Simposio Internacional Oportunidades de Eficiencia Energética en el Sector Agro-Alimentario. 7 de Octubre Centro Español San Fernando

Transcription

1 Simposio Internacional Oportunidades de Eficiencia Energética en el Sector Agro-Alimentario 7 de Octubre Centro Español San Fernando

2 GREENFOODS needs of SMEs of the European Food and Beverage industry towards energy e fficiency and the integration of renewables Christoph Brunner AEE Institute for Sustainable Technologies (AEE INTEC) 8200 Gleisdorf, Feldgasse 19 Austria

3 Overview The Vision and Challenges Overview on work and first results Best practice example Green brewery concept Lesson learned

4 Food and beverage industry 287,000 companies in the European food and beverage industry 99.1% of these are SMEs accounting for 51.6% of the industry s turnover and 64.3% of employment (Source: FoodDrinkEurope, 2011) More than 10% of final energy demand in the industry of the EU-27 are consumed in the food, beverage and tobacco industry (Source: Eurostat, 2009) Meat, beverage, dairy and bakery are 4 of top

5 Energy efficiency and renewable energy

6 Product quality Grown companies Challenges Old structured supply and distribution system (steam) and technologies used Low energy efficiency, high energy costs and large dependency on fossil fuels Missing Awareness and knowledge Know-how-transfer of identified solutions Funding and financing systems (inefficient)

7 Overall Objective To lead the European food and beverage industry to high energy efficiency and reduction of fossil carbon emissions in order to ensure and foster the world wide competitiveness, improve the security of energy supply and guarantee the sustainable production in Europe

8 Main outputs Development of the GREENFOODS branch concept Guideline for the user to identify tailor-made solutions for green production for SMEs in the food and beverage industry Performance of energy audits as basis for the branch concept GREENFOODS training module Impart essential knowledge about smart and green technologies in the food and beverage sector by introducing participants into the use of the GREENFOODS branch concept Special funding and financing schemes Facilitate the implementation of identified energy efficiency potentials and renewable energy sources in SMEs Virtual Energy Competence Centres Contact points within a European network

9 Branch concept

10 Training program 60 trainers and 150 trainees have been trained in Austria, Germany, Poland, UK, Spain and France Theoretical and practical knowledge on energy saving methodologies and RES for producing companies in the food and drink industry Going to be part of the EUREM training program

11 Special funding and financing schemes Survey in all consortium countries in order to identify the country specific needs More industry sector specific requirements than country specific Campaign to raise awareness and inform SMEs about value of their energy efficiency measures ( savings units ) Services to find best option future duty of Virtual Energy Competence Centers - VECC Development of financing schemes (e.g. trusts

12 Overall Basic Analysis Largest subgroups 1- Manufacturing of beer 4- Bread and pastry goods 2- Dairy and cheese making 5- Meat preservation 3- Fruit and vegetable preservation 6- Wine production

13 Identified Savings from 29 detail energy audits 6 5 Energy Saving Energy Generating Process Opt. Heat Recovery Cold Supply Opt. Heat Supply Opt. Other Solar Heat Biomass CHP ACM PV HP Meat Fruits and Vegetabels Dairy Bakery Other Beverage Total CO2 emissions from these 29 companies: 163,000 t CO2 Identified savings: 31,083 t CO2 (142,888 MWh/a)

14 Examples process optimization (1) Food production processes Reduction of heat losses in the process chain by covering of baths Reduction of losses of the cooking and smelt vessel as well as the binder cooker Technology shift (steaming and evaporation): Change from batch processes to semi continuous processes Efficient process technologies process intensification

15 Examples process optimization (2) Food production supply Change of the supply with steam to hot water distribution (easier for heat recovery and solar thermal energy) Use of condensate returns especially from cooking devices (condensate returns) Insulation of boiler feed water tanks and distribution pipes Optimization of condensate splitter Insulation of condensate tanks

16 Examples system optimization Food production Use of waste heat from cooling and freezing devices Use of waste heat from flue gases from boilers Use from waste heat from processes Maturation chambers, Pasteur, production of wash water in the production and box washers, fruit juice concentration device Heat recovery between Waste heat and tanks with product Waste heat and cleaning water

17 Solar Integration - examples Meat production industry and slaughter houses Post heating of the cleaning water in the production Fruits and vegetables industry Supply of Pasteur Pre-heating of fresh water Post heating of cleaning water in the production and pre heating of CIP Bakeries Dairies Post heating of cleaning water in the production Fat separation of whey preheating of fresh water Post heating of cleaning water in the production

18 Best Practice example - The GREEN BREWERY CONCEPT

19 Main steps towards the Green brewery vision Vision: To develope the brewery Goess to the first fossil CO 2 -emission brewery in the Heineken group Green brewery phase I: Development of a methodic approach in order to reach innovative energy concepts in breweries Development of an overall concept for the brewery and a technical guideline for other breweries Implementation of an energy consumption measurement network SolarBrew Realization of a large scale solar thermal plant for the brewing process Green brewery phase II: Optimized usage of biogenic waste streams (spent grains) for a conversion into heat and electricity Erection of a Biogas plant based on spent grains and installation of a Combined Heat and Power - CHP facility

20 Definition of the target

21 Realisierte Maßnahmen Waste water Quelle: ewing/e

22 Biogas from waste water Anaerobic treatment of waste water - purification Optimized integration of biogas from waste water Quelle: Bosch

23 Optimized wort cooking process Hertl System: retrofit rectification column for wort cooking Reduction of electricity by kwh and water of m³ per year

24 Introduction to SolarBrew Solar Brew: Solar Brewing the Future EU FP7 ( ) Projekt Nr PROJECT CONSORTIUM - AEE INTEC (coordinator) - HEINEKEN Supply Chain B.V. - GEA Brewery Systems GmbH - process engineering - Sunmark A/S - solar engineering

25 BREWERY GOESS State of the project - Solar assisted mashing process m² ground mounted flat plate collector field - 200m³ pressurized hot water energy storage tank - Commissioned: June million pints of beer per year brewed with the power from the sun* * assuming 60 MJ thermal energy consumption per hl of beer in the brewery Goess

26 System Concept Göss, Austria Mashing Boiler Feed Water

27 Erection of 200m³ energy storage

28 Implementation of 1,500 m² collector field

29 State of the project

30 New Mash Tune Hot Water Supply 6 internal dimple plate heat exchanger panels with 58 m² surface area and a capacity of kw

31 Case Study: Solar Brew, Austria Preliminary Costs Analysis Specific Costs Brewery Goess Flate plate collectors (100 pieces) 50% Process integration 11% 18% 7% Support + Fundament + Collector flied piping Equipment Solarcircle (primary + secondary) Storage + Fundament 39% 13% Diverse (MSRT, IBS, Planing) 3% 9% Processintegration mashing" Processintegration Preheating" 50% Solar integration Source: AEE INTEC, 2013

32 Solarertrag [MWh/a] Monitoring Energy gains from the solar thermal plant April 2013 April 2014 Solar gains 525 MWh/a 530 MWh/a tatsächlich simulated simuliert Actual reached

33 Last realization phase: Biogas plant from spent grain Input of the substrate: t/a ( t spent grain, t yeast, 900 t filter cake) Combined Heat and power use of electricity for the production as well the heat Remaining biogas for the gas boiler to produce steam

34 Result District heating Solar thermal Bio gas waste water Hot water Steam Hot water net Steam net Bio gas plant CHP electricity Heat losses losses Source: BDI BioEnergy International AG

35 Lessons learned Awareness-rising and Know-How-Transfer Contact and information points Trainings for SMEs Easy-to-use-tools to identify and evaluate optimization potentials (branch concept) Standards for energy audits Funding and financing systems for different company sizes Best practice examples in different sub sectors R&D demand Innovative and efficient process technologies Integration of System solutions for hybrid renewable energy supply New financing schemas R&D for different RES technologies in order to increase the potential for installation

36 Multiplier projects (1) Towards zero fossile CO 2 -Emissions in the European food and beverage industry (IEE project) Online: Newsletter: Twitter: GREENFOODS_AEE, #GREENFOODSproject Facebook: GREENFOODS Project

37 Further contact details Christoph Brunner AEE Institute for Sustainable Technologies (AEE INTEC) 8200 Gleisdorf, Feldgasse 19 Austria

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