Energy Audit in Industries

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Brewery & Distillery
Since this industry functions on a seasonal demand basis, achieving a consistently low Utility to Brew ratio turns out to be difficult.

Boiler fuel for steam generation, accounts for 40% of the total utility cost. In the brewing process, steam is used for the process of heating, cleaning, and pasteurizing. A large proportion of the steam produced in a brewery is used in the extraction of sugars and flavors in the mashing process and for wort boiling, where beer is sterilized and stabilized. These two processes alone account for up to 50 % of the connected steam load. Other areas of the brewing process that use steam include bottle washing, racking and canning besides also being required in CIP systems.

Forbes Marshall- CII joint studies reveal differences in fuel consumption per KL of brew within the industry, i.e. Specific Fuel consumption (SFC).

By partnering with breweries across the country we have been successful at reducing the avg SFC across the industry and have also now set ourselves a new benchmark to beat.

Case Study

A leading manufacturer of spirits located in Maharashtrahas  two distillery units of capacity 20KPLD and a 30+10 KPLD with a bottling unit and an alcohol based chemical manufacturing unit. The plant implemented the following suggestions:

1. Optimized boiler combustions and operations. Installed effective monitoring systems in place to sustain the savings.
2. Improved the condensate recovery from 45% to 88%
3. Returning condensate and flash to feedwater tank along with proper feedtank water control system raised the feedwater temperature from 54oC to 65oC.
4. Additionally by implementing an innovative solution provided in the audit, the plant has been able to reduce the Specific Steam Consumption from 3 to 2.7 kg /liter of ENA.

The plant has a zeal for reducing its energy consumption and undergoes regular energy audits to optimize their systems and be in synch with the latest in steam engineering.

Case Study 2:

A brewery in South India opted for our Energy Audits and implemented our recommendations. This resulted in:

1. SFC improved from 52 Lt (FO)/KL Beer to 36 Lt (FO)/KL.
2. By improving the combustion in the boiler and sustaining the performance via an online boiler monitoring system,  the boiler efficiency improved from 79% - 84%
3. By increasing the Recovered condensate from 11,000 kg to 14,000 kgs the feedwater temp improved by 15oC.
4. The energy from boiler blowdown was recovered to save 100kg/hr of steam.

The prime reasons for difference in SFC across plants are:

1. Efficiency of steam generation

Avg Direct efficiency: 74.8%
Avg Indirect efficiency: 78%

Reasons for gap:
1. Fluctuating steam demand, load can go down to less than 25% of the capacity. This occurs when only the bottling plant is in operation.
2. 90% of the plants control the feed water tank manually.

2. Optimized steam distribution and utilization

1. Line size esp. for processes like wort boiling and mashing not based on peak loads.
2. Selection of appropriate pressure reducing stations.
3. Correct trap selection and sizing

3. Recovering condensate and flash steam

Reasons for gap
1. In most plants flash steam is not recovered.
2. Poor condensate recovery from bottle washers, hot water generation system and CIP sections.
3. Inadequate condensate evacuation from wort kettles.

4. Capacity Utilization:

Owing to the seasonality associated with brewing, in the off seasons factors like boiler efficiency need to be addressed in the steam and condensate loop. Our audits recognize this pattern of production and suggest SOP to optimize fuel consumption.