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Lion Brewery (Ceylon) PLC
Chief Engineer
Asst.Manager Electrical Engineering
Asst.Manager- Mechanical Engineering
Engineering Executive
Projects Executive
Engineering Assistant -Instrumentation
Engineering Assistants
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Execution
of Operation and Maintenance of Utilities for the Production and Packaging Preventive Maintenance of Machineries Breakdown Maintenance of Machineries Calibration of Process Instrumentation Facility Management (Building & Yard Maintenance) Projects Capacity Expansion Projects Process Improvement Projects Kaizen Projects
Operation
and maintenance of waste water treatment plantLion Brewery (Ceylon) PLC
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Utility
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Power
system is consist of 3x1000 KVA Transformers and 3x1000 KVA generators CEB supply is 33KV and step downed to 400 V by transformers Generators supply power within 4s of CEB power failure CEB supply is switched on after 5 minutes when the supply is back Capacitor banks are used to improve the power factor3/18/2013 Lion Brewery (Ceylon) PLC
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CEB Supply
Generators
Re-Transferring of CEB CEB Supply in 4s Generator ON CEB power failure Waits for 5within minuits supply
Bus Busbar bar
Factory with power Factory without power
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Time
of Use Tariff Unit Price Peak Rs.13.40 Off Peak Rs.7.15 Day Rs.10.25
Duration 18.30-22.30 22.30- 05.30 05.30- 18.30
Fixed
Charge Rs.3000 KVA Charge Rs.7503/18/2013 Lion Brewery (Ceylon) PLC
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2.13% 1.80%5.20% 7.94% 8.37%
0.32%
Ref 42.26% Packaging+Logistic Air Conditioning+Office+Work Shop WWTP
10.50%
Brewing Compressed Air CO2 11.03% 10.45% water Steam Fire and storm water pumps
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Water
is the most important utility since 95 % of beer is water Water is used in three different ways for the process as, Hot Water Cold Water Ice Water Capacity
80 m3/hLion Brewery (Ceylon) PLC
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Water Intake
Cl2 and Alum mixing
Removal of Alum and particles
Sand filter
Cold Water Tank
Activated Carbon Filter
Raw water tank
Iron removal Filter
Heat Exchanger
Ice Water Tank
Hot water Tank3/18/2013 Lion Brewery (Ceylon) PLC
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Hot Water Brew House Chiller Ice Water Bottling Pasteurizer Wort Cooler Cold Water DA Plant CIP & Yeast Plant Brew house & Bottling Museum, Canteen & washroomsLion Brewery (Ceylon) PLC
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Glycol
is used for cooling purposes Ammonia is used as the refrigerant to cool Glycol in Refrigeration plant Highest Energy consumer in the plant which is 42% of the total load Latest technology is used in this plant where the plant can be operated remotely Cooling Capacity 1800 KW3/18/2013 Lion Brewery (Ceylon) PLC
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Ice
water Cooler Centrifuge D/A water cooler Bottling Beer Cooler Canning Beer Cooler Keg Beer Cooler Green beer Cooler Filtered beer Cooler FV tank BBT3/18/2013 Lion Brewery (Ceylon) PLC
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CO2 generation in brewery Fermentation of sucrose produces ethanol and CO2 as per the following reaction. C6H12O6 Every
2 C2 H5 OH + CO2 + Others
100 Kg of sucrose fermented would produce 48.4 Kg ethanol, 46.6 Kg CO2 & 5 Kg of other compounds.Lion Brewery (Ceylon) PLC
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CO2 plant description Carbon
Dioxide is recovered and purified by two CO2 recovery plants namely,Seeger Hypro
Capacities of two plantsSeeger - 200 Kg/hr flow rate
20000m3 Storage tankHypro - 300 Kg/hr flow rate
20000m3 Storage tank3/18/2013
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Filtering Pressure and push the unfilted buffer tank Pressure and Mix the Kieselguhr recovery tank Empty and push back filter buffer tank Carbonator mixing BBT Pressure and empty B.B.T tanks Pressure and push keg line Pressure and Push Bottling and canning line Bottling plant Pressure bottling filler ball Push bottling beer line3/18/2013 Lion Brewery (Ceylon) PLC
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Centrifuge Pressure PVP tank mixing line Canning
Pressure Canning ball For bubble breaker FV tanks Pressure and empty the FV tank line Keg plant
Pressure filling head Pressure filling tank3/18/2013 Lion Brewery (Ceylon) PLC
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Compressed air is used for the operation of pneumatic valves
Compressed Capacity
air is dosed to the process
28 m3/min
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Dry
Air
Compressed air is used in all pneumatic cylinders CIP Process FV tank head in out
Wort areation Wet
Air
Spent grain
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A boiler is used to generate steam for the process
Capacity With
10 T/h
the expansion another boiler will be
added to the existing system
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Cereal
Cooker Mash Tun Wort Kettle Bottling Pasteurizer Canning Pasteurizer Bottle Washer CIP Keg Plant Generate hot water3/18/2013 Lion Brewery (Ceylon) PLC
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All
waste water from process and factory is purified up to the given European environmental standards before sent to river Anaerobic and Aerobic methods are used It is the 3rd highest energy consumer in the plant There is a ongoing research to use the by product methane for electricity generation Capacity 52 m3/h3/18/2013 Lion Brewery (Ceylon) PLC
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Annual
Preventive Maintenance 1st week of
July Monthly Preventive maintenance 2nd Monday in the month In critical situations online maintenance is done
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Calibration
of pressure, temperature gauges and flow meters is mandatory requirement of ISO 22000 Calibration is done according to manufacturers standard Number of instruments in the plant are about 400
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Project Electricity Generators Main Switch Board LV Distribution Water Treatment Plant Air Compressors Refrigeration plant CO2 recovery plant FV Tanks BBT Tanks Brewing Expansion3/18/2013
Previous 2000 KVA
Upgrade to 3000 KVA New switch board with 3 feeders New cable management system 80 m3/h 28m3/min 1800 KW 500 Kg/h 21 Tanks 8 Tanks 10 Brews43
50 m3/h 23 m3/min 1200 KW 200 Kg/h 16 Tanks 6 Tanks 8 BrewsLion Brewery (Ceylon) PLC
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Installation
of UPS System Power factor improvement Energy Management System Inline alcholizer Office Upgrade Energy Saving Projects Dust Extraction System
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THANK YOU3/18/2013 Lion Brewery (Ceylon) PLC
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