Designing your own home brewery Mike Heydenrych Presented at the Worthogs meeting of 12 February...
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Transcript of Designing your own home brewery Mike Heydenrych Presented at the Worthogs meeting of 12 February...
Designing your own home brewery
Mike Heydenrych
Presented at the Worthogs meeting of
12 February 2003
What do you want to achieve?The six most important aspects of
making good beer
1. Big yeast starters
2. Temperature control
3. Full wort boils
4. Cool your wort quickly
5. Oxygenate your wort
6. Keep good records
Mark Tumarkin, Hogtown Brewers, posted on HBD
How much will your wife allow you to spend?
Beginner
R500
Hobbyist
R1500
Enthusiast
R10 000
Mash Kit/stove
R0
Partial/zap-zap
R100
All-grain
R3000
Cool Pot in sink
R0
Immersion
R110
Counterflow
R300
Ferment Bucket
R50
Fridge
R800
Cylindro-con
R1500
Dispense Bottles
R50
Bottles
R50
Cornelius kegs
R5000
This presentation
Beginner
R500
Hobbyist
R1500
Enthusiast
R10 000
Mash Kit/stove
R0
Partial/zap-zap
R100
All-grain
R3000
Cool Pot in sink
R0
Immersion
R110
Counterflow
R300
Ferment Bucket
R50
Fridge
R800
Cylindro-con
R1500
Dispense Bottles
R50
Bottles
R50
Cornelius kegs
R5000
Mash/lauter systems: Cooler box
Mash
Pipe with holes under to drain away wort
Mash/lauter designs:The Zap-Zap system
(Charlie Papazian)
Make holes 2-3mm
Cheap, easy
Lautering is by pouring water from a jug by hand
No direct heat
Immersion cooler
Cold water inWarm water out
Kitchen pot
Hot wort
Beginner
R500
Hobbyist
R1500
Enthusiast
R10 000
Mash Kit/stove
R0
Partial/zap-zap
R100
All-grain
R3000
Cool Pot in sink
R0
Immersion
R110
Counterflow
R300
Ferment Bucket
R50
Fridge
R800
Cylindro-con
R1500
Dispense Bottles
R50
Bottles
R50
Cornelius kegs
R5000
Chemical Engineers’ heaven
Three-tier
HotLiquorTank
Mash/Lauter
Kettle
No pumps
Recirculate by carrying buckets
Climb to look into HLT
Two-tier
HotLiquorTank
Mash/Lauter
Kettle
Easier to check vessels
Needs a pump
Not a great deal of flexibility
Single-tier
HotLiquorTank
Mash/Lauter
Kettle
Easy to work with vessels
Relies on pumps
Needs at least 2 pumps for sparging
My preferred layout
HotLiquorTank
Mash/Lauter
Kettle
To chiller,fermenterSample
tap
OptionalHLT recirc.
Fill Mash tun
HotLiquorTank
Mash/Lauter
Kettle
To chiller,fermenterSample
tap
OptionalHLT recirc. Green = open/on
Red = closed
Recirculate/ramp
HotLiquorTank
Mash/Lauter
Kettle
To chiller,fermenterSample
tap
OptionalHLT recirc.
Sparge
HotLiquorTank
Mash/Lauter
Kettle
To chiller,fermenterSample
tap
OptionalHLT recirc.
Chill
HotLiquorTank
Mash/Lauter
Kettle
To chiller,fermenterSample
tap
OptionalHLT recirc.
Vessel sizes
HotLiquorTank
2volumes
Mash/Lauter
0.8volumes
Kettle
1.5volumes
Fermenter
1.2volumes
Brew length = 1 volume
Does size matter?(Prices of vessels from Sinvac, May 2002)
0
100
200
300
400
500
600
700
0 100 200 300 400 500
Volume, litres
Co
st,
Ran
d Cost = (11.2)2/3
Typical 60ℓ setup
Detailed vessel design
Principles Practicalities
Kettle and Hot Liquor Tank heating Mash/lauter tun design Counterflow chiller Fermenter
Hot liquor tank - principles High W/m2 on heater element OK Thermostat control useful, not essential If you have a HERMS coil, then movement
of the water around the coil is essential, else you get: cold layers of water at the bottom of the tank poor transfer of energy to the wort in the tube
Hot liquor tank Need volume - plastic tanks are economical Geyser elements are acceptable
1¼” (32mm) thread Power rating unimportant Geyser thermostat OK Recirculation useful for good temperature
control
Hot liquor tank schematic
2kW geyser element with thermostat
Optional HERMS
Outlet valve
Inlet for recirc.
Kettle principles For a given kW heater element, you will
evaporate a given amount of water per hour, whether the lid is on or off.
Rolling boil serves several purposes Agitation for agglomerating protein particles Evolution of steam to drive off volatiles Temperature to drive -acid isomerisation Temperature to drive Maillard (darkening) reactions
Wort ingredients foul heater elements and cause them to fail unless the energy density per m2 is reduced.
Kettle - practicalities Use stainless steel if possible, and heat using gas Plastic works well, but specify large-area Incoloy
heating elements (approx. R250). Strive for 24kW/m2 (4m for a 3kW element).
3kW elements for kettles from 40-100ℓ You need a good rolling boil, even with the lid
off.
Heating elements: sealing detail
Electrical connector
Electrical box
Kettle wall
Securing nut 12 mm
Sealing washer
Electric element
Mashing Temperature ramping: 3 methods
Add hot water, thinning the mash Heat up recirculated wort, either by
HX with hot liquor (HERMS), Directly heating wort under the sieve, or Directly heating wort electrically (RIMS)
Heat up mash and grains directly: Decoction mashing Heating container directly Stirring with a heated mashing fork
Mashing - principles Thinning the wort reduces enzyme activity
(but OK for -amylase?) Heating up recirculated wort denatures
enzymes, so keep temp. rise low, and minimise the time the wort spends hot
Heating up mash and grains directly:
Movement of particles relative to the hot surface NB to prevent burning (phenols)
Mashing – Pros and Cons HERMS (Heat Exchanger tube in HL tank)
You can’t overheat the wort You need to stir your HLT with HERMS
RIMS (Recirc. Infusion Mashing System), electrical heating of recirculating wort Best used by controlling the electrical energy
input based on the wort temperature. Direct heating by gas
Long residence time of heated wort under sieve (keep this volume low!)
Sparging – principlesStuck mash - Compressible filter bed
Lowpressure dropMedium flow
Mediumpressure drop Med-fast flow
Highpressure drop
Slow flow
Sparging – principlesStuck mash - Compressible filter bed
Pressure drop
Flo
w r
ate
1 cm/min
Sparging – principlesLauter plate designThere tend to be more openings on the edge, hence
more flow down the sides.Make as many 2-2,5mm holes as practical, preferably with a greater density of holes in the middle
Try to get as close to plug flow as possible – clean water fully replacing sugary wort as it moves down. Start sparging only when the liquid level falls below the top of the grain bed
Sparging – practicalities
For mashing, you want an approximately equal height/diameter ratio to keep heat loss down.
For sparging, you want to keep the surface area as large as possible, but have at least 30cm of bed
Balance large surface area with the heat loss, or use separate mash tun + lauter tun.
Mash/lauter tun: design
Mash
RecirculationKeep volume here minimum
Vessel diameter should be slightly more than the height to get fastest recirc and lautering
Apply flame close to outlet
Well insulated
Counterflow chiller: principles Maximise heat transfer area Fluid velocity improves heat transfer Heat transfer rate determined by the side
with the lowest fluid velocities
Heat transferoccurs across
the wall
Cold stream
Hot stream
Counterflow chiller: principles
Temperature
Distance along the length of chiller
Hot wort
Cooling water
These lines become parallel if water flow rate decreases to wort flow rate. Typically, you’ll use 3-5x more water than wort.
Counterflow chiller: practicalities Use 15.2m of 10mm soft copper tubing Use 15m of 20mm garden hose Roll out copper tubing flat on the lawn, and
push it into the hosepipe. Use a copper connector (ask Moritz) to
make the seal on each end:
Hot wort in Cold wort out
Warm water out Cold water in
Counterflow chiller: practicalities Where the chilled wort leaves the counter-
flow chiller, put it through a 10mm copper coil (5m) dipped in an ice bath
Ensure movement of ice water past the tubing by Jigging the tube bundle, or Putting a fountain pump in the bath
C/flow chillerIce bath
To fermenter
My first counterflow chiller
Cylindroconical fermenter Need < 30° included angle
underneath 5% of volume below side
offtake Sinvac 180ℓ, Pioneer 70ℓ Need to make a stand Open fermenter (loose lid)
has worked fine
Grain roaster
DiscussionFor a counterflow chiller design spreadsheet,
Added later, some suppliers (details on Worthogs web site):
Metraclark (Mitchell St, Pta) for 10mm copper tubing
Sinvac (Pretoria West, near Iscor) for most plastic drums
Pioneer plastics (Rosslyn) for 80 liter conical fermenter
Plastilon for silver insulation, plastic buckets, packaging materials in general