Brewery Process Optimization

Author

EPFL IPESE

Published

September 20, 2024

Introduction

This report presents energy integration results for a brewery process including pinch analysis, valorization of waste products, utilization of different technologies such as heat pumps and refrigerators, and optimization of the overall process to minimize cost and maximize revenues.

Problem Definition

This project will use a model named BreweryProcess.

A brewery process is composed of a high temperature section, low temperature section, cleaning in place section, biodigestion section, and it can also be equipped with a (co)electrolysis and utilities section (market, coolingtower, heatpumps, supercritical CO2 cycles and a cogeneration unit).

Brewery Process

The calculated parameters are defined as follows:

Brewery Process ET Layers

OSMOSE LAYERS breweryprocess
Layer	Display name	shortname	Unit	Color
ELEC	Electricity	elec	kW	yellow
NATGAS	Gas	ng	kW	green
BEER	Beer	beer	m3/h	white
HUSK	Husk	husk	kg/h	black
MALT	Malt	malt	kg/h	grey
SODA	Soda	soda	kg/h	black
CORN	Corn	corn	kg/h	green
WATER	Water	water	m3/h	blue
CO2	CO2	co2	kg/h	red

Brewery Process Units

The brewery process contains the following units

OSMOSE UNIT breweryprocess
unit name	type
HotPart_Batch1	Process
HotPart_Batch2	Process
HotPart_Batch3	Process
ColdPart_Batch1	Process
ColdPart_Batch2	Process
ColdPart_Batch3	Process
ColdPart_Batch4	Process
Bottle_Clean	Process
MassBrewery	Process

Hot part Batch 1

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	0	0	0	1	1

Hot part Batch 1 Streams

The heat Streams:

name	period	Tin	Tout	Hout	DT min/2	alpha
Water_MAK1	default	15.00	51.50	369.90	2	1
MAK_Heating1	default	48.00	65.00	188.60	2	1
Water_MAT2	default	15.00	54.50	823.60	2	1
MAT_Heating2	default	48.00	65.00	420.10	2	1

Hot part Batch 2

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	0	0	0	1	1

Hot part Batch 2 Streams

The heat Streams:

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
MAT_and_MAK	default	65.00	75.00	0.00	368.40	2	1
Water_Filter_and_CIP	default	15.00	80.00	0.00	1608.9	2	1
WOK_Boiling	default	78.00	105.00	0.00	1662.90	2	1
WOK_Evaporation	default	105.00	105.00	0.00	3319.80	2	1
Vapour_Cond1	default	105.00	100.00	17.2	0.00	1	1
Vapour_Cond2	default	100.00	100.00	3487.9	0.00	2	1
Vapour_Cond3	default	100.00	25.00	482.8	0.00	2	1

Hot part Batch 3

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	0	0	0	1	1

Hot part Batch 3 Streams

The heat Streams:

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
Centrifuge	default	5	80.00	0.00	857.90	2	1
Wort_Cooling	default	102.50	10.00	5434.60	0.00	2	1

Cold part Batch 1

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	0	0	0	1	1

Cold part Batch 1 Streams

The heat Streams:

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
Fermentation	default	10.00	10.00	534.80	0.00	2	1

Cold part Batch 2

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	0	0	0	1	1

Cold part Batch 2 Streams

The heat Streams:

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
Cooling	default	10.00	6.00	233.80	0.00	2	1
Maturing	default	6.00	6.00	425.50	0.00	2	1

Cold part Batch 3

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	0	0	0	1	1

Cold part Batch 3 Streams

The heat Streams:

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
Chilling	default	6.00	1.00	714.50	0.00	2	1
Chillage	default	1.00	1.00	427.70	0.00	2	1

Cold part Batch 4

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	0	0	0	1	1

Cold part Batch 4 Streams

The heat Streams:

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
Beer_preheat	default	1.00	15.00	0.00	822.05	2	1
Pasteurization	default	15.00	80.00	0.00	4854.05	2	1
ColdBath	default	70.00	5.00	4858.40	0.00	2	1

Bottle Cleaning

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	0	0	0	1	1

Cold part Bottle Cleaning

The heat Streams:

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
BathRinse	default	65.00	85.00	0.00	251.90	2	1
PreRinse	default	40.00	60.00	0.00	472.80	2	1
Soda_Bath	default	15.00	85.00	0.00	39.80	2	1
Water_Bath	default	15.00	85.00	0.00	1287.10	2	1
Vapour_Pre_rinse	default	15.00	60.00	0.00	29.30	2	1
Water_Final_rinse	default	35.00	60.00	0.00	399.34	2	1
BathRinse_Out	default	85.00	60.00	472.70	0.00	2	1
PreRinse_Out	default	40.00	20.00	713.70	0.00	2	1
CIP	default	15.00	80.00	0.00	1841.1	2	1

Visualization of Brewery Process

Furnace

Layers of the Furnace ET

OSMOSE LAYERS furnace
Layer	Display name	shortname	Unit	Color
NATGAS	Gas	ng	kW	green

Furnace unit of the Furnace ET

OSMOSE UNIT furnace
unit name	type
Furnace	Utility

Parameters of the Furnace unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	13772.807687141723	0	0	0	100

Furnace Streams

Resource Streams Defining the resource streams, in this case natural gas to the furnace

layer	direction	value
NATGAS	in	1030.9278350515465

Heat Streams

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
radiation	default	1050	1050	480.26584125000005	0	2	1
convection	default	1050	100	482.04866749999997	0	8	1
preheating	default	25	26	0	0.37098249999999994	8	1

Visualization of Furnace

Cooling tower

Cooling Tower

Layers of the Cooling Tower ET

OSMOSE LAYERS coolingtower
Layer	Display name	shortname	Unit	Color
ELEC	Electricity	elec	kW	yellow
WATER	Water	water	kg/h	blue

Cooling tower unit of the Cooling Tower ET

OSMOSE UNIT coolingtower
unit name	type
CoolTower	Utility
EnvironHot	Utility

Parameters of the Cooling Tower unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	11411.988413145207	0	0	0	100

Cooling Tower Streams

Defining the resource streams, in this case electricity to the Cooling Tower

Resource Streams

layer	direction	value
ELEC	in	21.0
WATER	in	731.751592356688

Heat Streams

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
cooltowerheat	default	15	30	0	1000	5	1

Parameters of the Environment unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	0	0	0	0	1000

Cooling Tower Streams

Defining the heat streams

Heat Streams

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
environhotstr	default	20	20	1000	0	0	1

Visualization of CoolingTower

Refrigerator

: OSMOSE ET refrigerator

Layers of the Refrigerator ET

OSMOSE LAYERS refrigerator
Layer	Display name	shortname	Unit	Color
ELEC	Electricity	elec	kW	yellow

Refrigerator unit of the Refrigerator ET

OSMOSE UNIT refrigerator
unit name	type
Refrigerator	Utility

Parameters of the Refrigerator unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	158557.32306493403	0	0	0	10

Refrigerator Streams

Resource Streams Defining the resource streams, in this case electricity to the refrigerator

layer	direction	value
ELEC	in	2674.8971193415637

Heat Streams

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
evaporation	default	-30	-30	0	5000	2	1
condensation	default	35	35	7674.897119341564	0	2	1

Visualization of Refrigerator

Market

Layers of the Market ET

OSMOSE LAYERS market
Layer	Display name	shortname	Unit	Color
NATGAS	Gas	ng	kW	green
ELEC	Electricity	elec	kW	yellow
WATER	Water	water	kg/h	blue
SALT	Salt	salt	kg/h	grey
SUGAR	Sugar	sugar	kg/h	grey
FRESHMILK	Fresh milk	f_milk	kg/h	white
THICKENER	Thickener	thick	kg/h	orange
CREAM	Cream	cream	kg/h	white
CHEESE	Cheese	cheese	kg/h	white
MESOST	Mesost	mesost	kg/h	white
CO2	CO2	co2	kg/h	red
EnvCO2Em	EnvCO2Em	envco2	kg/h	red
RIVELLA	Rivella	rivella	kg/h	white
BIOGAS	Biogas	biogas	kg/h	green
FERTZ	Fertilizer	fertlizr	kg/h	green

Units of the Market ET

OSMOSE UNIT market
unit name	type
ElecSell	Utility
ElecBuy	Utility
NatgasSell	Utility
EnvCO2tax	Utility
WaterSell	Utility
WaterBuy	Utility
FreshmilkSell	Utility
ThickenerSell	Utility
SaltSell	Utility
SugarSell	Utility
CO2Sell	Utility
CreamBuy	Utility
CheeseBuy	Utility
MesostBuy	Utility
RivellaBuy	Utility
BiogasBuy	Utility
FertilizerBuy	Utility

Electricity Selling Unit

Electricity sold by the grid to the process

Parameters of the Electricity Selling unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	250.0	0	0	0	0	0	1000

Electricity Selling Streams

Resource Streams

Electricity sold from the market to the process and the indirect CO₂ emissions from the electricity generated by the grid.

layer	direction	value
ELEC	out	1000
EnvCO2Em	out	62.63

Electricity Purchasing Unit

Electricity purchased by the grid from the process

Parameters of the Electricity Purchasing unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	-175.0	0	0	0	0	0	100

Electricity Purchasing Streams

Resource Streams

Electricity purchased by the market from the process

layer	direction	value
ELEC	in	1000

Natural Gas Selling Unit

Parameters of the Natural Gas Selling unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	119.0	0	0	0	0	0	1000

Natural Gas Selling Streams

Resource Streams

Natural gas sold from the market to the process. In addition to total CO₂ emissions (direct and indirect) from the use of natural gas

layer	direction	value
NATGAS	out	1000
EnvCO2Em	out	215.64

Environment Unit

Environmental atmosphere receiving the fossil emissions TAXED.
This unit receives the CO₂ emitted by the process via burning fuel (both direct and indirect) or using electricity (indirect). The resulting cost of this unit is then defined by the CO₂ tax using a base value of 100 €/tonne of CO₂ emitted (reference value for Europe, in Switzerland it is slightly higher at ~120- 140 €/tCO₂)

Parameters of the Environment unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	100.0	0	0	0	0	0	1000

Environment Streams

Resource Streams

Total CO₂ emitted from the process (input) and Overall CO₂ tax (output)

layer	direction	value
EnvCO2Em	in	1000

Water Selling Unit

Water from the market to the process

Parameters of the Water Selling unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	2.5	0	0	0	0	0	10000

Water Selling Streams

Resource Streams

Water sold from the market to the process

layer	direction	value
WATER	out	1000

Water Purchasing Unit

Water purchased by the market from the process (in case of biodigestion there is a large wasetwater stream that is discharged)

Parameters of the Water Purchasing unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	-1.75	0	0	0	0	0	10000

Water Purchasing Streams

Resource Streams

Water purchased by the market from the process

layer	direction	value
WATER	in	1000

Freshmilk Selling Unit

Parameters of the Freshmilk Selling unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	500.0	0	0	0	0	0	1000

Freshmilk Selling Streams

Resource Streams

Fresh milk sold from the market to the process

layer	direction	value
FRESHMILK	out	1000

Thickener Selling Unit

Parameters of the Thickener Selling unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0.87	0	0	0	0	0	1000

Thickener Selling Streams

Resource Streams

Thickener sold from the market to the process

layer	direction	value
THICKENER	out	1

Salt Selling Unit

Parameters of the Salt Selling unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0.13	0	0	0	0	0	1000

Salt Selling Streams

Resource Streams

Salt sold from the market to the process

layer	direction	value
SALT	out	1

Sugar Selling Unit

Parameters of the Sugar Selling unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	64.0	0	0	0	0	0	1000

Sugar Selling Streams

Resource Streams

Sugar sold from the market to the process

layer	direction	value
SUGAR	out	100

CO₂ Selling Unit

Parameters of the CO₂ Selling unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0.0084	0	0	0	0	0	1000

CO₂ Selling Streams

Resource Streams

CO₂ sold from the market to the process

layer	direction	value
CO2	out	1

Cream Purchasing Unit

Parameters of the Cream Purchasing unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	-221.0	0	0	0	0	0	1000

Cream Purchasing Streams

Resource Streams

Cream is a product which is purchased by the market from the process

layer	direction	value
CREAM	in	100

Cheese Purchasing Unit

Parameters of the Cheese Purchasing unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	-877.9999999999999	0	0	0	0	0	1000

Cheese Purchasing Streams

Resource Streams

Cheese purchased by the market from the process

layer	direction	value
CHEESE	in	100

Mesost Purchasing Unit

Parameters of the Mesost Purchasing unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	-2000	0	0	0	0	0	1000

Mesost Purchasing Streams

Resource Streams

Mesost purchased by the market from the process

layer	direction	value
MESOST	in	100

Rivella Purchasing Unit

Parameters of the Rivella Purchasing unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	-2500.0	0	0	0	0	0	1000

Rivella Purchasing Streams

Resource Streams

Rivella purchased by the market from the process

layer	direction	value
RIVELLA	in	1000

Biogas Purchasing Unit

Parameters of the Biogas Purchasing unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	-44.03611111111111	0	0	0	0	0	1000

Biogas Purchasing Streams

Resource Streams

Biogas purchased by the market from the process

layer	direction	value
BIOGAS	in	100

Fertilizer Purchasing Unit

Parameters of the Fertilizer Purchasing unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	-900.0	0	0	0	0	0	1000

Fertilizer Purchasing Streams

Resource Streams

Fertilizer purchased by the market from the process

layer	direction	value
FERTZ	in	1000

Visualization of Market

Heat pumps

Heat Pump

Note: Heat pumping will be profitable only if it allows to transfer heat from below to above the pinch, i.e., if it transforms excess heat from the system heat source into useful heat for the system heat sink.

Layers of the Heat Pump ET

OSMOSE LAYERS heatpump
Layer	Display name	shortname	Unit	Color
ELEC	Electricity	elec	kW	yellow

Heat Pump unit of the Heat pump ET

OSMOSE UNIT heatpump
unit name	type
HeatPump	Utility

Parameters of the Heat Pump unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	123955.26918427552	0	0	0	10

Heat pump Streams

Resource Streams Defining the resource streams, in this case electricity to the heatpump

layer	direction	value
ELEC	in	755.3648068669528

Heat Streams

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
evaporation	default	54.5	54.5	0	5244.635193133047	2	1
condensation	default	76.5	76.5	6000	0	2	1

Visualization of Heat Pump

{r child = 'model/Heatpump/Heatpump2.Rmd'} -->

Heat Pump 3

Layers of the Heat Pump 3 ET

OSMOSE LAYERS heatpump3
Layer	Display name	shortname	Unit	Color
ELEC	Electricity	elec	kW	yellow

Heat Pump 3 unit of the Heat Pump 3 ET

OSMOSE UNIT heatpump3
unit name	type
HeatPump3	Utility

Parameters of the Heat Pump 3 unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	123955.26918427552	0	0	0	10

Heat pump 3 Streams

Resource Streams Defining the resource streams, in this case electricity to the heatpump

layer	direction	value
ELEC	in	317.46031746031747

Heat Streams

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
evaporation	default	95	95	0	5682.539682539682	2	1
condensation	default	105	105	6000	0	2	1

Visualization of Heat Pump 3

Heat Pump 4

Layers of the Heat Pump 4 ET

OSMOSE LAYERS heatpump4
Layer	Display name	shortname	Unit	Color
ELEC	Electricity	elec	kW	yellow

Heat Pump 4 unit of the Heat Pump 4 ET

OSMOSE UNIT heatpump4
unit name	type
HeatPump4	Utility

Parameters of the Heat Pump 4 unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	123955.26918427552	0	0	0	10

Heat pump 4 Streams

Resource Streams Defining the resource streams, in this case electricity to the heatpump

layer	direction	value
ELEC	in	557.2755417956656

Heat Streams

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
evaporation	default	35	35	0	5442.724458204335	2	1
condensation	default	50	50	6000	0	2	1

Visualization of Heat Pump 4

Cogeneration system

Cogeneration

Layers of the Cogeneration ET

OSMOSE LAYERS cogen
Layer	Display name	shortname	Unit	Color
NATGAS	Gas	ng	kW	green
ELEC	Electricity	elec	kW	yellow

Cogeneration unit of the Cogeneration ET

OSMOSE UNIT cogen
unit name	type
cogen	Utility

Parameters of the Cogeneration unit

period	cost1	cost2	cinv1	cinv2	imp1	imp2	fmin	fmax
default	0	0	0	198328.4306948408	0	0	0	5

Cogeneration Streams

Resource Streams Defining the resource streams, in this case natural gas to, and electricity from, the cogeneration unit

layer	direction	value
ELEC	out	2400.0
NATGAS	in	6000

Heat Streams

name	period	Tin	Tout	Hin	Hout	DT min/2	alpha
fg	default	450	150	1320.0	0	2.5	1
cw	default	90	40	1500.0	0	2.5	1

Visualization of Cogeneration Unit

Heat pump superstructure

Before anything, we define the supestructure as heat pump and provide a name for the ET.

Low-grade residual heat is produced in practically any existing industrial process that converts high quality energy (e.g. fuels and electricity) into other value-added products. Exothermic reactions and dissipative devices are responsible for producing more or less amount of waste heat. Industry has traditionally regarded this thermal waste as an undesirable side-product of the main production activity and it has devised means to collect and reject the excess low-temperature heat to the environment, provided that internal heat recovery is not further applicable. Clearly, this approach entails larger process inefficiencies and worsened environmental impact. To tackle these issues, waste heat can be upgraded using a specialized equipment called heat pump, whose working principle is similar to that of a refrigeration cycle.

To this end, heat pumps also use working fluids called refrigerants that can absorb heat by evaporating in a heat exchanger at low temperature in order to supply that heat at a higher temperature (i.e. “pump heat up”). When the evaporated fluids are recompressed, the temperature significantly increases, thus facilitating the heat exchange with other process streams in a condensation heat exchanger. The capacity of these fluids to achieve lower temperatures is due to the Joule-Thomson effect, by which certain fluids exhibit a rapid cooling accompanied by partial vaporization when throttled or expanded through a valve, a capillar tube or an expander. In this regard, a typical heat pump cycle requires different components, namely an evaporator, a compressor, a condenser and an expansion device. The main electricity input is the compressor power consumption, which in turn depends on the isoentropic efficiency and other compressor design details.

Although some transcritical heat pump cycles can be implemented, the minimum evaporator Evap_Tin and maximum condenser temperatures Cond_Tin are typically limited by the freezing and critical temperatures of the fluid employed. Moreover, since for pure substances in the subcritical two-phase region, both temperature and pressure properties are not independent, the selection of the temperature also fixes the operating pressure. On the one hand, in order to avoid air leakage into the evaporator, the lowest cycle pressure is preferably set slightly above the ambient pressure. On the other hand, the maximum pressure (and temperature) is chosen to enable the heat exchange at high temperatures relevant to the process units. In practice, other structural constraints and fluid properties influence the selection of the refrigerants, as well as the operating conditions and the materials used in the heat pump components. In order to avoid a heat pump misplacement, low-grade waste heat must be only shifted from below to above the pinch: if placed below the pinch, it increases the cooling requirement, and if placed above, it behaves as a simple electricity dissipation device (i.e. no heat pumping beneficial effect).

Other financial parameters are summarized in the following chunk of code, whereas the commentaries provide further details on the meaning and relevance of each term. For each industrial application, some parameters, such as the temperature levels of the heat pump model, should clearly be adapted.

Since a heat pump is a thermal cycle, the actual coefficient of performance (COP) is limited by the theoretical Carnot COP (= T_{cond}/(T_{cond}-T_{evap})), which is only a function of the temperatures, and not of the substance. In practice, this ideal COP is virtually impossible to achieve, but it can be approached by reducing the technology inefficiencies. Commercially, the ratio between COP_{actual} and COP_{Carnot} is around 0.45-0.55, which can be used as an heuristic correction factor to estimate the actual performance. Based on the previous parameters, it is possible to calcualte the total power demand for the reference heat pumping capacity W_heatpump and the corresponding evaporation heat absorption Evap_Qmax. Finally, the annualization factor can be determined based on the assumed life time of the energy technology and the interest rate adopted to calculate the annualized investment cost.

Fluid list

Define the fluids list from which Osmose can choose the fluid during the optimization process. Use one of the following list: R141b, R123, n-Butane, IsoButane, Ammonia, R12, R134a, n-Propane, R22, R1234yf, Propylene, R115, R32, Ethane, CarbonDioxide, R13, Ethylene, Methane.

OSMOSE FLUIDS heatpump_ss
Fluid
IsoButane
Methane
Ethylene
water
Ammonia
n-Propane
R1234yf
Propylene
R32
Ethane
CarbonDioxide
R245fa
R1233zd(E)
R1234ze(Z)
R1234ze(E)
R365MFC
n-Pentane
Isopentane
n-Butane
R134a
R152a

Other fluids are being phased out due to its environmental impact, including: R141b, R123, R12, R134a, R13. (Still debbuging some problematic fluids: n-Butane, R22, R115)

Temperatures table

Define the temperature related parameters as rows.

Temperatures [C]: Evaporation and condensation temperatures in descending order, as many temperatures as desired

SuperheatDT [C]: Superheating temperature difference corresponding to the temperature level

SupercoolingDT [C]: Supercooling temperature difference corresponding to the temperature level

DT [C]: Minimum temperature difference contribution corresponding to the temperature level

OSMOSE TEMPERATURES heatpump_ss
Parameter	T1	T2	T3	T4	Unit	Comment
Temperatures	115	55	5	-8	C	Evaporation and condensation temperatures
SuperheatDT	0	0	0	0	C	Superheating temperature difference
SubcoolingDT	2	2	2	0	C	Minimum temperature difference contrib
CompressorDT	0	2	2	2	C	Superheating temperature difference
DT	2	2	2	2	C	Minimum temperature difference (dTmin/2)
MixForceUse	0	0	0	0	-	Sensible heat contained

Layer type and supercriticality

Define the layer of electricity and the possibility to have supercritical fluid states.

OSMOSE LAYER heatpump_ss
Balance_type	LayerOfElec	Supercritical
ResourceBalance	ELEC	no

Parameters of the Compressors

Define the sizing and economic parameters of the compressor (Inv2 is REQUIRED, all the other three are OPTIONAL).

Fmin: Minimum load factor [-]

Fmax: Maximum load factor [-]

Inv1: Fixed cost coefficient [Eur/y]

Inv2: Variable cost coefficient [Eur/kW/y]

OSMOSE COMPRESSORS_PARAMS1 heatpump_ss
Fmin	Fmax	Inv1	Inv2
0	100	0	0

The following parameters can be set by default or changed by experts to help convergence (OPTIONAL).

Define the quantity of compressors allowed per fluid, per model and per cluster. Define the efficiency of the compressor. Define the following bounds:

size: min and max size of compressor [kW], note the difference with the Fmin/Fmax, as this defines the bounds of compressor for design
pressure: min and max pressure levels [bar]
ratio: min and max pressure ratio [-]

OSMOSE COMPRESSORS_QUANTITY heatpump_ss
Per_fluid	Per_model	Per_cluster
4	4	4

OSMOSE COMPRESSORS_EFFICIENCY heatpump_ss
Efficiency
0.8

OSMOSE COMPRESSORS_SIZING heatpump_ss
Param	Min	Max	Unit	Comment
size	7	500	kW	Compressor size
pressure	0.5	20	bar	Range cost linear
ratio	1.2	7	-	Pressure ratio

Parameters of the Heat Exchangers

Define the sizing and economic parameters of the heat exchangers (OPTIONAL)

Fmin: Minimum load factor [-]

Fmax: Maximum load factor [-]

Inv1: Fixed cost coefficient [Eur/y]

Inv2: Variable cost coefficient [Eur/kW/y]

OSMOSE HEX_PARAMS1 heatpump_ss
Component	Fmin	Fmax	Inv1	Inv2
Evaporator	0	100	0	0
Condenser	0	100	0	70

The following parameters can be set by default or changed by experts to help convergence (OPTIONAL)

The area of the evaporator and condenser can be estimated as: cost = a * Area ^ b (used only to avoid too many small HEX units, not used in costing as Inv1 and Inv2), with area of the evaporator or condenser in [m2]

OSMOSE HEX_PARAMS2 heatpump_ss
Param	Value	Unit	Comment
U	1	W/m2K	Heat transfer coefficient
dT	10	K	Minimum temperature difference
a	500	Euro	Cost multiplication coefficient
b	0.8	-	Cost power coefficient
Min	100	kW	Minimum size of heat exchangers
Max	1000	kW	Maximum size of heat exchangers
force	0	-	Binary {0,1} to force the sizing of HEX
DSH	0.2	-	Percent use of desuperheating % of a condensation level

Parameters of the Valves

Define the bounds of the valves pressure drop, dp: differential pressure [bard] (OPTIONAL)

Min: Minimum absolute pressure drop (different from Fmin concept) [bard]

Max: Maximum absolute pressure drop (different from Fmax concept) [bard]

OSMOSE VALVES_PARAMS heatpump_ss
Min	Max	Unit	Comment
0.5	20	bard	differential pressure

Parameters of the Vessels

Define the maximum and maximum multiplication factors of vessel units (OPTIONAL).

Fmin [-]: Minimum load factor

Fmax [-]: Maximum load factor

OSMOSE VESSELS_PARAMS heatpump_ss
Vessel	Fmax	Comment
FlaD	100	Flash Drum
MixS	100	Mix separator
DSHQ	100	Desuperheater

References

[1] Arpagaus, C., Bless, F., Uhlmann, M., Schiffmann, J., Bertsch, S. (2018). “High temperature heat pumps: Market overview, state of the art, research status, refrigerants, and application potentials.” Energy 152: 985-1010.

[2] Florez-orrego et al, 2023, Techno-economic and environmental analysis of high temperature heat pumps integration into industrial processes: the ammonia plant and pulp mill cases, Sustainable Energy Technologies and Assessments Volume 60, December 2023, 103560

name	value	unit	description
beer_massflow_ref	19.0793	kg/s	Nominal capacity for sizing multiplier definition
beer_massflow_act	30	kg/s	Actual capacity for sizing multiplier definition https://www.the-top-twenty.com/the-top-20-biggest-brewery-companies-in-the-world/
maltflow_ref	2.5969	kg/s	Malt https://www.mdpi.com/2071-1050/10/11/4191
cornflow_ref	0.2197	kg/s	Corn
waterflow_ref	19.6276	kg/s	Water
sodaflow_ref	0.3816	kg/s	Soda
huskflow_ref	0.7583	kg/s	Almost dry spent grain to the biodigestion process
CO2_from_ferm	0.0373	kg_CO2ferm/kg_beer	0.0185 kg/0.5 L = 0.0373 kg/L = 30 kg/m3
CO2_excess_factor	0.667	kg_CO2_excess/kg_CO2ferm	Fermentation yields 3x CO2 than actually needed (including brewing, canning, and bottling)
beer_density	1060	kg/m3	Beer density http://brewwiki.com/index.php/Specific_gravity
water_density	1000	kg/m3
CO2_density	0.0019	kg/m3
ethanol_density	790	kg/m3
dt_min	2	K
n	40.0	yr	lifetime
i	0.06	-	interest rate
CEPCI_2020	596.2	-	actual CEPCI
mult_brew	1.5723847310960046	-	Sizing multiplier
beer_volflow	64.79762264150943	m3/h	referece beer volumetric flow
maltflow	9348.84	kg/h	Malt
cornflow	790.9200000000001	kg/h	Corn
water_volflow	70.65936	m3/h	Water
sodaflow	1373.76	kg/h	Soda
husk_waste	2729.88	kg/h	Husk spent grain to the biodigestion process
CO2_excess	1708.832925468	kg/h
Tad	2025	C	Adiabatic flame temperature of the fuel
dtmin_radiation	2	C	radiation delta t mininum
dtmin_convection	8	C	convection delta t mininum
To	25	C	Tamb = To = Tchemicalreference
Trad	1050	C	Radiation temperature threshold, actual temperature is 1050°C but 400 can be used for plot visualization
Tstack	100	C	Stack temperature threshold for no dew point
MWair	29	kg/kmol	Molecular weight of dry air = 79% N2 + 21% O2
MWfuel	16	kg/kmol	Molecular weight of methane
losses	0.03	-	3% Furnace losses
LHV	50000	kJ/kg	Lower heating value of methane
molratst	9.52	kmol/kmol	Stoich molar air to fuel ratio
a	1.02	-	excess air as in: CH4 + a2(O2+3.76N2) –> CO2 + 2H2O + 23.76N2 + 2(a-1)(O2 + 3.76N2)
cpair	1.075	kJ/kg/K	Air heat capacity @427°C, 1bar (Engineering toolbox)
Tprin	26	C	Preheating temperature
Furnace_natGas_LOAD	1000	kW	Reference furnace load
Spec_heaterCost	200	Euro/kW
CEPCI_2008	575.4	-	CEPCI 2008
v	17.255	kg/kg	stoich air to fuel mass ratio
cpg	0.5	kW/K	Flue gases heat capacity @1bar
Tad_corr	1995.7553698403285	C	Corrected adiabatic flame temperature
cpg_corr	0.50741965	kW/K	Corrected flue gases heat capacity @1bar
Q_rad_gross	479.89485875	kW	Heat flow rate at the radiation threshold temperature
Q_conv_gross	482.04866749999997	kW	Heat flow rate at the convection threshold temperature
Q_preh	0.37098249999999994	kW	Air preheating load
Q_stack	38.05647375	kW	Stack losses
Q_radpreh	480.26584125000005	kW	Preheating load added to the highest temperature
Q_demand	1030.9278350515465	kW	Total energy consumption by the furnace
Annuity	0.0664615359206755	-	annualization factor
Cinv2_NGFur	13772.807687141723	Euro/y
Cool_Tin	15	C	Cooling tower inlet temperature
Cool_Tout	30	C	Cooling tower outlet temperature
Cool_Qmax	1000	kW	Cooling tower reference heat load
Cool_Elec	0.021	kW/kW	Cooling Tower electricity input kWel/kWth
dtmin_liq	5	C	delta Tmin of the cooling water (w/ liquid streams)
deltaH	62.8	kJ/kg	Enthalpy change for cooling water @1 bar between 15 to 30°C
Twetbulb	12.17	C
E_ref_CT	21.0	kW	Electricity consumption
deltaT_CT	15	C
approach	2.83	C
water_flow	57324.84076433122	kg/h	water flow rate
watermu_CT	731.751592356688	kg/h	makeup water in the CT system
CTCost	165717.67605234808	Euro
Cinv2_CT	11411.988413145207	Euro/y
Evap_Tin	35	C	Evaporator temperature inlet
Evap_Tout	35	C	Evaporator temperature outlet
Cond_Tin	50	C	Condenser temperature inlet
Cond_Tout	50	C	Condenser temperature outlet
Evap_Qmax	5442.724458204335	kW	Evaporator heat flow rate
exeff	0.5	-	Second law efficiency
dtmin_2ph	2	C	phase-change delta t minimum
COPcarnot	21.533333333333335	-	Carnot COP
COP	10.766666666666667	-	Actual COP
W_refrig	2674.8971193415637	kW	Heat pump power consumption
Cond_Qmax	6000	kW	Condenser reference heat flow rate
Cinv2_RF	158557.32306493403	Euro/y	300 Euro/kWth at the condenser
water_cost	0.0025	Euro/kg	Water price in Switzerland is 2-2.5 CHF/m3 (wfw.ch and Swiss gas and water industry association)
CW_ref_LOAD	1000	kg/h	Reference capacity of water supply
elec_cost	0.25	Euro/kWh	price of electricity for businesses in Switzerland 2023 (Oiken)
ELEC_ref_POWER	1000	kW	Reference capacity of electricity supply
natgas_cost	0.119	Euro/kWh	price of natural gas for businesses in Switzerland (globalpetrolprices.com)
NATGAS_ref_LOAD	1000	kW	Reference capacity of natural gas supply
CO2_cost	0.0084	Euro/kg	price of CO2 sold by the market to the process (highly volatile prices due to energy crisis)
CO2_ref_LOAD	1	kg/h	Reference load of CO2 needed by the process
dioxidetax_cost	100	Euro/t	Tax of CO2 emitted to the market (range 100 - 120 €/tonne in Europe)
CO2taxed_ref_LOAD	1000	kg/h	Reference capacity of CO2 emitted
fmilk_price	0.5	Euro/kg	Average price of milk paid to farmers between 500-650 euro/m3
FRESHMILK_ref_LOAD	1000	kg/h	Reference capacity of fresh milk feed
thick_price	0.87	Euro/kg	corn starch price in Switzerland
THICK_ref_LOAD	1	kg/h	Reference capacity of thickener requirement
salt_price	0.13	Euro/kg	salt price in Switzerland
SALT_ref_LOAD	1	kg/h	Reference capacity of salt requirement
sugar_price	0.64	Euro/kg	sugar price in Switzerland
SUGAR_ref_LOAD	100	kg/h	Reference capacity of sugar requirement
cream_price	2.21	Euro/kg	Average price of cream in Switzerland
CREAM_ref_LOAD	100	kg/h	Reference capacity of cream product
cheese_price	8.78	Euro/kg	Average price of cheese in Switzerland
CHEESE_ref_LOAD	100	kg/h	Reference capacity of cheese product
mesost_price	20	Euro/kg	Average price of mesost (brown cheese) in Switzerland (Migros 15-25 CHF/kg)
MESOST_ref_LOAD	100	kg/h	Reference capacity of cheese product
rivella_price	2.5	Euro/kg	Average price of rivella in Switzerland (Migros 2.8 CHF/L)
RIVELLA_ref_LOAD	1000	kg/h	Reference capacity of rivella product
biogas_price	0.083	Euro/kWh	biogas is 30% cheaper than natural gas (assuming it is 50% CH4 and 50% CO2)
BIOGAS_ref_LOAD	100	kg/h	Reference capacity of biogas product
fertilizer_price	0.9	Euro/kg	Average price of urea based fertilizer in Europe
FERTZ_ref_LOAD	1000	kg/h	Reference capacity of fertilizer product
I_CO2fuel	2.75	kg/kg	Methane direct CO2 emissions factor kgCO2/kg/CH4 (Florez-Orrego 2015)
r_CO2fuel	0.0049	g/kJ	Methane indirect CO2 emission factor in gCO2/kJCH4 (Florez-Orrego 2015)
r_CO2ee	62.63	g/kWh	Electricity indirect CO2 emission factor in gCO2/kWh (Florez-Orrego 2015)
LHV_biogas	19100	kJ/kg	Lower heating value of biogas
CW_COST	2.5	Euro/h	Reference cost of water supply
CW_COST_BUY	-1.75	Euro/h	Assume a factor of 30% for the waste water treatment costs. It can be computed as well assuming the operating costs of a WWT plant
ELEC_SELL_COST	250.0	Euro/h	Reference cost of electricity supply
NATGAS_COST	119.0	Euro/h	Reference cost of natural gas supply
ELEC_BUY_COST	-175.0	Euro/h	Reference cost of electricity purchased by the market from the process, although less attractive to avoid the engine over sizing
CO2_SELL_COST	0.0084	Euro/h	Reference cost of CO2 sold from the market to the process
CO2_TAX_COST	100.0	Euro/h	Reference tax of CO2 due to emissions to atmosphere
FRESHMILK_SELL_COST	500.0	Euro/h	Reference price of fresh milk sold from the market to the process
THICKENER_SELL_COST	0.87	Euro/h	Reference price of thickener sold from the market to the process
SALT_SELL_COST	0.13	Euro/h	Reference price of salt sold from the market to the process
SUGAR_SELL_COST	64.0	Euro/h	Reference price of sugar sold from the market to the process
CREAM_BUY_COST	-221.0	Euro/h	Reference price of cream purchased by the market from the process
CHEESE_BUY_COST	-877.9999999999999	Euro/h	Reference price of cheese purchased by the market from the process
MESOST_BUY_COST	-2000	Euro/h	Reference price of mesost purchased by the market from the process
RIVELLA_BUY_COST	-2500.0	Euro/h	Reference price of rivella purchased by the market from the process
BIOGAS_BUY_COST	-44.03611111111111	Euro/h	Reference price of biogas purchased by the market from the process
FERTZ_BUY_COST	-900.0	Euro/h	Reference price of fertilizer purchased by the market from the process
TotalEmittedNG	215.64	kg/h	Total flow rate of CO2 emissions from natural gas as fuel
DirectEmNG	198.0		Direct flowrate of CO2 emissions from natural gas
IndEmittedNG	17.639999999999997	kg/h	Indirect flow rate of CO2 emissions from natural gas
IndEmittedEE	62.63	kg/h	Indirect flow rate of CO2 emissions from electricity
W_heatpump	557.2755417956656	kW	Heat pump power consumption
Cinv2_HP	123955.26918427552	Euro/y	300 Euro/kWth at the condenser
eta_el	0.4		electrical efficiency
eta_th_fg	0.22		thermal efficiency - high grade heat if form of flue gases (typically available @ 450 can be cooled down to 150°C)
eta_th_cw	0.25		thermal efficiency - low grade waste heat in form of cooling water (@ 90 - 50°C)
Cogen_natGas_LOAD	6000	kW	Reference cogeneration unit load
fg_Tin	450	C	high-grade waste heat (Flue_gas) available temperature
fg_Tout	150	C	high-grade waste heat (Flue_gas) exit temperature
cw_Tin	90	C	low-grade waste heat (cooling_water) available temperature
cw_Tout	40	C	low-grade waste heat (cooling_water) exit temperature
Cogen_elec	2400.0		Power generation assuming ~40% efficiency
Q_cogen_fg	1320.0		high grade heat generated from flue gases assuming 22%
Q_cogen_cw	1500.0		high grade heat generated from flue gases assuming 25%
Cinv2_cogen	198328.4306948408	Euro/y	1200 Euro/kW natural gas load of the cogeneration unit

OSMOSE OPTIONS mathProg
Property	Value	Comments
language	ampl
solver	gurobi

The result of solve is available in the R variable osmose_result (see Plots section for usage).

Serialization

The following code is about reporting the optimization results and plotting the pertinent plots for the corresponding optimization scenarios

Optimization Results

Capital and Operational Expenditures

CAPEX: 337358

OPEX: 5762962

Plots

Hot and cold Composite curves

Grand Composite Curve

Integrated Composite Curve

Thermal Exergy of Integrated Utilities

Heat Exchanger Network

The heat exchanger network area required to attain the minimum energy requirement is extracted from OSMOSE optimization results. The minimum number of heat exchangers for the network and average area per heat exchanger can also be calculated from the simulation outputs. Next the cost of this heat exchanger network can be computed based on the equations published in Turton 1998 and corrected by the chemical engineering plant cost index (CEPCI) for 2023.

Heat exchanger network area: 4184.3303 m².

Minimum number of heat exchangers: 60.

Average area per heat exchanger: 69.7388 m².

Annualized cost of heat exchanger network: 389588.6773 $/y.

Annualization factor: 0.0963.

Introduction

Problem Definition

Brewery Process

Brewery Process Units

Hot part Batch 1

Hot part Batch 2

Hot part Batch 3

Cold part Batch 1

Cold part Batch 2

Cold part Batch 3

Cold part Batch 4

Bottle Cleaning

Visualization of Brewery Process

Furnace

Visualization of Furnace

Cooling Tower

Visualization of CoolingTower

Refrigerator

Visualization of Refrigerator

Market

Electricity Selling Unit

Electricity Purchasing Unit

Natural Gas Selling Unit

Environment Unit

Water Selling Unit

Water Purchasing Unit

Freshmilk Selling Unit

Thickener Selling Unit

Salt Selling Unit

Sugar Selling Unit

CO2 Selling Unit

Cream Purchasing Unit

Cheese Purchasing Unit

Mesost Purchasing Unit

Rivella Purchasing Unit

Biogas Purchasing Unit

Fertilizer Purchasing Unit

Visualization of Market

Heat Pump

Visualization of Heat Pump

Heat Pump 3

Visualization of Heat Pump 3

Heat Pump 4

Visualization of Heat Pump 4

Cogeneration

Visualization of Cogeneration Unit

Heat pump superstructure

Optimization Results

Capital and Operational Expenditures

Plots

Heat Exchanger Network

CO₂ Selling Unit