brewing beer – efficient and sustainable technologies in ... · dr. ludwig scheller, dr. rudolf...

GEA Brewery Systems Huppmann Tuchenhagen GEA Brewery Systems Huppmann Tuchenhagen

ERSCP workshop, Bregenz, 3 May 2012 Dr. Ludwig Scheller, Dr. Rudolf Michel

Brewing Beer – efficient and sustainable technologies in regard to energy and raw material input

GEA Brewery Systems

• 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

Agenda

2 ERSCP Bregenz_120503

GEA Brewery Systems

Steeping conditioning

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Husk humidity: 20 %

Steeping conditioning

chute

ERSCP Bregenz_120503

GEA Brewery Systems

Capacity impact of milling technique


GEA Brewery Systems

MILLSTAR™ / Mash kettle


GEA Brewery Systems

• 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

With surplus hot water I

Heating of mash kettle


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With surplus hot water II

Heating of mash kettle


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Of extraction and sparging at Kulmbacher Brewery

Efficiency

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Results from the trials in the brewery Kulmbacher

ERSCP Bregenz_120503

GEA Brewery Systems

Designed for internal top pressure 0,5 bar

Wort kettle


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Homogenization / Particle size reduction


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Design of pilot plant


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HoEx suspension - Pictures


Left sample: dispersed HoEx suspension from CO2 and ethanol extract Sample in the middle: homogenized HoEx suspension from CO2 and ethanol extract Right sample: homogenized and isomerized HoEx suspension (Mixture for suspension of 35 % ethanol extract and 65 % CO2 extract)

GEA Brewery Systems

• 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

Total cost savings for hop extracts and thermal energy required for wort boiling

Calculation of profitability/ ROI


GEA Brewery Systems

• 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 CO2

The GEA solution: ECO-FERM™


GEA Brewery Systems

• 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 CO2

• 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

The GEA solution: ECO-FERM™


GEA Brewery Systems

The result: Occupation time


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0 50 100 150 200 250 300 350 Time in [h]

CCT #29 ECO-FERM™ vs. #31 Standard

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

Time saving

Total time saving 50 h

GEA Brewery Systems

• 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

Agenda


GEA Brewery Systems

• 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

Best Available Technique (BAT) in breweries


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Process layout of dyn. LPB


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Heat flow without energy storage


Total heat consumption: 10.44 kWh/hl CW

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Heat flow with energy storage


Total heat consumption: 5.79 kWh/hl CW

GEA Brewery Systems

• 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 €

Life steam or superheated hot water supply


GEA Brewery Systems

Energy input and emissions: Climate change and global warming

Beer production with energy of fossil sources

State-of-the-art


CO2-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

Electricity of fossil fuels

7,5 -11,5 kWh/hl

Heat energy of fossil fuels 23,6 -33,0 kWh/hl

GEA Brewery Systems

• 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: GEA Brewery Systems recommends the direct

combustion of dewatered spent grains in the HEAT-STER™ to gain heat energy with sustainability

Biogas generation by spent grains fermentation


GEA Brewery Systems

• 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

Ingredients of spent grains

Spent grains combustion


GEA Brewery Systems

• 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:

Dewatering of spent grains


GEA Brewery Systems

Anaerobic fermentation of spent grains press water

Press water of spent grains for biogas production


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 GEA Brewery Systems

Sponsorship by:

GEA Brewery Systems

Dewatered spent grains


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• 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

Availability and use of thermal energy from spent grains:

Energy generation by spent grains combustion


At present Future 2011

GEA Brewery Systems

Coverage by spent grains combustion and renewables

Thermal energy demand


• 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

GEA Brewery Systems

Use of spent grains combustion in European breweries, 1 Mio. hl sales beer

Consumption figures


Fresh water 3,7 bis 4,7 hl/hl

Thermal energy spent grains comb. 14,4 kWh/hl

Waste water 2,2 bis 3,3 hl/hl

By products Yeast/ lees 1,7 bis 2,9 kg/hl Kieselgur 0,4 bis 0,7 kg/hl

CO2–emission of fossil fuel 2,1kg/hl

Solid waste Glas 0,3 bis 0,6 kg/hl Paper 0,14 bis 0,27 kg/hl Cardboard 0,04 bis 0,11 kg/hl Wood 0,017bis 0,03 kg/hl Plastic 0,01 bis 0,04 kg/hl Metal 0,01 bis 0,06 kg/hl

Thermal energy fossil fuel or renewables 10,6 kWh/hl

Electricity 7,5 bis 11,5 kWh/hl

Kieselgur 90 bis 160 g/hl

Quelle: The Brewers of Europe, 2002

GEA Brewery Systems

High temperature-level

Temperature profiles in production and packaging


Medium temperature-level

Angewandte Energierückgewinnung

GEA Brewery Systems

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 GEA Brewery Systems 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.

GEA Brewery Systems

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 CO2-reduction of about 0,6 kg/hl or about 17 % of the CO2-emission resulting on electricity generated with fossil fuel.

GEA Brewery Systems

About the sustainable thermal heat energy supply in a brewery

Simplified overview and outlook


GEA Brewery Systems 37 ERSCP Bregenz_120503

Vielen Dank für Ihre Aufmerksamkeit!

GEA Brewery Systems GmbH Dr. Ludwig Scheller Technologie - F & E EUREM European Energy Manager (IHK) Tel. +49 9321 303-153 Fax +49 9321 303-254 [email protected] www.gea-brewery.com

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