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 Huppmann Tuchenhagen
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
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
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
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
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
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
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
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