CASE STUDIES
Guntner supplies European malt producer
E
uropean malt producer Malteurop recycles waste heat from germination process refrigerating machines to support its malt kiln at its plant in Heidenau, Germany. The company opted for Guntner air heater coils working in conjunction with thermowave plate heat exchangers.
When malting barley germinates with water and oxygen, this generates heat. In the process of malting the barely, as the temperature in the germination chamber rises, so does oxygen demand. The germination process in the malthouse takes place under optimal conditions, where the malting barley is kept at 12-16 °C for several days. Fresh, chilled, humidified and oxygen-rich air is fed into the germination chamber.
In Malteurop’s machine room, two frequency- controlled water chillers with screw compressors are connected in parallel, running R134a. By means of a TL0500 TAGL thermowave plate heat exchanger, the cold from the glycol-water mixture is transferred to the process water of the spray water cooler in the germination chamber. A standby plate heat exchanger of the same type is used during cleaning and maintenance work. The process water for the germination chamber is filtered and circulates through the refrigeration plant. The spray water cooler atomises the water in the ambient air which thereby cools and saturates it with process water, which is then directed through the germination chamber.
44 June 2018
The usable heat from the refrigeration machines, as well as the waste air from the kiln, are transferred to a 34 % glycol-water circuit. This circuit, in turn, heats the hot air for the kiln from 29 °C to approximately 46 °C. Ten Guntner GCO air heater coils are used during this process for maturing the germinated barley. In order to achieve the required overall capacity, the coils were built one above the other as a tower, and the fluid passes through each coil in parallel. Each coil has a capacity of 156 kW and heats the air from around 29 °C to approximately 44 °C and, at the same time, the brine cools from 47 °C to about 42 °C. The air volume flow at the outlet of each unit is around 33,000 m³ per hour. An adjoining Guntner heating element, composed of six GCO air heater coils, stands directly in the kiln. This further heats the air by means of a hot water circuit to temperatures of between 85 °C and 95 °C as required. The air volume flow at the outlet of each unit is about 42,000 m³ per hour. The germ buds fall off during the drying process and are sieved off and sold as a high-quality ingredient for mixed feed. During the summer, not all of the waste heat from the compressors is required for the air preheating. Two additional thermocline series TL0250 TAGL thermowave plate heat exchangers (one running, one on standby) function as emergency coolers to conduct the excess heat from the cooling process to well water via a glycol-water circuit.
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