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Utility Optimization in a Brewery Process Based on Energy Integration

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 Utility Optimization in a Brewery Process Based on Energy
Integration Methodology

Monika Dumbliauskaite a , Helen Becker a , François Maréchal a

a Industrial Energy Systems Laboratory (LENI), Ecole Polytechnique Fédérale de Lausanne (EPFL),
CH-1015 Lausanne, Switzerland

Abstract: This paper presents a methodology aimed at improving the energy efficiency of a brewery
applying process integration techniques. The different steps of the analysis are presented. The first
step is the identification of the process energy requirements and the corresponding heat loads, which
allows the definition of the process hot and cold streams. The Pinch Analysis of the brewery reveals
a heat recovery potential of 36% by improving the heat exchanger system. In order to satisfy the
minimum energy requirements, optimal energy conversion technology configurations are calculated,
taking into account economic and environmental criteria. The integration of suitable utilities is consid-
ered (cogeneration engine combined with heat pumping and refrigeration systems) and the interaction
between them is analyzed. In addition, a thermo-economic optimization is performed in order to de-
termine the optimal heat pump operating temperatures. The results show the opportunity to reduce by
36% the brewery heating bill and by 44% the CO2 emissions through the set up of an optimized utility
configuration when compared to the current one. In addition, the optimal integration shows that the
cooling water consumption of the refrigeration can be suppressed and appropriately be replaced by a
heat pumping effect. The comparison between French and German conditions shows that contrasting
results can be obtained due to the different economic and energy supply configurations. The process
system analysis shows that when considering the recovery of the plant organic waste, bio-methane
can be produced and valorized in the cogeneration engine. In that case, it is demonstrated that the
process can become self sufficient in terms of energy.

Keywords: process integration, pinch analysis, brewery, thermo-economic optimization.

1. Introduction the process energy requirements, called composite

curves, and describes how it is possible to achieve
Beer production (28Mt in 1999, EU-15) ranks 5th the determined energy targets with a correctly de-
in European food industry and the European beer is signed network of heat exchangers.
widely exported. Breweries use significant amounts The systemic approach consists of the identifica-
of water and energy to produce this fresh and tasty tion and characterization of the main Process Unit
drink. In the current trend of high energy price, en- Operations (PUOs). The Top-Down approach [9]
ergy efficiency improvement of industrial processes shows that more than 80% of the energy consump-
represents an important way to reduce production tion can be explained by describing only 20% of
costs. In addition, growing environmental concern the units of a factory. For these important PUOs,
encourages companies to consider innovative solu- models are used to characterize the set of hot and
tions not only to reduce the carbon footprint but also cold streams that are needed to achieve the oper-
the water consumptions. ation. The choice of the minimum approach tem-
In the Top-Down approach developed by D. Muller perature ∆T min allowed by the heat exchangers en-
et al. [9] for analyzing the energy efficiency of in- ables the determination of the process Minimum
dustrial processes in the food industry, Pinch Anal- Energy Requirements in heating and cooling. Grand
ysis is used to identify the possible heat recovery composite curve analysis helps towards identify-
by heat exchange between the streams to be cooled ing opportunities for energy-efficient utility inte-
down and the streams to be heated up. Pinch Anal- gration to satisfy the energy requirements, such as
ysis [6] targets the minimum heat requirement of combined heat and power (CHP) systems or heat
a process through the graphical representation of pumps (see for example [3]). Optimal utility inte-

Corresponding author: Monika Dumbliauskaite, Email: [email protected]

gration can be achieved using a Mixed Integer Lin- Figure 1: Block Flow Diagram of the Hot Part
ear Programming (MILP) formulation, as described
by Maréchal and Kalitventzeff [7].
This paper presents the implementation of the pro-
cess integration methodology on a brewery. The re-
sults are presented based on two different scenar-
ios in terms of equivalent CO2 emissions accord-
ing to the substitution options of the electricity mix.
In addition the methodology will be used to assess
renewable energy integration using bio-methanation
of the process waste.
Figure 2: Block Flow Diagram of the Cold Part
2. Pinch analysis of a brewery
2.1. Process Description

The brewery studied corresponds to a typical brew-

ing process. The target temperatures of the streams
and the proportions of ingredients are determined by
the product recipe. The brewing house is associated
with beer production and is split into two parts:

• a hot part(mashing), described by the block 2.2. Process Integration Assumptions

flow diagram of Figure 1, where the blend of
Table 1: Chosen Values of ∆T min /2
water and malt (Mash) is firstly brewed at high
temperature (76◦ C) so that the activated en-
Stream State ∆T min /2 [∆◦ C]
zymes transform malt starch into sugar. The
Liquid 2.5
Mash is then filtered to obtain the wort, which Evaporating 0.8
is boiled with hops to develop beer flavors. Condensing 1.7
Wort boiling is an energy intensive operation.
The wort is clarified in a whirlpool to remove
the hops and eventually cooled to the pitching The Pinch Analysis of the brewery is performed us-
temperature. ing the following key hypotheses:

• Thermal losses during heat transfers are not

• a cold part, illustrated in Figure 2, mainly taken into account.
consisting of the wort fermentation by yeast, at
constant temperature (11◦ C), during 2 weeks. • Despite the fact that the units are operated in
The beer is then chilled (-2◦ C) and clarified batch mode, we consider a time averaging ap-
before being stored in insulated tanks where it proach, where all the process operations are
ends its maturation. considered as being simultaneous. This is done
by calculating the overall energy consumed per
unit of product and dividing it by the mean
hourly production. The yearly operating time
The rest of the process consists of the beer packag- of the brewery is 4992h.
ing. In the process under study, four conditioning
lines package the beer in new bottles, in kegs and in • For each stream, the corresponding ∆T min /2
returnable bottles that are washed beforehand. The was chosen according to the existing equip-
bottles filled with beer are then pasteurized. ments. The associated values of ∆T min /2 may
A Cleaning in Place (CIP) system with effluent re- not be optimal; however they are used in the
covery, designed to wash the tanks, is also modeled study, as they correspond with the existing heat
in the study. exchangers available in the factory.
2.3. Modeling of the Conditioning Lines Figure 3: Bottle Pasteurization Device (Line 4) Com-
posite Curves
The opportunity of recovering heat from the condi-
tioning lines is worth studying, since bottle washing
and pasteurization devices represent important en-
ergy consumers in breweries. In the process under
study, the conditioning lines account for more than
32% of the current heating demand, which reveals
the importance of modeling and integrating these
units when undertaking the Pinch Analysis of brew-
eries.
As an example, the modeling of the bottle pasteur-
ization device is presented in this paragraph. The
device is considered as a sequence of soaking baths
transferring their heat to the beer bottles passing
through them. The bottles are successively heated
and cooled; the baths thus require respectively heat- Figure 4: Bottle Pasteurization Device (Line 4) Grand
ing and cooling supplies in order to keep a constant Composite Curve
temperature level.
The model considers the different baths at their
corresponding temperatures. This representation
enables the determination of internal heat recovery
potential, as well as between the baths and other
process streams.
In the study, permanent regime is considered. The
current bottle pasteurization device consists of ten
baths maintained at constant temperature levels.
The input and output temperatures of the bottles are
respectively 8◦ C/281K and 30◦ C/303K. The main
soaking bath is kept at 62◦ C/335K.
The computed heat loads of the different baths cor-
respond to the sum of the bottle heat loads and the The chosen value of ∆T min /2 (2.5◦ C) leads to
heat losses to the surroundings (from conduction- a pinch corrected temperature T pinch ∗ =15◦ C
convection and from radiation). The composite (288.2K), which corresponds to the minimal
curves associated with the device can thus be ob- bath temperature (T pinch,cold = 12.5◦ C= T pinch∗ −
tained and represented in a (T − Q̇) diagram. Figure ∆T min /2). As a result, the device does not need ex-
3 shows the composite curves corresponding to the ternal cooling, since it is possible to transfer all the
device operating on the production line n◦ 4. 40000 heat excess from the hot streams to the cold ones.
bottles of 0.33L/unit are currently pasteurized per The chosen value of ∆T min is an optimal one, since
hour by the machine. it is associated with the minimal MER feasible for
In Figure 3, the hot streams are associated with the the current device (220kW in heating and 0kW in
baths in heat excess and the cold ones with those cooling).
requiring heat. The grand composite curve corre- In addition, it can be noted that the device heat
sponds to the enthalpy (heat) difference between the recovery potential is determined not only by the
hot and cold streams for each temperature interval. ∆T min , but also by the number of baths and by their
In Figure 4, the integration shows the possible heat temperature levels. Thus, the bottling system design
recovery that can be obtained by transferring hot can be optimized using Pinch Analysis, in particular
water from one cooling bath (hot stream at constant through the definition of the minimum number of
temperature) to a heating bath (cold stream at con- baths and their corresponding volumes that can be
stant temperature). expressed as a function of the speed of the bottle
processing.
2.4. Process Integration Process Units (NIPUs), i.e. 604kWth , are added to
The process requirements identified for the PUOs define consistently the minimum heat requirement
are used to calculate the maximum energy recovery for the entire process. The targeted heating savings
in the system. Figure 5 presents the brewery com- represent 36% of the total heat consumptions.
posite curves resulting from the definition of the hot Table 2: Estimated minimum energy requirement for
and cold streams identified in the process. ∆T min,liquid =5◦ C

Type MER Present Savings Savings

Figure 5: Brewery Process Composite Curves
[kW] [kW] [kW]
Hot Utility 1386 2529 identi f ied 1143 45%
1990total 3133 total 36%
Cooling
Water 0 NA NA NA
(>10◦ C)
Refrigeration
837 NA NA NA
(<10◦ C)

3. Energy conversion integration

The analysis of the energy conversion system inte-
gration is based on the energy costs [4] and the CO2
emissions [1] of the French industrial sector in 2007
Figure 6: Brewery Process Grand Composite Curve and will be compared to the German case (table3).

Table 3: Energy Costs (without taxes) and CO2

Emissions- France FR and Germany GER (2007)

Cost CO2 Emissions

Electricity FR 54.1 e/MWhe 55kgCO2 /MWhe
GER 92.7 e/MWhe 624kgCO2 /MWhe
Nat. Gas FR 27.1 e/MWhLHV 231kgCO2 /MWhLHV
GER 41.7 e/MWhLHV 231kgCO2 /MWhLHV
Water 0.00657 e/m3 -

3.1. Grand Composite Curve analysis

The analysis of the Grand composite curve (Figure
6) leads to the following observations:
The first observation that can be established is re-
lated to the pinch, detected at the corrected temper- • Heat is required at relatively low temperature
∗
ature T pinch =285.5K (or 12.5◦ C). The pinch point levels which offers the opportunity to inte-
coincides with the temperature of cold water enter- grate combined heat and power (CHP) and heat
ing the process at ambient temperature. As a con- pumping systems.
sequence, all the effluents (hot streams) leaving the ∗
• The pinch temperature (T pinch =12.5◦ C) corre-
process at a temperature above the ambient tem-
sponds to the ambient conditions. It allows for
perature must deliver their heat to the process cold
integrating the hot stream of the refrigeration
streams.
system as a heat source for the process.
The computation of the MER for the identified
PUOs enables the identification of opportunities for • Provided that a heat pumping system is used
energy saving. The results are shown in Table 2 and to satisfy the needs at medium temperature, an
reveal a heat recovery potential of 1143kW. The re- MVR system can be used to recover the con-
maining heating requirements of the Non Identified densation of wort steam at high temperature.
 This would enable lower temperature heating pressure and temperature generates exergy losses,
requirements to be satisfied by the cooling wa- since the process requires heat at lower tempera-
ter of a cogeneration engine. Thus, the size of tures. On the other hand, it can be seen that below
the MVR system will be related with the heat the condensation temperature of the refrigeration
delivered by the cogeneration system. cycle, the process heating requirements are lower
than the heat provided by the condensation of the re-
• A refrigeration utility with multiple levels of frigerant. This excess of heat must be evacuated by
evaporation represents an appropriate solution cooling water. It is therefore necessary to consider
in order to minimize the exergy losses below solutions allowing the improvement of the current
the pinch temperature. utility configuration.
Using a linear programming formulation [7] the
flows of the utility streams are calculated to satisfy In order to reduce the exergetic losses due to the use
the process requirements at minimum cost. of high pressure steam, the integration of a cogen-
eration internal combustion engine is considered as
3.2. Improving the conversion system
an alternative to the boiler currently in operation.
Currently, a natural gas boiler generates steam at It appears to be the most relevant technology, as it
high pressure (8.5bar) that is distributed and con- is possible to recover heat from both exhaust gases
densed after expansion at 2.2bar and 123.3◦ C. For and cooling water, which can be used in low tem-
the cooling supply, the factory uses cold water and perature processes like breweries. Natural gas is
an NH3 -refrigeration cycle with two levels of evap- firstly considered. As can be seen in Figure 8, the
oration, at -4◦ C and -8◦ C. exhaust gases enable wort evaporation (T*=373K),
The flows in the utility system are computed to min- whereas the engine cooling water provides heat to
imize the yearly operating costs. In practical terms, the process streams below 360K. Fuel conversion
the stream heat loads of the energy conversion tech- leads to the generation of 1047kW of mechanical
nologies are optimized and added to the process hot power. Part of this power can be used to drive the
and cold streams refrigeration cycle compressors, which represents
an important reduction in process electricity bill.
Figure 7: Current Utility Setup: Boiler & Refrigeration
Cycle (RC) Figure 8: Boiler Replaced with a CHP System

Figure 7 shows the integrated composite curves of

the utility system. The utility streams are repre-
sented by the line “brewery utility” and the process However, the size of the CHP system can still be
requirements correspond to the grand composite optimized and the losses caused by refrigeration
curve “Others”. The mechanical work supplied to cycle condensation remain a problem that has not
compressors (heat pump and refrigeration cycle) been solved yet. The integration of heat pumps is
is represented by the line “Mech. Power”. The eventually considered. The mechanical vapor re-
analysis of Figure 7 reveals that the current utility compression (MVR) of the wort vapor can assist
configuration does not prove optimal for multiple the evaporation and will reduce the CHP system
reasons. On the one hand, the use of steam at high size. In addition, this high temperature heat pump is
making the condensation of the refrigeration cycle Two optimized configurations, including the inte-
useful for process water preheating. gration of MVR and heat pump systems, are pre-
The heat pump operating conditions may influ- sented in Figures 11 and 12. It can be seen a clear
ence the flows and the sizes of the other utility reduction of exergy losses: utility temperatures are
systems. In order to determine the optimal heat as close as possible to the temperatures of the pro-
pump operating temperatures, a multi-objective cess energy requirements. One can also observe a
thermo-economic optimization is performed. Three drastic reduction in the energy losses: for the case
decision variables are considered: the heat pump where the heat pump condenses at 77.5 ◦ C (351K),
condensation temperature, the refrigeration cy- external cooling water requirement is close to zero.
cle condensation and high pressure evaporation Table 4 presents the results associated with the dif-
temperatures. Using the evolutionary algorithm ferent utility setups. It is considered that the re-
QMOO ([5],[8]) a set of Pareto-optimal points is maining heating needs of the NIPUs can be fulfilled
obtained, representing the trade-off between invest- by the use of the current boiler (efficiency 85%),
ment costs and operating costs. The Pareto-optimal fed by natural gas. The French case is compared
set of figure 10 is divided into two distinct clusters, with the German case where the electricity supply
characterized by a single value of the heat pump is sensibly different : higher electricity price when
condensation temperature (see Figure 9), namely compared to natural gas cost and electricity being
66.5◦ C for cluster 1 and 77.5◦ C for cluster 2, which mainly produced by coal power plants (Table 3).
corresponds to the maximal temperatures of the One can observe that in France, from both an eco-
conditioning line units. nomic and an environmental point of view, the most
interesting utility setup consists of using heat pump-
Figure 9: Pareto Front (84 Pareto-optimal points after ing systems. The best configuration feature a de-
2000 iterations) crease by 36% of the operating costs and 18% of
the total costs when compared with the current util-
ity setup. It shows a drastic reduction in CO2 emis-
sions (44%) and in water consumption. On the con-
trary, in Germany, the higher electricity to gas price
ratio favors cogeneration systems, which in turn en-
ables important reductions in operating costs and
CO2 emissions. It is important to note that only en-
ergy costs are taken into account in the yearly oper-
ating costs. If carbon taxation was considered, the
most environment-friendly setups would be associ-
ated with an increased economic savings.
Figure 10: Two Pareto-Optimal Clusters of Heat Pump
Condensation Temperatures
Figure 11: CHP System+MVR, Heat Pump Condensing
at 66.5◦ C, COP=5.37

The high pressure evaporation temperature of the re-

frigeration cycle is converged at 6◦ C. The condensa-
tion temperatures are preferably distributed between
45◦ C and 50◦ C.
Figure 12: CHP System+MVR, Heat Pump Condensing temperature (35◦ C) [2], which results in additional
at 77◦ C, COP=5.71 electricity and heat consumptions.

Table 5: Results Bio-Methanation integration with

maximum heat recovery
1. Boiler, 2. CHP, 3. CHP+MVR +HP(Tcond =66.5◦ C), 4. CHP+MVR+HP(Tcond =77.5◦ C)

Unit 1. 2. 3. 4.
Biogas Engine Size [kWe ] 0 -1232 -677 -677
Process Identified Elec. [kWe ] 184 184 295 379
Digester Elec. [kWe ] 80 123 80 80
Total Elec. [kWe ] 264 -925 -298 -219
Biogas Extra Heat [kWth ] 39 0 196 434
Boiler (NIPU) [kWLHV ] 664 711 480 200
Operating Costs FR [ke/year] 161 -31 -16 -32
Operating Costs GER [ke/year] 260 -280 -38 -60
Invest. Bio-methanation [ke] 895 2030 1418 1418
Invest. Heat Pumps [ke] 0 0 198 290
TOTAL COSTS FR [ke/year] 238 145 124 115
Savings /ref. [%] -28 -56 -63 -65
TOTAL COSTS GER [ke/year] 338 -105 101 88
Savings /ref. [%] -35 -120 -81 -83
CO2 (EDF mix) [tons/year] 839 566 471 170
Savings /ref. [%] -66 -77 -81 -93
CO2 (GER mix) [tons/year] 1588 -2060 -377 -452
Table 4: Results with maximum heat recovery Savings /ref. [%] -47 -169 -113 -115

1. Boiler, 2. CHP, 3. CHP+MVR +HP(Tcond =66.5◦ C), 4. CHP+MVR+HP(Tcond =77.5◦ C)

Unit 1. 2. 3. 4.
Fuel consumption [kWLHV ] 2088 3279 1677 1140
Electricity [kWe] 184 -863 -80 142 Table 5 presents the comparison between the differ-
Operating Costs FR [ke/year] 332 210 205 212
Saving potential [%] 0 -37 -38 -36 ent options when converting the biogas. The cal-
Operating costs GER [ke/year] 520 283 312 336
Saving potential [%] 0 -46 -40 -35
culated energy consumptions include the NIPU heat
TOTAL COSTS FR4 [ke/year] 332 308 274 274 loads that are satisfied by the current boiler supplied
Saving potential [%] 0 -7 -17 -18
TOTAL COSTS GER
Saving potential
[ke/year]
[%]
520
0
380
-27
381
-27
398
-24
with biogas. The reference investment cost of a bio-
CO2 (EDF mix) [tons/year] 2459 3544 1912 1372 gas installation is 450ke(digester+cogeneration of
Saving potential [%] 0 +44 -22 -44
CO2 (GER mix) [tons/year] 2987 1094 1686 1976 100kWe ) [2].
Saving potential [%] 0 -63 -44 -34
Cooling water [kg/s] 17.1 17.1 3.0 0.1 Table 5 reveals that bio-methanation on site is the
Saving potential [%] 0 0 -82 -99
most economic and environmental solution. In-
deed, the investment in a bio-methanation installa-
tion is highly profitable and makes the process self-
3.3. Husk Bio-Methanation sufficient. In France, bio-methanation allows the
yearly total energy bill to be reduced by 65% and
Breweries offer the opportunity of recovering en- 2’289tons of CO2 /year to be saved (93% with re-
ergy through husk bio-methanation. The recovered spect to reference). The results are also very dif-
biogas can be used as an alternative to natural gas to ferent between France and Germany. The higher
feed the cogeneration engine. Knowing the amount cost and CO2 content of German grid electricity pro-
of husk produced per year, it is possible to calculate motes the cogeneration operated with biogas, which
the primary energy that can be recovered : results in important economic and environmental
profits.
Mhusk × M
eCH4 × vCH4 × LHVCH4
QLHV =
ev 4. CONCLUSION
A methodology based on process integration tech-
75 Nm3 of methane can be recovered from 1 ton of niques has been applied to improve the energy effi-
husk [2], which represents, for the brewery studied, ciency of a brewery.
8287MWhLHV /year=1660kWLHV , corresponding The definition and the modeling of the identified
to a combined production of 677kWe of electric- process units allows the determination of the heat
ity and the corresponding heat load. The organic recovery potential between process streams using
matter is blended and its transformation into bio- Pinch Analysis. The analysis of the process com-
gas by microorganisms requires a specific operating posite curves enables a first identification of the util-
Total Yearly Costs = Operating Costs+Annualized Invest-
4 ities that can be used to fulfill the determined Mini-
ment (interest rate=5%, payback time=15 years) mum Energy Requirements.
 A multi-objective optimization method is applied References
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Q̇th Heat Load [kW]
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M Mass[kg]
MVR Mechanical Vapor Recompression Acknowledgments: The authors wish to thank
vCH4 Methane Content of Brewery Waste [m3 /kg] ECLEER (European Centre and Laboratories for
Energy Efficiency Research (http://www.ecleer.com)
MER Minimum Energy Requirement [kW] for supporting this research and collaborating in its
e Molar Mass [kg/kmol]
M realization.
v
e Molar Volume of Perfect Gases [m3 /kmol]
NIPU Non Identified Process Unit
PUO Process Unit Operation
T Temperature [K]

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