Brunner Christoph

Muster-Slawitsch Bettina,

Weiss Werner AEE - Institute for Sustainable Technologies (AEE INTEC)

A-8200 Gleisdorf, Feldgasse 19

AUSTRIA

Solutions for a low carbon production

in the food industry

Sustainable Thermal Energy Management in the Process Industries International Conference

(SusTEM2011)

Content

Vision Green Brewery

Methodology and Green Brewery tool

Implementation concepts

Conclusions

Fossil CO2 Emission

Aim - Zero fossil CO2 emission production

Challenges

Time difference between energy supply and energy

demand:

Batch processes

Use of waste energy

Renewable energy sources mainly solar thermal

Temperature connection between energy supply and

energy demand (exergetic considerations):

Knowledge on temperature profile of processes

Knowledge on efficiency of energy supply technology at

temperature level

Knowledge on network and heat transfer losses

Basic steps towards a Green Brewery

Energy demand analysis

Measurements of energy supply of specific processes

(reality)

Calculations of minimal energy demand of specific processes (theory)

Consistent overall energy balance

Evaluation of process / distribution inefficiencies

Definition of targets for optimization

Stiegl, 2010

Pinch point analysis and storage management

Minimum heating and cooling demand

Maximum of heat recovery

Based on practical approach

AIM: fast calculation for

first concept generation

Adapted time slice approach for heat

exchanger calculation

Storage management calculation

Konzeptrealisierung V1

Brew water

tank 1

93-94°C

Brew water from wort cooler

94°C

Wort preheating

94°C

85°C

District Heat

Energy StorageBrew water

Tank 2

85°C

95°C

District Heat

86°C

District Heat

93°C

District Heat

Process water tank

70-75°C

Liquor for lauter tun

Liquor for mash tun

Packaging

WW

tank

80-

85°C

Heat recovery

cooling installtions

65°C

Vapour condensate recovery

Service water

HR Cooling Compressors

Liquor for mash tun

Liquor for mash tun

Waste water CIP brewhouse

Packaging

Green Brewery - tool

Green Brewery - tool: thermal energy demand

distribution

Energiebedarf Sudhaus

1% 12%1%

23%

4%

55%

1%0%

2%

1%

Erw ärmung auf Einmaischtemperatur

Maischen

Erw ärmung auf Läutertemperatur

Erw ärmung auf Kochtemperatur

Ankochen

elektr. Energie w ährend BV

Dampf für Kochen

Erw ärmung auf CIP Temperatur

Nachheizung CIP

Energieinhalt aus Brauw asser

Flaschehalle Wärmebedarf

20%

67%

6% 6%

1%

Flasche KZE

Flaschenw aschanlage

Füller

Kistenw äscher

CIP

KEG Wärmebedarf

16%0%

83%

0%0%

1%

KEG KZE

KEG Außenw äscher

KEG Wäscher

CIP Füller

CIP Rohre

CIP KZE

Energiebilanz

66%

15%

16%1% 2%

Sudhaus

Flaschenhalle MEHRWEG

KEG Abfüllung

Brauchwassererwärmung

CIP Anlagen Gärkeller, Filtration

KEG heat demand Energy balance

Energy demand brew house packaging heat demand

Solar Process heat

collector typeworking-temperature in °C

FPC flat plate collector30 80*

30 – 90**

EFPC evacuated flat

plate collector

60 – 100

VTC Vacuum tube -

collektor with or without

reflector

50 – 190

collector with reflector

CPC Compound

Parabolic

Concentrator

60 – 180

parapolic through collector

-

70 – 290*

Glas

Absorber

Copper tube

Insulation

Glas

Absorber

Copper tube

Support

Glas

Absorber

Copper tube

Reflector

Glas

Copper tube

Reflector

Support

Glas cover

Glas tube

Receiver

Reflector

collector typeworking-temperature in °C

FPC flat plate collector30 80*

30 – 90**

EFPC evacuated flat

plate collector

60 – 100

VTC Vacuum tube -

collektor with or without

reflector

50 – 190

collector with reflector

CPC Compound

Parabolic

Concentrator

60 – 180

parapolic through collector

-

70 – 290*

Glas

Absorber

Copper tube

Insulation

Glas

Absorber

Copper tube

Support

Glas

Absorber

Copper tube

Reflector

Glas

Copper tube

Reflector

Support

Glas cover

Glas tube

Receiver

Reflector

0%

2%

4%

6%

8%

10%

12%

14%

16%

18%

20%

Jan Feb Mrz Apr Mai Jun Jul Aug Sep Okt Nov Dez

Sf

an

d S

N [

%]

-20

0

20

40

60

80

100

120

140

160

180

Irra

dia

tio

n [

kW

h/m

²a];

SE

[kW

h/m

²mo

nth

]; T

Ou

tsid

e [

°C]

System efficiency SN [%] Solar fraction Sf [%]

T Outside - Climate G Horizontal

Solar energy yield SE [kWh/m²a] Inclined Irradiation [kWh/m²a]

Case studies

Four breweries and two malting plants have been

considered for solar process heat with

varying production capacities

varying brew house technologies and packaging

processes.

different climatic zones (northern, middle and

southern Europe, Africa)

Different energy benchmarks

Different fuel prices

One brewery with supply by local district heating

network (bio mass CHP)

Production data

0 500000 1000000 1500000 2000000 2500000

hl/a

bre

we

rie

s

Capacity [hl/a] - breweries

Brewery D

Brewery C

Brewery B

Brewery A

0 50000 100000 150000 200000 250000 300000

ton barley/a

ma

ltin

g p

lan

ts

Capacity [ton barley/a] - malting plants

malting plant II

malting plant I

Energy benchmarks

0 20 40 60 80 100 120 140

MJ/hl

thermal energy total

brew house [MJ/hl]

packaging [MJ/hl]

Energy benchmarks

Brewery D

Brewery C

Brewery B

Brewery A

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7

MWh/ton

ma

ltin

g p

lan

ts

Energy benchmarks - malting plants

malting plant II

malting plant I

Frame work conditions

Solar thermal concept

14702580

17602100

40003220

200350

200220

0300

182593237

280610

289 660403

900

0 500 1000 1500 2000 2500 3000 3500 4000

collector size [m²]

storage size [m³]

solar fraction %

solar gain [kWh/m²a]

Malting plant II

Malting plant I

Brewery D

Brewery C

Brewery B

Brewery A

Brewery A

Brewery B

Brewery C

Brewery D

Malting plant I

Malting plant II

Fossil fuel price

Brewery A Brewery B Brewery C Brewery D Malting plant I Malting plant II Fossil fuel price

heat

co

st,

€ p

er

MW

h

Price for solar thermal generated heat vs.

fossil energy sources

Economical considerations

100

30

Flow sheets of concepts brewery A

Flow sheets of concepts brewery B

Flow sheets of concepts malting plant II

Brewery for district heating connection

Capacity: approximate 900.000 hl beer per year

Specific energy demand of 65 MJ/hl.

District heating system:

several process technologies have to be changed by

systems with more efficient heat and mass transfer

Due to this higher efficiency - the future supply

temperature will be reduced to 120°C for some energy

intensive processes like the mashing process or the wort

cooking process

Replacement of the external wort cooking equipment

Flow sheet for district heating connection

Conclusions

Key influencing parameters: existing technologies, operation parameters and fluctuations in operation times

The hot water management as a key factor for integrating waste heat or new energy supply technologies influenced in production capacities (brewing vs. packaging) and used technology

Ideal storage sizing and management based on heat integration and renewable energy integration

Exergetic considerations of the energy supply system - if necessary technology optimization

Interaction between process temperature, climate zone, heat integration, fossil fuel price and investment costs

Thank YOU for your attention

Brunner Christoph

AEE - Institute for Sustainable Technologies

(AEE INTEC)

A-8200 Gleisdorf, Feldgasse 19

AUSTRIA