Patent Application
20120240522
The invention relates to a system as well as a method for the production, filling, packaging and/or transport of beverages.
Economic units, manufacturing systems and all types of handling facilities or handling systems etc. require different types of energy. Foremost mechanical drive energy is required, which can be provided in the form of hydraulic and/or pneumatic pressure, thermal energy and electrical energy. The electrical energy is usually provided through an energy supply company and delivered over a public line network. For the supply with thermal energy different ways of delivery, production and/or use are possible. Mechanical energy as well as the energy source used for pneumatic and/or hydraulic drives and pressure supplies are usually obtained by conversion of electrical energy, typically by means of electric motors.
Until now the machinery used in beverage production is usually provided with energy and other media by completely independent energy supply routes and media supply routes. The required thermal energy is provided by a heat generating unit or generated in the machinery itself. Compressed air is provided through an air generator or a compressor. The electric current is supplied through a power distribution system. For the energy and media supply it is conventionally assumed, that the different types of energy and media are essentially available and can be obtained from outside. Some kind of connection between energy generating processes and energy consumption units is either only rudimentary available or nonexistent.
Combined heating and power stations are increasingly used for the supply with thermal energy. They are especially used in other areas, for example in private homes or in business units with distinct thermal energy needs. These combined heating and power stations provide thermal energy and additionally electrical energy. This electrical energy can be either used up or fed into a public line network. In addition, other energy generating devices can be used, for example, photovoltaic elements for transforming solar energy into electricity or solar collectors for heat production. If several energy sources are used, it is in principle possible to coordinate them appropriately. Thereby the use of the different energy sources can be adjusted to be as efficient and cost saving as possible.
From DE 10 2005 036 703 A1 a system is known, which provides warm water and thermal energy, cooling, air conditioning and which simultaneously provides mechanical power or electricity.
From DE 296 05 939 U1 a system for forecasting, scheduling and optimization of the components in an energy production system is known. The provision of electrical and/or thermal energy or fuel as well as the supply, management and planning of the electrical and thermal energy is based on the current load profile.
It is an object of the present invention to provide a system for the production, filling, packaging and/or transport of beverages should be considered as a system of interlocking consumption units, whereby the energy need of the system should be covered in the most efficient way, if necessary using an energy generating device. Furthermore, an energy-efficient method for the production, filling, packaging and/or transport of beverages is proposed.
The present invention provides a system for the production, filling, packaging and/or transport of beverages in beverage containers, whereby the system components are coupled physically and by a common control. Additionally the system components are at least partially energetically coupled. Furthermore the system components each form mutually coupled energy conversion units, energy storage units and/or energy consumption units, which are supplied with energy from at least one common energy generating device. The energy generating device supplies mechanical operating power (wave energy) and/or electrical energy and/or thermal energy. The energy generating device especially comprises at least one gas turbine, which is mechanically coupled to an electrical generator and/or to a compressor of a compressed air system. The gas turbine may furthermore comprise a heat exchanger, which is coupled to at least one of the system components. Particularly an exhaust gas heat exchanger is used as heat exchanger. The exhaust gas heat exchanger uses the thermal energy contained in the hot exhaust gas and supplies this thermal energy to other heat consumption units. For instance, the exhaust gas heat exchanger supplies this thermal energy to a shrinking tunnel or a film heating device or the like. Additionally or alternatively a heat exchanger can be provided that uses the thermal energy contained in the coolant fluid of the gas turbine and makes this thermal energy available to other consumption units.
When coupling the mentioned units of the inventive system, the energy generating device or the gas turbine may advantageously supply at least one dry end-block of the container processing system and/or of the beverage filling system or a part thereof with energy. Thus, a part of the exhaust heat or the whole exhaust heat, which is obtained from the heat exchanger units of the gas turbine, can be used energetically for different purposes. It may be advantageous, for example, to energetically couple the energy generating device or the gas turbine to at least one heating unit of the container processing system. The exhaust heat can be used effectively for a pre-heating unit for preforms and/or for a blow molding unit. A shrinking tunnel of a packaging system can be advantageously supplied with heat, since the energy consumption in a shrinking tunnel is particularly high. Furthermore the energy generating device or the gas turbine can be energetically coupled to a compressed air supply of at least one packaging system. This is typically a mechanical coupling, whereby the mechanical operating power (wave energy) of the gas turbine is used for powering the compressors, generating the compressed air either directly or indirectly. An indirect drive can, for example, be generated via a transformation of the driving power into electrical energy by a generator and a compressor drive with an electric motor.
A further embodiment of the system may provide that the energy generating devices as well as the energy conversion units, energy storage units and/or energy consumption units are coupled to a regional, national and/or public line network for electric power supply and/or for thermal energy supply. Normally, however, the different types of energy generated by the energy generating device or the gas turbine are made available and used locally. Especially the energy generated through the energy generating device or the gas turbine is used within the system, whereby the system is formed by the various mutually coupled components of the beverage processing system.
The present invention furthermore relates to a method for the production, filling, packaging and/or transport of beverages in beverage containers, whereby the components of the system are physically coupled and whereby the components of the system are coupled through a common control and whereby the components of the system are furthermore coupled at least partially energetically. The system components each form mutually coupled energy conversion units, energy storage units and/or energy consumption units, which are supplied with energy from at least one common energy generating device. The energy generating device supplies mechanical operating power (wave energy) and/or electrical energy and/or thermal energy. The method furthermore provides that the energy generating device is not arranged externally, but close to the other system components. This means, for example, that the energy generating device is located within the same production line or even within a larger manufacturing facility. The spatially more or less closely located consumption units such as the shrinking tunnel or other container processing units are at least arranged adjacent in a reachable distance. The different forms of energy provided through the energy generating device—mechanical energy, electrical energy, thermal energy, etc.—can thereby be used without long transport distances. A sensible arrangement may provide that the energy generating device is housed in a separate section of the building, in a separate room, in a building extension or the like. From there the energy is supplied to the various manufacturing units and system components. The spatial setup of the energy generating device may optionally be formed as an integrated unit or an external unit.
A particularly suitable drive for the energy generating device may for example be a gas turbine, which drives an electrical generator and/or a compressor of a compressed air system, whereby different forms of mechanical drives can be provided. The exhaust heat provided by the gas turbine can be made available to at least one further system component, such as a shrinking tunnel or the like. The electrical energy can be used in many different ways, for example, for the electric drives of a filling system. The compressed air can be used for example in a stretch blow molding device.
Another useful variation of the method may provide that the energy generating devices as well as the energy conversion units, energy storage units and/or energy consumption units are coupled to a (regional and/or public) line network for electric power supply and/or for thermal energy supply. Optionally, an additional capacity, which is sometimes required but cannot be supplied by the energy generating device at that time, can be provided through a storage unit. The storage unit is coupled to the system components and provides a buffer capacity for the required additional capacity. Suitable storage units are for example a pressure storage unit, an electrical storage unit or a thermal storage unit for storing the exhaust heat produced by the gas turbine or other energy generating devices. Furthermore an additional capacity, which is sometimes required but cannot be supplied by the energy generating device at that time, can be provided through a regional and/or public line network. The line network is coupled to the system components and provides the necessary electrical energy and/or thermal energy. In this context it may furthermore be advantageous, to provide additional electrical energy to a public network and/or neighboring consumption units. Additional energy refers to energy, which is provided at certain times through the energy generating device, but which is not required at that time by the consumption units and/or which cannot be stored at that time in the at least one storing unit. Of course, embodiments are also possible, wherein the thermal energy, which is delivered and available at certain times from the energy generating device and which is not required by the consumption units at that time and/or which cannot be stored in the storing unit at that time is provided to neighboring consumption units.
The inventive system thereby forms a coupled heat and power system, which is also called combined heating and power station or CHP. The inventive system can be operated in a heat controlled manner. This means that the amount of thermal energy, which is required and requested respectively during a given time period, can define the operational mode of the system. Thus, it may for example be useful, to run the gas turbine only at times when it can be ensured that the total thermal energy that is generated is also needed. During times in which too much exhaust heat is produced, it might be sensible to get the mechanical operating power (wave energy) and/or electrical energy, which is required in parallel, from a third-party. In some cases this may turn out cheaper.
Another useful variation of the method for controlling the system according to the invention may provide that all the coupled systems communicate with a central control center. With an increased public demand for electrical energy they can be configured in such a way that depending on the current demand one, some or all of the coupled systems are used to supply electric energy to the public network.
The present invention describes both the potential use as well as the integration of a heat and power coupling in the process of beverage production, filling, packaging and transportation of pallets and other related and/or coupled processes. It thereby describes a method for the integration of alternative energy generating devices in the process of beverage production, filling and beverage packaging, and transportation of beverage pallets. Since the system components and machinery in the beverage industry usually require heat, electricity and compressed air for production, electricity is produced by the inventive heat and power coupling, particularly electricity is generated through the combustion of gas or biogas in a micro gas turbine. The exhaust heat resulting from the combustion of the gas can for example be used for heating buildings. Moreover, other system components can be supplied with this thermal energy. Through the intelligent coupling of a beverage production system with a micro gas turbine, the heat dissipated by the machinery can be used directly or indirectly for shrinking processes, material heating processes, heating processes of media etc. The resulting power can be used for the operation of drives, fans, motors etc. Excess electricity can be fed back into the network (public or on-site) and/or used elsewhere. Through a mechanical extension of the micro gas turbine, a compressed air system can be integrated, which provides the necessary air pressure to the beverage machinery. Organic waste from the beverage production process can be fed to the micro gas turbine and used as fuel. There are significant advantages compared to the known systems in beverage industry, whereby the various system components are supplied with energy and media via completely independent energy and media supply routes. Traditionally the required heat is provided by a separate heat generating system or generated in the machinery itself. According to the inventive system the heat and power coupling provides the exhaust heat as a kind of waste product. According to the invention the required air is not provided through an air generator, but produced from the mechanical operating power (wave energy) of the combustion engine. Also, the electric power is not obtained from a conventional power distribution system, but generated by the heat and power coupling. In the case of conventional energy and media supply, it is assumed that these are available to 100%. An intelligent coupling of energy production processes and energy consumption units is not yet known in traditional systems.
The invention helps to overcome these drawbacks by using a micro gas turbine which drives a generator to produce electric power. The micro gas turbine is furthermore connected directly or indirectly to a compressor for generating compressed air. Both the generator and the compressor can be independently switched on or off. The exhaust gas resulting from the combustion in the micro gas turbine is cooled via a suitable exchange medium in an exhaust gas heat exchanger. The exchange medium (steam, hot water, air, . . . ) should be usable as a heat source for a beverage machinery (shrink tunnel, blow molding oven, CIP-system, . . . ). Both purchased gas as well as biogas, which can be intrinsically derived from organic waste of the beverage production process, can be used as fuel. An intelligent control system coordinates and optimizes the control processes of the micro gas turbine, the exhaust exchange system and the beverage production machinery.
In addition it should be mentioned, that the coupling of energy generating devices—especially of the so called micro gas turbine—and the energy consumption units of the inventive system can also be used only in a so-called dry end-block of the processing system. This variation is slightly restrictive and not always necessary. It may well be advantageous to provide energy consumption units, which are part of the so-called wet end-block of a filling system, either energetically, thermally, electrically or in another suitable way through a gas turbine or through one of the other energy generating devices.
According to the invention the thermal energy and electric energy and/or pneumatic energy required by the various components of a processing system can be provided advantageously by the energy generating device. Thereby not only the total energy cost of the entire system can be significantly reduced. The inventive system furthermore shows a significant reduction in the emissions of climate-damaging carbon dioxide. Thereby the invention can provide a valuable contribution to the conservation of energy resources and to the protection of the environment from climate-relevant emissions.
In the following passages, the attached figures further illustrate exemplary embodiments of the invention and their advantages. The exemplary embodiments of the invention are illustrative, but not limiting in any way.
The schematic representation of
The generator may furthermore drive a compressor for generating compressed air (depicted in the right block, located below), which is thus driven by an electric motor. Optionally, the gas turbine can drive an air compressor by means of mechanical coupling, which is indicated by the block depicted in the middle. The compressed air supply system in each case comprises a pressure storage tank, through which the compressed air supply system is connected to the consumption unit. Thereby the consumption units are additionally provided with pneumatic energy through the system. The pneumatic energy is marked with “DL”. Two different embodiments are illustrated for generating compressed air, using either electrically or mechanically driven compressors. The two different embodiments can be used either together or alternatively.
The third energy component, which may be supplied from the gas turbine, is exhaust heat. The exhaust heat may be withdrawn in particular from the exhaust gas through an exhaust gas heat exchanger and delivered as heat to the consumption units. The exhaust heat resulting from the combustion of the gas can for example also be used for heating buildings. In addition, all other system components can be supplied with this thermal energy. Through the intelligent coupling of the beverage production machinery with a micro gas turbine, the heat dissipating from the machine can be fed directly or indirectly to the appropriate system components and used for shrinking processes, material heating processes, heating processes of media. The resulting power can also be used for the operation of drives, fans, motors, etc. Excess electricity can be fed back into the network (public or on-site) and/or used otherwise. A compressed air system can be integrated through a mechanical extension of the micro gas turbine. Thereby the beverage processing machinery can be provided with the necessary compressed air.
In principle any conceivable fuel can be used as fuel for the micro gas turbine, for instance natural gas, biogas or the like. Organic waste from the beverage production process can also be used as fuel. Optionally a biogas production system can be integrated in the beverage production process. The inventive system has significant advantages compared to the known systems in the beverage industry, whereby the system components are traditionally supplied with the required energy and media via completely independent energy and media supply routes. Traditionally the required heat is provided by a separate heat generating system or generated in the machinery itself. According to the inventive system the heat and power coupling provides the exhaust heat as a kind of waste product. According to the invention the required air is not delivered by an air generator, but produced from the mechanical operating power (wave energy) of the combustion engine. The electric power is not obtained from a conventional power distribution system, but generated by the heat and power coupling. In the case of conventional energy and media supply, it is assumed that these are available to 100%. An intelligent coupling of energy production processes and energy consumption units is not yet known in traditional systems.
The invention helps to overcome these drawbacks by using a micro gas turbine which drives a generator to produce electric power. The micro gas turbine is furthermore connected directly or indirectly to a compressor for generating compressed air. Both the generator and the compressor can be independently switched on or off. The exhaust gas resulting from the combustion in the micro gas turbine is cooled via a suitable exchange medium in an exhaust gas heat exchanger. The exchange medium (steam, hot water, air, . . . ) should be usable as a heat source for a beverage machinery (shrink tunnel, blow molding oven, CIP-system, . . . ). Both purchased gas as well as biogas, which can be intrinsically derived from organic waste of the beverage production process, can be used as fuel. An intelligent control system coordinates and optimizes the control processes of the micro gas turbine, the exhaust exchange system and the beverage production machinery.
As indicated by the narrow block depicted below the three blocks “micro turbine” and “compressed air” arranged side by side, all coupled units are interconnected via a suitable control and regulating unit. The control and regulating unit comprises a user interface and appropriate display units. The coupled units are interconnected in such a way that the distribution to and the use of the various types of energy by the energy consumption units are done most energy efficiently and at the same time considering the current demand.
The schematic block diagram of
The subsequent system component comprises the so called stretch blow molding. First the preforms are cleaned and subsequently fed into a stretch blow molding device. Here the preforms are first tempered and then placed in the blow molds, where they are blow molded in the desired shape through the application of inner pressure. The heat required for tempering the preforms may optionally be recovered from the exhaust heat of the gas turbine. Alternatively the required heat can be provided through electrical heating devices such as infrared radiators. Particularly the electrical heating devices can be supplied with electrical energy from the energy generating device. The containers formed by stretch blow molding are then cooled down. Depending on the system configuration this can be done by using suitable heat exchangers. The heat exchangers can also be energetically coupled to the energy generating device and/or to other system components.
The final shaped containers together with the cleaned caps (see cap cleaning unit) are then transferred to the so-called wet end-block of the filling system, where the filling of the beverages takes place. The cleaning of the containers prior to filling with liquid may be done, for example, in a so-called rinser. Subsequently the bottles are filled in a filler and closed in a capper. The stages of product processing, especially the processing technique, and the cleaning technique are coupled to the wet end-block. This is shown by the arrangement of this processing & cleaning block above the wet end-block. The product to be filled, for example the beverage, is delivered from the product processing system to the filler. Optionally a short-time heating system is arranged between the product processing plant and the filler. In the so-called cold filling a short-term heating is not required. A conventional filling generally provides that the beverage is heated before filling to ensure the stability and sterility or to ensure that germs are eliminated at least to a large extend. This short-time heating system can also advantageously utilize the exhaust heat of the energy generating device, for instance through the exhaust gas heat exchanger of the gas turbine or something similar. Both mentioned system components of the product processing as well as the rinser and the filler are additionally connected to a cleaning system.
After filling the containers and their subsequent closure via the capper, the full containers are fed via suitable container transportation means to a drying unit. The drying unit can for instance comprise a hot air blowing system. Hereby the exhaust heat of the gas turbine can be used again. The containers are usually labeled after drying. According to
A so called dry end-block of the system is located downstream of the wet end-block. This dry end-block comprises a packaging unit, which is for instance a so-called Variopack-system. This Variopack-system comprises a film wrapping unit for wrapping packs of several containers with shrinking film, subsequently heating the film in a shrinking tunnel and further subsequently arranged transport means. The shrinking tunnel is a particularly energy consuming unit of the system. Therefore the operation of the shrinking tunnel with the exhaust heat from the gas turbine is particularly desirable. The use of energy obtained through the exhaust gas heat exchanger has a large energy saving potential, since the operation of such shrinking tunnels usually causes relatively high energy costs. The subsequent transport of the packs conveys these packs to a grouping unit and a downstream palletizing unit. The pallets can then be transported to a warehouse for storage or the pallets are transferred to further transportation means such as delivery trucks or the like. These mentioned units can also be supplied with electrical or pneumatic energy provided by the system.
The schematic block diagram of
After filling the containers and their subsequent closure via the capper, they are fed via suitable container transportation to a pasteurization machinery and a subsequent drying unit. The drying unit comprises, for instance, a hot air blowing system. Hereby the exhaust heat of the gas turbine can be used again. The containers are usually labeled after drying. According to
A so called dry end-block of the system is located downstream of the wet end-block. Again it comprises a packaging unit, which may be formed, for example, by a suitable device for the production of packs in a desired configuration. The subsequent transport of the packs conveys these packs to a grouping unit and a downstream palletizing unit. The pallets can then be transported to a warehouse for storage or the pallets are transferred to further transportation means such as delivery trucks or the like. These mentioned units can also be supplied with electrical or pneumatic energy provided by the system.
The system shown in
Many of the aforementioned units require a certain amount of heat, for example, the cleaning machinery. This heat can be preferably obtained from the exhaust heat of the gas turbine. In addition, many of the units require electricity to drive electric motors and other electrical consumption units. This energy can also be provided advantageously through the at least one generator of the energy generating device.
The features of the invention disclosed in the foregoing description, the drawings and the claims can be used in its various embodiments either individually or in any combination for the realization of the invention. The invention is not restricted to the described preferred embodiments. To the expert it is also conceivable, however, to make changes and modifications without leaving the scope of protection of the appended claims.
The illustrated figures, which have been described above, represent only possible embodiments. Especially it cannot be derived, that a use of the invention in a multi-line or in processing technique should be excluded. Even in such applications, the inventive energy coupling can be used advantageously.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2009 044 258.8 | Oct 2009 | DE | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/EP10/63211 | 9/9/2010 | WO | 00 | 5/23/2012 |
