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Sustainable Brewery Concept Presented by Chris Woods share your - - PowerPoint PPT Presentation
Sustainable Brewery Concept Presented by Chris Woods share your - - PowerPoint PPT Presentation
Sustainable Brewery Concept Presented by Chris Woods share your experiences today #BevExpo2016 Core Services share your experiences today #BevExpo2016 Contents Reduce, Reuse & Recycle Nijhuis Sustainable Brewery
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Contents
- Reduce, Reuse & Recycle
- Nijhuis Sustainable Brewery Concept
- Water, Waste & Energy Audits
- Process Water Reuse
- Waste Water to Value
- Our Experiences
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The Global requirement for change
- Food and beverage manufacturing uses high volumes of water, heat and energy
– 10 to 70 tonnes of water used per 1tonne of product
- 10% of a countries energy use goes into the growing, processing, packaging and
shipping of food
- 50% of all food is wasted, approximately 1.2-2 Billion tonnes
- Typically 70% - 80% of incoming water is discharged as waste water
- Water and energy supplies are rapidly diminishing
Reducing our water, heat and energy use and reducing waste...........
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Reduce Reuse & Recover Water Resources
The challenges in the beverage market typically concerns:
- reduce the fresh water intake and reduce wastewater discharge costs
- reuse wastewater for process cleaning purposes, reuse process water from pasteurisation lines and
cooling water towers
- recover resources to use them as an energy source, heat source or sell them as fertilizer
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Sustainable Brewery Concept
Water
Brewery Plant
Energy Heat
Wastewat er
Process Water
Process Water Disinfection
Reuse Water
Sludge Management
Solid Fertilizer Reduced Disposal Cost
Modular Solutions
Fit for Future
Recovered Water
Wastewater to Value Plant
Recovered Heat Recovered Energy Water discharge to river or sewer Recovered spent grains
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- Improve efficiency
- Reduce cost
- Create value
A Four Stage Process
- Discovery
: what we are doing right
- Dream
: what we can achieve
- Design
: the ideal we can co-create
- Destiny : where do we want to go
Water, Energy & Heat Audits
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Process Water Disinfection
Industry description: Pasteurisation and filling lines will suffer from Biomass contamination that exists of filamentous bacteria in a layer of EPS (exo polymer sugar) resistant to chlorine Conventional / Challenge:
- Production stops for cleaning
- Require disinfection in situ online without
chemicals
- Keep the system continuously clean
The Smart Solution
- Nijhuis Ozone Solutions water re-use
- Redox control for ozone dose rate results
in optimal OPEX
- Expected ROI 1.5 – 2.5 years
Additional advantage
- Ozone cannot contaminate
- Bacteria cannot become resistant to
Ozone
- In situ CIP without production stop
Beverage pasteurisation line
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Aerobic vs Anaerobic Treatment
Requires typical 0.5 kWh/kg COD
- Good effluent quality
- Biological nitrogen removal
- Watercourse discharge possible
- High sludge production
Produces typical 3.5 kWh/kg COD
- Low sludge production
- No biological nitrogen removal
- No phosphorus removal
- Often post-treatment required
CO2
Aerobic treatment Anaerobic treatment
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BIOCTOR – Aerobic Solution
Flow COD COD TSS TSS Source m3/year mg/L kg/d mg/L kg/d Influent 64,150 3291 211 605 39 Effluent 64,150 78 5 19 1
Sequencing Batch Reactor
- Aerobic degradation of organics
- Discharge to watercourse
Sludge Thickening
- Reduction of sludge volume
Modular Construction
- Rapid site installation
- Off site fabrication
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BIOCTOR – Aerobic Solution
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AECOMIXTM – Anaerobic Solution
Payback Calculation Additional Benefits
- >95% COD removal
- Return of water to watercourse
- Reduced carbon emissions
- Low operator input
- Low odour risk
- Tertiary treatment possible for
reuse
Aerobic brewery example Operational Costs 175m3/day Sewer Cost Without Treatment £ 442,469 Watercourse Discharge Cost £ 20,000 Electrical Cost £ 13,248 Sludge Disposal Cost £ 98,000 Chemical Supply Cost £ 10,915 Labour Cost £ 10,800 CAPEX Investment £ 695,000 Gain From Investment £ 289,506 Payback Period (years) 2.40
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AECOMIXTM – Anaerobic Solution
Flocculator/Dissolved Air Flotation (DAF)
- Removal of suspended solids
- Prevents solids build up
Performance
Aecomix - UASB
- Up-flow Anaerobic Sludge Blanket Reactor
- Biogas with a high concentration of methane is
produced as a by-product Flash Aeration
- Removes excess H2S
Flow COD COD TSS TSS Source m3/year mg/L kg/d mg/L kg/d Influent 109,500 4811 527 573 63 Effluent 109,500 342 37 516 57
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AECOMIXTM – Anaerobic Solution
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AECOMIXTM – Anaerobic Solution
Payback Calculation
Anaerobic brewery example Operational Costs 300m3/day Sewer Cost Without Treatment £ 993,869 Sewer Cost With Treatment £ 270,456 Electrical Cost £ 16,425 Sludge Disposal Cost £ 15,330 Chemical Supply Cost £ 104,504 Labour Cost £ 10,800 CAPEX Investment £ 980,000 Gain From Investment £ 576,354 Payback Period (years) 1.70
Additional Benefits
- 1,350m³ biogas per day
- Trade Effluent Compliance
- Reduced Carbon Emissions
- >90% COD Removal
- Low power consumption
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Achieve your goals with Nijhuis solutions
Chemical free Meeting sustainable requirements Lower the environmental footprint Combine productivity & energy efficiency Ensure minimum life-cycle cost 4 important goals to achieve at the same time!
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