Uganda Breweries Assessment

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Uganda Breweries Ltd. In-plant Water CP-assesment Final presentation

January 25th 2007 Richard Harrow & Steffen Wissing Danbrew

Our Brew-How makes your business more successful

Agenda1. Presentation 2. The UN assignment 3. Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews who, how and what Management and Training Packaging Beer Processing

3. 4. 5. 6.

6. 7. 8. 9.

10. Conclusion and Next Steps

Danbrew Ltd. Design and build Breweries Tender for plant developments Investment strategies and plans for breweries Optimising of Breweries

25 years of consultancy in the brewing industry Nearly 100 million hl design/build in more than 60 Countries including 7 African countries 60 consultants working in 7 countries presently

Project organisation for Uganda Breweries CP water assesmentNile Brewery Operations Director Mumbi Muiruri Engineering manager, Bardsley Msagha, Utilities manager, Matthew Mungai Head of Quality & Environment, Mrs. Agnes Acom.

Danbrew Senior Consultant Richard Harrow Senior Consultant Steffen Wissing UN Programme Manager Niclas Svenningsen UCPC Technical Officer Patrick Mwesigye

Agenda1. Presentation 2. The UN assignment 3. Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews who, how and what Management and Training Packaging Beer Processing

3. 4. 5. 6.

6. 7. 8. 9.

10. Conclusion and Next Steps

The assignment of Danbrew UN Environmental Programme have asked Danbrew to perform In-Plant CPassessments with a focus on water saving and waste water. This is part of the UN water saving initiative within the African brewery sector (The Abrew project). This project will Identify the potential for water savings in the African brewery sector and suggest solutions. Develop a UN project for external funding for implementing water conservation measures in the brewing sector and subsequently in the entire beverage sector in Africa. The preliminary assumption of the project is that water usage is 32 hl water per 1 hl beer. If so the water saving potential is 1.7 billion hl. l Cleaner Production methods are assumed to generate savings of 20 to 50%.

Agenda1. Presentation 2. The UN assignment 3. Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews who, how and what Management and Training Packaging Beer Processing

3. 4. 5. 6.

6. 7. 8. 9.

10. Conclusion and Next Steps

Cleaner Production

The purpose of Cleaner Production is to reduce resource consumption and emissions from a production. Preferably by reduction of waste at source.

UN Technical Report N 33 p.39- 40

Solutions within the CP

Training

No part of the solution must be seen isolated

Engineering

Plant equipment

UN Technical Report N 33 p. 40

High consumption breweries and the CP

Training

High Consumption Breweries can immediately achieve substantial reduction by addressing management issues and small changes in ancillary operations

Engineering

Plant equipment

UN Technical Report N 33 p. 40

Low consumption breweries and the CP

Training

Engineering

Plant equipment

Low Consumption Breweries need to begin focusing on all three functional groups in detail

UN Technical Report N 33 p. 40

Low consumption breweries and the CP

Training

Engineering

Plant equipment

Low Consumption Breweries need to begin focusing on al three functional groups in detail

UN Technical Report N 33 p. 40

Low consumption breweries and the CPHigh Consumption Breweries

TrainingLow Consumption Breweries

Engineering

Plant equipment

UN Technical Report N 33 p. 40

Cleaner Production Focus AreasFunctional areas Process Focus areas to reduce resource consumption Production methods Operations System design Maintenance Training Operations Individual system design System integration (process / utility) Maintenance Training

Ancillary operations

Management

Target setting, monitoring control, responsibility allocation TrainingAreas in which Resource Consumption May Be Reduced. UN Technical Report N 33 p. 39

Recognized need for CP Planning and Organisation Task 1: Obtain management commitment Task 2: Identify barriers and solutions Task 3: Set plant-wide CP goals Task 4: Organize project team Assesment organisation established

Is there a large potential of water sawing ? Planning and Organisation Task 1: Obtain management commitment Task 4: Organize project team

Abrew water assesment

Assesment organisation established Pre-Assesment Task 5: Develop process flow chart Task 6: Evaluate inputs and outputs (water balance) Task 7: Select audit focus Audit focus selected Assesment Task 8: Verify water balance Task 9: Assess waste generation causes Task 10: Generate CP options Task 11: Screen CP options Comprehensive set of CP options Feasibility Studies Task 12: Preliminary evaluation Task 13: Technical evaluation Task 14: Economic evaluation Task 15: Environmental evaluation Task 16: Selection of feasible options List of feasible options

UNEP Technical report N 33 p. 101 Environmental Management in the Brewing Industry

UN CP assesment

Pre-Assesment Task 5: Develop process flow chart Task 6: Evaluate inputs and outputs Task 7: Select audit focus Audit focus selected Assesment Task 8: Derive materials balance Task 9: Assess waste generation causes Task 10: Generate CP options Task 11: Screen CP options Comprehensive set of CP options Feasibility Studies Task 12: Preliminary evaluation Task 13: Technical evaluation Task 14: Economic evaluation Task 15: Environmental evaluation Task 16: Selection of feasible options List of feasible options Implementation and Continuation Task 17: Prepare CP plan Task 18: Implement feasible options Task 19: Monitor CP progress Task 20: Sustain CP On going CP successes

Agenda1. Presentation 2. The UN assignment 3. Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews who, how and what Management and Training Packaging Beer Processing

3. 4. 5. 6.

6. 7. 8. 9.

10. Conclusion and Next Steps

Material Balance for a Typical Brewery High Consumption

Malt/Adjunct, 18 kg. Brewhouse Energy, 350 MJ Fermentation / Beer Processing Packaging Ancillary Operations

1 hl Beer

Electricity, 20 kWh

Water, 20 hl

Waste Water 18,5 hl 1,2 kg BOD

By-products Spent Grains, 17 kg Yeast, 3 kg

UN Technical Report N 33 p. 19

Material Balance for a Typical Brewery Low Consumption

Malt/Adjunct, 15 kg. Brewhouse Energy, 150 MJ Fermentation / Beer Processing Packaging Ancillary Operations

1 hl Beer

Electricity, 8-12 kWh

Water, 5 hl

Waste Water 3,5 hl 0,8 kg BOD

By-products Spent Grains, 14 kg Yeast, 3 kg

UN Technical Report N 33 p. 19

Water balance for Uganda Brewery Medium Water Consumption and Low pollution

Malt/Adjunct, 15 kg. El + Diesel input Energy, 150 MJ

Brewhouse Fermentation / Beer Processing Packaging Ancillary Operations

1 hl Beer

Electricity, 8-12 kWh

20 hl Water 9,2 hl 5 hl Waste Water 18,5 hl 7,7 hl 3,5 hl HIGH. COD is 2,6 kg. This will make an BOD outlet higher than 1,2 kg. 1,2 kg BOD 0,8 kg BOD

NEMA target for BOD discharge is 50 mg/l equivalent to 0,04 kg per hl of beer for Uganda Breweries

BOD

Agenda1. Presentation 2. The UN assignment 3. Cleaner Production Assesment Methodology Pre Assesment Overall Material Balance Audit tool based on process flow chart for water Water costing Focus areas Assesment Interviews who, how and what Management and Training Packaging Beer Processing

3. 4. 5. 6.

6. 7. 8. 9.

10. Conclusion and Next Steps

U A D B E E IE LTD W TE B LA C D G A , R G N A R WR S A R A N E IA R M efer itemn 2.6.10 oH ydrant R eservoir B oilers 4 and 5 C arbon filter and softener backw ash w ater B rew H se ou B oiler feed w ater reservoir C ondesate R eservoir Tow er R eser voir M ash K ettle Lautertan C opper and w hirlpool C IP E 7 ID U S ofte ning plant C arbon Filters P rocess R eser voir O peration toilets and kitchen S eptic tank E 8 S tormdrain B dow low n E vaporation S team S tormdrain H ell/B dow pit otw low n Total E vaporation

.S pent grain E vaporation U sedw ash w ater, Final runnings, w eak w ort E 3 E 4 E 5 E 6

Water Flow for Uganda Breweries

S oftw ater R eservoir

E 9 E aporation v E 10

E 11 C ol Lake w ater W ater treatm ent P lant G P W P p um H ouse d Liq uor H eat exchanger Y east plant D V P s, A ddives tank and scrabber C R S s Filter and B Ts B T reatm ent Loses H liquor ot E vaporation U sed filter aid Y east,Tank bottom s, used w ash w ater and usec cleaaning w ater W ater E ngine R oom R eservoir plant/lab E ngineR oom condensers,cleani ng w ater. Toilets, K itchen m ain C anteen R eservoir K ieselguh r pit H liquor ot tanks E 13'A E 14 E 1 5 E 13 E 12

M unicipal w ater

E 16 A

E 1 6

E 18

Interceptor to S torm W arehouse, diversey S eptic Tank E 4'A C anteen,C linic Toilets,H block R S eptic tank C leaning w ater to storm