Brewery Process Design

BE 4380 - Bioprocess Engineering Design Dr. Walker

Conor Bury, Jeremiah Davis, Ashleigh Hough, Katie Love, Ian Melville

April 23, 2015

Project Goalscreation of a regional brewery

high quality productmaximum profit40,000 barrels per yearsustainable manufacturing practices

minimal energy consumptionminimal material waste

Brewhouse Phase

Mashing - Saccharification EnzymesAlpha-amylase - Cuts glucose chains indiscriminately - Most active between 154 - 162*FBeta-amylase - Can only cut branches

of amylopectin - Creates maltose (2 glucose chain)

Mashing Inputs and OutputsOverall reaction9 Starch + 1 Water → 10 Glucose

INStarch (Corn Grits) 727.34 g/L 4,379.3 kg/batchStarch (Malted Barley) 699.4 g/L 8,398.4 kg/batchWater 51,259 L/batch OUTGlucose 204.5 g/L 12,781 kg/batchStarch 20.45 g/L 1,278 kg/batchWater 49,806 L/batch

Lauter TunGrant TankSparging of remaining grain

Utilizes starch still in grain

Removal of excess used grain

Provides easy transportation of thicker material

Acts as a holding tank for wort accumulation

Smooths variable flow rate caused by lauter process

Boiling WortStoichiometric Equation:

100 Hops → 3 Alpha Acids + 97 Spent Hops

Boiling Wortmin1 + min2 + Q1 + Q2 = mout

min1 = wort in - (129,884.49 L)min2 = charging wort - 30 kg/min - (min-total 130,283.89 L)Q1 = preheating (2530339141 kcal/hr)Q2 = boiling (12093925.34 kcal/hr)min-total - mvapor vented - mconsumed in rxn = mout(130,283.89 L - 17276.66 L - 301.73 L = 112,705.5 L)

WhirlpoolRemoval of protein precipitate (trub)

Trub degrades taste and hinders fermentation

1st ChillerWort: 87% H20, 11% GlucoseQ=U1A1(ΔT)=mCp(ΔT)ṁ=108.6 m3/batchΔT=18-95=-77°CU=1500 W/m2KA=54.18 m2

Qin= 5384824 kCal/hrQcalc= 4996202 kCal/hrQwaste heat= 388622 kCal/hr

Coolant: 100% H20Q=U1A1(ΔT)=mCp(ΔT)ṁ=1072201 kg/hΔT= 5-10=-5°CCp= 4181 J/kg KQc= 5361005 kCal/hrQc= 6226211 WQwort ≈ Qcoolant5384824 kCal/hr≈ 5361005 kCal/hr

Fermentation & Aging Phase

Wort Oxygenation Yeast ChargeOxygen added to wort at concentration of 0.02 g/L

Necessary for fermentation

Yeast added to brew

Enables fermentation process

Fermentation - Stoichiometry Overall Reaction:

1 C6H12O6 → 2 CO2 + 2 CH3CH2OH● IN:

○ Glucose: 12396.6 kg/batch → 68870 moles○ Yeast: 105.52 kg/batch → 44.4 moles

● Out:○ Glucose: 1487.59 kg/batch → 8264.4 moles○ Yeast: 622.54 kg/batch → 261.96 moles○ Ethanol: 5066.75 kg/batch → 110147 moles○ CO2: 4741.27 kg/batch → 107756 moles

● Reaction acting at 88%

Fermentation - EnergyReaction Enthalpy:

-500 kcal/kg glucoseTotal glucose consumed

10909 kg/batchEnthalpy Produced:

5.45 * 106 kcal/batchTotal enthalpy into the system

-7.34*105 kcal/batchTotal enthalpy leaving the system

4.29*105 kcal/batch

Filtration Governing Equation: Vslurry= A∙Ncycles∙J∙tp

= 63.1077 m2 ∙ 1cycle/batch∙ 500 L/m2-hr ∙ 240 min

∙1 hr/60min Vslurry= 126215.4 L/min-batch

Mass Balance: min = myeast/trub-out + mfiltered beer-out (126668.576 kg = 1105.235 kg + 12556.341 kg)

Energy Balance:Hin = Hyeast/trub-out + Hfiltered beer-out (-5160.929 MJ = -44.431 MJ + -5116.499 MJ)

Filling & Packaging Phase

Batch Process SummationWater: 212,000 kgBarley Malt: 12,000 kg, Hops: 150 kg, Corn Grits: 6000 kg9,000 kW-h electricity

Yields:200,810 12oz.bottles (1 hr gameday weekend)500 ½ kegs 126,000 kg of delicious, delicious beer

SustainabilityBeer is about 90% water

Need more efficient ways to heat up water during brewing process\

Efficient boilers, tankless water heater, solar water heaterSolar/wind power to power brewery

Steam recaptureRainwater capture - to reduce municipal/local stream water demandRefrigeration is the largest use of energy in a brewery

Airlocks and proper insulationAmbient cooling during colder weatherUnderground cellar

Social SustainabilityBreweries play important role in moving communities towards sustainabilitySustainable business - provide jobs, put $ into economy, donate goods and expertise

Social sustainability - serve as gathering place where new ideas are generated, friendships strengthened, and new contacts are made with community members

Social events often occur at a drinking event or involve the consumption of alcohol

All this is an acknowledgment of the type of camaraderie that can develop due in large part to these social hubs

Economic Analysis: CostCapital (initial): $28,000,000Working Cost per batch: Brewhouse: $81,899 Fermentation & Aging: $64,780 Filling & Packaging: $32,568 Total: $179, 247Annual operating cost: $6,632,000

Cost per bottle: $0.505

Critical Costs:Stirred Reactor: $

750,000Engineering: $

3,605,000Operator: $ 46/hr

Aqueous Waste :$42,705/yr(rinsing and cleaning)

Marketing and transportation costs not factored in

Economic Analysis: RevenueBottles Revenue: 3,715,000 $/yrKeg Revenue: 371,500 $/yr

Total Revenue: 4,087,000 $/yrAnnual operating cost: 6,632,000 $/yrNet Profit: -2,545,000 $/yr

Represents failing business model

Solutions:Residual materials like trub could be resold

Sustainability measures not taken into account

Sale price too low

Fin