WEA Tech Presentation ProcessModelling

National Conference Technical Paper

So, Why do I need to Model ?Presented by John Ioannou

August 2003, Mildura

2

Agenda

• APV Australia

• What is Modelling

• APV Modelling Methodology

• Yalumba Wine Company case study

• So, Why Model

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APV Australia

• Head office in Clayton, Victoria• Offices in Sydney, Brisbane, Adelaide and Perth• Manufacturing in Brisbane factory• 125 employees• APV Australia business units:

– Product component sales– Contracting Engineering– Service

• Key markets:– Dairy and Processed foods– Brewing and Beverage– Industrial

4

What is Modelling

• Modelling takes a system and breaks it up in to a series of logical steps.

• Analyze how the system behaves.

• A system can be defined as:– Continuous process. Winery– Discrete process. Assembly line– Unit process. Fermentation reaction

5

What is Modelling

Winery Wine Out

Grapes In Crushing Line

Pre-Fermentation

Fermentation

Post-Fermentation

Bottling Wine Out

Grapes In

6

Types of Models - STATIC

• Focus on specific area of process• Does not show interaction between areas• Is NOT time dependent• Mathematical expression(s)• Usually use spreadsheets

Tank Storage CalculationGrape Intake 2000,2001 & 2002

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Types of Models - STATIC

Available Storage• Site• Non-Site

Stock Position• Previous vintage• Current vintage

Working Space

Required StorageCalculation

Risk Scenarios•Over yield •Sales Slow

8

Types of Models - DYNAMIC

• Wider focus of a process • Shows interactions between areas• Simulation. i.e. “What If” scenarios• Are time dependent

Yalumba Wine Company Model

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Modelling Tools

• Market Tools– Flow sheets– Spreadsheet (tailored by user or proprietary)– Propriety software on the market

• APV Modelling Methodology– Performed various modelling exercises

• Important to have a clear vision on your objectives so an appropriate tool can be selected.– High level versus Specific applications– Model – Simulation

10

APV Modelling Overview

• Process Engineering – Develops Design. Greenfield projects– Maps current operation Improve current performance– Distinguish between Modelling & Engineering

• Collect and Validate Data– Important to be accurate– Allows weeding out of irrelevant items

• Develop Models– Static– Dynamic

• Analyze Models– Validates a process design.

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APV Modelling Methodology

• Phase 1 – Modelling Objectives

• Phase 2 – Define the Boundary

• Phase 3 – Define the Process

• Phase 4 – Define the Equipment

• Phase 5 – Define stock position

• Phase 6 – Material & Energy Balances

• Phase 7 – Time related data

• Phase 8 – Modelling

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Phase 1 – Modelling Objectives

• Create a Scoping document outlining the Objectives, Resources & Timeframe.

• Develop a list of questions that the modelling process needs to answer.

• For example:– Will the current plant setup handle a growth intake of 50% ?– How many centrifuges are required to handle the peak?– How many tanks are required?

• List & Test Assumptions

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Phase 2 - Define the Boundary

• Map Overall process

• Highlight the area that the modelling will focus on

• Assumption is made that the non modelling zones will not impact on the modelling zone

CRUSHING

PRE-FERMENTPROCESSING

FERMENTATION

POSTFERMENTATION

PROCESSING

BLENDING

FILTRATION

COLD STABILISATION

PRE-BOTTLINGPROCESSING

BOTTLING

GRAPES IN WINERY

DISTRIBUTION

VINEYARD

Materials Inputs

Water Inputs

Utility Inputs

EffluentOutputs

Wine WasteOutputs

Solid WasteOutputs

ModelBoundar

y

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Phase 3 – Define the Process

• The process outlines how the incoming raw materials are converted into the final product(s) through a series of operations.

• APV generally document the information collected on a flow diagram.

• The level of detail will depend on the objectives and timeframe to produce this drawing

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Phase 3 – Define the Process

Receival BinsCapacity30 ton/bin

Crusher/DestemmerCapacity Max 70 ton/hr

Capacity Average 40 ton/hr

MustHeater/Chiller

SWAPTanks

Swap Recirculation

RackValve

CAP

RotaryScreen

CAP cooler

gravity empty

Wet Marc Pump

1st Pressing

2nd Pressing

RDV ORDecanter OR

Belt Press

SludgeDisposal

Dry MarcBay

CoarseCentrifuge

Juice processed daily

SludgeNot Thick

Sweet Juice

100 HL

PressingAccumulation

1400 HL

Storage toallow Ferment

to finish5 Days

Temp @ 20o

RDV ORDecanter OR

Belt Press

SludgeDisposal

CoarseCentrifuge

WineSludge

Juice

N/A

N/A

free run juice

1400 HL

MLF3 weeks

Temp @ 22o

(1 DegCwarm/day)

FineCentrifuge

RDV ORDecanter OR

Belt Press

SludgeDisposal

Sludge

2800 HL

Age StorageUp to 12months

Temp in 22o

Control tempto 18-20o

(staves)

Wine

Grapes from Vines

MustPump

Red GrapesVarieties - see Basis of DesignQuantities - see Basis of Design

ConveyorStalks &Stems

18 to 20 DegC30 DegC max

??

Red Fermentation6 Days duration

Temp @ 20 to 30 DegCMaintain juice at 22 DegC

Drain and return juice not colder than 5 DegCFermentation controlled at 2 - 3 Baume decrease

per day (Starts at 12 to 15 & ends at 0)

30 DegC8 DegC

Drain and Return Tank

CellarHand

to Press

260 hL/hr

??

Purging??

Cellar Handto Collect

& Return toSwap

(small amount?)

Pressing kept agitated andwhen enough has been

accumulated it is processedthrough the centrifuge

Additions:Bacteria

N/A

To PostFermentation

Diagram

Yalumba Wine CompanyMoppa Winery Project

Red Vintage Process BLock DiagramRevision 3 Issued 4th June 2003

Additions:Red YeastEnzymes

TanninTA / MA

30O Max

Additions:Red Yeast

SO2TA / MA

WeighbridgeSampling &

Testing

Additional cooling for white grapes

rack to nextstep

rack to Drain &Return area

Drain and Return Tank

Are 2 lines ok ??

There will be one available(Must chillers used as backup)

Cap cooler is critical and willbe required on demand

Incline Drainer

Recycle line toavoid drying

free run juice

RotaryScreen

Turbidity100 - 150 ?

ProcessBuffer Tank

Collected and transferred tonext stage within time window.

End of day / next day

clear

Lees1 to 2%

tank volumeTransfer LeesUsing PumpProcess

Buffer Tank

Wine

Lees

ProcessBuffer Tank

Chilled Water4o

(2o with ice water)

Volume skins approx wheel barrowPump used to send to swap tank

CTS Press

3nd Pressing

Flow =% Solids =Pressure =

Flow =% Solids =Pressure =

ProcessBuffer Tank

% Solids =L/discharge =Discharge/hr =

Flow =% Solids = 5 to 8

Pressure =

Flow = 60-80 hl/hr% Solids = 1-2

Pressure =

% Solids = 90L/discharge =17

Discharge/hr =8-10

ProcessBuffer Tank

ProcessBuffer Tank

CAPApprox 1/3 of SWAP volume is the CAP

Auto Blending

1400 HL

Sauv BlancFermented18 - 20 oC

RDV( Decanter )

SludgeDisposal

2800 HL

ChardonnayBatching

Temp @ 10o

RDV( Decanter )

SludgeDisposal

FineCentrifuge

Temp @17 to 18o

Cellar Bright Wine

2800 HL

Sem BlancBatchingCooling

down to 10o

@ 1o per day

RDV( Decanter )

SludgeDisposal

2800 HL

Sem BlancBlended

1400 HL

ChardonnayFermented18 - 20 oC

Auto Blending

2800 HL

ChardonnayBlended onlight lees

Temp @ 10o

RDV( Decanter )

SludgeDisposal

FineCentrifuge

2 x 1400HL

ChardonnayTemp @ 10o

2 x 1400HL

ClarifiedBlend

Temp @ 10o

Cold StablisationHeater

2 x 1400HL

ClarifiedBlend

Temp @ 14o

FilterDE

RDV( Decanter )

2 x 1400HL

ClarifiedBlend

Temp @ 10o

Cold StablisationHeater

2 x 1400HL

ClarifiedBlend

Temp @ 10o

Storage10O

Sterile FilterTangential / DE

PreBottlingStorage15 - 20o

Bottling15-20o To Market

2800 HL

RedAge StorageCellar Bright18 - 20 oC

Auto Blending

RDV( Decanter )

SludgeDisposal

2800 HL

Red BlendedCool to 12o

in tank

2800 HL

RedBlended &Polished

PolishedWIne

Concentrate

Cold Stablisation

2 x 1400HL

RedPolished &

Cold Stabl'd12o

N/A

N/A

N/A

Angaston Site

Moppa SiteUnload Line


Red & White Post FermentationProcess BLock Diagram

Revision 3 Issued 4th June 2003

N/A

Additions:SO2

Fining -ClarificationFining - Remedial

Red Flow StreamSauv Blanc & Aromatic Flow StreamChardonnay Flow Stream

Sludge

Wine

Light Lees2%

Additions:SO2

Fining -Clarification

Fining - Remedial

SludgeDisposal

HeatRecovery 90 hL/hr

Additions:Nitrogen (degas)

B/P

N/A

Light Lee Wine95% by volume

N/A

Additions:Fining -ClarificationFining - Remedial

Light Lees& Finings2% solids

Wine

B/P

CellarBrightWine

Sludge

RDV( Decanter )

SludgeDisposal

HeatRecovery 90 hL/hr


Gross Lees5% by volume

Light Lee Wine95% by volume

Gross Lees5% by volume

Additions:SO2

Intermittentagitator action

Trigger toproceed to nextstage by Sales

pull.

All ChardonnayBlended by August

Intermittentagitator action

ProcessBuffer Tank

Additions:SO2

ProcessBuffer Tank

ProcessBuffer Tank

All Sem BlancBlended by August

Collect gross less& process within 1

day window

Solids

Polished WineFilterDE

FilterDE

SolidsSmall Amount

Polished Wine

N/A

N/A

10O 14O

Bottle Ready Wine10O 14O

Bottle Ready Wine

N/A

18 - 20 oC

ProcessBuffer Tank

Finings / Light lees

B/P

Note: Down to 12o

Want to maximisetartrate removal tominimise load on

electrodialysis plant.Aim to Cold stabilise

down to 4o

Note: TO Resolve:a) Handling residual

volumesb) Process Ullage

Managemant(Yes for Wine / No

for Juice & Ferments

Single Tanker 270 HL => Fill in ? minutesDOuble Tanker 400 HL => Fill in ? minutes

Heater MembraneFilter

ProcessBuffer Tank

ProcessBuffer Tank

ProcessBuffer Tank

ProcessBuffer Tank

ProcessBuffer Tank

Light lees1%

ProcessBuffer Tank

ProcessBuffer Tank

ProcessBuffer Tank

Light Lees1%

ProcessBuffer Tank


pull.


pull.

ProcessBuffer Tank

Heater12O 14O


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Phase 4 – Define the Equipment

• List the major pieces of equipment that make up the process.

• Define the maximum capacity for each.

• Define the design capacity for each.

• Define Upper and Lower capacity range

• Review plant layout

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Phase 4 – Define the Equipment

Option A = Seperate Drain & Return Task.use pump and delivery line to retun product to

drain

Option B = Overlap Drain & Return Task.REquire seperate fil and empty lines

Assume we will adopt Option A

CrusherCapacity Max 70 ton/hr


MustHeater/Chiller





MustHeater/Chiller

MustHeater/Chiller

Bypass if H/E not required



Dry MarcBay

Pressing

Incline Drainer

Millers ContinuousDrainer

Free run juice

skins

CTS Press

RotaryScreen

RotaryScreen

Pressing

Incline Drainer


Free run juice

skins

CTS Press

RotaryScreen

RotaryScreen

Pressing

Incline Drainer


Free run juice

skins

CTS Press

RotaryScreen

RotaryScreen

Recycle line towet marcpump??

THis area can process theRed and White streams atthe same time.

White => MCP + CIDRed => Press only

Aim to handle peak for aweek or two

What happens to whiteskins from incline drainer?

Red (OR Sauv Blanc) Grapes(Chardonnay / Aromatics)

Sauv. Blanc ( OR Red ) Grapes(Chardonnay / Aromatics)

Chardonnay / AromaticGrapes only

1400

1400

1400

1400

1400

1400

1400

1400

1400

1400

1400

1400

1400

1400

1400

1400

1400

1400

1400

1400

900

900

900

900

900

900

900

900

900

900

CAP Cooler

700 700 700 700 700 700

6 off 700hL Drain & Return tanks

RotaryScreen

RotaryScreen

SWAPS to empty under gravity. 1) Rotary screen are to be fixed ?? => No. RS are mobile & are to be placed directly under SWAP tank 2) How is the juice going to get to the rotatry screen? => By Gravity

Issues to resolve?* How many rotary screens - ie is 1 or 2 or moreto handle Drain & Return, cap cooling & empty

SWAP to presses?* Line configuration - supply & return to Drain

and Return tank* How to return skins to SWAPS from Rotaryscreens & what volumes will be genarated?

Water HoseWater HoseWater Hose

Water Hose

Water Hose

Stalks &Stems

450 HL Tank Farm

Used for:

* Pressing Accumulation* Ullage management

1400 HL Tank Farm

900 HL Tank Farm

150 HL Process Tanks

Qty = 5 is this ok?Used for Processing with Centrifuges / RDV's / TF

recycle lineto sludge?

Allowsdilution ofsludge to

RDV better -Reds only?

Whiteoption to 1400?

Redoption to 900?

number of linesdepends on whatfunctions can runsimultaneously

RDV Large RDV Medium

RDV Small

Earth Mixing plant.Pump slurry to oneonly or more thanone RDV at the

same time?

Sludge &Earth

Sludgesmall

Polished wine

Must Pump

Must Pump

Must Pump

125mm

125mm

125mm

PressingsFree Run

PressingsFree Run

PressingsFree Run

Chardonnay/Aromatics Stream Sauvingnon Blanc Stream Red Stream

OperatorInterface

Citect

OperatorInterface

Citect

OperatorInterface

Citect

Do all three sets oflines needs coolers

for the whites?

what other rolefor cap cooler?

125mm

125mm

Wet Marc Streams

Free Run StreamsRed to 1400 (900?)

White to 900 (1400?)

Rotary Screens? max entry velocity

? how to avoid splashing

? recycpe line. Does volumejustify installing line

Red

Sauv Blanc

Red

Sauv Blanc


Equipment Process Flow DiagramRevision 1 Issued 5th May 2003

Pump or Conveyorsystem



Heater 1 or 2 ?

2800 HL Tank Farm

BLENDINGOccurs from 2800to 2800 tank only

Pressing to 450's

DeGas

GrapeIntake

GrapeIntake

GrapeIntake

?????Does theRed lineneed to

havefacility toalso go tocrusherdirectly?

?????Do the Swap Wet Marclines need to have the

facility to go to anydejuicer/press?

NOTE: Must H/E bypassmay not be required for

MOPPA. To Be Resolved

D/Earth Filter

D/Earth Filter

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Phase 5 – Define stock position

• Collect Stock data:• Grape Intake

• Define grape varieties• Intake schedule & time frame (raw material entering)

• Stock on Hand• Define wine products• Previous stock at commencement of vintage

• Bottled Product• Define bottling capacity• Sales data (product leaving)

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Phase 6 – Balances

• The scope of the modelling project will dictate what Balances are to be developed

• A list of the various balances are:– Mass balance (mandatory)– Energy balances– Waste estimations– Water balances– Other Utility balances

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Phase 7 – Time Related Data

• Time Motion studies

• Break down data

• Shift data

• Material Delivery Schedule

21

Phase 8 – Develop Model(s)

• STATIC– Tanks Storage Calculation– Grape Intake

• DYNAMIC– Process Model from grape intake to wine filtration

• TANK LAYOUT– Tank farm layout and process model to to validate tank size &

tank mix over the vintage period

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INPUTS MODEL OUTPUTS

Grape Intake

PreviousVintage Stock

Bottling Rates

Main ProcessSteps

Main Equipment& Capacity

PROCESS

MODEL

Intake Profile

Volume Profile

Crush Line Loading

Wine Stream Steps

Centrifuge Loading

Filtration Loading

RDV to process

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Sauvingnon Blanc Phases1 - Crushing / Depectinising - Floating Daily HL2 - Total Product in Fermentation Cumul HL3 - Fermentation Complete after 25 days => Daily HL

95% Racked HL to centrifuge Daily HL5% Gross Lees HL to RDV Daily HL

4 - Wine Batched into 2800's & cooled for 10days Daily HL100% Centrifuged Wine Daily HL90% RDV Wine Daily HL

5 - Wine Ready for Blending Cumul HL32,104 % Vintage

6 - Wine Blended Wine to Blended Cumul HL16 450 Daily Wine Blended Daily HL2% Light Lees to RDV Daily HL90% RDV Wine Blended RDV Wine Daily HL

31,462 Blended Racked Wine Cumul HL578 Blended RDV Wine Cumul HL

Total Blended Wine Daily HL32,039 Total Blended Wine Cumul HL

7 - Wine to Tangential Filter Wine Ready to Filter Total HL

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CENTRIFUGE TOTAL LOADING Hours Total.=> % Capacity ALL 22 production / 24 hrs

3 No of centrifugesNumber of Vintage Days = 119

0.0% No. of Days above 100% = 00.0% No. of Days b/w 80% & 100% = 021.0% No. of Days b/w 60% & 80% = 2548.7% No. of Days b/w 30% & 60% = 5824.4% No. of Days below 30% = 2994.1% No. of Days Centrifuges in use 112

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CENTRIFUGE TOTAL LOADING Hours Total.=> % Capacity ALL 22 production / 24 hrs

2 No of centrifugesNumber of Vintage Days = 119

7.6% No. of Days above 100% = 925.2% No. of Days b/w 80% & 100% = 3027.7% No. of Days b/w 60% & 80% = 3321.0% No. of Days b/w 30% & 60% = 2512.6% No. of Days below 30% = 1594.1% No. of Days Centrifuges in use 112

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So, Why do I need to Model?

• Greater understanding of the process variables and how they affect your process performance.

• Know the process limitation (back up plans).• Know or design process bottlenecks.• Calculates what equipment is required to handle the

peak loads on the process (avoid over capacity capital).– Centrifuges (2 now 1 later) ?– Transfer lines (space for expansion) ?

• Know the limitation for future growth.• So you control the process and not the other way

- Able to anticipate issues earlier & take proactive action

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Thank You

Documents

WEA Tech Presentation ProcessModelling