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Alfa Laval Innovations
Carlsberg Technology Seminar, 10 April 2018
Alfa Laval Brewery Systems
Søborg, Denmark
www.alfalaval.com
Agenda
Main topics:
• High yeild dry hopping based on Alfa Laval Iso-MIX
• Next generation high speed separators with eMotion and Integral
disc
Additional solutions to discuss during meetings with teams:
• Alfa laval LKH Prime
• Alfa Laval TJ40G Rotary Jet Head
• Alfa Laval Foodec decanter
• Mixed-fuel boilers using stripped ethanol
© Alfa Laval Slide 3
Dry Hopping with IMXD
Alyce Hartvigsen
www.alfalaval.com© Alfa Laval Slide 5
Problem: Efficient Dry Hopping
www.alfalaval.com
Problem: Dry Hopping Process Issues
© Alfa Laval
• Slugs of hop solids
• Blockages of lines, HEX, filters
• Carry-over of solids
• Product losses
• Unplanned down-time/outages
• Increased waste streams
www.alfalaval.com
Solution: ”Dynamic” Dry Hopping
© Alfa Laval Slide 7
• More effective dispersion of hops into beer
• Faster and more efficient aroma/flavour extraction
• Shorter hop residence times in beer
• Homogenization of hop particles during transfer
• Efficient separation of hops from beer
• Reduction of beer losses
• Reduction of process times
www.alfalaval.com
Iso-Mix External Drive (IMXD)
© Alfa Laval Slide 8
• Motor-driven Rotary Jet Mixer
• Tolerates high particulate loads
• Flexible hops introduction method
• Fast dispersion and flavour extraction
• Homogenization of feed to centrifuge
• Reduced hop residence time
• Reduced beer losses
• More efficient aroma/flavour extraction
www.alfalaval.com
IMXD system with hop slurry injection
© Alfa Laval Slide 9
Prepared hop
slurry dosed
into IMXD
loop during
circulation
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10
Efficient hop removal & reduced losses
• Homogeneous solids loading to centrifuge inlet
• Complete removal of hops solids and regular
discharge intervals
• Reduced losses means less waste streamsPRE POST CENTRIFUGESAMPLE OF SOLIDS DISCHARGE
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Customer results with IMXD
© Alfa Laval Slide 11
www.alfalaval.com
Summary: Dry hopping with IMXD• Significant reduction in process time & energy consumption
• Significant reduction in beer losses & waste streams
• Complete hop removal by centrifugation
• Faster and more efficient aroma/flavour extraction
• No significant differences in beer flavour
• Potential for larger product batches
• Potential for higher dry hop dosing
• Additional benefits with mixed fermentation and
accelerated cooling (reduced energy consumption)
• Product ROI << 1 year© Alfa Laval Slide 12
www.alfalaval.com
www.alfalaval.com
Creating values
by innovation
Latest innovations in centrifugation
Fernando Jimenez
Global Sales Brewery
BU High Speed Separators
Tumba Sweden
www.alfalaval.com
• Launching 35-40 new products
every year, whereof 8-12
separators
• More than 1 900 patents, whereof
appr. 500 separator related
• Investment (2016): MEUR 87 =
2.3% of total net sales. For
separators 4,8% of net sales
Focus on R&D
www.alfalaval.com
Alfa Laval design Philosophy
Power Consumption
Separation performance
Cost
Solid handling
Bactofuge
Center-to-
center
www.alfalaval.com
Innovations in centrifugation
Center to Center
Unidisc
Top StreameMotion
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Center to Center
Fundamentals of the fully hermetic bowl
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Center to Center design (C2C)
𝑉𝑔 =𝑑2∆𝜌
18𝜇ω²r
Gentlest feed acceleration
d
2Vg
4
www.alfalaval.com
, 4rpm,185 kg
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Flow Power
• Centripetal Pump (Static)
• ru² radius of level ring
• ω² Bowl Speed
• Q Flow
Paring disc
PQ = ρQω²ru²
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Center to CenterSummary
• Smooth acceleration of the feed minimizes yeast
micronization (particlle splitting) increasing
exponentially sedimentation velocity.
• No product Oxidation, No aroma / hop oil
stripping and virtually No Oxigen Pick up.
• Significant reduction in power consumption. Up
to 70% reduction compared to traditional top
feed bowl design.
• Bowl design capable to operate in a wide range
of flows without any further adjustment.
www.alfalaval.com
eDrive™ (patented innovation)
• Mechanical simplicity: rotor is
an integral part of the bowl
spindle.
• Fewer parts: No motor
bearings, motor shaft or flat
belts.
• Less moving parts, less
energy loss, less heat
generation, less need for
cooling.
• Extended service intervals.
eMotion – running
Lean & Cool
Low pressure technology for high speed centrifuges
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Separator Power Consumption
PQ: Flow Power
Pf : Friction from paring disc
Pair: Air Friction (bowl-casing)
Pother: Bearings, transmission, seals,
discharge system etc.
Contributions to HSS power consumption
Pq; 50%
Pf; 20%
Pair; 20%
Pother; 10%
Power = PQ + Pf + Pair + Pother
Idle Power
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eMotionRunning Lean & Cool - Theory
Air friction power (bowl-casing)
3 5
theory F airP c R
BREW 701
centrifuge
bowl
periphery
speed:
708 km/h
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eMotionRunning Lean & Cool - Technology
Low air pressure in centrifuge casing
using vacuum pump
0,5 bar
50 % vacuum
0,3 bar
70 % vacuum
0,1 bar
90 % vacuum
Mont Blanc Mount Everest eMotion
centrifuge
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0,1 bar ~10 000 m
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eMotionRunning Lean & Cool
Intermittant evacuation of air outside the bowl with liquid
ring pump
• Reduces idling power
• Better hygiene (less burning-on) – improved internal
aerodynamics with reduced secondary flow vortices
• Cooler surfaces on the outside of the separator
• Reduced sound level of separator
• Reduced cooling water consumption
• Facilitates PX solids discharge
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Power consumption to system
0
10
20
30
40
50
60
70
80
60 410 450 500 510 600 610 615 615 615 715
kWBREW 2001 with paring disc BREW 2001 hermeticBREW 2000
- 33%
eMotionRunning Lean & Cool
- 40%
- 40%
Open inlet & paring disc 1,2 kWh/m3
Semi Hermetic0,7 kWh/m3
Full Hermetic0,45 kWh/m3
eMotion0,28 kWh/m3
75 m3/h
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eMotionRunning Lean & Cool
eMotion
OFF
eMotion
ON
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eMotionRunning Lean & Cool
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UniDiscs
Boosting Separation Performance to new boundaries
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UniDiscsTheory
• Lambda – Flow pattern between rotating
discs. Radial-tangential velocities
• Substancial efficiency optimisation
possible by reducing lambda factor.
h
sin
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UniDiscsTechnology
• Radical production technology innovation. No welding.
• Micro-caulks as distance/spacers between discs
• Discs are thinner and caulk height lower. Disc stack can hold
more discs increasing efficiency.
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UniDiscsBenefits
• Equidistant space between discs. Separation
area is used more efficienctly.
• Optimal disc stack flow pattern.
• Significant improvement of Flow between
discs.
• No ”maldistribution” (unequal resistances
from flow) which greately improves
separation efficiency.
• Better cleanability. Formed from one single
element. Less risk of contamination.
• 30% Flowrate increase with equivalent
separation performance.
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Top Stream
Improved yeast handling in disc stack centrifuges for breweries using continuous solids discharge design
www.alfalaval.com
Traditional Mechanical separation liquid/solids
Flow
between
the discs
5000 g
0,5 mm
Liquid
Solids
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Top Stream Process
Feed stream
Clarified beer stream
Continuous solids stream
Conventional solids
discharge stream
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Top Stream process flows
Clarified beer stream
Continuous Solids stream
Intermittent solids discharge
stream
Feed stream
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~ flow rate ~ (rotation speed)2
Yeast concentrate
flow velocity
Particle settling velocity
18 μvG =
d2 ( ρp – ρl )rω2
Top Stream: Continous Yeast
flow in pipes over top disc
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Top Stream Technology
• Fully hermetic design. No Oxygen pick up
• Hybrid separator. It can operate in
continious discharge mode or intermittent
discharge.
• Higher solids handling capacity than
conventional self cleaning separators.
• Increase of beer yields. Beer recovery out
of tank bottoms in continous mode.
Minimum temperature pick up. No need of
beer recirculation. Absence of low flow
transitions.
• Centrifuge solids space is no longer a
process constraint.
Hermetic Separator with continous concentrate flow sectors over top disc
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Top Stream Summary
✓ Not limited by solids content at the inlet. Bowl solids space is not
longer a limitation to reach high flows with superior clarification
performance
✓ High flexibility in feed concentrations of solids
✓ Full control characteristics of effluent and/or yeast concentration
✓ Low power consumption
✓ Yeast Outlet. It is not contaminated with operating/flushing water
✓ High yeast viability ( > 95% vital yeast viability)
✓ Air/foam free design allows a continuous measurement of solids
concentration from outlet, for process control
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Center to Center
Integral discs
Top StreameMotion
• 30 – 60% decrease in power
consumption v.s traditional brewery
separator
• Less CIP need
• Reduces cooling water consumption
• 30% higher capacity in
existing machines
• Less CIP need
• Increased solids handling capacity
• High yeast viability
• Lower power consumption
• 30 – 60% decrease in power
consumption v.s traditional
brewery separator
• Optimal beer handling
• Low product losses
• No oxygen pick-up
Innovation in centrifugationSummary