Application of a Steam Accumulator for Pressure Stabilization and Energy Savings in a Brewery

Beer brewing processes typically involve periodic, intermittent steam demand. The start-up and shutdown of mashing, wort boiling, and packaging lines can cause sharp short-term fluctuations in steam load, directly triggering a series of problems, including boiler pressure oscillation, wet steam carryover, and water hammer in pipelines. These issues not only damage thermal equipment but can also affect brewing product quality.

The Spirax Sarco steam accumulator solution uses thermal storage and supplementary steam supply to shave peaks and fill valleys, providing a proven energy-saving solution for intermittent and fluctuating steam demand in breweries. The following section explains the practical value of Spirax Sarco steam accumulators in breweries through a real-world relocation and upgrade project implemented at a brewery in Ji’an, Jiangxi.

Steam System Challenges at the Old Plant

The old plant was designed for an annual beer production capacity of 150,000 tonnes and was equipped with three coal-fired boilers. The actual maximum steam load was 21 t/h, while the minimum load was only 5 t/h.

Fluctuations in steam demand caused by the mashing process and production changeovers on the packaging line created several operational challenges:

• Boiler pressure and water level fluctuated frequently, with recurring abnormalities such as wet steam carryover, pipeline water hammer, and low boiler water level alarms;
• To handle instantaneous peak steam demand, two boilers had to operate simultaneously. Frequent boiler start-ups, shutdowns, and load adjustments resulted in low actual thermal efficiency and high fuel costs;
• Boiler operators had to make frequent manual adjustments, increasing maintenance and operation workload and reducing overall system safety.

Spirax Sarco System Design for the New Plant

The company relocated its operations from the city to an industrial park and built a new production base. Phase I capacity was increased to 250,000 tonnes, with a maximum plant-wide steam load of 22 t/h and a minimum load of 4 t/h.

After extensive technical discussions, the project adopted a system centered on a Spirax Sarco steam accumulator within the boiler control systems portfolio: two 10 t/h boilers paired with one 150 m³ steam accumulator. The boilers were configured in a duty/standby arrangement. During normal operation, a single boiler working with the Spirax Sarco accumulator could meet the total steam demand of the plant. The accumulator volume was 33 times the volume of a single boiler drum, substantially strengthening the system’s peak-shaving and thermal storage capacity.

Two Key Spirax Sarco Technical Optimizations

Valve Assembly Upgrade to Eliminate Water Hammer Risk

Many similar projects use a check valve as the steam charging valve for the accumulator. Check valves have limited sealing performance and may develop internal leakage during long-term operation. If the boiler-side pressure drops, high-pressure water inside the accumulator can flow back into the boiler, causing severe water hammer.

Spirax Sarco engineers replaced the conventional check valve solution with a control valve combined with a bellows-sealed stop valve in the charging circuit. This configuration provides reliable shutoff performance and fast system response, eliminating the risk of high-pressure water backflow at the source.

Pipeline Thermal Stress Verification to Facilitate Future Maintenance

The initial pipeline layout prepared by the design institute was constrained by the available space. The pipeline expansion compensation structure would have resulted in limited operating space on site, making future equipment maintenance difficult.

Spirax Sarco used professional thermal stress analysis software to recalculate the system and optimize the pipeline routing. The revised design was confirmed and implemented by the design institute, providing sufficient maintenance access while balancing safety and ease of operation and maintenance.

Project Results

After commissioning, the steam system centered on the Spirax Sarco accumulator operated reliably and stably over the long term. During production, only one boiler needed to operate, while the other served as a standby unit. The accumulator maintained an operating pressure of 1.0-1.2MPa and supplied stable 0.6MPa process steam to the production workshops through shut-off valves and pressure-reducing equipment, fully matching the steam requirements of the brewing process.

After the upgrade, boiler operating conditions became stable, significantly reducing frequent boiler load adjustments and lowering the operation and maintenance burden on boiler-house personnel. The upgrade completely resolved the previous problems of pressure fluctuations, water hammer, and wet steam carryover, delivering combined benefits in energy efficiency, equipment safety, and production stability.

Key Takeaways

Intermittent production industries such as brewing, food processing, and papermaking commonly face fluctuating steam loads. Relying solely on boilers to follow load changes makes it difficult to achieve both stability and efficiency.

As a thermal buffer unit, the Spirax Sarco steam accumulator stores surplus thermal energy during low-demand periods and releases supplementary steam during peak demand, allowing boilers to operate within their high-efficiency range for longer periods. In new plant construction or boiler-house upgrade projects, a properly configured system centered on a Spirax Sarco accumulator can effectively stabilize network pressure, protect equipment, and reduce fuel consumption. It is an important approach to optimizing steam systems in the brewing industry.

If your plant also experiences significant steam load fluctuations or unstable boiler pressure, contact us for a free Spirax Sarco steam system assessment and solution recommendations.