Energy Saving System in Industry

(1)

Energy Saving System in Industry

Jun 2016

Shigeru Sakashita

Ai-Ai Energy Associates Co., Ltd.

Ai-Ai Energy Associates

(2)

Energy Saving System in Industry

 Economical need of Energy Saving

 Concept of Cleaner Production

 Energy Saving Technology

 Heat pump as the Energy Saving Technology

 History of Heat Pump in Brewery

 Virtual Factory as the Energy Saving Tool

 Sample of Virtual Factory

 Reference of Energy Audit with Virtual Factory

 Reference of Energy Saving CDM

(3)

Factory Management/ Break Even Point Analysis

World wide increase of the Energy Cost Push up the Break Even Point.

Back ground

>industrialization,

>exhaustion of resources

>population increase,

Fixed costs

Sales

$

Break-even point

Worldwide Increase of raw

material &

Energy cost Break-even point

shifts to higher sales amount and less profit

1.Economical need of Energy Saving

(4)

Global warming Effect as External Diseconomy

Global Warming Effect is one of the huge

External Diseconomy.

The effect of Climate Change may be

physical, ecological, social or economic.

External Diseconomy should be change into Internal Diseconomy

waste

waste Residence

effluent effluent exhaust

gas & CO2

river pollution

public pollution

cost

Outside Diseconomy medical cost

waste treatment cost etc.

sea pollution

1.Social need of Energy Saving

(5)

Definition of Cleaner Production (CP)

 Cleaner production is a preventive, company-specific environmental protection initiative. It is intended to minimize waste and emissions and maximize product output. By analyzing the flow of materials and energy in a company, one tries to identify options to minimize

waste and emissions out of industrial processes through source reduction strategies. Improvements of

organization and technology help to reduce or suggest better choices in use of materials and energy, and to avoid waste, waste water generation, and gaseous emissions, and also waste heat and noise.

Concept of Cleaner Production

(6)

Terms Related to Cleaner Production

 Waste minimization

 Pollution prevention

 Eco-profitability

 Low/non-waste technologies

 Zero waste emission

 Green productivity

 Lean manufacturing

Concept of Cleaner Production

(7)

80 90 100

20

Material Balance Model

Raw

materials Finished

products

Waste (material, water) 10

80 90

Product waste/ negative economic value

Concept of Cleaner Production

(8)

80 90 100

20 Improved Specific Energy Consumption

Raw

materials Finished

products

Waste (material, water) 10

90 100

Product waste/ negative economic value

80 Specific Energy input

100/90

Specific Energy output

100/90 >>

Energy saving Waste heat Reduction

Concept of Cleaner Production

(9)

Efficiency

Material & Energy Stream of Factory

Factory

Process 1 Process 2 Process 3

Raw material Product

Energy, Utility

Waste heat

Waste water, Waste

Production efficiency (yield)=

Product

Raw material

Specific energy (utility) consumption=

Energy, Utility

Product

(10)

The Natural relationship in CP

Increase in yield

Increase in profit

Decrease in waste

Environ ment- friendly Decrease

in waste treatment

cost

Increase in energy efficiency /productio

n

CO2 emission reduction Energy

efficiency improvem

ent Production efficiency

improvement and Energy efficiency improvement will contribute to factory

management and environment conservation.

Concept of Cleaner Production

(11)

Benefits of Cleaner Production

 Increased productivity

 Reduced operating costs

 Public health and environmental benefits

 Improved worker health and safety

 Reduced risk of liability

 Improved corporate image

 Improved global competitiveness

Concept of Cleaner Production

(12)

Before CP: unorganized workflow and production area

After CP: layout modification

Benefits:

 Organized workflow

 Reduced water spillages

 Increased productivity

Fresh Catch International Company

CP Activity in Philippines for reference under ICETT in Philippine

(13)

Uses continuous flow of water Water overflows from the tub

Uses cooling tower that recycles water for the cooling tank

After CP

Benefits:

•Reduced water consumption and wastewater

generation by about 160

m

³

/month (75%

reduction)

• Dry area

• Reduces workers’ risk

Savings: 1,920 m

³

water/ year

M.M. Guanzon Inc.

CP Activity in Philippines for reference under ICETT in Philippine

(14)

3 Approaches which contributes to Energy Saving in Factory

 Production Technology > Process Engineering

 Manufacturing Technique > Manufacturing Engineering

 Energy Saving Technology > Thermodynamic Engineering

 Cooperation of these 3 kind of Engineer should realize a effective Energy Saving System.

Energy Saving Technology

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Production Technology

 Production Technology can save the Energy by….

a. Modification of production process.

b. Developing new process.

c. Developing new method.

Energy Saving Technology

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Manufacturing Technique

 Manufacturing Technique can save the Energy by….

a. Increasing productivity b. Modification of Layout

c. Better operation Technique

Energy Saving Technology

(17)

Thermodynamic Technology

 Thermodynamic Technology can save the Energy by….

a. Efficient Use of Energy; Cascade use of Heat b. Heat recovery and Recycle; Heat Pump

c. New Energy generation from Waste; Biogas utilization Technology from Waste water & Biomass Energy

generation from Waste.

d. Energy Efficient improvement of Equipment

Energy Saving Technology

(18)

Improvement of Thermal efficiency of Cooking Sweat Bun (for understanding )

Microwave oven

faster

reduce heating period

more 3 stage

low cost

effective utilization Gelatinization of starch

soft, sweet & delicious steam 100%

d

fuel

G

fuel

Simple Steamer Effective Use of Steam

1^STstep Efficiency Improve

with Boiler Steam Microwave Oven

1^stStep ²^nd^Step ³^rd^Step

Production

Technology Making Recipe.

Cooking with high density steam to avoid dryness.

Analyze the gelatinization

Manufacturi ng

Technique

Supply much steam to keep steam density.

Multi use of steam and productivity increase with multi steam box

Use of boiler or Microwave oven to reduce running cost

Thermo

Dynamics Observation of

Steam behavior Analysis of Heat

demand Improve Thermal

efficiency with Boiler steam or Microwave 50% steam is

exhausted from top

Thermal efficiency should be 35%

with gas burner

Only 5% steam is exhausted

Thermal eff. of Heat Energy

100%

Energy 52%

Energy 24%

Energy 54%

Thermal efficiency should be 35%

with gas burner Thermal efficiency should be 97%

with steam Thermal efficiency should be 85%

with microwave

Boiler Efficiency

80% Power Generation Efficiency

40%

(19)

Thermal Efficiency according Heat Source of Cooking

「火なしオーブン」と「火なしコンロ」

　電子レンジは「誘電加熱」方式を、電磁調理器（ＩＨヒーター）は「誘導加熱」方式を使って加熱します。正しくは電磁誘導加熱(lnduction Heating)'略してＩＨを説明しましょう。

　特徴は外に火がなく、鍋自体が熱くなることです。「熱」という現金を渡すのではなく、為替手形を鍋に渡して、鍋が現金化するのです。この為替が磁力線で、電磁調理器から磁力線を受け取ると、鍋の金属内部に電流が流れ、電気抵抗により熱が発生する仕組み。

　この原理を理解するには、電界（電気）ができると影のように磁界（磁気）ができる見えない世界を想像する必要があります。電界がプラスとマイナスに激しく変化する高周波の電界を使う点や、外部で発熱しない点で、電ｆレンジと似ている点も多いので、ＩＨを「火なしコンロ」、電子レンジを「火なしオーブン」と呼ぶのもひとつでしょう。

環境工学研究所ホームページ http://windofweef.web.fc2.com/index.html Microwave Oven

Thermal Efficiency 80~90%(35%)

(20)

Continuous Steamer

Continous Steamer Continous Steamer (Heat Recovery)

d d d d d d d d d d d d d d d

in

Vapor

Steam Steam

∂ ∂

Hot Water

in

Scrubber for Heat recovery

Heat Exchanger Blower

Blower

Air

Air Air Air

Key: Fill the equipment with high density steam To reduce the intrusion of air as much as possible.

Too much air increase drying. > quality problem

>Increase the heat requirement.

Blower control is very important.

It should be control to minimize the air leak from open space (inlet and outlet of product) and minimize the exhaust from blower.

Heat recovery from the exhaust vapor as hot water with water scrubber.

It is important to minimize the air intrusion to increase the temperature of recovered heat.

If we can realize the 0 intrusion of air, recovered hot water temperature will be 100℃.

(21)

Vapor recovery and recycle System

Steam

∂ ∂

in

Air Air

Boiler Steam Scrubber for

Heat recovery

Flash Tank

Steam Ejector

(22)

Heat Pump as the Energy Saving Technology Pump & Heat Pump

Pump Heat Pump

High temperature

Tc

Low temperature Te

Power requirement Pr.=f(G, H)

Pr=0.163*G*H G; m3/min H; m

Power requirement Pr; f(Qh,dT)

Pr=Qh/COP

COP; Coefficient of Performance

COPc=(273.16+Tc)/(

Tc-Te)

Qh; kW/h

Qc; kW/h Heat Pump as the Energy Saving Technology

(23)

COP of Heat Pump

 COP: Coefficient of Performance

 COP=output energy / input energy

 Theoretical COP: Carnot COP=(273.16+Tc)/(Tc-Te)

• Tc: Condensing Temperature Te: Evaporative temperature

 COPec: Economical Marginal COP

• COPec: Electricity cost(yen/kWh)/Fuel Cost(yen/kWh)

 COPem: Environmental Marginal COP

• environmental impact of electricityper kWh/ environmental impact of fuelper kWh

• Environmental impact: global warming, pollution, etc

(24)

Heat Pump for Air-conditioning

Room

Atmosphere

Room Atmosphere

Winter Summer

Heat Pump as the Energy Saving Technology

(25)

Heat Recovery by Heat Pump (Industrial Use)

Waste Heat

Usable Heat Heat Pump as the Energy Saving Technology

(26)

Carnot Cycle and Reverse Carnot cycle > current situation

 Carnot Cycle : Turbine

 Turbine efficiency has reached 55% of Carnot equitation.

 Reverse Carnot Cycle* Heat Pump, Refrigeration

 Current Heat Pump COP is only 20% of Carnot COP

 Big Temperature difference of Condenser (Air cooled)

 Big Temperature of Air Cooler

 Improvement possibility

 Water cool or Evaporative condenser can increase COP

 Water scrubbing Cooler can increase COP

 It is possible to reduce 3% of Total Energy Consumption of Japan.

 Barrier

 Hassle of handling of water

 Big Inertia of current market Technology

800℃

72%

35~40%

30℃

15℃

19 5 Current COP

Theoretical Output=

Current Out Put

Turbin e

HP ambient Temp :30℃

cooling Temp :15℃

Carnot Cycle

Reverse Carnot cycle Carnot Equata on

Output Work:(High Temp-Low Temp)/(273.16+High Temp.)

Carnot Equata on

COP:(273.16+High Temp.)/(High Temp-Low Temp)

(27)

VRC; Vapor Re-Compression System

>Primitive and Efficient Heat Pump

History of Heat Pump in Brewery

(28)

VRC; First implementation 1982

 Barrier for implementation a. Can not change the

operation condition

b. Process Engineer afraid of Kettle crash

 Performance a. COP; 7.3

 Specification of VRC a. Recover Vapor; 10ton/h b. Motor 1000kW

History of Heat Pump in Brewery

1000kW (850kWh) 10ton Vapor 6267kWh

COP; 7.37 3bar 133 degree C

(29)

VRC; Following effort

 Brewing Engineer

 Analysis of Function and

Mechanism of Wort Boiling >

reduction of evaporation ratio 10% to 6.7%

 Process Engineer

 Increase Efficiency of Cocker (Heater) > Discharge pressure became lower; 3bar(133dC) to 1.5bar(113dC)

 Heat Pump Engineer

 More effective utilization of Energy

History of Heat Pump in Brewery

Numbers of Abstract/Session (given by NOC) - 4 -

10^thIEA Heat Pump Conference 2011, 16 - 19 May 2011, Tokyo, Japan

Vast time and cost were spent for mutual understanding for the first project. But, it was absolutely necessary before implementing heat pump and helped greatly to accelerate implementation in the following steps later.

2.2 Following development in brewery plants

Brewery plant is known to be a consumer of massive energy in food and beverage industry.

In particular, brewing process (brewhouse) including boiling process consumes 40 to 50% of entire energy.

Brewery industries in Europe and Japan are energy conscious and have developed extensive energy conservation measures during the last 30 years. Especially, energy conservation and quality improvement have been progressed in parallel. Following is a simple explanation of improvements in wort kettles and boiling method during the last 30 years.

2.2.1 Efforts made in brewing technology

Functions and mechanism of boiling have been analyzed thoroughly. As I mentioned before, there are a lot of functions in boiling. Following mechanism and results were found after analyzing each individual function.

The most important element of boiling capacity is the number of turns going through boiling. However, certain shape of kettle creates dead space and wort can not pass through the cooker uniformly.

10 to 15% of vapour evaporation ratio (80 to 90 minutes) was standard for boiling capacity at the time of initial development. It is now 6.7% to 10% (60 to 80 minutes). It may be as small as 3% in the case of a special boiling method.

2.2.2Efforts made by process engineers

Process engineers tried to eliminate the dead space after seeing the results of brewing engineers. Following are major items

studied.

The shape of kettle eliminating dead spaces

To increase amount of wort spraying out from the cooker Uniform distribution of wort sprayed out from the cooker

The shape of the kettle has been changed to be deep and longer vertically.

Cooker is a thermo-siphon heat exchanger. Water evaporated in the cooker is sprayed out upwards together with wort. Wort sprayed out changes its direction by an upper distribution plate and distributed over

the surface of wort pool. Figure 2 Wort movement

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VRC; Latest VRC System

History of Heat Pump in Brewery

(31)

VRC; Comparison Table, First vs Latest

First Latest Difference

Capacity of

Compressor 10t/h 4.7ton/h 5.3on/h

Tc 133 degree C 113 degree C 20 degree C

Motor 1000kW 200kW 800kW

COP 7.34 14.7 7.4

History of Heat Pump in Brewery

(32)

“Virtual Factory”

as the Energy Saving Tool by Process Analysis

 Understanding the process in detail

 Understanding the energy usage mechanism in the process.

 Making the Virtual Factory in computer is very effective to understand the factory process mechanism.

 Virtual Factory is the communication tool for 3 kind of Engineer;

Production, Manufacturing , Thermodynamic Engineer .

 Virtual Factory verifies the theoretical energy consumption to compare with the actual data.

 Virtual Factory accepts any changes easily and estimates the improved energy consumption accordingly.

 Energy-saving equipment and system can be also designed and implemented in the Virtual Factory.

“Virtual Factory”

(33)

Energy consumption in process units

based on the Material & Energy balance analysis

“Example of Wort boiling in Brewery”

Material &

energy balance

Process description

Estimated energy consumption

“Virtual Factory”

(34)

Structure of Virtual Brewery

“Virtual Factory”

(35)

Energy-saving analysis using Virtual Factory

Virtual Factory (existing)

Virtual Factory (Energy saving Plan)



Compare to Calculated result with actual data.



Investigate the reason of differences

material loss, heat loss?

mistake in program?

control system ? bad efficiency of equipment



Try to modify or adjust actual factory operation



Try energy-saving operation referring to Virtual Factory data



Design the energy saving System



Estimate energy saving amount



Feasibility study

location, available space budget estimation

estimation of CER: Carbon Emission Reduction

CDM Project or not

economical analysis: IRR, PBP

“Virtual Factory”

(36)

Energy-saving activity

 Search the points of losses and repair or modify them.

 Modify or adjust control system.

 Clean or modify the heat exchanger.

 Add more data in monitoring system.

 Add more and appropriate buffers with control system in order to keep high-efficiency operation for the utility

equipment such as boilers and compressors.

 Add heat recovery or biogas recovery system in order to reduce energy consumption.

 Modify the production process itself.

“Virtual Factory”

(37)

Sample of Virtual Factory- Brewery Summary

Summary of Brewing Simulation ( Existing)

Brewing Conditions ( Ex) Process BH Uni T Filtr. BBT Pack others Total Specific surplus Specific "CO2 Consumption

Cold Wort 1, 000 HL Product 1366 HL Steam Consumption 8. 04t 0. 43 t 17. 49 t 5. 2 t 31. 14 t 22. 8kg/HL Package C. Fill 600 g/HL

Temp. 10℃ Raw W. Temp. 33℃ CO2 Consumption -‐‐‒5

9

81kg 442kg 428kg 574kg 433kg 1877kg1. 4kg/HL 4104kg3. 0kg/HL Package B. Fill 360 g/HL

First Plato 15. 0 kg/HL HW. Brew Temp 80℃ Air Consumption 0 0 0 Packaging Mix 420 g/HL

Final Platon 1. 8 Kg/HL HW. Id. T emp 80℃ Water Consumption 1304HL 393HL 1487HL 2865HL 6049HL 4. 4HL/HL CO2 Specific W. 1. 96 kg/m3

Original G 11 kg/HL Packaging Mix. Hot Water Consumption 866HL 866HL0. 6HL/HL Deaeration 700 g/Hl•DA

Brewing N 8 Bottle 75% Hot Water Generation 1133HL 1133HL 0. 8HL/HL 267HL 0.2HL/HL Press. Of BBT 0. 6 bar

Ice Water 4℃ Can 25% 100% 24% 76% CO2 content. 5. 1 g/L

25. 95 t 5981kg - 1444kg = 4537kg ※ 　pacaging mix

Bottle 50%

8. 04t 17. 49 t Can 50%

0 .6 1 t 1 .2 2 t 6 .2 0 t 0 .4 3 t 4 .4 3 t 1 3 .0 6 t

8. 86 t 4. 20 t Rice Malt

3. 4 t 10. 5 t

4. 9 t/b 5981kg Carbonat in 186kg 428kg 369kg 205kg

Deaerat ion 256kg

95. 0dC.d 10dC -‐‐‒15dC -‐‐‒1C 35dC

Push W. 1000HL 1000HL 1393HL 1366HL

61dC 51dC 78dC 80dC 105. 8 t 97. 4 t 139. 2 t 750. 0 t

106HL 213HL 731HL 18. 0HL 15. 0P° 1. 8P° 1. 3P° 1. 3P°

Alc 6. 80% w/ w Alc 4. 76% w/ w Alc 4. 76% w/ w

64HL 83HL 701HL

BH 4dC 4dC 33dC Cooling Load Mcal/B Mcal/h

33dC 1101HL 393HL 1487HL Ice W. for Wort Cooling 3193 1064

1304HL Ice Water for Blending 1562 521

42HL 131HL 30HL 80dC 80dC Unitank 4012 1337

866HL 1133HL Yeast 177. 4 59

Filtration 459 153

Total Others 940. 3 313

33dC 80dC Total 10343 3448

3184HL 267HL

RC MK PT WK WHP

BW BF BP

CF CP

STM CO2 AI R

STM STM

CO2

Raw W.

Surplus HW MF

(38)

Sample of Virtual Factory- Sugar Mill Summary

G

Cane Receiving Cane Milling

Juice Heating

Concentration

Crystallization Bagass Boiler

Steam Turbine

Molasses Tank

Ethanol production Sugar storage

(39)

Sample of Virtual Factory- Palm Oil Summary

(40)

Reference of Energy Saving Audit by Virtual Factory -1

Industry or Factory country year Estimated Energy

Saving support

Brewery Japan 2009 30% Commercial

Canning factory of Fruits Philippines 2009 35% ICETT, METI Asphalt production Philippines 2009 70% ICETT, METI Ham, Sausage, Bacon Philippines 2009 80% ICETT, METI

Jam, Past Philippines 2009 37% ICETT, METI

Slaughter An dressing of

chicken Philippines 2009 50% ICETT, METI

Shrimp processing and

Freezing Philippines 2009 20% ICETT, METI

Fish processing Philippines 2010 55% ICETT, METI Paint factory Philippines 2010 20% ICETT, METI

(41)

Reference of Energy Saving Audit by Virtual Factory -2

Industry or Factory country year Estimated Energy

Saving support

Cane Sugar Mill Philippines 2010 Power generation

80MW ICETT, METI

Brewery Philippines 2010 40% ICETT, METI

Ham, Sausage production Japan 2010 35% Commercial

Brewery Japan 2010 25% Commercial

Brewery South Africa 2011 35% RENOVA, GEC

Cassava starch factory Thailand 2011 Bio ethanol NEDO

Brewery Vietnam 2012 35% Commercial

Soft drink (carbonated) Laos 2012 40% Commercial

Brewery Vietnam 2012 35% RENOVA, GEC

(42)

Reference of Energy Saving Audit by Virtual Factory -3

Industry or Factory country year Estimated Energy

Saving support

Instant Noodle factory Thailand 2013 40% RENOVA, JICA Ice Cream factory Thailand 2013 20% RENOVA, JICA

Sorbitol Factory Thailand 2013 15% RENOVA, JICA

Bakery Thailand 2013 25% RENOVA, JICA

(43)

Reference of Energy Saving Audit by Virtual Factory -4

Industry or Factory country year Estimated

Energy Saving support

Instant Coffee factory Thailand 2013 20% RENOVA, JICA

Soft Drink factory Thailand 2013 30% RENOVA, JICA Tuna Canning factory Thailand 2013 40% RENOVA, JICA

Brewery Thailand 2013 30% RENOVA, JICA

Cane Sugar Mill Philippines 2013 Power Generation

80MW USAID

40MW USAID

60MW USAID

20MW USAID

Soft drink Japan 2013 25% Commercial

(44)

Reference of Energy Saving Audit by Virtual Factory -5

Industry or Factory country year Estimated

Energy Saving support

Brewery Laos 2014 40% RENOVA, METI

Brewery Vietnam 2014 30% RENOVA, NEDO

Cane Sugar Mill Philippine 2014 Power Generation

80MW RENOVA, ANRE

Cane Sugar Mill Philippine 2014 Power Generation

40MW RENOVA, ANRE

80MW RENOVA, ANRE

Orange Juice factory Mexico 2014 50% RENOVA, NEDO

Cereal factory Mexico 2014 35% RENOVA, NEDO

Edible Oil factory Mexico 2014 25% RENOVA, NEDO

Soft drink factory Mexico 2014 25% RENOVA, NEDO

(45)

Reference of Energy Saving Audit by Virtual Factory -6

Industry or Factory country year Estimated

Energy Saving support

Brewery Mexico 2014 35% RENOVA, NEDO

Brewery Mexico 2014 40% RENOVA, NEDO

Brewery Brazil 2014 45% RENOVA, NEDO

Brewery Brazil 2014 40% RENOVA, NEDO

Palm Oil mill Cambodia 2014 45% OECC

Brewery Cambodia 29014 40% OECC

Soft Drink (carbonated) Brazil 2014 30% RENOVA, NEDO

Winery Japan 2015 35% Commercial

(46)

Reference of Energy Saving Audit by Virtual Factory -7

Industry or Factory country year Estimated

Energy Saving support

Tabaco factory Laos 2015 25% OECC

Hotel Laos 2015 30% OECC

Shoe Maker Laos 2015 30% OECC

Pig Farming Laos 2015 30% OECC

(47)

Reference of Brewery in Vietnam - Thanh Hoa Beer



Established in 1987



150km from capital Hanoi (3 hrs by car）



51ML annual beer production (in 2004, 7th largest production (1.2million kL-beer total in

Vietnam）



ISO9000 certified in 2002

Expanded production line in Apr 2004

(Capacity:8kL/brew ), and renewal of the exiting

brewhouse (30kL/brew) in Sep 2004



Products: Bia Thanh Hoa, Saigon, Hanoi

THANH HOA BREWERY BIA HAI PHONG

BIA SAIGON

Reference of Energy Saving with CDM-MYCOM Project

(48)

Implemented Energy-saving Systems

B B T C

C V

Latest VRC System

Chiller

Chiller Chiller

Cascade Cooling System Dynamic Ice Storage/Transportation System

Economical Methane recovery System

Optimal Pasteurizing System

Reference of Energy Saving with CDM- MYCOM Project

(49)

VRC System for Wort Kettle

Saving steam by reusing the discharged steam

Discharged steam has great energy!

Reference of Energy Saving with CDM-MYCOM Project

(50)

VRC System

Wort Kettle: evaporates about 2 tons of water in 1 batch. The conventional system

discharges waste steam into atmosphere

Drain

Scrubber: cleans the waste steam and generates hot water for pre-heating the wort for the following batch

99ºC

85ºC

Wort Pre- Heater

Hot Wort 97ºC

Wort 78ºC Energy

Storage Tank 61m³

Reference of Energy Saving with CDM-MYCOM Project

(51)

Heat Pump for pasteurizer

 Temperature of Showering for final cooling zone is kept by Heat Pump Chiller stably.

 Heat Pump supply the

condensing heat to the first heating zone to heat up the bottled Beer.

 Irregular operation (starting,finishing and temporary stop and restart),cooling tower

supply and recuperate the heat of the pasteurizer

depending on the situation.

Reference of Energy Saving with CDM- MYCOM Project

(52)

Biogas Recovery System

Waste Water from Brewhouse

UASB (high temperature)

Gas Holder

Bio-gas Boiler

Gas compressor

Steam Accumulator

Reference of Energy Saving with CDM-MYCOM Project

(53)

Cascade cooling system for ice water chilling

Water cooling from

28^oC to 5^oC (Large temp.

differential) .

Based on 1763kW (500TR) Cooling load.

Power consumption reduces to 60%.

Compressor capacity reduces to 70%.

Displacement volume of Compressor

Chiller

COP=4.87 Tc=35^oC

28^oC

5^oC Te=0^oC

Chiller

Cascade Cooling System

i

ii

Tc Te dT kW M3/h 35 0 35 362 1992 35 15 20 70 463 35 8 27 73 463 35 0 35 76 463 II Total 219 1389 II /I 60% 70%

II -I 143 603

Tc=35^oC COP=8.06

28^oC

18^oC

10^oC

5ôC Te=0ôC Te=15ôC

Te=8^oC

Based on 1763kW (500TR)

Conventional Cooling System

Reference of Energy Saving with CDM-MYCOM Project

(54)

Cascade Cooling System

No.1

No.2

No.3

30ºC

0ºC

Brewing Water Ambient Temp.

Ethanol Brine Tank

12m³

(Using existing Tank)

Chilled Water Tank

For Wort Cooling 140m³

Wort cooler Hot Brewing

Water Tank 85ºC

Hot Wort 99ºC

3ºC

Fermentation 30-40m³/1brew Tank

300-400m³/1day 30^oC

20ºC 10ºC

0ºC

Water cooler

Started operation in August 2005

Reference of Energy Saving with CDM-MYCOM Project

(55)

Dynamic Ice Storage &

Transportation System

Jacket cooling

Plate cooling

Air cooler

Dynamic Ice Transporting Loop Piping Dynamic Ice

Storage Tank

Reference of Energy Saving with CDM-MYCOM Project

(56)

Comparison table of Transportation Performance

Temperature Transport system

Specific heat transportation Diameter of Pipe Required volume of water

Required pump power Running cost

19.8W/kg

Chilled water Dynamic ice

0℃/3ôC -2ôC/3ôC

3.5W/kg 250mmNB 125mmNB

332m³/h 59m³/h

30.0kW 5.5kW

450yen/h 83yen/h

Cooling load is 1000Mcal/h Head of pump is 20m

Reference of Energy Saving with CDM-MYCOM Project

(57)

Dynamic Ice System

Dynamic Ice Storage tank -4ºC, 170m3

Dynamic Ice Maker

To use existing refrigeration compressor to make dynamic ice Refrig. Comp.

No.1 100kW Refrig. Comp.

No.4 100kW Pd:

Td: 110ºC

Heat recovery from NH₃ discharge gas to make hot water

Evaporative Condenser

Fermentation

2^ndBrewhouse WC 2^ndBrewhouse FT

Reference of Energy Saving with CDM-MYCOM Project

(58)

Total Energy Saving Performance

 Energy-saving: 3,386 Toe

 CO2 emission reduction: 10,376 Ton

Reference of Energy Saving with CDM-MYCOM Project

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