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13 th September, 2006

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

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13 th September, 2006

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

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

  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

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

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

  6. Outline of Bia Thanh Hoa • Established in 1987 • 150km 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. Initial Facility in Bia Thanh Hoa in 2003(at FS) • 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 Fig: Coal boilers Fig: Ambient air type condensers using massive water

  8. Outline of Energy Use in BTH

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

  10. Outlook of Energy Consumption of Brewery • Steam consumption @40~ 50% of steam is consumed in Brewhouse (large fluctuation) @ 20~30% of steam is consumed in the packaging area (constantly) @ 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. Chiller Chiller Chiller Introduced Energy-saving Systems Latest VRC System CO2 Recovery System Optimal Pasteurizing System PC Inv. M CCV BBT Economical Methane Recovery System Cascade Cooling System Dynamic Ice Storage/ Transportation System

  12. Effect of the Proposed 4 Systems

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

  14. VRC System Wort Kettle: evaporates about 2 tons of water in 1 batch. The conventional system discharges waste steam into atmosphere Scrubber: cleans the waste steam and generates hot water for pre-heating the wort for the following batch Hot Wort 97ºC 99ºC 85ºC Wort Pre-Heater Wort 78ºC Energy Storage Tank 61m3 Transfer to Wort Kettle Drain

  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. NH3 discharged gas in the refrigeration system and used in brewery instead of steam.

  16. Displacement volume of Compressor Conventional Cooling System Cascade Cooling System Based on 1763kW (500TR) Tc=35 C COP=8.06 i COP=4.87 Tc Te dT kW M3/h Tc=35 C 35 0 35 362 1992 ii 35 15 20 70 463 Chiller 35 8 27 73 463 Chiller Chiller 35 0 35 76 463 Te=15 C 28 C 28 C Chiller II Total 219 1389 Te=0 C 18 C Te=8 C II /I 60% 70% Te=0 C 5 C 10 C II -I 143 603 5 C 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. Cascade Cooling system Starting the operation in August 2005 Brewing Water Ambient Temp. 3-stage cascade cooling system Hot Brewing Water Tank 85ºC Hot Wort 99ºC 30ºC 30C 0ºC 3ºC 6ºC No.1 Ethanol Bine Tank 12m3 (Using existing Tank) Chilled Water Tank For Wort Cooling 140m3 20ºC Water cooler Wort cooler No.2 10ºC No.3 Fermentation Tank 30-40m3/1brew 300-400m3/1day 0ºC

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

  19. Dynamic Ice System Heat recovery from discharged NH3 gas to make hot water Evaporative Condenser Refrig. Comp. No.1 100kW Refrig. Comp. No.2 100kW Refrig. Comp. No.3 100kW Fermentation Dynamic Ice Maker 2nd Brewhouse WC Refrig. Comp. No.4 100kW Dynamic Ice Storage tank -4ºC, 170m3 2nd Brewhouse FT Pd: Td: 110ºC To use existing refrigeration compressor to make dynamic ice

  20. Comparison Table of Transportation Performance Transportation system Dynamic ice Chilled water Temperature -2℃/3℃ 0℃/3℃ Specific heat transportation 3.5W/kg 19.8W/kg Diameter of pipe 125mmNB 250mmNB Required volume of water 59m3/h 332m3/h Required pump power 5.5kW 30.0kW Running cost 83yen/h 450yen/h Cooling load is 1000Mcal/h Head of pump is 20m

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

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

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

  24. Implementation Schedule Sep. 2004 Installation of the consumption data monitoring unit Oct. 2004 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 2005 Installation 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. 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

  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.

  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.

  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.2006. Japanese reference Resulted from Energy Saving Activities

  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. Application to the other Industries

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