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Blaise Master's Project Presentation
- 1. BARLEY TO BOILER ENERGYAND RESOURCE CONSERVATION WITHIN CRAFT BREWING Aaron Blaise Treeson 5/7/15 CVEN 6960 Building Systems Engineering Master’s Report
- 2. What Lies Ahead ¨ Who am I? ¨ Why are we here today? ¨ Getting the Basics Down on Craft Brewing ¨ The Brewing Process ¨ Mapping out the Material and Energy Flows in a Brewery ¨ Energy & Resource Conservation Opportunities in the Brewing Process ¨ Meet Diebolt Brewing Company ¨ Proposed Energy & Resource Conservation Measures at Diebolt Brewing Company ¨ Conclusions
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- 4. Engineer, Architect &Brewer Candidate Master of Building System Engineering University of Colorado at Boulder, 2015 Masters of Architecture University of New Mexico, 2012 Bachelors of Fine Arts Colorado College, 2007 Aaron Blaise Treeson abtreeson@gmail.com 505.918.7071
- 5. Why are wehere today?
- 6. The State ofCraft Brewing Craft brewing is one of the fastest growing sectors of the beverage industry. A microbrew distinguishes itself through its quality of ingredients, its non-corporate and thoughtful production, and an implied system of values including wholesome ingredients, community involvement, and ecological stewardship. Unfortunately, craft brew is in fact a more energy, resource, and byproduct intensive product to make. “Barley to Boiler” is an investigation into why this is and how technological and brewing innovations can improve on the efficiency of craft brewing while maintaining if not improving the profitability of a microbrewery.
- 7. Social Sustainability --1516 Reinheitsgebotwas the first beer related legislation. It social sustainability decreed that in Bavarian, now Germany, beer could only be brewed only from barley, water, and hops during the summer months, avoiding bread famines from other grains midwinter.
- 8. What makes aCraft Brewery? ¨ No formal definition, though this is currently being decided in a class action lawsuit in the California courts ¨ Independently owned business in contrast to the three main publically traded industrial producers: Anheuser-Busch, MillerCoors, and Pabst Brewing. ¨ Currently produce at most 100,000 barrels (3,100,000 gallons) of beer per year, but this is an escalating target. ¨ Have a single brewery with limited distribution. ¨ Pride themselves in high quality beers made in a variety of traditional and avant-garde styles that command a higher retail price point.
- 9. Growth of CraftBeer Sector
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- 12. What is abbl? ‘Barrel’ is the standard volumetric unit in brewing = = Barrel (bbl) = 31 gallons 2 Standard Kegs 330 twelve ounce pours
- 13. Brewpubs = Taphouseonly Microbrewery < 15,000 bbl/yr 15,000 bbl/yr < Regional Breweries < 500,000 bbl/yr Large Breweries > 500,000 bbl/yr Classification of Craft Breweries
- 14. The System BoundaryQuandary 28 gallons irrigation water12 oz local microbrew 0.94 gallons fresh water Upstream Material InputsPoint of Consumption Production at Brewery
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- 16. Schematic Brewing Process 1:Milling malted grain to create grist 2: Heating of water for mashing 3: Mashing & lautering by steeping the grist in the hot water to make wort 4: Boiling wort to sterilize, blow off VOCs, add hops, and catalyze chemical reactions 5: Heat Extraction from boiled wort and the addition of oxygen and pitching of yeast 6: Fermentation takes several days to weeks at a prescribed temperature 7: Conditioning clarifies the beer from dead yeast and remaining sediment 8: Packaging involves kegs, bottles, or cans for onsite consumption or distribution
- 17. Malting & RoastingGrain Purpose Convert proteins to carbohydrates Location/Vessel Offsite in grain handling facility Duration Several hours Temperature Change Varies Energy Transfer Furnace to heat air and electric fans Mass Flows Raw grain, circulated hot air, water for germination => wastewater and vapor, malted grain
- 18. Milling Grain intoGrist Purpose Expose endosperm and de-husk Location/Vessel Onsite Mill Duration Negligible Temperature Change N/A Energy Transfer Induction motor Mass Flows Malted and roasted grain => grist
- 19. Mashing & Lautering Purpose Mixhot water with grist to make wort Location/Vessel Mash Tun Duration 60-90 minutes Temperature Change 130°F - 180°F Energy Transfer 8 – 13 kbtu/bbl Mass Flows Hot water & grist => spent grain, wort, steam
- 20. Boiling Purpose Integrate flavors, blowoff VOCs, hops additions, sterilize Location/Vessel Brew kettle Duration 60-120 minutes Temperature Change ~160°F - ~212°F Energy Transfer 44 – 46 kbtu/bbl Mass Flows Wort, natural gas, oxygen, hops => VOCs, CO2, sterile wort
- 21. Whirlpool Purpose Concentrate and filterout insoluble compounds & ease of cleaning Location/Vessel Brew kettle or separate vessel Duration 20 minutes Temperature Change ~212°F - 210°F Energy Transfer Negligible Mass Flows Pumped wort => extracted hops, sediment and remaining grain
- 22. Cooling/Heat Extraction Purpose Reduce thetemperature of wort for fermentation Location/Vessel Heat exchanger & chiller Duration 20-120 minutes Temperature Change 210°F - ~60°F Energy Transfer 35 – 36 kbtu/bbl Mass Flows Hot wort, chilled water and/or glycol => cool wort, warmed water or glycol
- 23. Filtering, Oxigenation &Pitching Purpose Strip wort and start fermentation Location/Vessel Fermentation Tanks Duration 20-60 minutes Temperature Change N/A Energy Transfer Minor pump energy Mass Flows Cooled wort, liquid yeast, oxygen => inoculated wort
- 24. Fermentation Purpose Creation of ethanol Location/Vessel Fermentationtanks Duration Several days to months Temperature Change ~60°F - 32°F Energy Transfer Variable Mass Flows Wort, yeast => green beer, trubb
- 25. Conditioning Purpose Clarify and maturebeer Location/Vessel Brite tanks Duration Weeks to months Temperature Change 32°F Energy Transfer Variable Mass Flows Green beer => mature beer
- 26. Packaging Purpose Allow for offsiteretail (keg, can, glass, or growler) Location/Vessel Onsite or vehicular Duration Several hours to days Temperature Change 32°F Energy Transfer Drives, compressed CO2, refrigeration Mass Flows Mature beer => retail beer
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- 28. KPI: Electricity 12.69 0.00 5.0010.00 15.00 20.00 25.00 US Range Min US Range Max Germany Average Yatala Brewery (AU) Efficient Canadian Min Efficient Canadian Max US Industrial Scale Top 75% US Industrial Scale Top 50% Atomspheric Boil (7.5% evap) Low Pressure Boil (4.5% evap) Internal Boiler (3% evap) GEA Brewery Systems Low GEA Brewery Systems High Green Brewery (854,700 bbl/yr) German Small Breweries Average AVERAGE Site kWh/bbl Onsite Electrcity Consumption Range (kWh/bbl) LBNL Study 46% -‐ Machine drives 32% -‐ Chillers 7% -‐ HVAC 7% -‐ Ligh;ng 8% -‐ Miscellaneous ESource Audit 35% - Chillers 25% - Packaging 12% - Other 10% - Compressed air 7% - Pumps 6% - Lighting 5% - Boiler management
- 29. KPI: Natural Gas LBNL Study 30-‐60% -‐ Steam boilers 20-‐30% -‐ Packaging & u;li;es 15-‐20% -‐ Domes;c hot water >10% -‐ Space hea;ng ESource Audit 45% -‐ Steam boilers 25% -‐ Packaging 20% -‐ U;li;es 10% -‐ Space hea;ng 1.13 0.00 0.50 1.00 1.50 2.00 2.50 US Range Min US Range Max German Average Yatala Brewery (AU) Canadian Average GEA Brewery Systems Low GEA Brewery Systems High GEA Brewery Systems Benchmark Green Brewery Required Min Green Brewery (854,700 bbl/yr) German Small Breweries Average AVERAGE Site therms/bbl Onsite Natural Gas Consump=on Range (therms/bbl)
- 30. KPI: Carbon Dioxide BIERReport 38 g CO2e – Assorted other 94 g CO2e – Malting 257 g CO2e – Brewing 319 g CO2e – Aluminum manufacturing ____________________________ 708 g CO2e/12 ounce can Climate Conservancy Report 12 g CO2e – Direct emissions 12 g CO2e – Paper production 21 g CO2e – Brewing 35 g CO2e – Assorted other 44 g CO2e – Consumer 45 g CO2e – Distribution 32 g CO2e – Malting 67 g CO2e – Barley cultivation 115 g CO2e – Glass manufacturing 149 g CO2e – Retail ____________________________ 532 g CO2e/12 ounce glass 13.76 0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 Asahi (JA) SAB Miller (US) Carlsberg (EU) Heineken (EU) Fosters (AU) Yatala 2008 (AU) Yatala 2001 (AU) Canadian Average New Belgium Brewery 1998 New Belgium Brewery with Wind 1998 UK Average GEA Brewery Systems Low GEA Brewery Systems High Green Brewery (854,700 bbl/yr) United Na;on Enviromental Program AVERAGE Site kg CO2e/hl Onsite Carbon Dioxide Consump=on (kg of CO2e/hl)
- 31. KPI: Wastewater :Beer 6.39 0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 German Average Asahi (JA) SAB Miller (US) Carlsberg (EU) Heineken (EU) Fosters (AU) Yatala 2008 (AU) Yatala 2001 (AU) Inbev (EU) US Range Min US Range Max Canadian Averaage UK Average Small UK Average Medium UK Average Large Anheuser-‐Busch New Belgium 1999 Hopworks Urban Brewery 2013 Ins;tute of Brewing Low Ins;tute of Brewing High Green Brewery (854,700 bbl/yr) AVERAGE Wastewater : Produced Beer Wastewater to Beer Produced Ra=o
- 32. KPI: Energy UseIntensity (EUI) Lawrence Berkley National Laboratory US average EUI: 335 kbtu/bbl Brewers Association of Canada’s average EUI : 643 kbtu/bbl German average EUI for industrial scale breweries : 278 kbtu/bbl German average EUI for small craft breweries* : 476 kbtu/bbl *This shows 71% increase in EUI due to the lack of economies of scale. This factors was applied to the applied to the Lawrence Berkley National Laboratory US average resulting a better estimate for Craft Brewery EUI in the US. ____________________________________________________________ Estimated average craft brewery EUI in the US: 573 kbtu/bbl
- 33. Meet Diebolt BrewingCompany
- 34. Diebolt Brewing Co.’sCase Study • Diebolt Brewing Opened in August 2013 • Located at 3855 Mariposa Street in Denver, CO • Father, Dan, & Son, Jack, team with several other employees • Currently working with a 15 bbl capacity batch system • The system was bought and installed as a single purchased • Focuses on contemporized French ales • No prior brewing experience beyond home brewing • Diebolt Brewing Company has won multiple awards • Currently transitioning to larger packaging, distribution and retail • Annual production is growing and around 250 bbl/yr • The space currently includes a total of roughly 8,000 sqft:
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- 37. Diebolt’s Beer Production y = 0.0478x -‐ 1970.4 R² = 0.38112 0 10 20 30 40 50 60 BBL BBL/Month Since Opening y = 13.803x + 23.456 R² = 0.61882 0 20 40 60 80 100 120 Q3 2013 Q4 2013 Q1 2014 Q2 2014 Q3 2014 Q4 2014 BBL BBL/Quarter y = 0.0013x -‐ 23.212 R² = 0.00014 0 10 20 30 40 50 60 BBL BBL/Month in Past Nine Months on Record
- 38. The Last TwentyTwo Months y = 2.6541x - 105623 R² = 0.26879 - 1,000 2,000 3,000 4,000 5,000 6,000 7,000 Electricity: kWh/month y = 0.0006x + 1.8072 R² = 0.00365 0 5 10 15 20 25 30 35 Power Demand: kW/month
- 39. The Last TwentyTwo Months y = 0.2284x - 9277.2 R² = 0.10815 0 100 200 300 400 500 600 700 Sewage: bbl/month y = 0.3038x - 12421 R² = 0.17784 0 100 200 300 400 500 600 700 Fresh Water: bbl/month
- 40. The Last TwentyTwo Months y = 0.5057x - 20846 R² = 0.13904 - 100 200 300 400 500 600 700 800 Natural Gas: therms/month y = 0.1204x - 4959.3 R² = 0.96098 0 20 40 60 80 100 120 140 Carbon Dioxide: kg/month
- 41. Monthly Cost sinceOpening $- $100 $200 $300 $400 $500 $600 $700 $800 $900 $1,000 $1,100 $1,200 $1,300 $1,400 $1,500 $1,600 $1,700 Diebolt Brewing Company’s Related Monthly Costs ELECTRICITY FEES LEASED GAS TANKS CARBON DIOXIDE KWH CONSUMED SEWAGE FRESH WATER KW DEMAND NATURAL GAS
- 42. Water and CO2Intensities 0.00 5.00 10.00 15.00 20.00 25.00 30.00 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 Fresh Water / Beer kg CO2/BBL CO2 & Fresh Water Intensity Kilograms of Carbon Dioxide/BBL Beer Fresh Water : Produced Beer Diebolt uses on average 11.5 units of water to each unit of produced beer, well within the range of 10 – 14.7. Municipal water data is very non-accurate data. Diebolt purchases 2.5 kg of CO2/bbl, while fermentation usually creates 2.56 – 4.5 kg CO2/bbl.
- 43. Diebolt’s Energy UseIntensity Diebolts estimated current EUI _______________ 642 kbtu/bbl Estimated average craft brewery EUI in the US _______________ 573 kbtu/bbl Percent Overage ______________ 12%
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- 45. Considerations in Conservation • Goals: Conserve money - Fuel – Electricity – Emissions – Other resources • System Boundaries: Entire brewery – Brewhouse – Single process • Closing the Loop: Reuse of thermal energy – Capture of waste coproducts • Timeframe: Simple payback – Ease of relocation – Scalability • Brewer/Owner’s Concerns: Desired outcome – Optimization
- 46. Efficiency Already inPlace LEDs in Taphouse 2-Stage Heat Exchanger Two VFDs on Induction Motors
- 47. Change Utility RateSchedule
- 48. Reduce Peak LoadSimulations y = 0.0006x + 1.8072 R² = 0.00365 0 5 10 15 20 25 30 35 Power Demand: kW/month Schedule C Max Draw : 25 kW Diebolt Average Draw: 27.8 kW Diebolt Peak Draw: 31 kW Solutions: Demand Side Management Onsite Generation
- 49. Demand Side Management Interviewwith Bill Brayden of Brayden Automation & Energy Sentry Paraphrase of Dr. Brayden’s Comments: DSM system to reduced peak demand from 31 kW to 25 kW from a limited number of significant draws (i.e. chillers) is very easy. The addition of onsite photovoltaic generation is beneficial. 40 kW is about the max demand before loads are not adequately met.
- 50. Photovoltaic Array Simulation 10kWd Flatplate Photovoltaic Array Simulation with NREL’s SAM All federal, state, city, and utility incentives taken into account Cost: $25,580 Generation: 15,138 kWh/yr Percent energy reduction: 22% Range in demand reduction: 0 kW – 5 kW
- 51. PV & DSMSchedule SG
- 52. PV & DSMSchedule C
- 53. Financial Analysis $- $100,000 $200,000 $300,000 $400,000 $500,000 $600,000 $700,000 8 Years15 Years 25 Years Total Costs : BAU with PV & DSM Avoided Costs PV & DSM Avoided Costs Compared to Business As Usual $0 $50,000 $100,000 $150,000 $200,000 8 Year 15 Year 25 Year Net Present Cost : BAU vs. PV & DSM BUA PV & DSM
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- 56. Proposed New HeatExchanger
- 57. Proposed New HeatExchanger
- 58. Proposed New HeatExchanger
- 59. Proposed New HeatExchanger
- 60. New Heat ExchangerFinances Savings NPV 10 Years $162 -$360 5 Years -$889 -$982 15 Years $1,323 $154 20 Years $2,606 $579 25 Years $4,021 $929
- 61. Currently Brewery Lighting • Observably over-illuminated given low occupancy • 7,200 square foot brewhouse is illuminated throughout the day & evening • 16 total luminaires • Each luminaire has six T8 florescent • Each T8 is rated at 2,800 lumens with a downward reflector • This effectively equates to over 37 fc (1 fc = 1 lumen/sqft) • This is well in excess of required by the Illuminating Engineer Society
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- 64. Lighting Iterations Analysis -‐ 2,000 4,000 6,000 8,000 10,000 12,000 14,000 -‐ 0.50 1.00 1.50 2.00 2.50 3.00 3.50 (1) BAU (2) Reduc;on (3) Reduc;on & Reschedule (4) Reduc;on, Reschedule, & LED Replacement kWh/yr Energy Consump=on kW Power Demand Ligh=ng Retrofit: Decreasing Power Demand and Energy Baseload Power Demand (kW) Total Energy Consump;on (kwh/yr)
- 65. Lighting Iterations Analysis 0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0% 80.0% 90.0% $-‐ $100.00 $200.00 $300.00 $400.00 $500.00 $600.00 $700.00 (1) BAU (2) Reduc;on (3) Reduc;on & Reschedule (4) Reduc;on, Reschedule, & LED Replacement Ligh=ng Retrofit: Annual Cost Savings & Percent Savings Schedule C Annual Costs Schedule SG Annual Costs Schedule C Percent Savings Schedule SG Percent Savings
- 66. Lighting Iterations: NPVvs Time NPV 5 Years NPV 10 Years NPV 15 Years NPV 20 Years NPV 25 Years -‐$6,000.00 -‐$4,000.00 -‐$2,000.00 $0.00 $2,000.00 $4,000.00 $6,000.00 $8,000.00 (2) Reduc=on (3) Reduc=on & Reschedule (4) Reduc=on, Reschedule, & LED Replacement NPV Mesh of (1), (2), & (3) at 5 Year Incriments
- 67. Reassessed Diebolt’s EUI Dieboltsestimated current EUI _______________ 642 kbtu/bbl Diebolted anticipated EUI after retrofits _______________ 421 kbtu/bbl Percent savings ______________ 36%
- 68. Thank You! Questions? Touch the earth lightly, use the earth gently, nourish the life of the world in our care: gi6 of great wonder, ours to surrender, trust for the children tomorrow will bear. -‐Shirley E. Murray