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Presented by Chris Woods

Sustainable Brewery Concept


Core Services


Contents

• Reduce, Reuse & Recycle• Nijhuis Sustainable Brewery Concept• Water, Waste & Energy Audits• Process Water Reuse• Waste Water to Value• Our Experiences


The Global requirement for change

• Food and beverage manufacturing uses high volumes of water, heat and energy

– 10 to 70 tonnes of water used per 1tonne of product

• 10% of a countries energy use goes into the growing, processing, packaging and

shipping of food

• 50% of all food is wasted, approximately 1.2-2 Billion tonnes

• Typically 70% - 80% of incoming water is discharged as waste water

• Water and energy supplies are rapidly diminishing

Reducing our water, heat and energy use and reducing waste...........


Reduce Reuse & Recover Water Resources

The challenges in the beverage market typically concerns:

• reduce the fresh water intake and reduce wastewater discharge costs• reuse wastewater for process cleaning purposes, reuse process water from pasteurisation lines and

cooling water towers• recover resources to use them as an energy source, heat source or sell them as fertilizer


Sustainable Brewery Concept

Water

Brewery Plant

Energy

Heat

Was

tew

ater

Process WaterProcess Water DisinfectionReuse

Water

Sludge Management

Solid Fertilizer

Reduced Disposal

Cost

Modular Solutions

Fit for Future

Recovered Water

Wastewater to Value Plant

Recovered Heat

Recovered Energy

Water discharge to river or sewer

Recovered spent grains


Goals

• Improve efficiency

• Reduce cost

• Create value

A Four Stage Process• Discovery : what we are doing right• Dream : what we can achieve• Design : the ideal we can co-create• Destiny : where do we want to go

Water, Energy & Heat Audits


Process Water Disinfection

Industry description:Pasteurisation and filling lines will suffer from Biomass contamination that exists of filamentous bacteria in a layer of EPS (exo polymer sugar) resistant to chlorineConventional / Challenge: • Production stops for cleaning• Require disinfection in situ online without

chemicals• Keep the system continuously clean

The Smart Solution• Nijhuis Ozone Solutions water re-use• Redox control for ozone dose rate results

in optimal OPEX• Expected ROI 1.5 – 2.5 years Additional advantage• Ozone cannot contaminate • Bacteria cannot become resistant to

Ozone • In situ CIP without production stop

Beverage pasteurisation line


Aerobic vs Anaerobic Treatment

Requires typical 0.5 kWh/kg COD •Good effluent quality•Biological nitrogen removal•Watercourse discharge possible•High sludge production

Produces typical 3.5 kWh/kg COD • Low sludge production• No biological nitrogen removal• No phosphorus removal• Often post-treatment required

CO2

Aerobic treatment Anaerobic treatment


BIOCTOR – Aerobic Solution

Flow COD COD TSS TSSSource m3/year mg/L kg/d mg/L kg/d

Influent 64,150 3291 211 605 39Effluent 64,150 78 5 19 1

Sequencing Batch Reactor• Aerobic degradation of organics• Discharge to watercourse

Sludge Thickening• Reduction of sludge volume

Modular Construction• Rapid site installation• Off site fabrication


BIOCTOR – Aerobic Solution


AECOMIXTM – Anaerobic Solution

Payback Calculation

Additional Benefits• >95% COD removal• Return of water to watercourse• Reduced carbon emissions• Low operator input• Low odour risk• Tertiary treatment possible for

reuse

Aerobic

brewery example

Operational Costs 175m3/day

Sewer Cost Without Treatment £ 442,469

Watercourse Discharge Cost £ 20,000

Electrical Cost £ 13,248

Sludge Disposal Cost £ 98,000

Chemical Supply Cost £ 10,915

Labour Cost £ 10,800

CAPEX Investment £ 695,000

Gain From Investment £ 289,506

Payback Period (years) 2.40



Flocculator/Dissolved Air Flotation (DAF)• Removal of suspended solids • Prevents solids build up

Performance

Aecomix - UASB• Up-flow Anaerobic Sludge Blanket Reactor• Biogas with a high concentration of methane is

produced as a by-product

Flash Aeration• Removes excess H2S

Flow COD COD TSS TSSSource m3/year mg/L kg/d mg/L kg/d

Influent 109,500 4811 527 573 63Effluent 109,500 342 37 516 57



Payback Calculation Anaerobic

brewery example

Operational Costs 300m3/day

Sewer Cost Without Treatment £ 993,869

Sewer Cost With Treatment £ 270,456

Electrical Cost £ 16,425

Sludge Disposal Cost £ 15,330

Chemical Supply Cost £ 104,504

Labour Cost £ 10,800

CAPEX Investment £ 980,000

Gain From Investment £ 576,354

Payback Period (years) 1.70

Additional Benefits• 1,350m³ biogas per day• Trade Effluent Compliance• Reduced Carbon Emissions• >90% COD Removal• Low power consumption


Achieve your goals with Nijhuis solutions

Chemical free

Meeting sustainable requirements

Lower the environmental footprint

Combine productivity & energy efficiency

Ensure minimum life-cycle cost

4 important goals to achieve at the same time!


Questions ?

sustainable brewery concept€¦ · • nijhuis sustainable brewery concept • water, waste &...

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