Wort boiling with the JETSTAR: Technology and energy management hand in hand - GEA Brewery Systems

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Wort boiling with the JETSTAR: Technology and energy management hand in hand - GEA Brewery Systems
Wort boiling with the JETSTAR :    ™

Technology and energy management
hand in hand.

GEA Brewery Systems
Huppmann Tuchenhagen
Wort boiling with the JETSTAR: Technology and energy management hand in hand - GEA Brewery Systems
In wort boiling a comprehensive approach pays off.
                                        In order to achieve optimal results in the hot                       process 1 , the actual wort boiling 2 and the
                                      phase in the brewhouse all processes and energy                        wort treatment during cast-out 3 . Each individual
                                      management need to be considered as one entity.                        step has a decisive impact on the next one. And
                                      This is precisely what GEA Brewery Systems                             each step contributes to the overall optimisation of
                                      does. We see state-of-the-art wort boiling as an                       the process in terms of outstanding beer quality
                                      interrelated package comprised of the heating-up                       and efficient production.

                                                Vapour
                                             condenser                     Return
                                                                           energy storage

                                                             Condensate
                                            Wort kettle
                                                                                                    Whirlpool

  From wort
                            From
                            energy                             2                                                                             Wort aeration
pre-run tank                storage

                                                                                                                                                       To the
                                                                                                                       3                               fermenting
                    Wort                                                                                                                               room
                   heater                                                                                         Wort cooler
                   1                                       Wort
                                                                            Energy storage
                                                                                                          Warm water

                                                                                                                                Cold water

FACTS & FIGURES
                                      External wort pre-heating
                                      When using an energy storage system the wort is gently raised
                                      to boiling temperature via an external plate heat exchanger.
                                      Compared to heating with a conventional internal boiler, this
                                      process protects the higher-molecular foam-positive nitrogen and
                                      considerably reduces the thermal stress, which benefits the taste
                                      stability of the beers produced using this technique.

               2
Wort boiling with the JETSTAR: Technology and energy management hand in hand - GEA Brewery Systems
Technical solutions to match all requirements.
  GEA Brewery Systems offers the entire range of                     wort kettles we can offer suitable solutions that
wort boiling options to perfectly meet the widest                    represent the state of the art in technology. For
ranging requirements. We have spent decades                          any type of brewhouse and for any type of beer.
perfecting the construction of low-pressure boiling
systems. From energy storage systems to vapour
compression units and combined whirlpool/

Gentle pre-cooling, less DMS
The DMS concentration in the finished product can be significantly
reduced using wort pre-cooling during cast-out. This is achieved
using a separate small plate heat exchanger or by cooling down
a partial wort flow with the customary wort cooler. This process
does not affect the warm water balance of the brewhouse.

                                                                                                                                        FACTS & FIGURES
                                                                     Vapour condenser
                                                                     Energy recovery in the brewhouse kicks in at the point where
                                                                     most thermal energy is used in the brewery: during wort boiling.
                                                                     Apart from the start-up and shut down quantities, which are
                                                                     technically unavoidable, the vapour condenser also significantly
                                                                     reduces vapour emission.

                                                                                                                                                3
Wort boiling with the JETSTAR: Technology and energy management hand in hand - GEA Brewery Systems
Dynamic with highest flexibility.
                    GEA Brewery Systems was the first company                       flexible, and the process is controlled even more
                  to develop low-pressure boiling to maturity. And                  accurately. During wort heat-up the Subjet is
                  we also continuously enhanced this technology,                    open and the wort flows back into the wort kettle
                  which subsequently developed into the Dynamic                     below the wort surface. Without counter pressure
                  Low-Pressure Boiling (Dyn. LPB). Today we                         the circulation rate of the internal boiler increases
                  combine this process with the JETSTAR ™, a novel                  and wort homogeneity improves, which reduces
                  internal boiler system with a unique flow pattern.                thermal stress during heat-up.
                  With this innovative internal boiler we managed
                  to completely redesign the wort boiling process.
                  Due to the Subjet – an adjustable opening below
                  the wort surface – wort boiling is becoming more

                    Pressure
                     [mbar]

                                                                                                                                         Time [min]
                        Filling                   Phase 1                             Phase 2                         Pressure relief
                       Heating                                                                                            Cast-out
                                                            Pressure build-up              Pressure reduction

FACTS & FIGURES
                  Dynamising the process
                  The advantage of the Dyn. LPB is the even faster evaporation of   As pressure is reduced the boiling temperature in the vessel
                  undesirable odorous substances due to the intense intermittent    decreases accompanied by a rapid steam bubble formation
                  boiling. As soon as the predetermined pressure is reached         throughout the entire kettle. This “controlled boiling delay” results
                  a systematic pressure reduction starts under strictly defined     in a very large gas/liquid contact surface thus ensuring an optimum
                  conditions.                                                       stripping of volatile odorous substances.

       4
Wort boiling with the JETSTAR: Technology and energy management hand in hand - GEA Brewery Systems
Phase 1 – Thermal conversion                                                            Phase 2 – Evaporation
  At the beginning of the boiling process the                                             For the evaporation phase the lower Subjet
Subjet stays open. Then, a boiling phase with an                                        opening is now closed. By adjusting steam
extremely low evaporation rate follows, however,                                        pressure the evaporation rate is increased to the
offering the possibility to individually influence                                      necessary value, and the wort circulates via the
the temperature-dependent reactions, such as hop                                        two-level wort deflector. The large surface area
isomerization, protein coagulation, reduction of                                        thus created ensures an intense evaporation
undesirable odorous substances and formation                                            of undesirable odorous substances. Due to the
of important flavour components, via the time                                           extensive reduction of the DMS precursor in phase
parameter. High circulation rates at low steam                                          1 a comparably low evaporation rate is sufficient
pressure preserve the foam-positive substances in                                       to achieve the desired final content of free DMS
the wort.                                                                               and other flavour components in the cast-out
  The perfect mixing of the kettle content ensures                                      wort. This two-phase wort boiling process is not
a homogeneous wort temperature.                                                         only suitable for atmospheric kettles, but can also
                                                                                        be combined with Dynamic Low-Pressure Boiling
                                                                                        (as shown here).

                 Phase 1                                                                   Phase 2

                                                                                                                                                             FACTS & FIGURES
                                                         Conventional        JETSTAR™   Wort distribution in the kettle
                 1.0

                 0.9
                                                                                        Implementing the JETSTAR ™ results in a dramatic improvement of
                 0.8
                                                                                        the mixing process in wort kettles with internal boiler. Due to an
                 0.7                                                                    increased impulse exchange the formerly known short circuit flows
                                                                                        are almost completely eliminated, and temperature distribution
rel. DMS-P [-]

                 0.6

                 0.5                                                                    is improved. The more homogeneous temperature distribution
                 0.4                                                                    accelerates conversion processes. The chart illustrates the
                 0.3                                                                    comparison of DMS-P degradation between a conventional internal
                 0.2                                                                    boiler and a JETSTAR ™.
                 0.1

                  0
                   0   10   20   30   40     50     60      70          80   90   100   Trial conditions: constant atmospheric boiling, same brewhouse,
                                           Time [min.]                                  brew lenth, raw material composition etc.

                                                                                                                                                                     5
Wort boiling with the JETSTAR: Technology and energy management hand in hand - GEA Brewery Systems
Technically superior: the JETSTAR™.
                    GEA Brewery Systems has been relying on the         than with external boilers. During boiling, wort is
                  internal boiler for wort boiling for a long time      circulated 20–30 times per hour, which ensures
                  now. It offers marked advantages over an external     a homogeneous temperature throughout the
                  boiler. The internal boiler works on the basis of     entire wort kettle. The tube bundle is located
                  a purely physical principle: steam bubbles create     right in the middle of the medium to be heated;
                  a density difference between the wort in the          it emits heat straight into the wort and not to the
                  internal boiler and the surrounding kettle, thus      surroundings. With the JETSTAR ™, our newest
                  ensuring continuous circulation. This principle,      design of internal boilers, we achieve better
                  also known as natural circulation, operates without   homogeneity right from the start of wort heating.
                  additional circulation pump and minimizes
                  mechanical stress on the wort. With internal
                  boilers, wort circulation rates are much higher

                                                                                                               Vapour condenser

                                                                                                                                     to energy
                                                                                                                                      storage

                                                                                                                      Condensate
                                                                              Wort kettle            Wort kettle

                                                                                                                           from energy storage

                                                                                            Wort                    Wort

FACTS & FIGURES
                                                                        Pressure control during Dyn. LBP
                                                                        Depending on whether a vapour condenser is used or not, various
                                                                        methods can be employed to control the pressure. In plants without
                                                                        vapour condensation (see left) we install a bypass pressure control
                                                                        valve in the vapour pipe. When using a vapour condenser, the
                                                                        pressure is controlled via the water feed from the energy storage
                                                                        tank. The water feed is heavily throttled during the pressure build-up
                                                                        phase.

       6
Wort boiling with the JETSTAR: Technology and energy management hand in hand - GEA Brewery Systems
Efficient evaporation using the two-level
                                                    wort spreader.
                                                      The patent protected two-level wort spreader
                                                    distributes the wort over the wort surface on two
                                                    different levels. The more homogeneous flow
                              Two-level wort
                              spreader
                                                    conditions and the larger surface area ensure a
                                                    particularly efficient evaporation of undesirable
                                                    odorous substances, at the same time significantly
                                                    reducing foam formation on the wort surface.

                              Subjet orifice

                              Cone

                                     Tubular heat
                                     exchanger

                                                    Always hygienically safe
                                                    The JETSTAR ™ allows optimal cleaning. In contrast to systems
                                                    with circulation pump it enables complete drainage of water
                                                    and detergents without residues. A short intermediate cleaning
                                                    during the normal brewing process always ensures constant
                                                    boiling conditions. The short program includes pre-rinsing with
                                                    water, caustic cleaning, neutralizing and post-rinsing with water
                                                    and takes only 20 minutes. The time involved does not affect the
                                                    brew cycle time.

                                                                                                                        FACTS & FIGURES

Steam /Hot water   Condensate /Hot water

                                                                                                                                7
Wort boiling with the JETSTAR: Technology and energy management hand in hand - GEA Brewery Systems
JETSTAR :               ™

Technology and energy
management
At GEA Brewery Systems we understand state-of-the-art wort boiling as
an interrelated package comprised of the heating-up process, the actual
wort boiling and the wort treatment during cast-out. Only the holistic
approach achieves best values in terms of beer quality and in energy
efficiency. This brochure explains the individual aspects.

The JETSTAR™ development contributes considerably to efficiency
and quality improvements in wort boiling. Here we show you how we
implement the system.

                                                                                                                               JETSTAR ™.E.06.09 / © GEA Brewery Systems GmbH. / All rights reserved. Subject to modifications. Printed in Germany.

                                                                          Process Engineering
                                                                          GEA Brewery Systems GmbH
                                                                          Huppmann Tuchenhagen

                                                                          Locations:
                                                                          Heinrich-Huppmann-Str. 1, 97318 Kitzingen, Germany
                                                                          Phone +49 9321 303-0, Fax +49 9321 303-603
                                                                          Am Industriepark 2–10, 21514 Büchen, Germany
                                                                          Phone +49 4155 49-0, Fax +49 4155 49-2770
                                                                          info@gea-brewery.com, www.gea-brewery.com
Wort boiling with the JETSTAR: Technology and energy management hand in hand - GEA Brewery Systems Wort boiling with the JETSTAR: Technology and energy management hand in hand - GEA Brewery Systems
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