Solutions for a low carbon production in the food industry

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1 Solutions for a low carbon production in the food industry Brunner Christoph Muster-Slawitsch Bettina, Weiss Werner AEE - Institute for Sustainable Technologies (AEE INTEC) A-8200 Gleisdorf, Feldgasse 19 AUSTRIA Sustainable Thermal Energy Management in the Process Industries International Conference (SusTEM2011)

2 Content Vision Green Brewery Methodology and Green Brewery tool Implementation concepts Conclusions

3 Fossil CO 2 Emission

4 Aim - Zero fossil CO 2 emission production

5 Challenges Time difference between energy supply and energy demand: Batch processes Use of waste energy Renewable energy sources mainly solar thermal Temperature connection between energy supply and energy demand (exergetic considerations): Knowledge on temperature profile of processes Knowledge on efficiency of energy supply technology at temperature level Knowledge on network and heat transfer losses

6 Basic steps towards a Green Brewery

7 Energy demand analysis Measurements of energy supply of specific processes (reality) Calculations of minimal energy demand of specific processes (theory) Consistent overall energy balance Evaluation of process / distribution inefficiencies Definition of targets for optimization Stiegl, 2010

8 Pinch point analysis and storage management Brew water from wort cooler 94 C Minimum heating and cooling demand Maximum of heat recovery Wort preheating 94 C Brew water tank C Based on practical approach AIM: fast calculation for first concept generation Adapted time slice approach for heat exchanger calculation Storage management calculation District Heat District Heat Energy Storage 95 C 85 C District Heat District Heat 86 C 93 C Brew water Tank 2 85 C Packaging WW tank C Liquor for lauter tun Liquor for mash tun Packaging Vapour condensate recovery Waste water CIP brewhouse Process water tank C Liquor for mash tun Liquor for mash tun Heat recovery cooling installtions 65 C Service water HR Cooling Compressors

9 Green Brewery - tool

10 Green Brewery - tool: thermal energy demand distribution KEG heat demand KEG Wärmebedarf 1% 0% 0% 16% 0% KEG KZE KEG Außenw äscher KEG Wäscher 15% 16% 1% 2% Energiebilanz Energy balance Sudhaus Flaschenhalle MEHRWEG KEG Abfüllung Brauchwassererwärmung CIP Anlagen Gärkeller, Filtration CIP Füller 66% 83% CIP Rohre CIP KZE packaging heat demand Flaschehalle Wärmebedarf Energy demand brew house Energiebedarf Sudhaus Flasche KZE Erw ärmung auf Einmaischtemperatur Maischen 1% 6% 6% 20% Flaschenw aschanlage 1% 12% 1% Erw ärmung auf Läutertemperatur Erw ärmung auf Kochtemperatur Füller Ankochen 55% 23% elektr. Energie w ährend BV 67% Kistenw äscher CIP 1% 0% 2% 1% 4% Dampf für Kochen Erw ärmung auf CIP Temperatur Nachheizung CIP Energieinhalt aus Brauw asser

11 Sf and SN [%] Irradiation [kwh/m²a]; SE [kwh/m²month]; T Outside [ C] Solar Process heat 20% 18% System efficiency SN [%] Solar fraction Sf [%] collector type T Outside - Climate G Horizontal Solar energy yield SE [kwh/m²a] Inclined Irradiation [kwh/m²a] FPC flat plate collector Glas Absorber Copper tube Insulation workingtemperature in C * 30 90** % 14% EFPC evacuated flat plate collector Glas Absorber Copper tube Support % VTC Vacuum tube - collektor with or without reflector Glas Absorber Copper tube Reflector % 8% collector with reflector CPC Compound Parabolic Concentrator Glas Copper tube Support Reflector % - parapolic through collector Glas cover Glas tube Receiver Reflector * 40 4% 20 2% 0 0% Jan Feb Mrz Apr Mai Jun Jul Aug Sep Okt Nov Dez -20

12 Case studies Four breweries and two malting plants have been considered for solar process heat with varying production capacities varying brew house technologies and packaging processes. different climatic zones (northern, middle and southern Europe, Africa) Different energy benchmarks Different fuel prices One brewery with supply by local district heating network (bio mass CHP)

13 breweries malting plants Production data Capacity Capacity [ton barley/a] [hl/a] - breweries - malting plants Brewery D Brewery C malting plant II Brewery B malting plant I Brewery A hl/a ton barley/a

14 malting plants Energy benchmarks Energy benchmarks Energy benchmarks - malting plants packaging [MJ/hl] brew house [MJ/hl] Brewery D malting Brewery plant CII malting Brewery plant BI Brewery A thermal energy total 0 0,1 0 0,2 20 0,3 40 0,4 60 0,5 80 0, , MWh/ton MJ/hl

15 Frame work conditions

16 Solar thermal concept solar gain [kwh/m²a] solar fraction % storage size [m³] collector size [m²] Malting plant II Malting plant I Brewery D Brewery C Brewery B Brewery A

17 heat cost, per MWh Economical considerations Price for solar thermal generated heat vs. fossil energy sources 100 Brewery C Brewery A Brewery D Malting plant I Fossil fuel price 30 Malting plant II Brewery B Brewery A Brewery B Brewery C Brewery D Malting plant I Malting plant II Fossil fuel price

18 Flow sheets of concepts brewery A

19 Flow sheets of concepts brewery B

20 Flow sheets of concepts malting plant II

21 Brewery for district heating connection Capacity: approximate hl beer per year Specific energy demand of 65 MJ/hl. District heating system: several process technologies have to be changed by systems with more efficient heat and mass transfer Due to this higher efficiency - the future supply temperature will be reduced to 120 C for some energy intensive processes like the mashing process or the wort cooking process Replacement of the external wort cooking equipment

22 Flow sheet for district heating connection

23 Conclusions Key influencing parameters: existing technologies, operation parameters and fluctuations in operation times The hot water management as a key factor for integrating waste heat or new energy supply technologies influenced in production capacities (brewing vs. packaging) and used technology Ideal storage sizing and management based on heat integration and renewable energy integration Exergetic considerations of the energy supply system - if necessary technology optimization Interaction between process temperature, climate zone, heat integration, fossil fuel price and investment costs

24 Thank YOU for your attention Brunner Christoph AEE - Institute for Sustainable Technologies (AEE INTEC) A-8200 Gleisdorf, Feldgasse 19 AUSTRIA

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