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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

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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

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, 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