460 likes | 634 Views
MillerCoors Golden Brewery Sustainability Improvement . Energy Water Waste to Landfill. Julie Smith, PE, MS Plant Optimization Engineer Utilities/Technical Services. Brewery Sustainability Improvement. Agenda. Corporate Goals/Leadership Brewery Processes Brewery Utilities Opportunities
E N D
MillerCoors Golden BrewerySustainability Improvement.EnergyWaterWaste to Landfill Julie Smith, PE, MS Plant Optimization Engineer Utilities/Technical Services
Brewery Sustainability Improvement Agenda • Corporate Goals/Leadership • Brewery Processes • Brewery Utilities • Opportunities • Waste to Landfill • Culture
Corporate Sustainability Goals • Energy Usage of 128 MJ/HL by 2015 • Electricity • Steam • Vehicle Fuel • Water Usage of 3.5 HL/HL by 2012 • Zero Waste to Landfill by 2015 • CO2 Self-Sufficiency of 85% by 2015 • 50% Reduction in Green House Gas by 2020 • Why Sustainability? • Customer Demand • Continue our Business • Save Money • Marketing • Responsibility for Future Generations!
Brewery Process Overview Malting Brewing Fermenting Conditioning Packaging Warehousing
Golden Brewery Layout Aging Cellars, Hop Storage Power Still YDP Fermenting Turbine Brewing Conditioning Packaging/Warehouse/Gov. Cellar Malting/Kilns
Brewing Process • Mash In • Filter/Lauter • Boil Wort • Chill • Ferment
Fermenting • Yeast + Wort = Beer • Maintain Temperature • Residence Time • CO2 • Yeast • To Aging
Conditioning • Aging • Filter • Blend • To Packaging
Packaging • Bottles, Cans and Kegs • Rinse • Fill • Label • Package • Palletize • To Warehouse
Warehouse • Store Product • Move Product • Temperature • Docks
Utilities for Brewery Operations • Ammonia • Steam • Electricity • Plant Air • Steam • Electricity • Water Treatment • Electricity • Wastewater Treatment • Electricity • CO2 Recovery • Electricity • Power Plant – Co-Generation • Coal and Natural Gas Fired Boilers • 800 LB Steam • Electricity • 400 LB Steam • 50 LB Steam
Steam Savings Opportunities • “Low Hanging Fruit” • Leaks • Traps • Control Valves • Pressure Relief Valves • Process Optimization/Team Work • Compression Equipment Operation • Problem Solving • Metering - Short-Interval Control • Set Points • CIP Times • Quality/Efficiency • Projects • HVAC • Plant Air • Refrigeration • Brew Kettles
Plant Air Opportunities • Leaks • Operations • Compression Equipment • Set Points • Small Projects • Cabinet Cooling/Pressure • Venturi Vacuum • Low Pressure Uses • Condensate Drains • Pneumatic Valves and Equipment • Large Projects • Decentralization • Distribution Headers
Condensate • Return Benefits • Cost • Energy • Waste Treatment • Water Treatment • Where is it Going? • Sewer • Stack • Steam Leaks
Resource Savings Opportunities Electricity
Culture • Lights • Office Equipment • Phantom Energy • Process Optimization/Team Work • Metering/Short Interval Control • CIP Times • Pump Control • Hard Shut-Downs • Operating Strategy • Water Usage • Quality/Efficiency • Projects • Lights • Pump VFD’s • Controls • Equipment Right-Sizing • Facilities • Lights • HVAC • Insulation Electricity Savings Opportunities No! Yes!
Electricity Savings Opportunities Malting Lights Results
Electricity Savings Opportunities BOC HVAC Recommissioning Results
Electricity Savings Opportunities Packaging Green Shut-Down
Resource Savings Opportunities Water and Wastewater
Savings Opportunities – Water and Wastewater Save Water = Save Energy! • “Low Hanging Fruit” • Leaks • Controls • Nozzles • Team Work/Process Optimization • Problem Solving • Broom Not Hose • CIP Times • Cleaning Machines • Dry Lube • Seal Water • Quality/Efficiency • Projects • Re-Use • Once-Through Cooling Water • Empty Can Rinse Water • Reject Can Conveyance
Waste to Landfill • Currently ReUse or Recycle >98% of Total Waste • Spent Grain • Yeast • Ethanol Still • Glass • Cans • Single Stream • Industrial (Paper, Cardboard, Stretch Wrap, Metal) • Still, 100 Ton/Month to Landfill (2010) • Goal – Zero Waste in 3 years (or pretty close) • Sort, Label, Color Code • Optimize Collection • Source Reduction
Co-Products Golden Brewery Bill Coors: “Waste is Just a Resource Out of Place” • Yeast – 12 MM LBS/year • Fuel Grade Ethanol – 2.5 MM gal/year • Spent Grain – 400 MM LBS/year • All sold locally • Grain Dust • Malting • Malt Storage • Grain Load-Out • Brew House
YOU’RE INVITED TO • HELP US MAKE AN IMPACT! • As a first step to make the Golden Brewery • “The Largest Zero-Waste-to-Landfill Brewery in the World”, • we need your help to: • sort recyclables from the trash created at the brewery • paint examples of our new standardized color-coding system of lugers/dumpsters • draw up facts about trash and recycling at our brewery to create a great display • RSVP on the Volunteer Website (https://www.millercoorsvolunteers.com) What: Operation Zero Waste CARE & Volunteer Event When: Thursday, Sept. 15th Sorting: 7am – 8:30am 8:30 am – 10am Visit and learn: 1pm – 4pm Where: Pavilion at Investment Recovery What to bring: Pants, long sleeved shirt, PPE (bump-cap, steel-toes, safety-vest, and Kevlar gloves) Pavilion at Investment Recovery Employee Sales / Beer Trailer
Culture and People What is Culture?
Culture – What is Culture? Definitions: The quality in a person or society that arises from a concern for what is regarded as excellent in arts, letters, manners, scholarly pursuits, etc. That which is excellent in the arts, manners, etc. A particular form or stage of civilization, as that of a certain nation or period: Greek culture. Development or improvement of the mind by education or training. The behaviors and beliefs characteristic of a particular social, ethnic, or age group: the youth culture; the drug culture.
Culture Elements for Success • Leadership • Green Teams • Education • Communication • Recognition • Projects • Score Cards
Culture – Green Teams Golden Green Team – CARE “Committed to Active Responsibility for the Environment” • Established 2006 • Lunch and Learn Education • Recycling • Brown Bag Movies • Movie Library • Volunteer Opportunities • Clear Creek Watershed • Recycling Audit • Holiday Meal – Zero Waste Bin Stewards
AUDITS IDEAS Brewery Priorities & Sustainability Team Top Priorities & Assigned Leads
Golden Brewery Sustainability Results - 2011 • Golden Brewery 2011 Energy and Water Reduction – Most Improved of All Breweries!! • Reduced Total Energy by 11.9% • Reduced Water by 4.5% • Reduced Waste to landfill by 17% • MillerCoors Total Reductions – All 8 Breweries • Reduced Total Energy by 3.4% • Reduced Water by 0.9% • Three Zero-Waste Breweries