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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)
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
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: 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
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
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
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
Recommended