Development of beer filtration process control system

Contents

Introduction

Chapter 1 Analysis of the principle of beer filtration

1.1 Preparation of beer wort

1.2 Brew wort fermentation and beer packing

1.3 Determination of input and output parameters at

beer filtration

1.4 Filter filtration and washing process

1.5 Technical Problems with Filtration

1.6 Problems with application of preliminary layers

1.7 Problems with current dosing

Chapter 2 Development of mathematical model of beer filtration

Chapter 3 Development of the control algorithm

3.1 Description of control diagram

3.2 Description of the control algorithm

3.3 Implementation of the control algorithm

Chapter 4 Control Algorithm Efficiency Study

Conclusion

List of literature

Appendix A Economic justification of technical

thesis solutions

Appendix B Environmental and Safety

Appendix B Sketched Design

INTRODUCTION

One of the many production processes in the world is the process: filtration. For most industries, filtration is an auxiliary or preparatory step, but there are also those where it is one of the main technological processes. One such production is oil and gas production, as well as the production of soft drinks, including beer.

There are many filtering and filtering definitions. The most common of them is the following: Filtration is the movement of a liquid or gas through a porous medium. In industry, filtration is called filtration, meaning the separation of suspensions or aerosols using filters - porous partitions that pass liquid or gas, but retain solid particles.

For brewing, the definition will be as follows. Filtration is a separation process in which still remaining yeast cells and other suspended muti particles are removed from beer. Filtration also separates substances that can be released in beer in the coming weeks or months with the appearance of turbidity. The purpose of filtration is to make beer so stable that for a long time no visible changes would occur in it and the beer would retain its appearance. The main task at present is to increase the volume of filtered beer during the time between washes.

The purpose of this work is to develop a beer filtration process control system.

To achieve this goal, the following objectives must be achieved:

1. Analyze the principle of beer filtration.

2. Develop a mathematical model of the filtration process.

3. Develop a filtering process control algorithm.

4. Implement control algorithm in ADEM 9000 controller

1 analysis of the principle of beer filtration

The technological process of beer production consists of the following main operations: reception, storage, purification and crushing of malt, preparation of beer wort, preparation of pure yeast culture, fermentation of beer wort, clarification and bottling.

1.1 Preparation of beer wort

Freshly prepared dry malt cleaned from sprouts is fed into receiving hopper 1, from where norium 2 is lifted to scales 4, weighed and distributed by screw 5 over silos 6, where it is kept for 4 to 5 weeks. At the same time, the humidity of malt from 3%, 4% increases to 5%, 6%. Deposited malt from silos is sent by pneumatic conveyor for further processing. Under the action of a vacuum pump, a vacuum is created in the unloader and pipelines. Atmospheric air is sucked through the funnels, taking the malt with it, and raises it to the unloader. From the unloader through the lock gate, malt enters the polishing machine, where it is cleaned from dust, other impurities and norium is supplied through a magnetic separator to automatic scales. To accelerate extraction of grain components, malt after weighing is ground in roller crusher and accumulated in hopper. The crushed malt is mixed with hot water of about 54 ° C in a jammer. After thorough mixing (mashing), part of the jam (mixture of malt and water) is pumped to another jam, where it is heated to a temperature of 68 to 70 ° C. Under this regime, saccharification occurs - enzymatic hydrolysis of starch to form soluble, iodine-free sugars and dextrins. Most insoluble substances become soluble under the action of enzymes. Then the mash is brought to a boil and after a short boil (to boil large particles of malt - grits), the mash (first boil) is returned to the apparatus by the pump. When mixing the boiled part of the jam with the jam remaining in the apparatus, the temperature of the entire mass is set to about 70 ° C, which is necessary for its saccharification.

At the end of the saccharification, part of the jam is again pumped to the boiler (second boil) for heating to boil and boil. The second boil is returned to the apparatus, where after mixing both parts of the jam, the temperature rises to 75 ° C, 78 ° C. After that, the whole mass from the apparatus is pumped to one of the filtration apparatuses, where wort is separated from the crush. Wort-water solution of extractive substances obtained by malt mashing. The turbid wort produced at the beginning of the filtration cycle is returned by the pump back to the filtration apparatus. The transparent wort (first wort), passing through the filtration battery or through the pressure regulator, flows into one of the wort digesters. Washed malt crusher (thick remaining after filtering the mash and washing it with hot water) from the filtration apparatus is pumped to a hopper for sale to cattle feed. The washing water containing a small amount of extractive substances flows into the collector, from where it is pumped to the apparatus for preparing the next jam. In a wort apparatus, wort is boiled with hops. When boiling, bitter and aromatic substances of hops pass into wort, some water is evaporated, proteins are partially denatured and wort is sterilized. Hot wort is lowered into hop separator, where boiled hop petals are retained, and wort is pumped by pump 15 to hot wort collector. This method of preparing hot wort is not the only one, but it has become most common. From the collector, the hot wort flows into a centrifugal separator, in which it is purified from suspended protein particles. After the separator, the wort is passed through a plate heat exchanger (where it is cooled to 6 ° C) to the collector, from where it is pumped to fermentation machines. A clarified and cooled wort with a standard concentration of extractive substances is called an "initial wort."

1.2 Brew wort fermentation and beer packing

To ensure the purity of fermentation, seed yeast is periodically replaced by pure culture yeast obtained from one cell under sterile conditions. For propagation of pure culture yeast, crested wort is sterilised in the apparatus after clarification in the separator and pumped to fermentation apparatus, into which pure yeast culture is introduced (from laboratory). Further reproduction of yeast takes place in the apparatus. Cooled (initial) wort is poured into closed fermentation machines, yeast is added here for disintegration. At the end of the main fermentation, which takes place for 6 to 8 days, the young beer is pumped to the extra-fermentation apparatus. The yeast remaining at the bottom of the fermentation machines, by means of vacuum generated by the vacuum pump, is sent to the receptacle for reuse or to the receptacle for sale. Yeast is transferred from collector under pressure of compressed carbon dioxide to filter-press. The beer filtered in the filter press is drained into a processing tank. Yeast is washed from beer residues and cooled with water cooled in tank.

The addition of young beer takes place in devices for addition for 15 to 90 days, depending on the type of beer prepared and the technology adopted. Upon completion of the addition, the beer under the pressure of carbon dioxide drains into the mixer, then is pumped into the separators.

In the separator, beer is released from the yeast suspended therein, other microorganisms and fine particles. To give the finished drink full transparency and gloss, it is filtered in a special kieselgur filter after separation. The clarified beer is cooled with propylene glycol in a plate heat exchanger, saturated with carbon dioxide in a carbonizer and drained into farfs.

Filtered beer from the porcelain is fed under the pressure of CO2 to the bottling compartment. Boxes of dirty bottles come from the warehouse to the machine, which removes bottles from the boxes. By means of a plate conveyor, the bottles are sent to a bottle washing machine with alkaline solution coming from the tank. Empty boxes after cleaning from garbage in the machine are fed by a belt conveyor to the machine for placing bottles of products in them. Washed bottles from the washing machine are conveyed by a plate conveyor to the light screen for rejection, and then to the machine machine line: casting, closure, marriage semi-automatic, labeling and packaging in a thermoplastic film. Finished products are transferred by transporters to the expedition.

1.4 Technical problems in filtering

Filtering often presents problems, and a small error can have major consequences. The main sources of filtration problems may be;

- gas release; this means the appearance of air cushions in the filter or lamps;

- flow rate is too low or too high;

- uneven application of preliminary layers;

- defects in shaft compaction, or loosely installed plugs;

- the use of inappropriate filter aids;

- microbiological causes;

- hard-to-filter beer;

- process errors (e.g. O2 hit).

1.5 Problems with application of preliminary layers.

The task of applying the preliminary layers is to form a pressure-resistant primary layer, which is possible with a properly selected ratio of coarse and thin kieselgur. The first layer should be spent about 70% of the total amount of coarse kieselgur. The second layer is applied in the form of a fine kieselgur - approximately the same through which filtration will take place in the future.

In some cases, however, they refuse - and this cannot be called a violation - from two separate preliminary layers, and a layer consisting of a mixture of coarse and thin kieselgur is applied in one take. The consumption of kieselguhr in this case is from 800 to 1200 g/m2 (layer thickness from 1.5mm to 3 mm).

The volume flow rate of the liquid when applying the layers should be at a pressure of 2 bar from 1.5 to 2 times higher than the volume flow rate of the liquid during filtration.

Application of preliminary layers lasts about 10 minutes. With too fast filling and emptying, cracks and swirls occur, which demolish the layer to the side, and thereby impair the operation of the filter

1.6 Problems with current dosing

During filtration, the pressure difference between the inlet and the outlet of the filter constantly increases, as the filter layer becomes thicker and more resistant.

At the current dosage it is necessary to maintain the pressure difference growth at a constant level from 0.1 to 0.2 bar/h. If you work with a mixture of kieselgurs, you can change the ratio of kieselgurs in the mixture. If one class of kieselguhr is used, then the desired pressure increase can be achieved only by changing the dosing rate.

Normal consumption of kieselguhr is 80 to 120 g/hl during the entire filtration.

With proper dosing, the pressure difference increases linearly at a rate of 0.2 bar/h. When the dosage is too low, the pressure does not increase linearly, and the yeast gradually plugs the kieselgur layer. This leads to an irreversible loss of the porosity of the filter bed and eventually to a rapid increase in pressure (blocking). The breakthrough of yeast, that is, the so-called "yeast strike," also results in more or less severe blocking, as does the insufficient current dosing. High dosing of ingot results in slow increase of pressure difference and premature filling of filter working volume with kieselgur.