WATER REDUCTION IN THE WATER INTENSIVE BREWING INDUSTRY

Transcription

1 WATER REDUCTION IN THE WATER INTENSIVE BREWING INDUSTRY JULIE SMITH, PE, OPTIMIZATION ENGINEER 3/2/14

2 Brewery Water Reduction - Overview Corporate Goals and Score Carding Water Usage in the Brewery Processes Sources Evolution of Water Reduction 212 Water Reduction Projects Short Interval Control 213 Water Reduction Projects 213 Results Conclusions

3 Corporate Sustainability Goals Energy Usage of 12 MJ/HL by 215 Electricity Steam Vehicle Fuel Water Usage of 3.18 HL/HL by 212 Zero Waste to Landfill by 215 CO 2 Self-Sufficiency of 85% by 215 5% Reduction in Green House Gas by 22 BHAG 4 th Brewery or Better in MillerCoors

4 December 212 SIT Goals Water Energy Monthly Indicator* Mthly Actual Total Energy (MJ/hl) Mthly Stretch Target Mthly Budget Target Actual YTD 212 YTD Stretch Goal YTD Budget STPY % Change People/ Process MillerCoors % Milwaukee % Fort Worth % Eden % Albany % Irwindale % Trenton % Golden % Shenandoah % FEWER Tech Monthly Indicator* Mthly Actual Water (hl/hl) Mthly Stretch Target Mthly Budget Target Actual YTD 212 YTD Stretch Goal YTD Budget STPY % Change People/ Process MillerCoors % Milwaukee % Fort Worth % Eden % Albany % Irwindale % Trenton % Golden % NP Shenandoah % FEWER Tech Monthly Indicator Monthly/YTD/Budget KPI FEWER - People/ Process & Technology High Usage *Monthly Indicator relative to usage rates. Linear regression model Typical Usage factors include brewed, packed, weather, Reduced Usage rainfall, electrical generation. Above Upper Target Between Stretch &Upper Target Nothing Planned - NP < 6% 6-8% Stretch Reduction >8%

5 Brewery Process Overview Malting Brewing Fermenting Conditioning Packaging Warehousing

6 Brewery Water Overview Springs Lakes WTP A-Water B-Water Beer Everything Else C-Water Cooling Water Hot Water Ambient Water WWTP s Malting Packaging CIP Domestic Clear Creek

7 Brewery Water Value Value of Water Temperature Treatment Chemicals Beer! Condensate Hot/RO Hot CIP water Ambient water A Water, B Water Chemicals Cooling Water Wastewater Clean Wastewater High $ Low $

8 Evolution of Water Reduction Where do we Start?? I. Stop the Bleeding Leaks Turn it off II. Process Changes Simple Complex III. Focus on Energy Water Will Follow IV. Capital Projects Metering CO2 Scrubber Condensate/Flash Steam Recovery V. Water Re-Use

9 Golden Brewery Water Wins All Teams Leaks Steam, Plant Air, Water Beer Processing - Cold Sanitization in Cellar 12 Filtration, C1, SPF Packaging Water Savings Dry Lube, Spray Nozzle Pressure Reduction Green Shut-Downs Turbine Pump Seal Water Savings Close Eye Wash Drains Frick Evaporative Condenser Less Energy, More Water Short Interval Control Initiate Concept Facilities Waterless Urinals Condensate Return WH2 CIP HE, NB1 6 th Floor CIP HE, NB4 Cond Equalization HE Water Plant A Water Pressure Reduction, Supply Valve Replacement Brew House Decrease Water Brews CIP Reductions

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12 Savings Opportunities Water and Wastewater

13 SIC Example

14 Golden Brewery Water Reduction - 213

15 Golden Brewery Water Reduction - 213

16 Golden Brewery Water Reduction - 213

17 Packaging/CSS Brewing Tech Services BREWERY Enter Day : 11/2/213 (mm/dd/yyyy) Packaged Volume (BBLS) 49,59 Brewed Volume (BBLS) 13,5 Actual Week To Date Month To Date Target Actual Week To Date Month To Date Target MJ MJ/HL MJ/HL MJ/HL MJ/HL BBL BBL/BBL BBL/BBL BBL/BBL BBL/BBL Brewery 4,114, , Tech Services 655, , Brewing 2,528, , Packaging / CSS 858, , Golden Brewery Daily Scorecard With Area Breakout 9,, Energy Usage (MJ) 6, 16, Water Usage (BBL) 6, 8,, 7,, 6,, 5,, 4,, 3,, 2,, 1,, 1/18 1/23 11/17 11/12 11/7 11/2 1/28 Energy Use Brewery Energy Plan Packaged Volume Brewed Volume 11/22 5, 4, 3, 2, 1, 14, 12, 1, 8, 6, 4, 2, 1/18 1/23 11/17 11/12 11/7 11/2 1/28 Water Use Brewery Total Water Plan Packaged Volume Brewed Volume 11/22 5, 4, 3, 2, 1, 2,, 1,8, 1,6, Energy Usage (MJ) 6, 5, 4, Water Usage (BBL) 6, 5, 1,4, 1,2, 4, 4, 1,, 3, 2, 3, 8, 6, 2, 2, 4, 2, 1/18 1/23 11/17 11/12 11/7 11/2 1/28 Energy Use TS Energy Monthly Goal Packaged Volume Brewed Volume 11/22 1, 1/18 1/23 11/17 11/12 11/7 11/2 1/28 Water Use TS Water Goal Packaged Volume Brewed Volume 11/22 1, 6,, Energy Usage (MJ) 6, 1, Water Usage (BBL) 6, 5,, 5, 8, 5, 4,, 4, 6, 4, 3,, 2,, 1,, 3, 2, 1, 4, 2, 3, 2, 1, 1/18 1/23 1/28 11/2 11/7 11/12 11/17 11/22 1/18 1/23 11/17 11/12 11/7 11/2 1/28 Water Use Brewing Water Plan Packaged Volume Brewed Volume 11/22 Energy Use Brewing Energy Plan Packaged Volume Brewed Volume 1,4, Energy Usage (MJ) 6, 6, Water Usage (BBL) 6, 1,2, 5, 5, 1,, 4, 4, 4, 8, 6, 4, 3, 2, 2, 3, 2, 2, 1, 1, 1/18 1/23 11/17 11/12 11/7 11/2 1/28 Energy Use Pkg Energy Plan Packaged Volume Brewed Volume 11/22 1/18 1/23 11/17 11/12 11/7 11/2 1/28 Water Use Pkg Water Plan Packaged Volume Brewed Volume 11/22

18 Golden Brewery Water Reduction Reduce Kettle Evaporation.3 HL/HL Packaging Shut off B Water to Full Can Rinsers.23 HL/HL C14 Fire Pump Seal Water Leak Repair.2 HL/HL Aging Recovery of CIP Rinse.15 HL/HL Brewing Shut off Dead Leg Bleeders DA Manifold.4 HL/HL UOPS Correct Condensate Leak to GBL.15 HL/HL Prevent Hot A Water Overflow.11 HL/HL 4-Can Condensate Recovery.1 HL/HL Facilities Turf Reduction Water Savings.6 HL/HL Facilities Evaporative Cooling Reduction.23 HL/HL Brewing FIT Water Savings.59 HL/HL PWTP Waterless Dechlorination.3 HL/HL C12 Hot Water Heater for Liquid Adjunct Pump.16 HL/HL UOPS B1 Cooling Water Evap Reduction.44 HL/HL C11 Cold Sanitization.11 HL/HL YDP CIP Re-Use of Still Bottoms.5 HL/HL Packaging Vacuum Pump Seal Water Reclaim.5 HL/HL Gov Cellar re-use sanitization water for flushing tanks and headers.57 HL/HL Brewing Hot Water Cycle Time Reduction.25 HL/HL Brewing Reduce Wort Cooler CIP Flush Rates.28 HL/HL 7-Bottle Warmer Reduced Water Changes.5 HL/HL Fermenting CIP Pulse Cleaning.24 HL/HL YDP B-Water Overflow Valve Corrected.19 HL/HL C12 Basement Hot Water Heat Replacement.1 HL/HL UOPS C1 Cooling Tower Evap Reduction.15 HL/HL 1 HL/HL = 3 MG/Yr 6 gpm

19 Golden Brewery Water Reduction - 213

20 Golden Brewery Water Reduction - 213

21 Golden Brewery Water Reduction - 213

22 Flash Steam Recovery Heat Exchanger 3 Million LBS/yr steam 3.6 Million gal/yr condensate

23 Flash Steam Recovery Heat Exchanger

24 Water Re-Use/Recovery YDP use of still bottoms Liquid Adjunct Pump Recirculation Vac Pump seal water recirc CIP Pre-rinse Packaging Reclaim Cascade

25 Water Re-Use/Recovery Packaging Cascade Empty Can/Bottle Rinser Clean Use Full Bottle Rinser or Seal Water Can Crusher Dirty Use Sewer

26 Golden Brewery Water Reduction - 213

27 October 213 SIT Goals Water Energy Monthly Indicator* Mthly Actual Mthly SIT Mthly Glide Slope Total Energy (MJ/hl) 213 Actual YTD YTD SIT YTD Glide Slope STPY % Change BHAG MillerCoors % 129 Albany % 122 Eden % 125 Fort Worth % 1 Golden % 2 Irwindale % 112 Milwaukee % 121 Shenandoah % 99 Trenton % 121 Monthly Indicator* Mthly Actual Mthly SIT Mthly Glide Slope Water (hl/hl) 213 Actual YTD YTD SIT YTD Glide Slope STPY % Change BHAG MillerCoors % 3.42 Albany % 3.3 Eden % 3. Fort Worth % 3.25 Golden % 4. Irwindale % 3.35 Milwaukee % 3.63 Shenandoah % 3.29 Trenton % 3.31 Monthly Indicator High Usage Typical Usage Reduced Usage *Monthly Indicator relative to 212 usage rates. Linear regression model factors include brewed, packed, weather, rainfall, electrical generation. Mthly/YTD KPI Above Glide Slope Target Between Stretch & Glide Slope Target Below Stretch Target

28 Conclusions 1. Leadership 2. Scorecarding 3. Culture 4. Shared Learnings 5. Start Simple Build Momentum 6. Process Changes Minimum Cost High Impact 7. Capital Projects High Cost Impact Depends on Culture

29 Golden Brewery Energy Savings Culture NEVER DOUBT THAT A SMALL GROUP OF THOUGHTFUL, COMMITTED PEOPLE CAN CHANGE THE WORLD. INDEED, IT IS THE ONLY THING THAT EVER HAS. Margaret Mead