Brewing Beer efficient and sustainable technologies in regard to energy and raw material input ERSCP workshop, Bregenz, 3 May 2012 Dr. Ludwig Scheller, Dr. Rudolf Michel Huppmann Tuchenhagen
Agenda Efficient and Sustainable Raw Material Use MILLSTAR, Mash kettle and LAUTERSTAR : best use of available grain starch converted to malt sugars Wort boiling and dosing of hop bitter acids: homogenization and pre-isomerization Improvement of fermentation and cooling in CCT s: application of ECO-FERM Efficient and Sustainable Energy Supply Frame conditions - GHG-emission and minutes of Kyoto Request of European Commission Best Available Technique Heat recovery of kettle vapour with an energy storage system Life steam for heat transfer and closed condensate systems Spent grains (biomass) for energy supply: anaerobic fermentation to biogas or partial dewatering and firing as solid combustion material Further renewable energy sources in addition to biomass: Waste heat / Pinch-analysis: compressors for cooling and pressured air Solar thermal energy: stratified storage system Geothermal energy: in connection with an absorption cooling machine (Thermax) Separated network of thermal energy supply for production and packaging 2 ERSCP Bregenz_120503
Steeping conditioning Husk humidity: 20 % Steeping conditioning chute 3 ERSCP Bregenz_120503
Capacity impact of milling technique 4 ERSCP Bregenz_120503
MILLSTAR / Mash kettle 5 ERSCP Bregenz_120503
Heating of mash kettle With surplus hot water I Installation of mash kettle which is heated with hot water of about 95 C supplied by an energy storage tank Location: in a renown brewery in Germany (fulfilled in 1994) Technical design in accordance to drawing on the left side, part of a project in 1992 Supply with hot water via energy storage tank, which is collecting recovered vapour heat from wort boiling by a vapour condenser system Heating surfaces on the shell and as additional heat exchangers in the kettle, designed as dimple plates Additional heating surface on the bottom of the kettle for life steam application 6 ERSCP Bregenz_120503
Heating of mash kettle With surplus hot water II 7 ERSCP Bregenz_120503
Efficiency Of extraction and sparging at Kulmbacher Brewery Results from the trials in the brewery Kulmbacher 8 ERSCP Bregenz_120503
Wort kettle Designed for internal top pressure 0,5 bar 9 ERSCP Bregenz_120503
Homogenization / Particle size reduction 10 ERSCP Bregenz_120503
Design of pilot plant 11 ERSCP Bregenz_120503
HoEx suspension - Pictures Left sample: dispersed HoEx suspension from CO 2 and ethanol extract Sample in the middle: homogenized HoEx suspension from CO 2 and ethanol extract Right sample: homogenized and isomerized HoEx suspension (Mixture for suspension of 35 % ethanol extract and 65 % CO 2 extract) 12 ERSCP Bregenz_120503
Calculation of profitability/ ROI Total cost savings for hop extracts and thermal energy required for wort boiling Produced quantity of wort: 2,000,000 hl/year 1) Savings hop extract when dosing is reduced by 30 % on the basis of 70 mg/l alpha acid addition approx. 120,000 /year 2) Energy cost net savings when boiling is reduced by 50 % or total evaporation is reduced by 50 % 129,000 /year 3) Total savings approx. 249,000 /year 4) i.e. ROI is approx. 1.0 to 1.5 years max 13 ERSCP Bregenz_120503
The GEA solution: ECO-FERM Jet mixing in the tank with a jet pump Process support in the same direction ( centrally upward ) as the natural bubble column caused by the formation of CO 2 14 ERSCP Bregenz_120503
The GEA solution: ECO-FERM Jet mixing in the tank with a jet pump Process support in the same direction ( centrally upward ) as the natural bubble column caused by the formation of CO 2 A frequency controlled circulation pump is integrated into the loop Hygienic design and piping In-line measuring devices can be installed in the circulation line Due to the design of the jet only a small flow rate is required for driving the circulation 15 ERSCP Bregenz_120503
The result: Occupation time 18 16 14 12 10 8 CCT #29 ECO-FERM vs. #31 Standard Time saving Temperature #29 top Temperature #29 middle Temperature #29 low Extract #29 [ P] VDK*10 #29 Temperature #31 top Temperature #31 middle Temperature #31 low Extract #31 [ P] VDK*10 #31 JET #29 on/off 6 4 Total time saving 50 h 2 0 0 50 100 150 200 250 300 350 Time in [h] 16 ERSCP Bregenz_120503
Agenda Efficient and Sustainable Raw Material Use MILLSTAR, Mash kettle and LAUTERSTAR : best use of available grain starch as malt sugars Wort boiling and dosing of hop bitter acids: homogenization and pre-isomerization Improvement of fermentation and cooling in CCT s: application of ECO-FERM Efficient and Sustainable Energy Supply Frame conditions - GHG-emission and minutes of Kyoto Request of European Commission Best Available Technique Heat recovery of kettle vapour with an energy storage system Life steam for heat transfer and closed condensate systems Spent grains (biomass) for energy supply: anaerobic fermentation to biogas or partial dewatering and firing as solid combustion material Further renewable energy sources in addition to biomass: Waste heat / Pinch-analysis: compressors for cooling and pressured air Solar thermal energy: stratified storage system Geothermal energy: in connection with an absorption cooling machine (Thermax) Separated network of thermal energy supply for production and packaging 17 ERSCP Bregenz_120503
Best Available Technique (BAT) in breweries Overview about technique in BREF Documents (published Dec. 2005) ( Integrated Pollution Prevention and Control, IPPC-regulations since 1996): E.g. heat recovery of wort boiling Example of actual BREF: vapour condensor system combined with energy storage tank Technology of GEA Brewery Systems 18 ERSCP Bregenz_120503
Process layout of dyn. LPB 19 ERSCP Bregenz_120503
Heat flow without energy storage Total heat consumption: 10.44 kwh/hl CW 20 ERSCP Bregenz_120503
Heat flow with energy storage Total heat consumption: 5.79 kwh/hl CW 21 ERSCP Bregenz_120503
Life steam or superheated hot water supply Advantages of life steam supply: Very good heat transfer No power demand for distribution in life steam pipes Lower investment cost for steam pipe network Life steam network easy to enlarge Very good controllability Closed condensate system supports energy reduction for condensate heating on back run to boiler system with more than 8 % compared to atmospheric condensate system Additional cost of heating with superheated hot water supply: Example: brewhouse with 305 hl CW per brew, 12 brews/day Cost if investment for hot water pumps: 17.096 Additional electricity demand of pumps in network: 0,42 kwh/hl Additional cost of electricity per year: 37.885 22 ERSCP Bregenz_120503
State-of-the-art Beer production with energy of fossil sources Energy input and emissions: Climate change and global warming Electricity of fossil fuels 7,5-11,5 kwh/hl CO 2 -emission using light fuel oil, in total 11,5-16,9 kg/hl electricity 5,4-8,3 kg/hl heat energy 6,1-8,6 kg/hl Heat energy of fossil fuels 23,6-33,0 kwh/hl 23 ERSCP Bregenz_120503
Biogas generation by spent grains fermentation Anaerobic fermentation is recommended by different companies to gain energy as biogas from spent grains The generation of biogas from spent grains and the combustion in boiler or CHP-unit is discussed Actual situation of research & development: Hydrolysis of spent grains about 4 days Fermentation of spent grains about 14 days Sufficient tank capacity for hydrolysis and fermentation is requested Amount of solid particles in sludge after finished fermentation is about 1/3 compared to total spent grains amount used for fermentation Disposal of sludge with solid particles possible by land filling or by combustion Ideal combustion system for dewatered sludge: fluidized bed combustion Conclusion: recommends the direct combustion of dewatered spent grains in the HEAT-STER to gain heat energy with sustainability 24 ERSCP Bregenz_120503
Spent grains combustion Ingredients of spent grains Calorific value: Spent grains (dry matter) 18.640 kj/kg Spent grains (50 % moisture) 9.000 kj/kg Wood (37 % moisture) 10.500 kj/kg Brown coal 10.200 kj/kg The restrictions of the animal feed hygiene regulations (Futtermittelhygiene-VO (EG) Nr. 183/2005) will not be an obligation furthermore if spent grains will be used as combustion material In accordance to article 5 chapter 2 the brewery has to apply for the registration as feeding stuff producer and an HCCP-system has to be installed for this process area 25 ERSCP Bregenz_120503
Dewatering of spent grains Mechanical dewatering by screw press Target: Increase of dry matter from 20 % to 50 % Technique of dewatering has to be applicable for spent grains of lautertun and mash filter To increase efficiency of screw press the dosing of 1 % dry straw is useful Actual results: Next steps: Optimisation of dewatering efficiency Increase of throughput Reduction of installed engine power Sponsorship by: 26 ERSCP Bregenz_120503
Press water of spent grains for biogas production Anaerobic fermentation of spent grains press water Sponsorship by: Data collected in an actual and sponsored project for the sustainable use of energy rich biomass by the project team atz Entwicklungszentrum, Harburg-Freudenberger Maschinenbau und 27 ERSCP Bregenz_120503
Dewatered spent grains 28 ERSCP Bregenz_120503
Dewatered spent grains 29 ERSCP Bregenz_120503
Energy generation by spent grains combustion Availability and use of thermal energy from spent grains: Combustion is possible with less than 55 % moisture Dewatering: mechanical (e.g. screw press) and/or thermal (e.g. tube bundle dryer, fluidized bed dryer) If dewatering in two steps (mechanical and thermal) about 20 % of spent grains energy content necessary for thermal dewatering up to 50 % moisture Min. 80 % of dewatered spent grains available for generation of process heat with an specific energy content of about 14,4 kwh/hl 14,4 kwh/hl will be sufficient to cover 60 % heating energy of a brewery with a total demand of about 25 kwh/hl At present Future 2011 30 ERSCP Bregenz_120503
Thermal energy demand Coverage by spent grains combustion and renewables Thermal energy of spent grains combustion for: mashing, boiling, fermenting cellar, filtration department and other consumer Thermal energy of biogas-fired CHP-units or of solar- or geo-thermal systems or waste heat (e.g. cooling or air compressors) for: filling and packaging department 31 ERSCP Bregenz_120503
Consumption figures Use of spent grains combustion in European breweries, 1 Mio. hl sales beer Fresh water 3,7 bis 4,7 hl/hl CO2 emission of fossil fuel 2,1kg/hl Thermal energy fossil fuel or renewables 10,6 kwh/hl Waste water 2,2 bis 3,3 hl/hl Thermal energy spent grains comb. 14,4 kwh/hl By products Yeast/ lees 1,7 bis 2,9 kg/hl Kieselgur 0,4 bis 0,7 kg/hl Electricity 7,5 bis 11,5 kwh/hl Kieselgur 90 bis 160 g/hl Solid waste Glas Paper Cardboard Wood Plastic Metal 0,3 bis 0,14 bis 0,04 bis 0,017bis 0,01 bis 0,01 bis 0,6 kg/hl 0,27 kg/hl 0,11 kg/hl 0,03 kg/hl 0,04 kg/hl 0,06 kg/hl Quelle: The Brewers of Europe, 2002 32 ERSCP Bregenz_120503
Temperature profiles in production and packaging High temperaturelevel Medium temperaturelevel Angewandte Energierückgewinnung 33 ERSCP Bregenz_120503
High temperature level: source biomass Spent grains supplies a thermal energy content of about 12 kwh/hl at the consumer by the combustion with 50 % moisture content in the HEAT-STER, a fluidized bed combustion system. A brewhouse designed by consumes heat energy of about 7 kwh/hl. The surplus of the spent grains combustion is available for other processes on high temperature level, e.g. in the fermenting or storage cellar, filtration department or CIP plants. The press water of the mechanical spent grains dewatering can be metabolized very well in an anaerobic fermentation plant. Biogas of a Methane content above 60 % can be gained, firing in a boiler or in CHP-units is possible. 34 ERSCP Bregenz_120503
Integration of a CHP plant The use of biogas of anaerobic fermenter systems in CHP-units is state of the art. The strict separation of the different temperature levels allows the planning of the requested capacity of the CHP-unit in accordance with the demand of the packaging department. The anaerobic fermentation is able to produce electricity of about 1 kwh/hl from the press water of the spent grains. This is equivalent to about 16 20 % of the total electricity demand of the brewery. This can be calculated as CO 2 - reduction of about 0,6 kg/hl or about 17 % of the CO 2 -emission resulting on electricity generated with fossil fuel. 35 ERSCP Bregenz_120503
Simplified overview and outlook About the sustainable thermal heat energy supply in a brewery 36 ERSCP Bregenz_120503
Kontakt GmbH Dr. Ludwig Scheller Technologie - F & E EUREM European Energy Manager (IHK) Tel. +49 9321 303-153 Fax +49 9321 303-254 ludwig.scheller@gea.com www.gea-brewery.com Vielen Dank für Ihre Aufmerksamkeit! 37 ERSCP Bregenz_120503