075
3078
0
414 3
414 6
0
3684
14923
0
T O TA L E U R O P E A N C O 2 S A V IN G S F R O M P O L Y G E N E R A T IO N P O T E N T IA L in ton es C O 2/year.
C ogenera
97,82 2
4 146
1595
2 8622
600
7625
1236 6
0
T rigenerat
139,1 74
4 146
1619
4 9341
785
13860
1236 6
0
B iogas pro
0
0
0
0
0
0
0
0
52
868 54
868 54
0
11 References
1
53
28
Energy Best Practice Guide for Dong Suh Food Industry at Bupyang
http://www.seav.sustainability.vic.gov.au/ftp/advice/business/case_studies/DongSuhFoodCase0_a.pdf
29
54
OPTIPOLYGEN - APPENDIX VI
OPTIPOLYGEN
OPTimum Integration of POLYgeneration
in the sugar, chocolate & confectionary industry
WP2
Potential for Polygeneration in the
Sugar, Chocolate & Confectionary Industries
Mark Whiteley
Energy for Sustainable Development (ESD)
Ltd Overmoor, Neston, Corsham Wiltshire,
SN13 9TZ, UK
Table of Contents
1
2
EXECUTIVE SUMMARY
On-site power generation in conjunction with the processes involved in the food industry may form an
efficient alternative to and a step towards sustainability. It is, however, important to estimate the real
potential of on-site power generation methods which are currently available in the European food
industry.
This document focuses on the section of the food industry covered by the sugar, chocolate and
confectionary industries. The polygeneration potential in this sector is significant, as is demonstrated
in the following sections. The calculations were based upon available data for energy consumption,
which has proven to be difficult to obtain. The levels of detail required for the analysis of the project
are not available in the public domain and it has proven difficult to source information for these
industries. Where possible, data from Eurostat has also been used for sugar and chocolate
production across the EU, coupled with estimations for the size of the processing plants located in
every country.
Results show that the polygeneration potential for all EU15 countries for these specific industrial
sectors reaches 5,936 GWhe/year in the sugar industry and 243 GWhe/year in the chocolate industry.
These result in CO2 emissions savings of over 1,420 and 57 thousand tonnes of CO2/year for each
industry respectively.
Typically, cogeneration is best suited to the sugar manufacturing industry, while trigeneration is best
suited for chocolate. This is because sugar manufacturing has intensive electricity and heat
requirements, while chocolate also has a significant cooling requirement (but not freezing). Both
industries has the potential for biogas production from the raw product (sugar beet/molasses or cocoa
husks respectively), but this potential is currently hardly used. For the sugar industry, the by-products
are also used for other purposes (animal feeds, fertiliser, soil improving agent, bio-ethanol), so there is
limited scope for these products being rerouted for biogas applications in the short term. However, the
potential does exist. For the chocolate industry, the biogas potential is limited and only exists if the
relevant plant performs the whole chocolate process, starting with the cocoa beans themselves.
INTRODUCTION
2.1 GENERAL
The aim of this document is to describe the general processes in the sugar, chocolate andn
confectionary industries, focusing on energy usage (thermal and electrical) and the type of processes
using this energy, with the goal to estimate the total polygeneration potential in this sector in Europe.
PROCESS DESCRIPTION
Temperature (C)
Pre-first
First
Second
Third
Fourth
Source: Earle with Earle
85
73
60
51
Liquor
concentration (%)
65%
82%
84%
86%
89%
Crystallisation of the sugar takes place in vacuum pans which boil the juice at reduced temperatures.
At a pre-determined concentration the juice is seeded with small sugar crystals which act as nuclei for
6
larger crystal growth. When the crystals reach the correct size the resulting sugar crystal and syrup
mix (massecuite) is put into a centrifuge for separation. By spinning rapidly in a perforated cylindrical
basket, the syrup is thrown off through the screen holes. This syrup is boiled again in another series
of vacuum pans to produce raw sugar, and then a third time to generate final product sugar and
molasses. The raw and final product sugar is returned to the main process at the second filtration
stage in order to recover as much of the sugar as possible. The molasses is either mixed with the
diffusion pulp to form the animal feed pellets, or can be sent for fermentation and conversion to the
fuel bio-ethanol.
The damp crystallised sugar produced by the separation process is washed in hot water, and dried
with filtered air in a rotating drum granulator. The dried sugar passes over screens which separate the
various sizes of sugar crystals producing pure white sugar crystals.
sales
Sugar beet
top shoots
(fertiliser/
animal feed)
Cleaning &
preparation
pellets
(animal feed,
etc - 6%)
Diffusion
alcohol
Fermentation
final product
sugar
raw sugar
molasses (3%)
Vacuum
boiling
Vacuum
boiling
Purification
(carbonation)
conditioned
lime
Filtration
Evaporation
(vacuum
boiling)
steam
Filtration
Crystallisation
(vacuum boiling)
'seed' crystals
Separation
(centrifugal
spinning)
Washing
hot water
Drying (14%)
retail packs
Grading &
packing
bags
bulk
soil improving
agent (5%)
Electricity is used in all the processes, while heat is used as both steam and hot water. The most
energy intensive part of the system is at the evaporation stage, owing to the high latent heat
requirements of boiling the water off the thin juice.
The type of energy consumed in each plant does not vary very considerably, as the processes
required to refine the sugar are relatively standardised. Owing to high competition from sugar cane
imports and within the industry, the number of sugar beet factories having reduced by 35% between
1992/1993 and 2003/2004. This rationalisation across the EU means that only the larger scale and
efficient plants are the ones that are still in existence, which has increased the level of standardisation
across the industry. Typically, the energy ratio between the individual production processes is shown
in Table 3.2.
Table 3.2 Typical energy consumption breakdown in the sugar industry
Technology
Pumps
Fans
Stirring and mixing
Evaporation and distillation
Drying
Industrial buildings
Compressed air
Boilers & steam distribution
Refrigeration
Industrial cooling systems
Total
Source: Dalkia
4
5
6
7
Evaporation
Crystallisation
Separation
Washing & drying
0.19
0.17
0.16
0.11
There are a number of by-products from the sugar industry that could be use for biogas applications.
Anaerobic digestion is already used at some sugar factories across the EU, as part of the factories
water treatment circuits. In these cases, the resultant methane is used in the plants boilers to further
reduce fossil fuel consumption. At the current time, the beet tops, diffusion waste and molasses are
already used for other applications. However, all of these could be used for the production of biogas
and are considered for this report.
Table 3.4 Specific process energy need & solid generation used sugar industry
Sub process
name
1
2
3
4
5
6
7
Cleaning &
preparation
Diffusion
Carbonation
Evaporation
Crystalisation
(vacuum boiling)
Separation
Washing &
drying
Mass balance
relationship
expressed in 1kg
of sugar beet
Electricity
need
Heat need
Enter
Exit
kWhe/tonne
sugar beet
kWhthh/tonne
sugar beet
0.95
0.95
0.27
0.21
0.19
0.27
0.21
0.19
0.17
0.17
0.16
0.16
0.11
Peak
process
temperature
o
kg/tonne
sugar
beet
Nm of
Biogas/kg
solid wastes
50
0,05-0,07
1
4
35
8
25
10
400
30
70
85
85
80
680
60
0,05-0,08
4
8
0
90
0
93
90
10
0,05-0,08
0,05-0,07
taste depend on how the roasting goes ahead. After roasting, the shells are removed and the cocoa
beans are crushed into cocoa nibs.
Roasted and cleaned cocoa-nibs are carefully ground and refined. The finer the cocoa-nibs are
ground at this stage, the fuller and finer the taste of the chocolate. The size of the cocoa particles
passed through the grinding machinery, should not exceed 75 microns such cocoa is called coca
liquor.
The cocoa liquor contains 54% cocoa butter, the very valuable substance essential for the production
of real chocolate. Cocoa liquor is heated up to 95105C and is then pressed. As a result, cocoa
butter is separated from the solids, which are subsequently used for the production of cocoa powder.
The cocoa liquor, sugar and part of the cocoa butter are mixed in specified proportions. After mixing,
the mass is ground - the finer the crushing, the more delicate the taste. After mixing and grinding the
chocolate mass is subjected to conching: intensive mixing at high temperature. Conching is a very
long process (up to 24 hours) and as a result, the superfluous moisture and the residual tannins are
evaporated from the chocolate mass, and the cocoa solids are rounded off. After processing the
chocolate mass, the rest of the components are added according to the recipe: cocoa butter and
lecithin (for mass attenuation and optimized moulding); natural flavouring agent (vanilla - for a subtler
and more delicate aroma).
The next stage of the production process is to solidify the liquid chocolate. To do this, it is essential
that the fat in the chocolate sets in the correct crystal form, otherwise the chocolate will be damaged.
Tempering, which is a long and complex process, performs this task. In tempering, the hot chocolate
is firstly cooled down to 28 for crystal formation, and then reheated to 32 in order to melt out any
unstable crystals. Once the tempering is completed, the chocolate is now ready to be formed into its
final shape.
The final stage of the chocolate production process is the forming into its final shape. This can take
the form of enrobing, moulding or panning. Depending upon the process and the required product, the
chocolate undergoes cooling and/or drying until the final product is produced.
Following production, chocolate should be transported and stored within the range of 15 to 21,
with a relative humidity of less than 75%. If these conditions are not observed, the chocolate can
bloom and lose its marketable appearance.
The chocolate manufacturing process can be divided into three distinct stages, as is highlighted in
Figure 3.2. Some chocolate manufacturers only focus on one stage, while the ones that have multiple
stages keep them totally separate. This is because different quality standards are required at each
stage of the process, with different inputs and outputs. For example, the treatment of the cocoa beans
is a relatively dirty process, with significant (relative) waste involved. The other two parts of the
process are clean, with minimal wastage and higher quality levels required. For the purpose of this
analysis, the main energy impact occurs at the production of the cocoa butter, up until the stage where
it is ready to be formed into the final consumer product. This is the middle of the three stages.
10
Cocoa beans
Cleaning, shelling,
winnowing, alkalising,
roasting
Waste water,
cocoa shells
Heat (120-140C)
Liquor grinding
& refining
Pressing
Cocoa powder
Cocoa butter
Enrobing
Dairy,
confectionary &
baking
Heat (95-105C)
Mixing &
grinding
Conching
(stirring)
Tempering
Moulding
Panning
Cooling &
drying
Consumer
markets
Heating
Cooling
The type of energy consumed in each plant can vary, depending upon the final product being
produced, as it is the final product that determines which of the final processes is used, as in enrobing,
moulding or panning. However, the main energy consumption occurs in boilers and steam
distribution, as shown in Table 3.5. Cooling is also a significant user of energy at the chocolate
factory, which is an ideal opportunity for trigeneration.
11
The only by-product from the chocolate industry is the waste water and cocoa shells at the very
beginning of the process, so this is the only potential biogas application. However, as many chocolate
factories buy-in the processed cocoa butter, the factories have no wastes that can be practically used
for energy purposes. Therefore, for the OptiPolygen project, only the energy consumption aspects of
polygeneration have been considered.
Table 3.6 Specific process energy need & solid generation used chocolate industry
Sub
process
name
1
2
3
4
5
6
Cleaning,
winnowing,
roasting
Grinding,
refining &
pressing
Mixing &
grinding
Conching
Tempering
Enrobing,
moulding,
panning
Mass balance
relationship
expressed in
1kg of cocoa
beans
enter
exit
Electricity
need
Heat
need
kWhe/tonne
cocoa beans
kWhth
/tonne
cocoa
beans
Peak
process
temp.
o
Cooling
need
kWhth
/tonne
cocoa
beans
Cooling
temp.
Total solid
wastes
Kg
/tonne
cocoa
beans
Nm of
Biogas/kg
of solids
or COD
0.85
10
70
140
50
17.5
0.85
0.45
15
30
105
0.45
0.45
80
45
35
0.45
0.45
0.45
0.45
0.45
0.45
44
3
32
6
1
10
82
32
32
20
0
10
28
5
12
IN
THE
SUGAR
AND
There is significant potential in the sugar and chocolate industries for on-site power generation, as
both industries have significant heating requirements. Table 4.1 provides an overview of the power,
heating and cooling requirements of the industrial sectors covered in this part of the study and
Sugar
Chocolate
Confectionery
33
333
3
2
2
333
2
3
3
2
33
33
2
3
33
3
3
2
33
3
2
3
3
2
Based upon these conclusions, there are definite opportunities for polygeneration applications in these
industries, both of which are technically viable. In the sugar industry, there is already significant use of
CHP, but polygeneration technologies are underutilised in the chocolate industry.
A lot of attention, in recent years, has focused on small scale mini and micro CHP systems. These are
units with a nominal electricity generating capacity of less than 1 MW. With the on-going consolidation
in the sugar industry, the requirement for CHP units is increasing, with small generation units being of
the order of 5-10 MW, so mini and micro units are not suitable for the sugar industry. Chocolate plant
are smaller than in sugar processing factories, so there is some opportunity for mini CHP units, but not
for very small micro units.
13
Molasses (3%)
The largest of these is the wastes produced by the diffusion process (68%), which is currently dried,
pelleted and used for animal feed. However, some sugar plant in the EU does also use this waste for
biogas production, using anaerobic digestion.
The waste from the carbonation process are extracted from the lime and used as a soil improving
agent. The calorific value of this waste is not high and is not suitable for biogas production.
The top shoots from the initial treatment of the sugar beet consists of approximately 5% of the total
mass balance of the sugar beet. Currently, they are used in the animal feed industry, but there is the
potential to use them for energy purposes instead.
Molasses has relatively high calorific value and has the potential to be used for energy purposes.
However, this also is already used as a by-product. This can be in the animal feed industry or
fermented to create bio-ethanol. Both these processes make good use of the molasses and are
established technologies. However, the molasses will be considered for polygeneration applications.
14
POTENTIAL
TECHNOLOGIES
FOR
ON-SITE
POWER
GENERATION AND POLYGENERATION IN THE SUGAR AND
CHOCOLATE INDUSTRIES
By investigating the utilities and the by-products and effluents involved in the sugar and chocolate
industries, the following technologies have been identified as potential participants for polygeneration:
Trigeneration Use part of the heat generated in a CHP unit to meet cooling requirements via
absorption cycles
Use of by-products for energy consumption using anaerobic digestion to produce biogas
Each technology is associated with thresholds and economical values affecting applicability with
respect to the size and other important characteristics of the plant.
6.1 CHP
As already mentioned, the potential for CHP in both the sugar and chocolate industries is very high, as
both industries have high electricity and heat demand profiles.
For the sugar industry, CHP is already extensively used as a power source owing to the high energy
intensity of the sugar production process. Despite typically running on a single batch process, lasting
on average 21-22 weeks in the UK (British Sugar), the intensity of round the clock production during
this period makes the use of CHP economic, despite the relatively low overall load factor (38%-42% or
approximately 3,500 hours/year). Typically, sugar refining plant in the EU already has CHP plant
installed and operational.
In the chocolate and confectionary industries, there is the potential to install CHP plant, but as there is
also a significant cooling requirement in the manufacture of these products, it is better suited for
trigeneration plant (see below).
6.2 TRIGENERATION
Trigeneration is based upon the use of absorption cycles to produce cooling. The set-up of an
absorption cycle depends upon the temperatures where this cycle is operating, and is covered
elsewhere in this report.
As trigeneration also involves the need for cooling requirements in the production process, it is not
suitable for the sugar industry. However, it is ideal for the chocolate and confectionary industries, as
all three types of energy are used: electricity, heating and cooling. For these industries, each plant
should be configured to take into account the ratio and intensity of each of the three energy types. On
this basis, it is possible to determine the optimal configuration for trigeneration plant in these
industries.
15
Direct combustion
Anaerobic digestion
Gasification
Direct combustion of the by-products generates heat, which can be used to generate steam, which
can be used in the plants for heating purposes and/or for power generation. High water content of the
by-products (up to 70%) requires a significant amount of energy for drying before combustion, so the
energy needed to prepare the by-products for combustion limits the suitability of this option.
Anaerobic digestion occurs by digesting the by-products in insufficient oxygen, to produce biogas
(methane and other combustible gases). This is a promising way of treating by-products and is not
restricted by the water content of the waste material. The biogas produced can be used for driving
CHP units or generating steam and hot water. The post-digestion waste can be land filled, as its
organic content has been reduced and has been sterilised.
Gasification is a technology that is much less mature for industrial applications.
Very few
installations exist and because of this, gasification in the sugar and chocolate industries has not been
considered in the OptiPolygen project.
In both the sugar and chocolate industries, the by-products that are produced are already used in
other industries, leading to minimal wastage and use of landfill. At the current time, these by-products
are used in the most economic manner, with the recycling for energy purposes having already been
considered and discounted. However, for the purpose of the OptiPolygen project and despite the
situation, the by-products, where relevant, have been considered for energy purposes.
16
7.1 METHODOLOGY
7.1.1 General
The goal of this report is to determine the technical potential of polygeneration (CHP, trigeneration, byproduct use) in the sugar, chocolate and confectionary industries within the wider frame of the
European food manufacturing industry.
The results of the calculations will be the total electricity per year which can be generated with the full
use of polygeneration technologies. This part of the work is focused on the sugar, chocolate and
confectionary food products sectors, (i.e. the industrial plants whose products fall within NACE the
15.83 and 15.84 codes.
The countries covered by the analysis include the 15 Member States of the EU.
In addition to the electricity production calculations, the environmental impact of the polygeneration
potential has been estimated in terms of annual CO2 savings.
7.1.2 Assumptions
The assumptions that have been made for this calculation are as follows:
A CHP or trigeneration plant produces electricity, heat and cooling (trigeneration only) at all
times. Optimal use fuel has is assumed to take place during energy generation, so dumping or
excess heat is not considered as an option. Only electricity can be dumped, through exports
to the electricity grid.
For the chocolate and confectionary industries, it has been assumed that a minimum operating
profile of 4,000 hours (equivalent to a 46% load factor) is necessary for a CHP or trigeneration
unit to be economically attractive
The sugar industry contradicts the assumption that 4,000 operating hours per year are
necessary for economic attractiveness. Therefore, this factor has been reduced to 3,000 hours
for the sugar industry.
As this report is a technical analysis of the potential for polygeneration applications. financial
factors have not been taken into account.
7.1.3 Calculations
The calculations used for assessing the polygeneration potential in the sugar, and chocolate industries
are the standard ones for the OptiPolygen project. Details of the methodology are provided in the
section for the fish and meat industries. The specific energy demand and solid waste generation of
the processes in the sugar and chocolate processing industries are shown in the following tables.
17
Table 7.1 Specific process energy need & solid generation used sugar industry
Sub process
name
1
2
3
4
5
6
7
Mass balance
relationship
expressed in 1kg
of sugar beet
Cleaning &
preparation
Diffusion
Carbonation
Evaporation
Crystalisation
(vacuum boiling)
Separation
Washing &
drying
Electricity
need
Heat need
Enter
Exit
kWhe/tonne
sugar beet
kWhthh/tonne
sugar beet
0.95
0.95
0.27
0.21
0.19
0.27
0.21
0.19
0.17
0.17
0.16
0.16
0.11
Peak
process
temperature
o
kg/tonne
sugar
beet
Nm of
Biogas/kg
solid wastes
50
0,05-0,07
1
4
35
8
25
10
400
30
70
85
85
80
680
60
0,05-0,08
4
8
0
90
0
93
90
10
0,05-0,08
0,05-0,07
Table 7.2 Specific process energy need & solid generation used chocolate industry
Sub
process
name
1
2
3
4
5
6
Cleaning,
winnowing,
roasting
Grinding,
refining &
pressing
Mixing &
grinding
Conching
Tempering
Enrobing,
moulding,
panning
Mass balance
relationship
expressed in
1kg of cocoa
beans
enter
exit
Electricity
need
Heat
need
kWhe/tonne
cocoa beans
kWhth
/tonne
cocoa
beans
Peak
process
temp.
o
Cooling
need
kWhth
/tonne
cocoa
beans
Cooling
temp.
Total solid
wastes
Kg
/tonne
cocoa
beans
Nm of
Biogas/kg
of solids
or COD
0.85
10
70
140
50
17.5
0.85
0.45
15
30
105
0.45
0.45
80
45
35
0.45
0.45
0.45
0.45
0.45
0.45
44
3
32
6
1
10
82
32
32
20
0
10
28
5
18
tonnes/year -2003-
5,000,000
4,000,000
3,000,000
2,000,000
1,000,000
0
BE
DK
DE
GR
Es
FR
IE
IT
LU
NL
AT
PT
FI
SE
UK
Table 7.3 Plant capacity threshold for polygeneration applications for the sugar industry
Process heat
requirements
for cogeneration
400000
19
Process heat
requirements for
trigeneration
not appl.
Biogas
production
6410
The plant size and the applicability of polygeneration technologies in the specific plant are taken into
account. The data used for each country has been estimated based upon the relative size of each
countrys total production.
The following figure shows the total chocolate and confectionary production in the EU15. Unlike
sugar, Eurostat information is not provided for all Member States for all types of chocolate and
confectionary produced, so the numbers are likely to be understated. The chocolate and
confectionary sector is also divided into many different sub-sectors, as shown in
20
Confectionary
Chocolate
tonnes/year
1,000,000
800,000
600,000
400,000
200,000
0
BE DK DE GR ES FR
IE
IT
LU
NL
AT
PT
FI
SE UK
Figure 7.2: Chocolate and confectionary production in the EU15 in 2003 (Eurostat)
As already stated, the focus of the research for OptiPolygen has been on the chocolate industry.
Within this industry, total chocolate production has been divided into three main categories in
conjunction with the processes presented in Figure 3.2. These categories involve:
As these three parts of the production process occur in series, all of them use 100% of the product
available for them, rather than sharing a particular raw material.
One more parameter which would affect the polygeneration potential is the part of each countrys
production that comes from plants whose capacity is above the determined thresholds, as shown in
the following table.
Table 7.5 Plant capacity threshold for polygeneration applications for the chocolate industry
Tonnes/year
Process heat
requirements for
cogeneration
Process heat
requirements for
trigeneration
5760
82286
57600
5760
18581
28800
21
Biogas
production
12381
0
0
The plant size and the applicability of polygeneration technologies in the specific plant are taken into
account. The data used for each country has been estimated based upon the relative size of each
countrys total production.
7.3 RESULTS
Sugar industryFigure 7.3The following Figure 7.3 shows the polygeneration potential in the sugar
industry in Europe, split by Member State.
Cogeneration
800000
Trigeneration
Biogas
600000
400000
200000
0
BE DK DE GR ES FR IE
IT LU NL AT PT FI SE UK
In total, the EU15 results for the polygeneration potential are shown in Figure 7.4
22
Cogeneration
Trigeneration
Biogas production
2,472,787
3,462,734
Figure 7.4 Total EU15 sugar processing industry potential for polygeneration
The outcome of the above figures is that the higher potential comes from cogeneration applications,
as there is no trigeneration potential in the industry.
The polygeneration potential is also very important in terms of achieving CO2 reductions. The results
are shown in the following two figures.
23
tonnes CO2/year
250000
200000
Cogeneration
Trigeneration
150000
Biogas
100000
50000
0
BE DK DE GR ES FR
IE
IT
LU NL AT PT
FI SE UK
Figure 7.5 CO2 savings potential from polygeneration application in the EU15 sugar industry
519,285
Cogeneration
Trigeneration
Biogas production
900,311
0
Figure 7.6 Total CO2 savings potential from polygeneration in the EU15 sugar industry
24
35000
30000
MWhel /year
25000
cogeneration
trigeneration
20000
biogas
15000
10000
5000
0
BE
DK
DE
GR
ES
FR
IE
IT
LU
NL
AT
PT
FI
SE
UK
In total, the EU15 results for the polygeneration potential are shown in Figure 7.8
25
36,473
Cogeneration
115,425
Trigeneration
Biogas production
91,182
Figure 7.8 Total EU15 chocolate processing industry potential for polygeneration
The outcome of the above figures is that the higher potential comes from cogeneration applications,
plus there are significant opportunities from trigeneration. Biogas production is limited to the
production of cocoa butter, where the shells are created as a by-product.
The polygeneration potential is also very important in terms of achieving CO2 reductions. The results
are shown in the following two figures.
CO2 savings from polygeneration potential applications
12000
10000
Tonnes CO2/year
8000
cogeneration
6000
trigeneration
biogas
4000
2000
0
BE
DK
DE
GR
ES
FR
IE
IT
LU
NL
AT
26
PT
FI
SE
UK
Figure 7.9 CO2 savings potential from polygeneration in the EU15 chocolate industry
7,659
Cogeneration
30,011
Trigeneration
Biogas production
19,441
Figure 7.10 Total CO2 savings potential from polygeneration in the EU15 chocolate industry
27
CONCLUSIONS
The polygeneration potential in the sugar and chocolate industries has been calculated for the EU15
countries. The calculations were based upon available data for energy consumption, which has
proven to be difficult to obtain. The levels of detail required for the analysis of the project are not
available in the public domain and it has proven difficult to source information for these industries.
Where possible, data from Eurostat has also been used for sugar and chocolate production across the
EU, coupled with estimations for the size of the processing plants located in every country.
Typically, cogeneration is best suited to the sugar manufacturing industry, while trigeneration is best
suited for chocolate. This is because sugar manufacturing has intensive electricity and heat
requirements, while chocolate also has a significant cooling requirement (but not freezing). Both
industries has the potential for biogas production from the raw product (sugar beet/molasses or cocoa
husks respectively), but this potential is currently hardly used. For the sugar industry, the by-products
are also used for other purposes (animal feeds, fertiliser, soil improving agent, bio-ethanol), so there is
limited scope for these products being rerouted for biogas applications in the short term. However, the
potential does exist. For the chocolate industry, the biogas potential is limited and only exists if the
relevant plant performs the whole chocolate process, starting with the cocoa beans themselves.
28
REFERENCES
29
OPTIPOLYGEN
WP2
Potential for Polygeneration in the
Dairy Industry
Author:
Jonas Dahl, PhD, M.Sc. Chemical Engineer
FORCE technology, Denmark
Table of contents
TABLE OF CONTENTS ..................................................................................................2
1
INTRODUCTION.....................................................................................................3
METHODOLOGY ........................................................................................................................................ 12
CONCLUSIONS....................................................................................................19
1 Introduction
The aim of this report is to describe the general processes in the dairy industry, focusing
on energy usage (thermal and electrical) and the type of processes using this energy.
Thereby the total use of energy in the dairy industry in Europe and the potential for polygeneraton will be estimated.
2 Process description
The raw material for the dairy industry is raw milk which is transported in cooled tanks
from the farmers to the dairies for further processing. On arrival, the milk is tested for
appearance, smell and temperatures, and a sample is taken for analysis. Depending on
the regulations in the country a whole series of tests are carried out on this sample. The
reception of the cold milk includes preheating by so called thermisation in order to extend refrigeration time of the raw milk.
Thermisation requires temperatures of 57-68 C for 15 seconds. Afterwards the raw
milk is cooled down to <6 C again and stored in cooled silos waiting for the test results.
When the milk is approved, the milk is separated into cream and skim milk. These two
streams are pasteurised prior to the subsequent processing into dairy products (see
Figure 1) .
.
Pasteurization heating milk or cream to destroy microorganisms and enzymes requires heating the milk to at least 71.7 C for 15 seconds, followed by an immediate
cooling to <6 C again.
Depending on the type of consumer milk product aimed at, cream fat is again added to
the skim milk in order to reach a wanted fat content (standardization).
After the standardization some milk products are further heat treated in order to extend
storage. This types of thermal treatment could be sterilization or ultra heat treatment:
Sterilization filled milk bottles are sterilized after packaging bottles conveyed through
a steam chamber at 110-130 C for 10-30 minutes
Ultra heat treatment quick sterilization process that does not destroy milk chemistry
steam heats milk to 140 C for a period of 1-2 seconds
The type of treatment used depends on what dairy product will be produced from the
milk. Pasteurization of the milk is, however, minimum requirement and is performed in
all dairies prior to storage or further processing of the milk. The pasteurization is in modern dairies done in a continuous process in a stainless steal heat exchanger with hot
water as heat medium, but can in some older dairies still be performed in batch processes. The batch method requires however that the milk is heated to 62.8 65.6 C for
at least 30 min and subsequently immediately cooled to 6 C again. The batch method
is both less energy efficient and more time consuming than the continuous process and
therefore rarely used today.
Based upon the dairy product wanted, the further processing of the raw milk can be divided in two main categories:
3
1) Fluid milk processing involves processing of liquid milk for direct consumption,
as well as creams, chocolate and other flavoured milks and buttermilk
2) Industrial milk processing involves the processing of milk into value-added products. These include cheese, butter, ice cream and other frozen products, condensed and evaporated milk, dried milk powder, yogurt and other cultured milk
products..
Due to the complexity of industrial milk processing the category of industrial milk processing is further subdivided into 5 categories making a total of 6 categories which can
be used to describe the basic processes used in the dairy industry (see figure 1) .
These categories are:
Guide to energy efficiency opportunities in the diary processing industry, National Dairy Council of Canada; June, 1997
4
Cheese
Virtually all cheese is made by coagulating milk protein (casein) in a manner that traps
milk solids and milk fat into a curd matrix. This curd matrix is then consolidated to express the liquid fraction, cheese whey. Cheese whey contains those milk solids which
are not held in the curd mass, in particular most of the milk sugar (lactose) and a number of soluble proteins.
The processing of cheese:
1) If the milk has not been pasteurized before the milk is first homogenized and pasteurized to destroy bacteria and harmful microorganisms.
2) The milk is then coagulated in a process catalyzed by bacterial cultures or enzymes.
3) The resulting curd is cut into small pieces to aid in the expulsion of whey, which is
then drained from the curd by heat or mechanical means.
4) The next step, known as knitting, chemically changes the curd using lactic acid
and concludes in the salting and pressing of the cheese. The knitting process differs slightly for different varieties of cheese.
5) The cheese is ripened for an amount of time under specific temperature (32 80C) and humidity conditions. These variable conditions give cheese varieties a
unique aroma, appearance, texture, and taste.
6) Finally, cheese is packaged and stored in cooled storage.
2.3
Butter
Milk destined for butter making must not be homogenised, because the cream must remain in a separate phase. After separation, cream to be used for butter making is heat
treated and cooled under conditions that facilitate good whipping and churning. It may
then be ripened with a culture that increases the content of diacetyl, the compound responsible for the flavour of butter. Alternatively, culture inoculation may take place during churning.
Butter which is flavour enhanced using this process is termed lactic, ripened or cultured
butter. This process is very common in continental European countries. Although the
product is claimed to have a superior flavour, the storage life is limited. Butter made
without the addition of a culture is called sweet cream butter.
2.4
Ice-cream
Ice-cream is a dairy based product which typically contains 6 to 12 % fat, 7.5 to 11.5 %
non-fat milk solids, and 13 to 18 % sugars. Stabilisers, emulsifiers, colours and flavours
are also added. Sugar is usually added as sucrose, and the non-fat milk solids are usually from skimmed milk solids. The fat source may be milk, cream, butter or butter oil.
Most ice-cream contains vegetable fat. The ingredients are blended, heated to around
70 to 75 C and homogenised. The mixture is then pasteurised by heating to 80 85 C
for 2 to 15 seconds before cooling and ageing by holding at chilled temperatures for 4 to
24 hours.
Colours and flavours are added at the ageing stage. Continuous freezers are used to
rapidly freeze the ice-cream down to around -6 C, with compressed air being introduced into the icecream during the freezing process. The increase in volume due to the
addition of air is known as over-run. The ice-cream is filled into containers and frozen
further in tunnel freezers operating at -30 to -40 C.
2.6
Cultured products
Yoghurt is a fermented milk product which differs from cheese in that rennet is not
added and thickening occurs as a result of acidification by lactic acid bacteria. The main
ingredients of yoghurt include milk; milk powders or concentrated milk or ultra-filtered
milk, and stabilisers, such as modified starches. Most of the yoghurt produced is manufactured in bulk before the addition of fruit and/or flavourings. The main steps in the
manufacture of yoghurt are as follows. The fat and non-fat solids content of the milk is
first increased by the addition of milk powders. Stabilisers may be added at this stage.
The milk is then homogenised at a temperature of around 55 C and heat treated at 80
to 90 C for 30 minutes in a batch process, or 90 to 95 C for 5 minutes in a continuous
process. The heat treated milk is then cooled to around 40 to 43 C and seeded with
two starter organisms Streptococcus salivarius subspecies thermophilus and Lactobacillus delbruecki subspecies bulgaricus. Fermentation takes around 4hours. At the
end of the process, the product is cooled to 15 20 C, using either tank cooling coils
or, more commonly, tubular or plate heat-exchangers. Fruit and flavours are blended
into the yoghurt which is then cooled to less than 5 C and filled into pots ready for storage and distribution.
The energy utilization in a dairy varies extensively depending on the spectra of products
produced at the specific dairy plant, but also on the technologies applied. E.g. most
European dairies have today continues processing in contrast to old dairies with batch
processing. In dairies using continuous processing indirect heat exchanging between
cold and hot flows are frequently used and depending on how effective each installation
is performed and controlled, energy savings of up to 80% can be achieved.
Although seldom temperatures above 90 C are required, heating is mainly done by
steam from a steam boiler, as smaller and thereby cheaper installations of pipes are required as for hot water. The use of steam as the heating medium on the other hand
gives less opportunity for reusing some of the lower temperature waste heat from the
process. Given these facts the average energy utilization on a dairy can only roughly be
estimated as it is multidimensional dependant and varies widely from plant to plant.
As shown in Figure 1 the processing of milk to dairy products comprises several complex stages depending on the product. It is not the aim of this project to describe the
energy consumption of all these stages in detail, and thus general energy consumption
values for each product taken from the literature will be used for the estimations.
As previously shown the total energy consumed at a dairy depends on the range of
products being produced at this typical dairy. Processes which involve the concentration
and drying of milk (production of milk powder) are very energy intensive while the production of market milk is on the other extreme and only involves some heat treatment
and packaging (see Table 2)
Table 2: Example of specific energy consumption for various dairy products ii
Product
Electricity consumption
Fuel consumption
(GJ/ton product)
(GJ/ton product)
Market milk
0.20
0.46
Cheese
0.76
4.34
Milk powder
1.43
20.60
Butter
0.71
3.53
Moreover, the energy consumption is also depending on the age of the plants and modern plants have significantly lower energy consumption compared to older plants (see
Table 3)
Table 3: Example of energy consumption for a selection of milk plants
Type of plant
Total energy consumption
(GJ/ ton milk processed)
0.34
Modern plant with high-efficiency
regenerative pasteurizer and
modern boiler
Modern plant using hot water for
0.50
processing
Old, steam based plant
2.00
Range for most plants
0.5 -1.2
However, in order to be able to estimate the potential use of energy in dairies in Europe
today average energy consumption from the literature were extracted per kg produced
dairy products such as milk, cheese, butter, milk powder, cultivated products and ice
cream. Some of these values are available in the literature while others had to be estimated (see section 7 and 8).
On an average European dairy, 80 % of the energy consumption is heat and 20% is
electric energy used in motors (stirring and pumps), refrigeration and light. This does
however depend on the product spectra produced at the specific plant. More detailed
data and estimations are
www.agrifood-forum.net/publications/guide/
9
Power Reliability power failure and subsequent loss of refrigeration systems results in spoiled milk products and a loss of revenue
Food Safety a constant supply of steam and hot water ensures that milk products are being properly disinfected and processing equipment is being sanitized
Cost of Energy milk processing is an energy intensive industry.
Current CHP installations are typically installed in large dairies producing milk powder.
These dairies are also the plants with the highest energy demand. In Denmark five large
dairies have installed CHP and all these are based upon gas turbines in the size range
of about 4-5 MWe using natural gas for fuel.
In Sweden two dairies using renewable energy have been identified so far. The first is
the large milk powder production plant in Vimmerby, which is has installed a 38 MWth
biomass boiler for CHP productioniii . Another, example is the BIOTRANSiv dairy plant in
UME, Sweden. This dairy both produces and uses biogas from anaerobe digestion of
rest products in an integrated CHP process. BIOTRANS is also an EU-demonstration
project and will be included as a bets practice case in this project as well.
In Ireland the Ballyragget facility which is currently Europes largest multi-product dairy
facility is another example of a dairy plant using CHP v. The facility incorporates 11 factories which can handle 900 million litres of milk and 785 million litres of whey annually.
The heat to power ratio (HPR) for such a complex modern dairy producing several dairy
products is around 3.3:1
Electric demand of 11,5 MW and 85 tonnes of steam per hour. Electricity was previously
bought and heat for drying and evaporation was produced from heavy fuel oil in a 30
year old boiler. After extensive analysis two 5 MW gas turbines CHP units were selected and installed. The hot flue gas from the gasturbines are used in steam waste
boiler which also has the opportunity to burn more gas without affecting the electricity
production.
http://www.arlafoodsingredients.com/C1256E6E00365BBD/O/5E53A8831765D385C1256EA9003CD75C
www.biotrans.se
v
M. Tynan, Case study of the benefits of combined heat & power, part of the news letter 401-2005 Energy use in Dairy Processing
iv
10
odours. Nowadays, a number of opportunities exist for the recovery or utilization of the
lactose and protein content of whey. However, it has only been in recent years that they
have become technically and economically viable, by e.g. ultra filtration
Furthermore, another very large waste product is effluent water with contents of rest
milk and other products from the cleaning of pipes and other equipment at the dairy.
The organic load of these effluent streams varies depending on cleaning practices and
whether batch or continuous processes are used. Batch processes require a greater
frequency of cleaning and thereby higher amounts of effluents has to be disposed of.
New stringent requirements for waste streams from dairy plants have significantly reduced the amount of COD in todays dairy waste streams.
7 Technical Potential of on site power generation & emission savings by polygeneration in the dairy industry in
Europe
11
7.1 Methodology
7.1.1 Model development
In order to estimate the current energy usage and the potential polygeneration in the
dairy industry statistic data fro the production of milk, cheese and milk powder in the different European countries was collected. Based upon these data assumptions on the
total energy need (electrical and thermal) was estimated.
Moreover, from these values also the amounts of waste/rest products were calculated
and thereby the also potential for biogas production.
7.1.2 Used basic data for energy calculations
A general estimation of the potential polygeneration is very difficult to perform accurately as the energy solutions and use of energy are specific for each site and thus only
average assumptions can be made. In the following the estimations are done by generalising data from literature values from dairies in Canada, Denmark, Australia and Germany [ ?? ?? ?? ]. Table 4 show the average data chosen which are subsequently
used for the calculations of the polygeneration potential in this report. The data is subdivided for each of the main dairy products in order to be able to use available data for
the production of dairy products in Europe (see Table 5). Some specific energy data
was not found in the literature but was necessary for the calculation of the potentials.
This data was thus estimated by best possible assumptions ad are indicated in italics in
Table 4.
Table 4: Averaged specific data used for the calculations of polygeneration potential
Electric
kWh/tonne
product
% of el for
Heat
cooling resp
freezing
kWh/tonne
product
1 Pasteurised
55
40%
milk
2 Cheese
211
30%
3 Butter
197
25%
4 Milk powder
350
15%
5 IceCream
450
45%
6 Cultivated
55
40%
products
Explanations: figures in italics are estimated values
COD
Potential
Biogas production
kg/tonne
prod
Nm3 /
kg product
128
0.002
0.001
1 205
980
4 000
900
130
38
5
7
5
0.010
13.30
1.75
2.42
1.75
0.002
12
Germany
France
UK
Netherlands
Italy
Spanien
Ireland
Denmark
Sweden
Belgium
Austria
Finland
Portugal
Greece
Luxembourg
Consumer
milk 1
5.017
3.865
6.557
1.461
3.109
3.837
540
488
1.274
600
704
710
899
415
14
Butter 1
Cheese
(cows milk) 1
444
411
123
102
127
46
137
47
52
39
32
59
26
1
3
Conserved
milk products 1
382
458
167
164
0
13
97
104
48
237
7
23
18
0
0
IceCream2
555
400
0
64
471
309
27
27
124
151
2
51
20
29
0
Yoghurt2
1.747
1.548
402
165
198
0
25
45
28
0
183
115
80
24
0
vi
vii
www.mejeri.dk
www.eu.int/comm/eurostat
13
Table 6: Basic technical data used for the evaluation of threshold values
As a significant part of the heat needed is used for steam production the case of micro turbine is used as base scenario.
Minimum CHP driver nominal electric power
Heat /electricity ratio of the CHP driver (2.5 for turbine, 1.2 for
ICE)
Minimum yearly operating hours for viable operation
Minimum heat produced by this set is 1.250.000kWh /year. To
secure efficient use of heat
cogeneration can be applied in plants where minimum yearly heat
needs are more than
to secure applicability of CHP due to yearly variations and various proceessing conditions increased heat demand is needed by
As such minimum heat needs for the application of CHP are
100 kW
Useful
heat
2.5 /electricity ratio
4000 hours /year
Cogeneration
Trigeneration
tonnes /year
tonnes /year
1 Pasteurised milk
Biogas production
tonnes /year
11 719
32 727
2 Cheese
1 250
6 000
32 581
3 Butter
1 531
14 619
247 619
429
10 286
179 434
1 667
2 963
247 619
11 538
32 727
4 Milk powder
5 IceCream
6 Cultivated products
In order to use the threshold values on the production capacities the distribution of the
production of these dairy products is needed. i.e. how much of the products is produced
in what size of factories. In Table 8 the production distribution among dairies in Denmark listed.
Table 8: Production distribution among dairies in Denmark
Milk
powder
% of
% of prod
% of prod prod
77,2
87,9
100
Cheese
tonnes/y
over 6.000
2.000 - 5.999
1.000 - 1.999
800 999
400 799
Consumer
milk
Butter
17,9
3,3
0,3
1
5,7
2,1
1,7
0
under 400
0,3
Source: Danish dairy associationviii
2,7
tonnes/y
over 40.000
10.000 39.999
5.000 - 9.999
1.000 - 4.999
under 1.000
% of prod
87,5
9,4
2,8
0,2
0,2
By comparing the production distribution in Denmark, Table 8, with the threshold values
listed in Table 7 the percentage of the production complying with the threshold values
can be estimated. Due to lack of data from rest of Europe, these percentages are used
viii
www.mejeri.dk
14
as a fist assumption for all other EU-15 countries (see Table 9). In case of future available data these values can easily be adjusted.
1
2
3
4
5
6
Cogeneration
Trigeneration
% of EU-15 production
% of EU-15 production
Consumer milk
Cheese
Butter
Milk powder
Ice-Cream
Cultivated products
95
95
95
100
70
90
Biogas production
% of EU-15 production
90
40
40
100
50
50
0
5
0
0
0
0
After applying the percentage of the total production of dairy products Table 9 with the
production values in Table 8, the specific electric and thermal energy requirements in
Table 4 and the technical data in Table 10 the potential polygeneration energy in EU-15
countries was calculated according to equation 1-5 below.
Potel = Heat needed x (Pel/Ptherm)
[kWhel]
(1)
(Table 10)
(2)
When potential biogas production is examined the heat needed for the energy produced
was calculated as:
PotelBG = Biogas x Pel
(3)
(4)
(5)
15
Table 10: Technical data for calculation of polygeneration potentials and CO2 emission savings
GENERAL DATA
COP of conventional freezing cycle
COP of freezing for ammonia absorption cycle -30oC.
COP of conventional chilling cycle +4oC.
COP of chilling for ammonia absorption cycle +4oC.
1,2
0,8
2,5
1,2
70% %
0,35 Nm3/kg COD
6 kWh/Nm3
2,5
80
40
0,26
0,436
0,21
%
%
kgCO2/kWhel
kgCO2/kWhel
kgCO2/kWhbiogas
16
Table 11: Calculated potentials for polygeneration for EU-15 in the dairy industry
divided by product
1
2
3
4
5
6
sum
Cogeneration
Trigeneration
MWhel /year
MWhel /year
Pasteurised milk
Cheese
Butter
Milk powder
IceCream
Cultivated products
1 434 394
3 046 992
614 088
2 405 200
611 216
229 751
8 341 640
Biogas production
MWhel /year
513 618
643 790
64 294
100 217
477 512
81 002
1 872 432
0
10 664
0
0
0
0
10 664
Figure 2: Calculated potentials for polygeneration for EU-15 in the dairy industry
divided by country
2.500.000
Cogeneration
Trigeneration
Biogas production
1.500.000
1.000.000
500.000
17
Luxembourg
Greece
Portugal
Finland
Austria
Belgium
Sweden
Denmark
Ireland
Spane
Italy
Netherlands
UK
France
0
Germany
MWh el/year
2.000.000
2.240
815.945
Cogeneration
Trigeneration
Biogas production
2.168.826
400.000
300.000
200.000
100.000
18
Luxembourg
Greece
Portugal
Finland
Austria
Belgium
Sweden
Denmark
Ireland
Spane
Italy
Netherlands
UK
France
Germany
tonnes CO2/year
500.000
9 Conclusions
Polygeneration potential in the dairy processing industry has been calculated for the
Eur-15 countries.
Calculations were based on data for energy consumption, which exist in the open literature and collected via energy audits performed by the author. The data from Eurostat for
dairy production in Europe was also used combined with estimations of size distribution
of the dairy plants located in every country. This distribution was mainly done based on
data from the Danish dairy industry
The results show that the total technical polygeneration potential for all EU-15 countries
for dairy industry sector is estimated to 10,2 TWhel /year resulting in CO2 emission savings of 3 million tonnes CO2 /year.
The dominating part 82% of the technical potential is from co-generation and the rest is
tri-generation by absorption cooling or freezing. The potential for biogas production is
only valid for cheese production and the anaerobic digestion of waste whey. The total
amount of this is in comparison to the technical potentials for co- and tri-generation very
small.
19
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