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ENGINEERING can be defined as:

BASIC BREWERY - The activities or function of an Engineer;

ENGINEERING
Conducted by
Rofuat “Pat” L. Lu, PME, MSME
SME STUDENT CONFERENCE held in PLM on December 14, 2013
Part-time Professor - Mapua Institute of Technology
Operations Technical Manager - San Miguel Brewing, Inc.
Former President: PSME Manila (Host) Chapter
Former Members: International Institute of Ammonia Refrigeration (IIAR);
American Society of Heating, Refrigeration & Air-Conditioning Engineers
(ASHRAE) and American Society of Mechanical Engineers (ASME)
Member / Student Adviser: Society of Manufacturing Engineers (SME)
- The application of Science and mathematics by
which the properties of matter and the sources of
energy in nature are made useful to people; and,
- The design and manufacture of complex products.
BREWERY is a manufacturing plant where malt liquors
or an alcoholic beverages, commonly known as “Beer”,
are produced. (Beer is a drink soaked in tradition of malted barley, hops
and water. A tradition, which has been integrated with science to deliver
varied flavors and drinking pleasure)
BREWERY ENGINEERING is defined as having world
class Manufacturing Process & capability to achieve
excellent and consistent product quality at lower cost
with environment friendly technology.

Manufacturing Process
- Involves the detailed engineering of the product TOPICS FOR DISCUSSION:
process taking into consideration the utility requirements,
options available and try to determine the optimum
solutions using modern technology while ensure product
quality at optimum production cost. 1. Manufacturing Process
Procedures in Manufacturing Process: 2. Utility System & Fundamentals
▪ Flowcharting – Development of Manufacturing Process
Flowsheet based in the process, packaging and utility 3. Brewery Design Layout
systems requirement.
▪ Capacity Calculation – Determine the capacity of each
utility systems to manufacture the product using the
agreed design assumptions and parameters.
▪ Equipment Sizing – The production equipment are sized
based on the above computed capacity and operating
conditions.

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Cost

Electricity is the number one and

most expensive utility system in the
Safety &
Utilities:
most Manufacturing Plant.
Environment Electricity
Water System/Treatment What is Power Factor?
Compressed Air System
Steam System  Power factor is the measurement of how effectively electrical power is
Refrigeration System being used: The higher the power factor, the more efficient the
Raw Air-Conditioning System
Materials
Process
CO2 Recovery System plant…all the way back to the generator.
Waste Water Treatment System
 An electrical system’s power is composed of different parts:
Packaging Packaging Products  Active (working) power which performs the useful work
Materials
 Reactive (non-working) power which creates the magnetic fields for
inductive devices
By Product: CO2 Waste
 Apparent Power(kVA) = Active power (kW) + Reactive power (kVAr)

Quality Delivery / Time

Low Power Factor is like… Therefore:

Active Power ( kW ) Without
ApparentPower ( kVA) capacitor
kVAr Reactive power

Active power
OR Motors
Transformer
kVA
Available active
power
With
Drinkablebeer
capacitor
kW Full glassof beer

kW
PF  Transformer Motors Capacitor
kVA

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HYDROLOGICAL CYCLE Water Supply Resources are

categorized into main groups:
 THE SURFACE WATER
 Examples: river, lake and ocean
➢ Three sources of water for rivers and lakes
 Run-off or overland water
 Springs or discharging groundwater
 Melting of solids precipitation( snow)

 THE GROUND WATER

 Sub-surface water in the saturated zone below the
water table

COMPRESSED AIR SYSTEM

WATER TREATMENT SYSTEM
WHAT IS COMPRESSED AIR?
DEALKALIZER 3 3B USERS
 MORE ECONOMICAL TO USE &
3C

USERS PROCESS
PROCESS WATER
RESERVOIR
CONVEY
WATER
DEGASIFIER
SOFTENER 3 A  SAFER TO USE IN CERTAIN CASES
IN-LINE
CHLORINATION
2
4A 4B USERS  LIGHT WEIGHT COMPONENTS
RAW WATER
PRODUCT WATER
RESERVOIR PRODUCT
DEALKALIZER 4 RESERVOIR
WATER
DEGASIFIER
 CLEANER THAN SOME OTHER FORMS
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DEEPWELL 5
ANION
5B EXCHANGER  EASIER TO WORK WITH
5A 5C
5C USERS
CATION
EXCHANGER
DEMINERALIZED
DEMINERALIZED WATER RESERVOIR
WATER
DEGASIFIER

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IDEAL COMPONENTS FOR A

WHY USE COMPRESSED AIR? COMPRESSED AIR SYSTEM
• Elastic, to permit internal storage of energy  Compressor
• Low in viscosity, to minimize internal friction losses  Aftercooler
• Inexpensive  Wet Receiver

• Readily available  Pre-Filter

• Non-toxic  Dryer

• Non-polluting  After Filter

 Dry Receiver
Air is the one fluid, which satisfies all these requirements.

BASIC TYPES OF AIR COMPRESSOR

Ideal Components Layout

“Dry”
After-Cooler Pre-
Receiver
filter
To user
Dryer
Compressor

After-
filter
“Wet”Receiver

Typical 2-stage Reciprocating Air Compressor

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BASIC TYPES OF AIR COMPRESSOR BASIC TYPES OF AIR COMPRESSOR

Typical Rotary Screw Air Compressor Typical Centrifugal Air Compressor

INDUSTRIAL STEAM SYSTEM

WHAT IS STEAM?

Steam - a vapor into which water is converted when heated

to its boiling point.

Typical View of Horizontal Fire Tube Boilers

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WHY USE STEAM? BOILER TERMINOLOGY FOR WATER

 Water is cheap and abundant in most part of the Make-up Water - treated water which is added to
world. the system to replace steam and water lost.
 Its temperature can be adjusted accurately by the
control of pressure using simple valves.
Condensate - steam that is returned back to its
 Steam can easily be transmitted from point of
liquid state normally at steam temperature.
production to point of use. Feed water- water supplied to the boiler
 It carries relatively large amount of energy in a
small mass. and is the sum of the condensate and make-up.
 When condensed back to water, high rates of Boiler Water- water inside the boiler.
energy flow are obtained.
 It is non-toxic.

STEAM SEPARATOR
PRIMARY REQUIREMENTS OF A STEAM
EXPANTION JOINT
GENERATION SYSTEM

▪ Steam Boiler
▪ Feedwater
▪ Fuel
▪ Electricity
▪ Compressed Air

PROCESS FLOW OF STEAM GENERATION SYSTEM

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TYPES OF SET-UP FOR STEAM GENERATION SYSTEM

DISADVANTAGE
Bottling Bottling

Fr Fr

Additional fuel consumption due to:

WC Fresh WC Fresh
H2o H2o
Deaerator
Condensate CELLARS/FILT Condensate CELLARS/FILT

- Flash steam is lost and vented on the

Tank CIP HEAT Tank CIP HEAT
X’CHANGER X’CHANGER
FLASH FLASH

atmosphere
PASTEURIZER PASTEURIZER
To
Steam end To
users Steam end
Make up Make up users

- Lower condensate return temperature

Pressurized Tank Deaerator/ Tank
Main Pressurized
Condensate Condensate
Tank Tank

Condensate
Tank Boiler
Condensate
Boiler
- Additional chemical consumption
Tank

Brewhouse Brewhouse - High DO pick up of feed water

Condensate Pressurized Full Deaeration System

System

ADVANTAGE
Save in fuel consumption: STEAM BOILER
- Flash steam is maintained and utilized
- Higher boiler feed water temperature
A unit to which water, fuel and air are
Save of chemical usage:
supplied and in which steam is
- Guaranteed oxygen level of 7 ppb hence
generated. It consists of a fuel
reduce in chemical deaeration
burning equipment, furnace, heat
Save power and maintenance cost:
transfer areas, feedwater pumps, fuel
- Reduce the number of transfer pumps
pumps, blowers, and other auxiliaries
- Less maintenance due to less tank
required to generate steam.
auxiliary

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HOW STEAM BOILERS ARE RATED GROUPING OF BOILERS

•Construction
A TYPICAL STEAM BOILER IS RATED ACCORDING TO
ITS BOILER HORSEPOWER: •Working pressure
1 BoHP = 34.5 LBS OF STEAM/HR FROM &
AT 212oF •Fuel used

CAPACITY CAN ALSO BE BASED ON THE ACTUAL •Shape or size

EVAPORATION RATE, MEANING, THE AMOUNT OF
STEAM GENERATED AT THE GIVEN PRESSURE & •Usage
TEMPERATURE.

INDUSTRIAL FIRE TUBE

BASIC CLASSIFICATION OF BOILERS

•Maybe two, three or four pass

• Fire Tube Boiler – product of combustion (flue gas) is
inside the tube and feedwater (heated fluid) outside the
tube
• Water Tube Boiler – flue gas outside the tube and
heated fluid inside the tube
•Less expensive unit to build
•Riskier unit, in the event of failure, catastrophic
release of water possible
•Steam flows limited to 60,000 kg/h
•Operating pressure limited to 24 bars (350 psig)

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INDUSTRIAL WATER TUBE BOILER

•More expensive unit to build

•Safer unit, in the event of failure, relatively
small amount of water is released
•Higher steam flows possible
•Higher operating pressure
•Up to 255 bars (3750 psig)

Typical cut away view of a horizontal Fire Tube Boiler (four pass)

REFRIGERATION SYSTEM

External View of a Water Tube Boiler

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REFRIGERATION PRINCIPLES OF REFRIGERATION:

Refrigeration involves the withdrawal 1. P–T Relationship
of heat, producing in a substance or 2. Sensible & Latent Heat
within a space, a temperature lower 3. Heat Transfer
than that of the natural 4. P–H Diagram
surroundings. 5. Vapor Compression Cycle

Fundamental Concepts
Pressure – Temperature Relationship Sensible & Latent Heat
Steam Ammonia
Sensible Heat – heat added or removed
100 psig 170 oC 100 psig 18 oC
that causes a change in temperature.

Latent Heat – heat added or removed

0 psig 100 oC 0 psig -33 oC without effecting a change in
temperature.
✓ The higher the pressure, the higher the
temperature at which a substance will boil
or condense.

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Sensible & Latent Heat Sensible & Latent Heat

At 1 atm (14.7 psia): ✓ Refrigeration deals more with Latent

Heat and involves the evaporation and
1 kg H2O = 419 kJ Sensible condensation of refrigerants.
0 to 100 oC
➢ Evaporation – heat absorption (cooling)
➢ Condensation – heat release
1 kg H2O = 2,257 kJ Latent
liquid to vapor ➢ Refrigerant – working substance in a
refrigeration system

Heat Transfer Pressure – Enthalpy Diagram

Heat Transfer Equation: Q = UAdT Saturated
Saturated
Liquid
Heat transfer (Q) is proportional to: Vapor
Pressure (P)

a) A - area available for heat transfer

b) dT - difference in temperature Liquid
Region Liquid-Vapor
depending on the coefficient of heat transfer (U).
Mixture Region Vapor
✓ Heat transfer can only occur if there is a Region

difference in temperature between two

bodies.
Enthalpy (H)

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Vapor Compression Cycle Vapor Compression Cycle

High Pressure Side Gas Side Q Discharge
Condenser
/ Condensing
Heat Rejection
Pressure
Condenser
B
C B
Compressor

Pressure (P)
C W
Throttling
A
Device
Evaporator D A
Low Pressure Side D Refrigeration Load
Compressor Work
Liquid Side Q
Suction / Evaporating Pressure Enthalpy (H)

INDUSTRIAL REFRIGERANT:
Why Use Ammonia? Cooling Tower

1. High latent heat of vaporization

2. Relatively low cost
3. Environment friendly Receiver
Condenser

4. Thermodynamic properties are within Expansion

practical operating range

Compressor
Valve

5. Positive evaporating pressure

6. Easily detectable even in low
Evaporator

concentrations Accumulator

Separator

Pumper Drum

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INDUSTRIAL REFRIGERATION SYSTEM AIR CONDITIONING SYSTEM

Liquid Overfeed System
What is air conditioning ?
Definition by the Book
Evaporator
Condenser  Control of room temperature
Receiver  Distribute air in an area
 Help to clean the air
PRV
 Control/bring down the humidity
Separator
Our Customer’s Definition
Compressor “ COMFORT COOLING ”
NH3 Pump

PACKAGE UNIT
SIMPLE DX SYSTEM

AIR COOLED
CONDENSER

AIR COOLED
CONDENSER

COMPRESSOR

COMPRESSOR

SUPPLY AIR

SUPPLY
SU AIR

RETURN AIR
RETURN AIR

AIR HANLING UNIT

AIR HANLING UNIT

SIMPLE DX SYSTEM SIMPLE DX SYSTEM

RCPerez,Jr., PME

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Comparison of DX & Chilled Water CHILLED WATER SYSTEM

COOLING TOWER EVAPORATIVE CONDENSER
System

AIR COOLED
AIR COOLED CONDENSER
CONDENSER

CHILLER
COMPRESSOR

COMPRESSOR

SUPPLY Chilled
SU
AIR Water SUPPLY
Pump AIR

RETURN
AIR RETURN
AIR
AIR HANLING UNIT Three Way Modulating AIR HANLING UNIT
Valve

SIMPLE DX SYSTEM Chilled Water System

CO2 Recovery System

Properties of CO2
Definition:

In the brewery, CO2 recovered from 1. Colorless

fermentation is reused in brewing 2. Odorless
and bottling operations. 3. Non-toxic
It is a utility as important as steam, 4. Non-combustible
water, air and refrigeration. 5. Chemically inert in air

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CO2 Recovery Process: CO2 Recovery System

Scrubber Deodorizer
Recovered CO2
1. CO2 Collection from Fermentation

Blower
2. CO2 Purification
3. Compression Foam Compressor
Trap
4. Moisture Removal Condenser
Dryer
Pre-Cooler
5. Liquefaction
Liquid Storage
6. Distribution Tank
Surge
Tank

Purified CO2 gas

Vaporizer supply to end user

WASTEWATER TREATMENT SYSTEM  WHERE IS WASTEWATER GENERATED?

(SOURCES OF WASTEWATER)
 WHAT IS WASTEWATER?
Where there is water usage, there will be
 Water supply after it has been used in a variety of
applications: water discharged

 Contains organic and inorganic matter that Water becomes contaminated after use
prevents beneficial use
Type of contaminant will depend on where
 If left untreated will lead to nuisance conditions water was utilized
and/ or cause a hazard to health or environment

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Typical WWTP Diagram

 STAGES OF WASTEWATER TREATMENT:
Primary/Preliminary Treatment
 Screens
 Grit removals
 Flow Equalization/Buffer tank
 Primary Clarifier/Sedimentation
 Pre-acidification

Secondary Treatment (Biological

Treatment)
 Anaerobic System (MUR/UASB)
 Aerobic Systems

Tertiary Treatment
 Removal of residual suspended solids (after secondary treatment)
 Usually by granular media filtration or micro screens

Beer Bottling Process Flow Chart

Steam BREWERY DESIGN LAYOUT
H2O
NaOH

Empty-bottle Bottle Additive

Uncasing Depalletizing
Inspection Washing

Palletized
Beer

 Togenerate a plan / layout that would illustrate

empties
Crowns
CO2
Bottles for
Rejects
rewashing
Case Steam
the long-term physical allocation of the main
Bottle filling Reject-bottle Washing
and
Crowning
Inspection
Condemned bottles
for culletization
H2O
Detergent
functions (production, energy supply,
Restoing Bottles for
rewashing
Pallet
Stacking
administration, etc) and to show the
Fill-level
Inspection
To resto tank Washed
shells
configuration of all main systems such as
Rejects Rejects

Good bottled ACL bottle

(cases)
Palletized
fullgoods
production line, mechanical, electrical utilities
beer

Product Pasteurizing Bottle Packing/ Palletizing

among others.
Coding H2 O Fill-level Coater Recrating
Steam Inspection
Algaecide
Labeler

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DESIGN LAYOUT 1 : DESIGN LAYOUT 2 :

PROCESS UTILITIES

PROCESS UTILITIES

PACKAGING WAREHOUSE
PACKAGING WAREHOUSE

To allow each element to expand in all Compact layout shorten the lines of production
direction. Minimum disturbance but place it in the middle of construction when
expansion is being carried out.

DESIGN LAYOUT 3 : DESIGN LAYOUT 4 :

PROCESS UTILITIES PROCESS UTILITIES

PACKAGING WAREHOUSE PACKAGING WAREHOUSE PROCESS PACKAGING UTILITIES WAREHOUSE

Modular concept layout provides total

freedom to suit a “stage 2” without Elements placed side by side where expansion take place
disturbing operation. Minimum initial on the other side. Advantages includes: great flexibility,
investment cost. close and orderly product, personnel flow and expansion
work at undisturbed condition.

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Thank You Very Much

Have a nice day!

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