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1 13 th September, 2006 New Energy and Industrial Technology Development Organization (NEDO) Jakarta Office 13 th September, 2006 New Energy and Industrial.

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Presentation on theme: "1 13 th September, 2006 New Energy and Industrial Technology Development Organization (NEDO) Jakarta Office 13 th September, 2006 New Energy and Industrial."— Presentation transcript:

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

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

3 3 Outline of the Project with CDM Objective of the project 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 Objective of the project 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

4 4 Project Participants and the Roles NEDO (Entrusted to) MYCOM MOIHABECO BTH JAPAN VIETNAM CERs Credit Transfer Agreement Transfer of CERs Implementation of equipment Permits & Supervising 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. CDM

5 5 Outline of the Beer Sector in Vietnam Cf. Beer Sector in Japan: Approx. 7,000Million Ltr/year, 30 Breweries 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 joint- venture firms

6 6 Outline of Bia Thanh Hoa 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

7 7 Initial Facility in Bia Thanh Hoa in 2003(at FS) Fig: Coal boilers Fig: Ambient air type condensers using massive water 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

8 8 Outline of Energy Use in BTH EnergyCostCO 2 Emission Electricity (STD tariff) 984.5VND/kWh (0.065USD/kWh) 273.4VND/MJ0.695kgCO 2 /kWh (OM &BM Ave.) 0.193kgCO 2 /MJ (Average) Diesel oil8,360VND/L (0.53USD/L) 227.8VND/MJ2.62kgCO 2 /L0.0687kgCO 2 /MJ Coal1,342VND/kg (0.085USD/kg) 39VND/MJ3.14kgCO 2 /kg0.0915kgCO 2 /MJ

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

10 10 Outlook of Energy Consumption of Brewery 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. 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.

11 11 Introduced Energy-saving Systems BBTBBT CCV CCV Latest VRC System Chiller Cascade Cooling SystemDynamic Ice Storage/ Transportation System M Inv. PCPC Economical Methane Recovery System CO2 Recovery System Optimal Pasteurizing System

12 12 Effect of the Proposed 4 Systems SteamElectric powerOthers VRCSaving 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 powerEffective demand- side management Optimizing system for pasteurizer Saving steam by optimization N.A.Saving water consumption Biogas BoilerSteam generation by Biogas N.A.Anaerobic wastewater treatment added

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

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

15 15 High Efficient Refrigeration System Cascade cooling 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. Cascade cooling 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.

16 16 Refrigeration system-1: Cascade Cooling System Water cooling from 28C to 5C (Large temp. differential). Based on 1763kW (500TR) Cooling load. Power consumption reduces to 60%. Compressor capacity reduces to 70%.

17 17 Cascade Cooling system No.1 No.2 No.3 30º C 0ºC Brewing Water Ambient Temp. Ethanol Bine Tank 12m 3 (Using existing Tank) Chilled Water Tank For Wort Cooling 140m 3 3-stage cascade cooling system Wort cooler Hot Brewing Water Tank 85ºC Hot Wort 99ºC 3ºC6ºC Fermenta tion Tank 30-40m 3 /1brew m 3 /1day 30C 20ºC 10ºC 0ºC Water cooler Starting the operation in August 2005

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

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

20 20 Temperature Transportation system system Specific heat transportation transportation Diameter of pipe Required volume of water Required pump power Running cost 19.8W/kg 19.8W/kg Chilled water Chilled water Dynamic ice 0 /3 0 /3 -2 /3 -2 /3 3.5W/kg 250mmNB 250mmNB125mmNB 332m3/h59m3/h 30.0kW 5.5kW 450yen/h 450yen/h 83yen/h Cooling load is 1000Mcal/h Head of pump is 20m Comparison Table of Transportation Performance

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

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

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

24 24 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 2005Installation of VRC system Aug to Sep 2005 Startup of VRC and Refrigeration systems Jul to Nov 2005 Installation of Anaerobic+Biogas boiler system Jan 2006 Dissemination Seminar at BTH

25 25 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 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

26 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. 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.

27 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. 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.

28 28 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 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 Resulted from Energy Saving Activities Japanese reference

29 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

30 30 Application to the other Industries SystemOther Industries VRCDistilleries, Sugar plants, etc. RefrigerationSoft drinks, Dairy plants, etc. Opt-Past.Soft drinks Biogas BoilerAny other industries suitable for anaerobic waste water treatment


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