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Springer Proceedings in Energy
Manaswita Bose
Anish Modi Editors
Proceedings of the
7th International
Conference
on Advances in
Energy Research
Springer Proceedings in Energy
The series Springer Proceedings in Energy covers a broad range of multidisciplinary
subjects in those research fields closely related to present and future forms of energy
as a resource for human societies. Typically based on material presented at
conferences, workshops and similar scientific meetings, volumes published in this
series will constitute comprehensive state-of-the-art references on energy-related
science and technology studies. The subjects of these conferences will fall typically
within these broad categories:
– Energy Efficiency
– Fossil Fuels
– Nuclear Energy
– Policy, Economics, Management & Transport
– Renewable and Green Energy
– Systems, Storage and Harvesting
– Materials for Energy
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the world’s most extensive eBook collection, as part of the Springer Energy eBook
Collection. Please send your proposals/inquiry to Dr. Loyola DSilva, Senior
Publishing Editor, Springer (loyola.dsilva@springer.com).
Editors
123
Editors
Manaswita Bose Anish Modi
Department of Energy Department of Energy
Science and Engineering Science and Engineering
Indian Institute of Technology Bombay Indian Institute of Technology Bombay
Mumbai, Maharashtra, India Mumbai, Maharashtra, India
This Springer imprint is published by the registered company Springer Nature Singapore Pte Ltd.
The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore 189721,
Singapore
Preface
v
Contents
vii
viii Contents
xxi
Determination of Steam Energy Factor
for Wort Kettle as a Tool
for Optimization of the Steam Energy
Nomenclature
1 Introduction
Stringent energy conservation laws have been driving new ways and methods to
reduce energy demand either by developing energy efficient systems or by reducing
the total energy consumption directly. A significant portion of the world’s energy
requirement occurs in the form of steam. Steam is used in almost every industry
ranging from manufacturing to process industries at different capacities and condi-
tions. The steam requirement at different sectors may vary with regards to application
and capacity. Thus, steam distribution systems lack a generic structure which would
have helped in optimizing steam networks.
Process industries such as Food and Beverages (F&B) generally use substantial
amounts of steam for their varied applications and often incorporate complex steam
systems to meet their requirements which are both dynamic and highly critical. This
makes the estimation of actual steam requirement a very arduous process [1]. The
brewing industry is one of the fastest growing and also one of the most energy
intensive sectors in the world. A typical brewing plant in India consumes more than
200 tons of steam each operational day. The Wort kettle within a Brewhouse consumes
about 30% of the overall steam production in the plant. Thus, the steam saving
potential for a Brewhouse can be quite substantial through improved evaluation
methods for steam distribution networks.
Energy and exergy analysis of the brewing industries has helped many energy
auditors in understanding the various inefficiencies within the steam distribution
system itself [2]. EINSTEIN is a thermal auditing tool that has been used to some
extent in breweries [3]. The most common metric used in the present scenario for
evaluating the steam distribution system is the SSC or the specific steam consumption.
It is the energy consumption analysis with regards to the production data. It has so far
been the basis of benchmarking in the brewing industry [4]. But it does not indicate the
efficiency of the steam distribution network itself. This further inspired many other
steam enthusiasts to come up with different strategies to evaluate steam consumption
based on critical parameters such as enthalpy, fuel, work load [5]. Another method to
evaluate steam consumption was to do a complete process modeling of the brewing
facility. This allows to have a holistic view of the energy balance of the Brewhouse
which would further help in analyzing the energy load of the facility as a whole
[6]. Though all these methods brief about the actual steam requirement, the lack of
coherence with the realistic scenario deduces to a lower practicality when it comes to
saving steam. It becomes hard to trace the losses when systems exhibit high degree
of complexity and flexibility. Not to forget the seasonal variation that occurs over
time.
This paper assesses steam energy requirement for a Wort kettle which forms
the soul of the Brewhouse. The steam energy factor (SEF) is a proven metric for
evaluation of steam consumption for various F&B industries and steam-intensive
equipment. The following paper is an approach to determine the steam energy factor
using a model based on losses and critical parameters assisted by machine learning.
The list of all the critical parameters that were used to derive the SEF have been
listed in Table 1.
2 Steam Consumption
ii. Evaporation
The amount of water evaporated and the preheating time is purely an aspect of the
recipe and will vary from one industry to another. Even though steam requirement
could be fairly estimated only by monitoring these two parameters, it was found that
there were various other factors which interact with the system that also affect the
overall steam consumption.
Hence, it became evident to track all the factors to analyze the impact each
of these factors have on steam consumption. There are many methods that have
been proposed in the past to estimate steam consumption such as enthalpy-based
4 S. Kulkarni and A. Bernard
steam consumption [4] and equivalent steam requirement through fuel consumption
[1]. Both the approaches though very commendable, lack in capturing the steam
requirement inherited by the dynamic nature of process itself.
The process of increasing the Degree Plato of the cold wort entering the Wort
kettle to the required set point as per recipe is done by evaporating the moisture
content within the product. There are multiple factors that affect this process. The
list of all the factors taken into account for developing steam energy factors have
been listed below.
3 Process Flow
Figure 1 represents the schematic of the flow of sweet wort after the mash filter
and before the whirlpool cooler for different batch sizes. The inlet wort, before
entering the Wort kettle, is preheated using a heat recovery system. The estimation
for maximum possible efficiency has been calculated. The value of Degree Plato (°P)
is set according to the recipe. All the accountable losses have been calculated while
the other are taken as unavailable energy losses (UAL).
Most of the parameters required for determining the steam energy factor are
already monitored by the brewer. And likewise, the brewer also has control over all
of these parameters. SEF helps the brewer understand the interaction of all these
parameters with the equipment and the process variation and thus giving him a better
insight regarding the system performance and the impact each of these parameters
have on the overall steam consumption.
4 Development of SEF
The methodology used for the determination of steam energy factor is a crucial step in
its development and its usefulness. It shall not only brief the brewer about his excess
steam consumption but also help him negate the various losses that are identified
using SEF for the process. The development of this metric was addressed by two
methods out of which one was used for a very renowned brewing industry in Asia.
4.1 Method 1
In the first method, the steam energy factor is calculated directly by dividing the actual
steam consumption with the theoretical steam consumption. The theoretical steam
consumption is estimated by developing thermodynamic relations of the process
variables with the steam load demand. In simple terms, this model theoretically
evaluates the steam demand for the process and then compares it with the actual
steam consumed for the same process measured through steam flow meters.
4.2 Method 2
1
SEF(model 2) = (2)
100 − Losses(%)
The losses that were included for estimating the SEF for Wort kettle have been
listed in Fig. 2. The following relations were used to determine the losses:
V.L. f (E.R., Sweet wort %, sparge volume %, inlet DP)
H.R.L. f (HRS temperature, scaling, choking)
C.L. f (heat carried out by the hot condensate)
F.L. f (Condensate flashing into vapors)
6 S. Kulkarni and A. Bernard
The ideal value of SEF is 1, and hence, the best value of SEF is when there is minimal
loss. Most of the losses occurred because of the variations in the actual process. Initial
study depicted the variations in consecutive batches during the same shift. This was
reflected by a rise in the overall steam consumption.
Figure 2 is an empirical energy distribution diagram flow a Wort kettle. There are
multiple factors that give rise to a high evaporation ratio. This could be a result of a
low mashing efficiency, a higher percentage of Sparge volume, the quality of malt and
other ingredients, etc. The heat recovery system (HRS) also plays an important role
in the reduction of steam consumption. The steam pressure, trap leakages, ambient
conditions, poor insulation of steam lines are some of the other factors which are
categorized under site conditions also affect the overall steam consumption.
Determination of Steam Energy Factor for Wort Kettle … 7
The initial study was done to validate the difference between specific steam consump-
tion and steam energy factor. Specific steam consumption or SSC is total steam
consumed per unit quantity of product. SSC is a true reflection of the overall steam
consumption, but it fails to capture the variations occurring in the process which
account for the marginal excess steam consumption (Fig. 3).
The readings were taken for 400 HL batches. For batch 5, the SSC is not a true
indication of the excess steam consumption. It is indicated by a low SSC value of
18.45 against a high SEF value of 1.821. This helps the brewer identify the quality
of batch 5 as it accounts for a higher steam energy loss. The following are the results
obtained through SEF for an international beer production organization.
6.1 Before
The data recorded for the brewing process before the implementation of the SEF
indicated a high steam consumption when compared to the actual process demand.
Wort kettle running at sweet wort composition of less than 34% having an SEF of
1.76 accounted for 27% evaporation loss, 8.2% condensate loss, 2.4% flash loss,
1.3% heat recovery loss and 6.4% miscellaneous loss (Figs. 4, 5, 6, 7, 8, 9 and 10).
6.2 After
Through SEF, an efficient control strategy was applied. The data was collected again
after 7 months, and the results are as follows in Figs. 11, 12, 13, 14, 15, 16 and 17.
With the reduction in all these factors, the SEF was brought down. It was seen
that steam consumption per batch reduced by more than 600 kg. For the brewing