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Guide to Energy Efficiency Opportunities in the Canadian Brewing Industry

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Guide to Energy Efficiency Opportunities in the Canadian Brewing Industry GUIDE TO ENERGY EFFICIENCY OPPORTUNITIES IN THE CANADIAN BREWING INDUSTRY SECOND EDITION, 2011 IN COLLABORATION WITH THE BREWERS ASSOCIATION OF CANADA Disclaimer Every effort was made to accurately present the information contained in the Guide. The use of corporate or trade names does not imply any endorsement or promotion of a company, commercial product, system or person. Opportunities presented in this Guide for implementation at individual brewery sites do not represent specific recommendations by the Brewers Association of Canada, Natural Resources Canada or the authors. The aforementioned parties do not accept any responsibility whatsoever for the implementation of such opportunities in breweries or elsewhere. For more information or to receive additional copies of this publication, contact: Canadian Industry Program for Energy Conservation Natural Resources Canada 580 Booth Street, 12th floor Ottawa ON K1A 0E4 Tel.: 613-995-6839 Fax: 613-992-3161 E-mail: [email protected] Web site: cipec.gc.ca or Brewers Association of Canada 100 Queen Street, Suite 650 Ottawa ON K1P 1J9 Tel.: 613-232-9601 Fax: 613-232-2283 E-mail: [email protected] Web site: www.brewers.ca Library and Archives Canada Cataloguing in Publication Energy Efficiency Opportunities in the Canadian Brewing Industry Also available in French under the title: Les possibilités d’amélioration du rendement énergétique dans l’industrie brassicole canadienne Issued by the Canadian Industry Program for Energy Conservation. Cat. No. (online) M144-238/2012E-PDF ISBN 978-1-100-20439-0 Photos courtesy of the Brewers Association of Canada. © Her Majesty the Queen in Right of Canada, Second Edition, 2012, supplanting the 1998 original version and the reprint of 2003 GUIDE TO ENERGY EFFICIENCY OPPORTUNITIES IN THE CANADIAN BREWING INDUSTRY ACKNOWLEDGEMENTS The Brewers Association of Canada gratefully acknowledges the financial support and guidance from Natural Resources Canada (Canadian Industry Program for Energy Conservation (CIPEC)). The study could not have been realized without the technical assistance of Lom & Associates Inc., which is active in the fields of energy consulting and training, and has specialized practical knowledge of the Canadian and international brewing industry spanning 33 years. Sincere appreciation is also extended to the Brewers Association of Canada (BAC) for providing project leadership and organizational support, and to the Brewing Industry Sector’s Task Force for its supervision of the document. The Energy Guide Working Group, created by the BAC in 2009, provided important advice on the Guide, and its relevance and usefulness to brewers across a range of production sizes. Last but not least, appreciation is extended to the many brewers whose enthusiastic participation, tips and ideas were most helpful. Participating Brewers *Labatt Breweries of Canada *Yukon Brewing Company *Sleeman Breweries Ltd. Tree Brewing / Fireweed Brewing Corporation Sierra Nevada Brewing Co. Wellington County Brewery Inc. Great Western Brewing Company *Molson Coors Canada *Moosehead Breweries Limited Central City Brewing Co. *Storm Brewing in Newfoundland Ltd. Vancouver Island Brewery Heritage and Scotch Irish Brewing Wellington County Brewery Inc. Drummond Brewing Company Ltd. *BAC Energy Guide Working Group Note: The authors acknowledge the many sources of information, listed in the Bibliography in the Appendix 10.1, from which they liberally drew in revising and updating the Guide. GUIDE TO ENERGY EFFICIENCY OPPORTUNITIES IN THE CANADIAN BREWING INDUSTRY Natural Resources Canada’s Office of Energy Efficiency Leading Canadians to Energy Efficiency at Home, at Work and on the Road TABLE OF CONTENTS FOREWORD 1. INTRODUCTION ............................................................. 2 1.1 Profile of brewing in Canada .................................................... 4 1.2 Brewery processes ............................................................. 7 2.0 APPROACHING ENERGY MANAGEMENT ......................................10 2.1 Strategic considerations ....................................................... 10 2.2 Useful synergies – systems integration ........................................... 11 2.3 Defining the program ........................................................ 15 2.4 Resources and support – Accessing help ......................................... 21 2.4.1 Financial assistance, training and tools .................................... 21 2.4.2 Other resources ........................................................ 22 2.4.3 Tools for self-assessment ................................................ 22 3.0 ENERGY AUDITING .......................................................26 3.1 Energy audit purpose ..........................................................26 3.2 Energy audit stages ............................................................26 3.2.1 Initiation and preparation ................................................26 3.2.2 Execution ..............................................................30 3.2.3 Report .................................................................31 3.3 Post-audit activities ............................................................31 4.0 IDENTIFYING AND PRIORITIZING ENERGY MANAGEMENT OPPORTUNITIES (EMOs) ....34 4.1 Identifying energy management opportunities (EMOs) .............................34 4.2 Evaluating and calculating energy savings and other impacts of EMOs ................35 4.3 Selecting and prioritizing EMO projects ..........................................36 4.3.1 Initial scrutiny ..........................................................36 4.3.2 Risk assessment .........................................................38 4.3.3 Project costing ..........................................................38 4.3.4 Economic model for trade-offs ............................................39 4.4 Developing energy management programs .......................................43 GUIDE TO ENERGY EFFICIENCY OPPORTUNITIES IN THE CANADIAN BREWING INDUSTRY 5.0 IMPLEMENTING ENERGY EFFICIENCY OPPORTUNITIES ..........................46 5.1 Employee involvement .........................................................46 5.2 Effective communication .......................................................47 6.0 MANAGING ENERGY RESOURCES AND COSTS .................................50 6.1 Energy and utilities costs and management. .50 6.2 Monitoring, measuring consumption and setting targets ............................51 6.3 Action plans – Development, implementation and monitoring .......................53 6.4 Monitoring and Targeting (M&T) ...............................................55 7.0 TECHNICAL AND PROCESS CONSIDERATIONS .................................60 7.1 Fuels .........................................................................60 7.2 Electricity ....................................................................64 7.2.1 Alternate sources of electrical energy .......................................71 7.3 Boiler plant systems ............................................................72 7.3.1 Boiler efficiency .........................................................73 7.3.2 Environmental impacts of boiler combustion ................................75 7.4 Steam and condensate systems ..................................................81 7.5 Insulation ....................................................................84 7.6 Refrigeration, cooling systems and heat pumps ....................................86 7.6.1 Refrigeration and cooling systems .........................................86 7.6.2 Industrial heat pumps ....................................................90 7.7 Compressed air ...............................................................93 7.8 Process gases ................................................................102 7.9 Utility and process water ......................................................104 7.10 Shrinkage and product waste ...................................................110 7.11 Brewery by-products ..........................................................112 7.12 Wastewater ..................................................................113 7.13 Building envelope ............................................................116 7.14 Heating, ventilating and air conditioning (HVAC) ................................119 7.15 Lighting .....................................................................123 7.16 Electric motors and pumps ....................................................126 7.17 Maintenance .................................................................131 7.18 Brewery process-specific energy efficiency opportunities ...........................132 GUIDE TO ENERGY EFFICIENCY OPPORTUNITIES IN THE CANADIAN BREWING INDUSTRY 8.0 BREWERY EMISSIONS AND CLIMATE CHANGE ............................... 136 8.1 Calculating one’s carbon footprint ..............................................138 8.2 International carbon footprint calculations ......................................140 9.0 APPENDICES .......................................................... 142 9.1 Glossary of terms and acronyms ................................................142 9.2 Energy units and conversion factors .............................................146 9.3 Calculating reductions in greenhouse gas (GHG) emissions in breweries .............148 9.4 Energy efficiency opportunities self-assessment checklist ...........................150 9.5 “Best practices” in
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