The Project for renovation to increase the efficient use in Brewery by NEDO at Bia Thanh Hoa Brewery in Vietnam

Transcription

1 The Project for renovation to increase the efficient use in Brewery by NEDO at Bia Thanh Hoa Brewery in Vietnam 13 th September, 2006 New Energy and Industrial Technology Development Organization (NEDO) Jakarta Office 1

2 Outline of the Project Outline of the Project Objective Increase the efficient use of energy 2

3 Objective of the project Outline of the Project with CDM Renovation to increase the efficient use of energy in brewery at Bia Thanh Hoa in Vietnam Implementation VRC system: Vapor Re-Compression system=steam recovery Improvement of refrigeration system: To save electric power and manage power demand Improvement of pasteurizer: To save steam and water anaerobic waste water treatment and biogas boiler: To generate steam and treat waste water 3

4 CDM Project Participants and the Roles JAPAN CERs Credit Transfer Agreement VIETNAM NEDO (Entrusted to) MYCOM Transfer of CERs Implementation of equipment MOI Permits & Supervising HABECO BTH NEDO: New Energy & Industrial Technology Development Organization of Japan BTH: Bia Thanh Hoa HABECO: Hanoi Alcohol Beer Beverage Corp. MOI: Ministry of Industry MYCOM: Mayekawa Mfg. Co., Ltd. 4

5 Outline of the Beer Sector in Vietnam Outline of the Beer Sector in Vietnam 1. Beer industry is a fast growing industry in Vietnam 2. Small Breweries share the majority among 469 breweries in Vietnam. 3.Majority of the market is shared by state-owned and jointventure firms Cf. Beer Sector in Japan: Approx. 7,000Million Ltr/year, 30 Breweries ML-beer Beer Production Growth in Vietnam Scales of Breweries: Total 469 in 2004 Breweries <3ML 3-10ML 10-20ML >30ML Market Shares 27% State-owned Company JV Company 24% 49% Local Company 5 year

6 Outline of Bia Thanh Hoa THANH HOA BREWERY BIA HAI PHONG Established in km 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 the existing brewhouse (30kL) in Sep 2004 Products: Bia Thanh Hoa, Saigon, Hanoi BIA SAIGON 6

7 Initial Facility in Bia Thanh Hoa in 2003(at FS) Extremely inefficient coal boilers are used Use of ambient air type condensers (massive quantity of water is discharged) No waste water treatment is implemented (diluted by massive quantity of water) No measurement of the utility consumption Improvement of refrigeration system is desired due to high electricity tariff No concerns for fuel energy saving because of cheap coal prices Fig: Coal boilers Fig: Ambient air type condensers using massive water 7

8 Outline of Energy Use in BTH Outline of Energy Use in BTH Energy Cost CO 2 Emission Electricity (STD tariff) 984.5VND/kWh (0.065USD/kWh) 273.4VND/MJ 0.695kgCO 2 /kwh (OM &BM Ave.) 0.193kgCO 2 /MJ (Average) Diesel oil 8,360VND/L 227.8VND/MJ 2.62kgCO 2 /L kgCO 2 /MJ (0.53USD/L) Coal 1,342VND/kg 39VND/MJ 3.14kgCO 2 /kg kgCO 2 /MJ (0.085USD/kg) Tarif Tariff VND/kWh Tariff of Electricity 1,600 1,400 1, , h 2h 3h 4h 5h 6h 7h 8h 9h 10h 11h 12h 13h 14h 15h 16h 17h 18h 19h 20h 21h 22h 23h 24h 8

9 Beer Brewing Processes & Utility Consumption 30% ~40% of energy is consumed during wort boiling POWER... STEAM... WARM Water COOLING... 30%~50% of cooling load is used by wort cooling water production. 30%~50% of electricity is consumed for refrigeration load. MT MK LT WK WP Silo Mill Brewhouse FT CO2 ST Fermentation/Maturation Tank Zone High BOD effluent is drained from Brewhouse. BC BF Filtration WC WS FL WA BS Packaging & Warehouse 20%~30% of energy is consumed in the packaging area. 9

10 Outlook of Energy Consumption Steam 50% of steam is consumed in Brewhouse (large 20~30% of steam is consumed in the packaging area Large quantity of steam is consumed for CIP (for a short time) Electricity consumption 30~50% of electricity is consumed for Refrigeration Plant. Cooling load 30~50% of cooling load is used for water cooling. (especially for High Gravity Beer production) Water consumption Large quantity of water is consumed for cleaning purpose. Waste water High BOD effluent is drained from Brewhouse. t / h of Brewery Steam consumption (daily shift) min Brewhouse Others CIP Package Byproduct 10

11 Introduced Energy-saving Systems Introduced Energy-saving Systems Latest VRC System CO2 Recovery System Optimal Pasteurizing System PC Inv. M C C V B B T Chiller Chiller Chiller Economical Methane Recovery System Cascade Cooling System Dynamic Ice Storage/ Transportation System 11

12 Effect of the Proposed 4 Systems Effect of the Proposed 4 Systems Steam Electric power Others VRC Saving steam by Reusing the discharged steam Additional power required Mitigating the strong odor to the outside Refrigeration system Saving steam by heat recovery from discharged gas Saving power Effective demandside management Optimizing system for pasteurizer Saving steam by optimization N.A. Saving water consumption Biogas Boiler Steam generation by Biogas N.A. Anaerobic wastewater treatment added 12

13 VRC System VRC System Saving steam by reusing the discharged steam Discharged steam has great energy! This energy-saving system was developed with the aid from the Government of Japan. 13

14 VRC System VRC System Wort Kettle: evaporates about 2 tons of water in 1 batch. The conventional system discharges waste steam into atmosphere Scrubber: cleans the waste steam and generates hot water for pre-heating the wort for the following batch 99ºC Hot Wort 97ºC Transfer to Wort Kettle Drain 85ºC Energy Storage Tank 61m 3 Wort Pre- Heater Wort 78ºC 14

15 High Efficient Refrigeration Cascade cooling system System Multi-stage cooling consumes less energy than single stage cooling for a large temperature differential Dynamic ice system It stores ice during the off-peak period and shuts off refrigeration machines during the peak period. It reduces the electric power for pumps and the investment cost due to the high transportable heat density together with ice Heat recovery system Hot water is produced from high temp. NH 3 discharged gas in the refrigeration system and used in brewery instead of steam. 15

16 Refrigeration system-1: Cascade Cooling System Refrigeration system-1: Cascade Cooling System Water cooling from 28C to 5C (Large temp. differential). Based on 1763kW (500TR) Cooling load. Conventional Cooling System COP=4.87 Based on 1763kW (500TR) Power consumption reduces to 60%. Compressor capacity reduces to 70%. Displacement volume of Compressor Tc Te dt kw M3/h Cascade Cooling System Tc=35 C COP=8.06 Tc=35 C i C Chiller Te=0 C 5 C II Total II /I 60% 70% II -I ii Chiller Chiller 28 C Te=15 C Chiller 18 C Te=8 C Te=0 C 10 C 5 C 16

17 Cascade Cooling system Cascade Cooling system Starting the operation in August stage cascade cooling system 30º C Brewing Water Ambient Temp. Hot Brewing Water Tank 85ºC Hot Wort 99ºC 30C 0ºC 3ºC 6ºC No.1 No.2 20ºC Ethanol Bine Tank 12m 3 (Using existing Tank) Water cooler Chilled Water Tank For Wort Cooling 140m 3 Wort cooler 10ºC No.3 0ºC 30-40m 3 /1brew m 3 /1day Fermenta tion Tank 17

18 Refrigeration System-2: Dynamic Ice Storage and Transportation System Dynamic Ice Storage Tank Jacket cooling Plate cooling Air cooler Dynamic Ice Transporting Loop Piping 18

19 Dynamic Ice System Dynamic Ice System Heat recovery from discharged NH 3 gas to make hot water Evaporative Condenser Refrig. Comp. No.1 100kW Refrig. Comp. No.2 100kW Refrig. Comp. No.3 100kW Refrig. Comp. No.4 100kW Pd: Td: 110ºC Dynamic Ice Maker Dynamic Ice Storage tank -4ºC, 170m3 To use existing refrigeration compressor to make dynamic ice Fermentation 2 nd Brewhouse WC 2 nd Brewhouse FT 19

20 Comparison Table of Transportation Performance Transportation system Temperature Specific heat transportation Diameter of pipe Required volume of water Required pump power Running cost Dynamic ice -2 /3 19.8W/kg 125mmNB 59m3/h 5.5kW 83yen yen/h Chilled water 0 /3 3.5W/kg 250mmNB 332m3/h 30.0kW 450yen yen/h Cooling load is 1000Mcal/h Head of pump is 20m 20

21 Optimizing software for Pasteurizer(Opt-Past) Optimizing software for Pasteurizer(Opt-Past) Saving steam consumption by achieving optimum efficiency through computerized operation control Use Steam 21

22 Highly Efficient and Economical Methane Recovery System from Wastewater Waste Water from Brewhouse UASB Biogas Boiler Gas Compressor Gas Holder Steam Accumulator 22

23 Effects of Energy-saving Effects of Energy-saving Energy-saving: 3,386 Toe/yr CO2 emission reduction: 10,376 Ton/yr 23

24 Implementation Schedule Implementation Schedule Sep Installation of the consumption data monitoring unit Oct Installation of some parts of Refrigeration, following the renewal of the brewhouse by BTH. (Evap. condenser etc.) During Nov.2004 thru Mar 2005 Installation of some parts of VRC system (ES Tank, Scrubber, Drain tank, water seal, Hot water tank) Installation of refrigeration system, Opt-Past and a part of Biogas Boiler (Steam Accumulator) May to Jun 2005 Aug to Sep 2005 Jul to Nov 2005 Jan 2006 Installation of VRC system Startup of VRC and Refrigeration systems Installation of Anaerobic+Biogas boiler system Dissemination Seminar at BTH 24

25 Technology Transfer Technology Transfer Hardware Main equipment is made in Japan but the parts assembly and packaging are worked on by Vietnamese manufacturers under the supervision of Mayekawa. Software Human-machine interface improvement Group Activity (KAIZEN) Improve the motivation & increase Efficiency 25

26 Hardware Technology Transfer Transferred Technologies Developed in Japan after Oil-crisis in 1978 VRC: developed technology under Moonlight Project Cascade system Dynamic ice System Anaerobic waste water treatment system (high temp.) Main equipments are made in Japan, while the parts assembly and packaging are worked on by Vietnamese manufacturers under the supervision of Mayekawa. 26

27 Software Technology Transfer Process control and operation are fully automated in breweries in Japan. However, employees are more involved in the manual operation of the process rather than fully automated operation in Vietnam. Involvement of operator in the manual operation must be considered in designing the operation and control system and through training. 27

28 Group Activity (KAIZEN) Group Activity (KAIZEN) In Japanese Breweries, energy-saving effect is increased by Group Activity (KAIZEN) Thanh Hoa Brewery founded the Energy-saving team. Energy-saving team started the Group Activity in Feb Japanese reference Resulted from Energy Saving Activities 28

29 Dissemination The final objective of the project is the dissemination of energy saving technologies in Vietnam. For this purpose, breweries and beverage companies will be invited to inspect the actual reference and effectiveness of energy saving systems installed in BTH 29

30 Application to the other Industries System VRC Refrigeration Opt-Past. Biogas Boiler Distilleries, Sugar plants, etc. Soft drinks, Dairy plants, etc. Soft drinks Other Industries Any other industries suitable for anaerobic waste water treatment 30