Transcript www.eng.umd.edu

Modeling, Simulation, and Economic
Evaluation of a Brewery Process
Mengesteab Adera
Thomas Wescott
Michael Naas
Griffin Jayne
April 3, 2014
Presentation Overview
❏ Introduction
❏ Process Description
❏ Environmental/Health Concerns
❏ Brewing & US Economy
❏ Summary
Introduction
❏ Project description
❏ Main objectives and goals
❏ How we can utilize ChemCAD
❏ US beer market
Project Description
❏ Complete computer modeling of Abita’s
production capacity
❏
ChemCAD -- Excel -- Matlab -- MathCAD
❏ Abita currently produces 165,000 barrels /yr
❏
Annual growth rate is 5% volume
❏ No elements of process design change
❏
❏
Do not explore any high-gravity brewing
Keep traditional artisan roots (Craft Brewery)
Main Objectives and Goals
❏ Model current brewing capabilities
❏ Exploratory addition of unitanks should be
modeled
❏ End Goal:
❏
❏
❏
Computer model of current capacity, with..
Ability to experiment with additions and
modifications to process
Economic analysis of experimental
US Beer Market
Barrels
❏ Beer consumption has actually dropped
some since 1990
US Beer Market: A closer look
Barrels
US Beer Market: A closer look
❏ Craft Breweries are
actually growing
❏ 18% increase in
consumption
❏ 17% growth in revenue
❏ Total market share
increasing by about
.7% per year since
2009
Process Description
http://assuredautomation.com/wordpress/wp-content/uploads/2012/03/Assured-Automation-G2-Series-Flow-Meters-for-Brewery-Batching.jpg
Process Description
❏ Mash
❏
❏
Malt ground in special mills to keep shells as whole
as possible
Cooked
❏ Brewing Kettle
❏
mash and water are boiled
❏ hops are added
Process Description
❏ Fermentation Tank
❏
❏
Yeast added after brewing
Sits for extended periods turning sugars into ethanol
❏ Secondary Fermenter
❏
❏
Allows yeast to continue digesting sugars
Removes any dead yeast from beer
❏ Holding/Storage Tank
❏
Allows beer to mature to bring out more flavor
Process Description
❏ Filter
❏
❏
Removes particulate matter from the beer
Usually last step before bottling or kegging
❏ Overall
❏
Much additional heat is required for mash and
brewing
Unit Operations Required
❏ Mills or grinders
❏ Primarily a series of large tanks
❏
CSTR’s, storage vessels
❏ Mixers
❏ Filtration units
❏
Separation of solids from liquid phase
Our Project
❏ Model the Abita Brewing Company’s Current
Brewing Capacity
❏ Once model is complete, experiment with
configurations of fermentation and holding
tanks to optimize the process
Energy Consumption in Brewery
● The brewing process is energy
intensive
● Two major sources of energy
○ Thermal Energy - Natural
Gas
■ generate hot water &
steam for brewing,
packaging, heating
○ Electrical Energy
■ power all equipments
https://www.brewersassociation.org/attachments/0001/1530/Sust
ainability_Energy_Manual.pdf
Energy & CO2 Emission
Energy - large source of CO2
regardless of its source.
● Direct emissions
❏ combustion of fuel in an
onsite boiler
● Indirect emissions
❏ purchased electricity and
steam, packaging material,
transportation
CO2 Emission: ABITA Brewery
● ABITA Brewing Company annual production
■ 165,000 barrels of beer/yr
● At 1.5 therms/bbl and emission factor of 5.29 kg CO2/therm,
ABITA brewery produces
■ 1.309 *106 Kg CO2 per year
https://www.brewersassociation.org/attachments/0001/1530/Sustainability_Energy_Manual.pdf
Health Effects
● Beer - Alcoholic beverage
■ 2.4 - 9.4% alcohol/12oz
● Short-term Effects
■
■
■
■
Breathing difficulties
Distorted vision and hearing
Impaired judgment
Unconsciousness
● Long-term Effects -Chronic Heavy Drinking
■ Liver cancer
Brewing & US Economy
•
As far as the US market is concerned there
are two major companies and everyone else.
o
Ab InBev - formerly Anheuser-Busch

o
MillerCoors - Miller and Coors brands

•
Corona, Landshark, Michelob,
Rolling Rock, Goose Island and
many more.
Bluemoon, Becks, Coor’s light,
Foster’s,Icehouse…
Craft beer breweries such as Abita together
make up about 8% of the domestic beer
market by volume sold.
Brewing & US Economy
•
•
In general Americans are drinking less
beer per capita than in the past.
o Total US beer sales decreased 1.9%
by volume from 2012 to 2013.
o Sale of beer imports decreased by
0.6% in 2013.
Plots show general decline of beer
consumption in the US after 1985.
Brewing & US Economy
•
While overall beer sales decreased, the sale of
craft beers increased.
o
Average annual market volume increase of craft beers relative to total beer market from 2009
has been 0.85%. Furthermore this rate of increase seems to accelerating.
o
Projected to represent nearly 15% of beer industry by 2020
Where Americans Drink
•
•
Comparison of states by percent who drank within past 6 months.
Regional brewers typically dominant the craft beer market, for example
Dogfish head (based in Delaware) is the most popular craft beer in
Delaware as well as Maryland.
Brewing & US Economy
•
•
Some analysts warn of a craft beer
bubble, due to market saturation.
Vermont, the state with the most
craft breweries per capita actually
had breweries per capita and craft
beer market share drop from 20122013.
Where the breweries are
•
•
Abita, located in Louisiana is unlikely to be affected by craft
beer market saturation due to the low number of craft
breweries throughout the south.
Neighboring Texas is the second largest state in the
country both area and population but has a relatively low
amount of craft beer breweries.
Top left: Major craft breweries.
Bottom left: Number of craft
breweries per capita.
Bottom right: Make up of craft brew
sales.
Economic Impact
•
Breweries provide many jobs and the industry typically
produces less pollution than industries employing
comparable numbers of people.
o In the US breweries account for
 2,015,120 jobs
 49,123,807,000 dollars in taxes
 A net economic impact of $246,566,242,500
Summary
•
•
Our preliminary economic analysis indicates that there is economic room
for increased production by Abita.
Our project will consist of
o modeling the existing Abita brewery
o Explore ways of re-configuring the various units of the plant and/or
finding the optimal scheduling of the batch process.
o Analysis of adding additional “unitanks” to existing process.
o Optimal design and configuration of new brewhouse with the mandate
that the additional tanks have a utilization of 90%.
References
❏ https://www.brewersassociation.org/attachments/0001/1530/Sustainability_
Energy_Manual.pdf
❏ http://iere.org/wp-content/uploads/2013/10/IERE_Beer_LCA_Final.pdf
❏ http://beervana.blogspot.com/
❏ http://www.beerinstitute.org/