Tài liệu Energy Efficiency Improvement and Cost Saving Opportunities for Breweries pot

LBNL-50934

Energy Efficiency Improvement

and Cost Saving Opportunities for

Breweries

An ENERGY STAR® Guide for Energy

and Plant Managers

Christina Galitsky, Nathan Martin, Ernst Worrell and

Bryan Lehman

Environmental Energy Technologies Division

Sponsored by the U.S. Environmental

Protection Agency

September 2003

ERNEST ORLANDO LAWRENCE

BERKELEY NATIONAL LABORATORY

Disclaimer

This document was prepared as an account of work sponsored by the United

States Government. While this document is believed to contain correct

information, neither the United States Government nor any agency thereof, nor

The Regents of the University of California, nor any of their employees, makes

any warranty, express or implied, or assumes any legal responsibility for the

accuracy, completeness, or usefulness of any information, apparatus, product,

or process disclosed, or represents that its use would not infringe privately

owned rights. Reference herein to any specific commercial product, process, or

service by its trade name, trademark, manufacturer, or otherwise, does not

necessarily constitute or imply its endorsement, recommendation, or favoring

by the United States Government or any agency thereof, or The Regents of the

University of California. The views and opinions of authors expressed herein

do not necessarily state or reflect those of the United States Government or any

agency thereof, or The Regents of the University of California.

Ernest Orlando Lawrence Berkeley National Laboratory is an equal opportunity

employer.

LBNL-50934

Energy Efficiency Improvement and Cost Saving Opportunities

for Breweries

An ENERGY STAR® Guide for Energy and Plant Managers

Christina Galitsky, Nathan Martin, Ernst Worrell and Bryan Lehman

Energy Analysis Department

Environmental Energy Technologies Division

Ernest Orlando Lawrence Berkeley National Laboratory

University of California

Berkeley, CA 94720

September 2003

This report was funded by the U.S. Environmental Protection Agency’s Climate Protection

Partnerships Division as part of ENERGY STAR. ENERGY STAR is a government-backed

program that helps businesses protect the environment through superior energy efficiency. The

work was supported by EPA Contract DW-89-93934401-1 through the U.S. Department of

Energy Contract under No. DE-AC03-76SF00098.

iii

Energy Efficiency Improvement and Cost Saving Opportunities for Breweries

An ENERGY STAR® Guide for Energy and Plant Managers

Christina Galitsky, Nathan Martin, Ernst Worrell and Bryan Lehman

Energy Analysis Department

Environmental Energy Technologies Division

Ernest Orlando Lawrence Berkeley National Laboratory

September 2003

ABSTRACT

Annually, breweries in the United States spend over $200 million on energy. Energy

consumption is equal to 3 – 8% of the production costs of beer, making energy efficiency

improvement an important way to reduce costs, especially in times of high energy price

volatility. After a summary of the beer making process and energy use, we examine energy

efficiency opportunities available for breweries. We provide specific primary energy

savings for each energy efficiency measure based on case studies that have implemented

the measures, as well as references to technical literature. If available, we have also listed

typical payback periods. Our findings suggest that given available technology, there are

still opportunities to reduce energy consumption cost-effectively in the brewing industry.

Brewers value highly the quality, taste and drinkability of their beer. Brewing companies

have and are expected to continue to spend capital on cost-effective energy conservation

measures that meet these quality, taste and drinkability requirements. For individual plants,

further research on the economics of the measures, as well as their applicability to different

brewing practices, is needed to assess implementation of selected technologies.

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Energy Efficiency Improvement and Cost Saving Opportunities

for Breweries

Table of Contents

1. Introduction ................................................................................................................. 1

2. The Brewery Market ................................................................................................... 2

3. Process Description ..................................................................................................... 5

4. Energy Use .................................................................................................................. 9

4.1 Energy Consumption and Expenditures............................................................... 9

4.2 Energy Intensity................................................................................................. 11

5. Options for Energy Efficiency .................................................................................. 13

6. Process-Specific Measures ........................................................................................ 19

6.1 Mashing and Lauter Tun Processes ................................................................... 19

6.2 Wort Boiling and Cooling.................................................................................. 19

6.3 Fermentation ...................................................................................................... 24

6.4 Technologies for Beer Processing ..................................................................... 25

6.5 Technologies for Packaging............................................................................... 27

7. Cross-cutting Measures ............................................................................................. 28

7.1 Boilers and Steam Distribution.......................................................................... 28

7.2 Motors and Systems that Use Motors ................................................................ 31

7.3 Refrigeration and Cooling.................................................................................. 33

7.4 Other Utilities..................................................................................................... 35

8. Material Efficiency Opportunities............................................................................. 39

9. Future Technologies .................................................................................................. 43

10. Summary & Conclusions ......................................................................................... 44

11. Acknowledgements.................................................................................................. 47

12. References................................................................................................................ 48

Tables

Table 1. Major brewery products and shipments value, 1997 ............................................ 3

Table 2. 1994 Primary energy consumption and expenditures in malt beverages.............. 9

Table 3. Uses and sources of electricity in the brewery sector, 1994............................... 10

Table 4. Estimated percentage energy use for various brewing processes ....................... 11

Table 5. Process-specific energy efficiency measures for the brewing industry.............. 14

Table 6. Cross-cutting and utilities energy efficiency measures for the brewing industry15

Table 8. Specific primary energy savings and estimated paybacks for process specific

efficiency measures.................................................................................................... 45

Table 9. Specific primary energy savings and estimated paybacks for efficiency measures

for utilities .................................................................................................................. 46

Appendix I. Locations and capacity of large breweries.................................................... 56

Appendix II. Employee tasks for energy efficiency ......................................................... 57

Appendix III: Energy management system assessment for best practices in energy

efficiency.................................................................................................................... 58

Appendix IV. Support programs for industrial energy efficiency improvement.............. 60