maximalisation of efficiency and sustainability in...
TRANSCRIPT
Maximalisation of efficiency
and sustainability in breweries
Kris Gorissen – September 2015
How to reduce brewery water footprint?
CONTENTS
Introduction
How to reduce brewery water footprint?
Brewery water usage
Brewery housekeeping
BOOMERANG® Water
Bio-effluent re-use – Drivers
Bio-effluent re-use – Points of attention
Case study: Water mass balance
Case study: Return on investment
INTRODUCTION Organisation, technology, references, ...
PROTECTING THE 4 ELEMENTS OF NATURE
MISSION
WIND FIRE
WATER EARTH
CLEAN ENERGY
CLEANING UP WASTE
53 TECHNOLOGIES, 29 PATENTS
CLEAN WATER
BIOTIM® AD Anaerobic wastewater treatment
LUCAS® AD Anaerobic wastewater treatment
ENERGIZE® Multistage grate incinerator
TURNOVER® Rotary kiln
HELIOSOLIDS® Fluidized bed incinerator
BIOTIM® Wastewater treatment
LUCAS® Wastewater treatment
KROFTA® Solid-Liquid separation
WATERPROOF® Drinking water
COBRA® Core and Brains
ATLANTIS® Submerged MBR
X-TRACTOR Crossflow MBR
AQUALITY® Process water
EXSEL® Desalination
BOOMERANG® Water reuse
BIOTON® Biofilter
BELAIR® Biotrickling/biofilter
BIOWAVE® Bioscrubber
DYNACYCLE® VOC concentrator
CALVERT® Quench-scrubber
BELGAS® Biogas cleaning
WATMONIA® Ammonia scrubber
HYDROGONE® Horizontal sludge drying
PUTTART® Vertical dryer granulator
ENERGIZE® Grate incinerator
TURNOVER® Rotary kiln
HELIOSOLIDS® Fluidized bed incinerator
CLEAN AIR
TODAY: +5.000 REFERENCES IN 85 COUNTRIES
HOW TO REDUCE BREWERY
WATER FOOTPRINT?
BREWERY WATER USAGE
6hl/hl 4,5hl/hl 3hl/hl
Brewery housekeeping • Recovery sand filter
Backwash- water • Monitoring H2O
consumption • Water efficient
CIP/packaging • membrane filtration
instead of Kieselguhr filtration
• Process chemical use: Optimisation
• ...
1 2
Bio-effluent recovery - Boomerang® • Ultra filtration • Reverse osmosis • Potable water from bio-effluent
BIO-EFFLUENT RECOVERY - BOOMERANG®
Purifying bio-effluent for re-use as process water
Two possible technology trains:
AQUALITY® Ultrafiltration + EXSEL® Reverse Osmosis
ATLANTIS® MBR + EXSEL® Reverse Osmosis
6hl/hl 4,5hl/hl 3hl/hl
2
BIO-EFFLUENT RE-USE
≠ water qualities for ≠ applications:
Grey water (cleaning, irrigation)
Potable water
Process water
DEFINITION BOOMERANG® Water
Bio-effluent recovery
Membrane technology: UF + RO
High quality applications
SUCCES OF BOOMERANG® WATER
3 CONDITIONS:
1. Bio-effluent must be of acceptable quality
2. Generated concentrate stream must be disposable
3. Production must allow re-use:
Technical = no problem !
Financial
Psychological
EXSEL® AQUALITY®
UF = Retention of particles,
turbidity & microorganisms
RO = Retention of viruses,
organics, pesticides & salts
Capacity: 50 m³/h RO permeate
2-pass RO-design
Dimensions: 20m x 10m
BOOMERANG® - DRIVERS
FINANCIAL DRIVERS:
City water costs ↑↑
Wastewater discharge costs ↑↑
WATER AVAILABILITY DRIVERS:
Water scarcity
Limited ground water permit
Limited city water production capacity
Less dependant on external water providers
BOOMERANG® - DRIVERS
WATER QUALITY DRIVERS:
E.g. hardness ↓, salt content ↓, corrosivity ↓, ...
Ground water quality
Drinking water quality
Required process water quality
CSR – Decrease Water Footprint / Zero Discharge
COMBINATIONS!
BOOMERANG® - POINTS OF ATTENTION
BIO-EFFLUENT QUALITY – WWTP required !
WHAT WITH RO-CONCENTRATE ?
Direct sewer discharge
Dilution & Discharge – Only part bio-effluent re-used
RO-concentrate polishing treatment (bio, AOP, evap)
Note: Evaporation – Zero discharge is possible (> 99,5% recovery)
RO-Concentrate = higher concentration, but same load !!!
Is dilution solution for pollution ?!?
BOOMERANG® - POINTS OF ATTENTION
ECONOMY OF SCALE FEASIBILITY
Case-by-case: Legal & permit/WWTP available?/Water quality
Savings not only on water intake but also on reduced discharge
REQUIRED WATER QUALITY ?
PSYCHOLOGICAL BARRIER
Last, but not least!
CASE STUDY
Brewery water mass balance
DESIGN BASIS - BREWERY
Brewery Capacity: 6 mio hl
Peak week: 20,600 hl/d
Water ratio: 4,5 hl/hl 10,000 m³/d
1,5 hl/hl product + losses 3,333 m³/d
3 hl/hl wastewater 6,666 m³/d
COD ratio: 1,0 kgCOD/hl 20,600 kgCOD/d
WATER MASS BALANCE – without Boomerang®
BREWERY
4,5 hl/hl
WWTP
LUCAS anaer
new H2O
10,000 m³/d
4,5 hl/hl
Product + Losses
3,333m³/d
1.5 hl/hl
Wastewater
6,666 m³/d
3 hl/hl
Discharge
6,666 m³/d
3 hl/hl
10,000
3,333
6,666
WATER MASS BALANCE – with Boomerang®
BREWERY
4,5 2,4 hl/hl
WWTP
LUCAS anaer
new H2O
5,333 m³/d
2,4hl/hl
Product + Losses
3,333 m³/d
1,5 hl/hl
Wastewater
6,666 m³/d
3 hl/hl
Discharge
1,999 m³/d
0,9 hl/hl
3,333
=
1,999
↓↓↓↓
BOOMERANG
UF + RO
Bio-Effluent
6,666 m³/d
3 hl/hl
Process Water
4,666 m³/d
2,1 hl/hl
5,333
↓↓
70% Recovery
WATER MASS BALANCE – with Boomerang®
New H2O (city/borehole):
4.5 2.4 hl/hl
Up to 50% water saving
Discharge:
3 0.9 hl/hl
More than 70% discharge reduction
Psychological Barrier:
No bio-effluent to beer req’d! New H2O to beer!
Boomerang H2O = Process H2O ≠ Brewing H2O
New H2O = Brewing H2O: 2.4 hl/hl >> 1.0 hl/hl
CASE STUDY
Brewery Industry – Return On Investment
RETURN ON INVESTMENT
Capacity:
195 m³/h process water production
1.500.000 m³/yr process water production
70% over-all recovery
CAPEX:
Investment: 1.800.000 €
OPEX
Electricity: 0,65 kWh/m³ = 975.000 kWh/yr
Chemicals: 60.000 €/yr
Membrane replacement: 45.000 €/yr (UF: 8 years; RO: 4 years)
Maintenance: 30.000 €/yr
Operator hours: 500 h/yr
RETURN ON INVESTMENT
Benefits
Saving city water intake: + 1,1 €/m³ = + 1.650.000 €/yr
Saving discharge tax (Vlaamse vervuilings eenheden) = + 50.000 €/yr
Low conductivity = Very good boiler feed water quality!
Total: + 1.700.000 €/yr
Operational Costs
Electricity: 975.000kWh/yr x 0,65 €/kWh = - 635.000 €/yr
Chemicals: - 60.000 €/yr
Membrane replacement: - 45.000 €/yr
Maintenance: - 30.000 €/yr
Operator hours: 500 h/yr x 30 €/h = - 15.000 €/yr
Total: - 785.000 €/yr
CAPEX: 1.800.000 €
Depreciation: 10 years
OPEX: - 785.000 €/yr
Operational Benefit: + 1.015.000 €/yr
IRR: 25 %
ROI: 2 years
WTP life time: > 20 years
> 25 m³/h
> 1-2 €/m³ total cost savers
< 3,0 hl/hl
To be studied case by case
RETURN ON INVESTMENT
RULES OF THUMB
Contact:
Kris Gorissen
Waterleau Process & Sales Manager
Nieuwstraat 26
3150 Wespelaar (Leuven)
Belgium
M +32 (0)497 536 669
Office : +32 (0)16 650 657 Ext. 40
F +32 16 650 663
waterleau.com