Brewery Industry PREPARED BY Selin KAYA Reyhan ŞENGÜR Ayça TANRIÖVER Sibel KIZILGÜL

BREWERY PROCESSING Malt Production and Handling Wort Production Beer Production

BEER PRODUCTION Figure1: Steps of Beer Production in Efes Pilsen

Beer Production Milling Mashing&Lautering Wort Boiling&Cooling Fermentation Cask Racking&Filtering Bottle Filling Pasteurization&Packaging

Fermentation Sub fermenting tecnique : Lager fermenting period :8-10 days Top fermenting tecnique :Ale fermenting period: 3-6 days

Types of productions in Efes Pilsen Shelf- life:12 months Shelf -life: 4 months Shelf- life: 1 month

EFES PİLSEN Water consumption for breweries: 4 – 6 m3 water/m3 beer produced Production process 21 days

EFES PİLSEN Organic components in brewery effluents are : Sugar Soluble starch Ethanol Volatile fatty acids

Effluent of Plant The waste water consist of: Process water Domestic waste water CIP (cleaning in-line) wastes

Brewery effluent composition Parameter/benchmark per unit Unicer Typical Opaque beer COD (m/L) 800-3500 2000-6000 8200-20000 BOD (mg/L) 530-2300 1200-3600 TSS (mg/L) 200-1000 2901-3000 TS (mg/L) 5100-8750 T(°C) 30-35 18-20 25-35 pH 6.5-7.9 4.5-12 3.3-6.3 Nitrogen (mg/L) 12--31 25-80 0.0196-0.0336 Phosphorous (mg/L) 9-15 10--50 16-24 Water/beer (m3/m3) 4..87 Liquid effluent / beer (m3/m3) 3.3 2--8 COD/beer (kg/m3) 13..2 5-30 BOD/ beer (kg/m3) 2--20 TSS / beer(kg/m3) 1--5 Table1.Typical Characteristics of Brewery Effluent

Waste Characterization in Efes Pilsen   Qww (m3/d) COD(mg/L) VFA(mg/L) COD at inlet of COD removal in COD efficiency in Qbiogas Anaerobic Reactor calculated date plant inlet Anaerobic inlet equalization anaerobic outlet kg COD/d (%) (m3/d) 27.10.2009 1.413 1.069 2615 616 20,03 3,90 2795 2137 76 1066 748 28.10.2009 528 1.058 2345 744 17,76 1,87 2481 1694 68 805 593 29.10.2009 234 1.111 2050 749 16,54 1,88 2278 1446 63 491,3 506 30.10.2009 376 1.110 2920 709 9,64 1,68 3241 2454 440 859 31.10.2009 831 1.086 2420 8,92 1,47 2628 1754 67 409,9 614 Table2 : Waste characterization of the Plant(October 2009)

Waste Characterization in Efes Pilsen   Qww (m3/d) TSS(mg/L) COD(mg/L) F/M aeration COD outlet removal efficiency date plant inlet Aeration inlet inlet(mg/L) inlet(kg/d) (mg/L) (%) 27.10.2009 1.413 830 7550 30 20,03 616 70 89 0.06 28.10.2009 528 953 6810 60 17,76 744 56 92 0.03 29.10.2009 234 473 5630 40 16,54 749 57 0.02 30.10.2009 376 527 5560 50 9,64 709 45 94 31.10.2009 831 560 5240 8,92 805 53 93 0.07 Table 3: Waste characterization of the Plant(October 2009)

Treatment Plant Design Information Waste water Screens Mixing&Equalization tank Neutralization tank Anaerobic Treatment Sedimentation Tank Thickener tank Effluent to sewer

Treatment Plant Design Information Capacity of plant: 3000 m3/day Neutralization Tank:150 m3 Caustic soda HCl FeCl3 as tracer UASB reactor biogas production biogas burning

Sludge Treatment Pathway Thickener tank Decanter thickening dewatering Landfill sites

Average values in plant Temperature: 45°C COD : 53 mg/L TSS : 40 mg/L VFA :1.47 mg/L COD removal efficiency : 92% Biogas flowrate : 614 m3/day

Figure 2 : Schematic View of Treatment Plant in EFES PİLSEN

Comparison with discharge standards in the EU PARAMETER UNIT LIMITS COD mg/l 125 BOD5 25 TSS 35 N 10-15 P 1-2 Table 4: Indicative discharge standards in the EU

Comparison with İSKİ discharge standards PARAMETER UNIT EFFLUENT COD mg/L 600 pH - 6-9 Table5. Discharge Standards of İSKİ(Table 6.3: Sektör: İçki Sanayii (Malt Üretimi, Bira İmali ve Benzerleri)Water pollution control regulations)

Rehabilitation of Plant Biogas (CH4 ) Construction a biogas plant energy Primary sedimentation Lamella seperator

References Multilateral Investment Guarantee Agency Environmental Guidelines for Breweries The Institute and Guild of Brewing Convention, Livingstone, Zambia, March 2-7, 2003 Resmi Gazete Tarihi: 31.12.2004 Resmi Gazete Sayısı: 25687 Brewery and Winery Wastewater Treatment: Some Focal Points of Design and Operation, Anto´nio G. Brito, Joa˜o Peixoto, Jose´ M. Oliveira, Jose´ A. Oliveira, Cristina Costa, Regina Nogueira, and Ana Rodrigues,2004 http://www.efespilsen.com.tr/bira/ Brewery Industry