1

13th September, 2006New Energy and Industrial Technology

Development Organization (NEDO) Jakarta Office

The Project for renovation to increase the efficient use in Brewery by NEDO at Bia Thanh Hoa Brewery in Vietnam

2

Outline of the ProjectOutline of the Project

Objective

Increase the efficient use of energy

Objective

Increase the efficient use of energy

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Outline of the Project with CDM

Outline of the Project with CDM

Objective of the projectRenovation to increase the efficient use of energy in brewery at Bia Thanh Hoa in VietnamImplementation

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 wateranaerobic waste water treatment and biogas boiler: To generate steam and treat waste water

Objective of the projectRenovation to increase the efficient use of energy in brewery at Bia Thanh Hoa in VietnamImplementation

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 wateranaerobic waste water treatment and biogas boiler: To generate steam and treat waste water

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Project Participants and the Roles

NEDO

(Entrusted to)MYCOM

MOI HABECO

BTH

JAPAN VIETNAMCERs Credit Transfer Agreement

Transfer of CERs

Implementation of equipment

Permits & Supervising

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.

CDM

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Outline of the Beer Sector in VietnamOutline of the Beer Sector in Vietnam

Scales of Breweries: Total 469 in 2004

28 14 12

415

0100200

300400500

<3ML 3-10ML 10-20ML >30ML

BreweriesScales of Breweries: Total 469 in 2004

28 14 12

415

0100200

300400500

<3ML 3-10ML 10-20ML >30ML

Breweries

Beer Production Growth in Vietnam

0

200

400

600

800

1000

1989 1991 1993 1995 1997 1999 2001 2003

ML-beer

year

49%

24%

27% State-ownedCompany

JV Company

Local Company

Market Shares

Cf. Beer Sector in Japan:

Approx. 7,000Million Ltr/year, 30 Breweries

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

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Outline of Bia Thanh Hoa

Established in 1987150km 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 2004Products: Bia Thanh Hoa, Saigon, Hanoi

THANH HOA BREWERY BIA HAI PHONG

BIA SAIGON

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Initial Facility in Bia Thanh Hoa in 2003(at FS)

Fig: Coal boilers

Fig: Ambient air type condensers using massive water

Extremely inefficient coal boilers are usedUse 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 consumptionImprovement of refrigeration system is desired due to high electricity tariffNo concerns for fuel energy saving because of cheap coal prices

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Outline of Energy Use in BTHOutline of Energy Use in BTH

0.0915kgCO2/MJ3.14kgCO2/kg39VND/MJ1,342VND/kg(0.085USD/kg)

Coal

0.0687kgCO2/MJ2.62kgCO2/L227.8VND/MJ8,360VND/L(0.53USD/L)

Diesel oil

0.193kgCO2/MJ(Average)

0.695kgCO2/kWh(OM &BM Ave.)

273.4VND/MJ984.5VND/kWh(0.065USD/kWh)

Electricity(STD tariff)

CO2 EmissionCostEnergy

Tarif

0

200

400

600

800

1,000

1,200

1,400

1,600

1h

2h

3h

4h

5h

6h

7h

8h

9h

10h

11h

12h

13h

14h

15h

16h

17h

18h

19h

20h

21h

22h

23h

24h

Tariff

VND/kWh

505895

1480

Tariff of Electricity

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Beer Brewing Processes & Utility Consumption

Beer Brewing Processes & Utility Consumption

Silo Mill Brewhouse

MT MK LT WK WPWC

Filtration Packaging & WarehouseBC

WS

FL WABS

BFFermentation/Maturation Tank Zone

FT ST

CO2

POWER ......... STEAM.......... WARM Water……COOLING........

30% ~40% of energy is consumed during wort boiling

30%~50% of electricity is consumed for refrigeration load.

30%~50% of cooling load is used by wort cooling water production.

20%~30% of energy is consumed in the packaging area.High BOD effluent

is drained from Brewhouse.

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Outlook of Energy Consumption of Brewery

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 consumption30~50% 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 consumptionLarge quantity of water is consumed for cleaning purpose.Waste water

High BOD effluent is drained from Brewhouse.

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 consumption30~50% 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 consumptionLarge quantity of water is consumed for cleaning purpose.Waste water

High BOD effluent is drained from Brewhouse.

Steam consumption (daily shift)

0

5

10

15

20

25

30

16

31

25

18

72

49

31

13

73

43

54

97

55

96

21

68

37

45

80

78

69

93

19

93

10

55

11

17

11

79

12

41

13

03

13

65

14

27

min

t/h

Brewhouse

Others

CIP

Package

Byproduct

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Introduced Energy-saving SystemsIntroduced Energy-saving Systems

BBT

CCV

Latest VRC System

ChillerChiller

Chiller

Cascade Cooling System Dynamic Ice Storage/Transportation System

M

Inv.

PC

Economical Methane RecoverySystem

CO2 Recovery System Optimal Pasteurizing System

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Effect of the Proposed 4 SystemsEffect of the Proposed 4 Systems

Anaerobic wastewater treatment added

N.A.Steam generation by Biogas

Biogas Boiler

Saving water consumption

N.A.Saving steam by optimization

Optimizing system for pasteurizer

Effective demand-side management

Saving powerSaving steam by heat recovery from discharged gas

Refrigeration system

Mitigating the strong odor to the outside

Additional power required

Saving steam by Reusing the discharged steam

VRC

OthersElectric powerSteam

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VRC SystemVRC System Saving steam by reusing the discharged

steam

※ This energy-saving system was developed with the aid from the Government of Japan.

Discharged steam has great energy!

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VRC SystemVRC SystemWort Kettle: evaporates about 2 tons of water in 1 batch. The conventional system discharges waste steam into atmosphere

Drain

Scrubber: cleans the waste steam and generates hot water for pre-heating the wort for the following batch

99ºC

85ºCWortPre-Heater

Hot Wort

97ºC

Wort

78ºC

Transfer to Wort Kettle

Energy Storage Tank

61m3

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High Efficient Refrigeration System

High Efficient Refrigeration System

Cascade cooling systemMulti-stage cooling consumes less energy than single stage cooling for a large temperature differential

Dynamic ice systemIt 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.

Cascade cooling systemMulti-stage cooling consumes less energy than single stage cooling for a large temperature differential

Dynamic ice systemIt 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.

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Refrigeration system-1: Cascade Cooling SystemRefrigeration 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%.

Displacement volume of Compressor

Chiller

COP=4.87

Tc=35 C

28 C

5 C

Te=0 C

Chiller

Chiller

Chiller

Cascade Cooling System

i

ii

Tc Te dT kW M3/h

35 0 35 362 1992

35 15 20 70 463

35 8 27 73 463

35 0 35 76 463

II Total 219 1389

II /I 60% 70%

II -I 143 603

Tc=35 C COP=8.06

28 C

18 C

10 C5 C

Te=0 C

Te=15 C

Te=8 C

Based on 1763kW (500TR)Conventional Cooling System

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Cascade Cooling systemCascade Cooling system

No.1

No.2

No.3

30ºC

0ºC

Brewing Water

Ambient Temp.

Ethanol Bine Tank

12m3

(Using existing Tank)

Chilled Water Tank

For Wort Cooling

140m3

3-stage cascade cooling system

Wortcooler

Hot Brewing Water Tank 85ºC

Hot Wort

99ºC

3ºC 6ºC

Fermentation Tank30-40m3/1brew

300-400m3/1day

30C

20ºC

10ºC

0ºC

Water cooler

Starting the operation in August 2005

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Jacket coolingJacket coolingPlate coolingPlate cooling

Air coolerAir cooler

Dynamic Ice Transporting Loop PipingDynamic Ice Transporting Loop Piping

Dynamic Ice Dynamic Ice Storage TankStorage Tank

Refrigeration System-2: Dynamic Ice Storage and Transportation System

Refrigeration System-2: Dynamic Ice Storage and Transportation System

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Dynamic Ice SystemDynamic Ice System

Dynamic Ice Storage tank-4ºC, 170m3

Dynamic Ice Maker

To use existing refrigeration compressor to make dynamic ice

Refrig. Comp. No.1 100kW

Refrig. Comp. No.2 100kW

Refrig. Comp. No.3 100kW

Refrig. Comp. No.4 100kW

Pd: Td: 110ºC

Heat recovery from discharged NH3 gas to make

hot water

Evaporative Condenser

Fermentation

2nd Brewhouse WC

2nd Brewhouse FT

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TemperatureTemperature

TransportationTransportationsystemsystem

Specific heatSpecific heattransportationtransportation

Diameter of Diameter of ppipeipe

Required volume Required volume of waterof waterRequired Required pump powerpump power

Running costRunning cost

19.8W/kg19.8W/kg

Chilled waterChilled waterDynamic iceDynamic ice

00℃℃/3/3℃℃--22℃℃/3/3℃℃

3.5W/kg 3.5W/kg

250mmNB250mmNB125mmNB125mmNB

332m3/h332m3/h59m3/h59m3/h

30.0kW30.0kW5.5kW5.5kW

450450yenyen/h/h8383yenyen/h/h

Cooling load is 1000Mcal/hCooling load is 1000Mcal/hHead of pump is 20mHead of pump is 20m

Comparison Table of Transportation Performance

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Optimizing software for Pasteurizer(Opt-Past) Optimizing software for Pasteurizer(Opt-Past)

Use Steam

Saving steam consumption by achieving optimum efficiency through computerized operation control

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Highly Efficient and Economical Methane Recovery System from Wastewater

Highly Efficient and Economical Methane Recovery System from Wastewater

Waste Water from Brewhouse

UASB

Gas Holder

Biogas Boiler

Gas Compressor

Steam Accumulator

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Effects of Energy-savingEffects of Energy-saving

Energy-saving: 3,386 Toe/yrCO2 emission reduction: 10,376 Ton/yrEnergy-saving: 3,386 Toe/yrCO2 emission reduction: 10,376 Ton/yr

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Implementation ScheduleImplementation 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

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Technology TransferTechnology 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.SoftwareHuman-machine interface improvement Group Activity (KAIZEN)Improve the motivation & increase Efficiency

Hardware Main equipment is made in Japan but the parts assembly and packaging are worked on by Vietnamese manufacturers under the supervision of Mayekawa.SoftwareHuman-machine interface improvement Group Activity (KAIZEN)Improve the motivation & increase Efficiency

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Hardware Technology Transfer

Hardware Technology Transfer

Transferred TechnologiesDeveloped in Japan after Oil-crisis in 1978 VRC: developed technology under Moonlight ProjectCascade system Dynamic ice SystemAnaerobic 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.

Transferred TechnologiesDeveloped in Japan after Oil-crisis in 1978 VRC: developed technology under Moonlight ProjectCascade system Dynamic ice SystemAnaerobic 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.

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Software Technology Transfer

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.

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.

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Group Activity (KAIZEN) 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.

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.

0.41

0.28

0.26 0.26 0.26

0.25

0.2

0.25

0.3

0.35

0.4

0.45

1997 1998 1999 2000 2001 2002

Resulted from Energy Saving Activities

Japanese reference

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DisseminationDissemination

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

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Application to the other Industries

Application to the other Industries

Any other industries suitable for anaerobic waste water treatment

Soft drinks

Soft drinks, Dairy plants, etc.

Distilleries, Sugar plants, etc.

Other Industries

Biogas Boiler

Opt-Past.

Refrigeration

VRC

System