Accurate Flow Measurement in Steam & Specialty Gases in breweries
Measurement Challenge / Difficulty :
Steam being used in breweries had always been overlooked as a source or “ reusable ” or “ capturable ” energy . Averaging Pitot tubes typically used were not only inaccurate , but still required costly pipe runs along with very regular and expensive maintenance and replacement . In generating steam , thermal mass meters had been used but presented some of the same problems . Brewers looking to improve their efficiencies needed a new method to obtain and measure a thermal mass balance around the plant for steam generation and usage . Specialty gases such as Carbon Dioxide , Nitrogen , and Chlorine were being used in the utilities and process areas of the brewery . All of these were measured with previously mentioned flowmeter technologies , usually inadequately . The brewers needed a better flowmeter that would reduce the use of expensive purchased gases or be able to monitor use of generated steam and energy demands more accurately .
In beer production , accurate temperature control is critical to any wort boiling kettle since it is a sensitive process and one of the most energy-intensive aspects of beer production . In this case , the kettle is a large vat with tubing coiled around the exterior wall . The tubing carries a mix of steam and water to heat the wort in the kettle . Modulating the proportion of steam vs . water in the tubing enables the brewery to control the thermal transfer profile of the batch process .
The wort boiling process demands a high volume of steam in its initial phase , enough to bring the large batch up to temperature quickly but without burning the wort at points of direct heat transfer . Once the entire contents of the wort kettle reach a boil , a much lower rate of steam feed can then be used to maintain a desirable temperature for the remainder of the heating cycle .
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In beer production , accurate temperature control is critical to any wort boiling kettle since it is a sensitive process and one of the most energy-intensive aspects of beer production .
Previous Method :
Steam measurement was made with orifice plates , then averaging pitot tubes . Specialty gases were measured with thermal mass dispersion meters . All of these technologies had similar problems with pipe diameter restriction , maintenance and replacement frequency and costs , and inaccuracies of the devices . Vortex meters especially could not generate accurate readings at low flows in a condensed environment crowded with fittings and tight turns .
Solution : V-Cones were installed , reducing operating costs and virtually eliminating replacement expenses . The accuracy of the flowmeters helped the brewery to better calculate their steam / heat balance . V-Cones on specialty gas lines helped reduce usage and more accurately measure produced Carbon Dioxide , resulting in a more economical production . V-Cones measuring Chlorine gas aided in the cleansing cycles thereby reducing gas purchases . V-Cones used in Nitrogen applications measured the gas more accurately , reducing the overall use of gas . Date Installed : 1997 .
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