{"id":17103,"date":"2017-11-22T19:10:55","date_gmt":"2017-11-22T18:10:55","guid":{"rendered":"https:\/\/www.sacome.com\/?p=17103\/"},"modified":"2020-02-11T13:56:23","modified_gmt":"2020-02-11T12:56:23","slug":"worts-coolers-for-whisky-production","status":"publish","type":"post","link":"https:\/\/www.sacome.com\/en\/worts-coolers-for-whisky-production\/","title":{"rendered":"Worts Coolers for Whisky Production"},"content":{"rendered":"

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Worts Cooling in the Whisky Production<\/h2>\n

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Heat Exchangers for Worts Cooling: Background<\/h2>\n

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A Scottish world-leading company in the whisky production, has contacted SACOME to design and manufacture a worts cooler<\/strong> of 250 m3\/h of worts.<\/p>\n

The cooling of worts<\/strong> after cooking and prior to fermentation<\/strong> in the production of spirits, is an essential part of the process<\/strong>, since at high temperatures there is a decrease of the fermentation power, together with a loss of evaporated alcohol and aroma diminution.<\/p>\n

With this in mind, our Technical Staff got involved to the maximum in the design of the worts coolers<\/strong>, paying special attention to the special design conditions<\/strong>, the high solids contents<\/strong> (grain, stones, straws etc.) suspended in the product to be cooled, the necessity of a precise final temperature of the worts <\/strong>at the exit of the cooler or the strict cleaning conditions of the heat exchanger<\/strong> after the production cycles. These factors make the tubular solution<\/strong> the most convenient.<\/p>\n

In the following sections we talk about the special details in our design of tubular heat exchangers for the worts cooling<\/strong> with which the most important Scottish distilleries are working nowadays.<\/p>\n

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Corrugated Tube Heat Exchangers: The Solutions<\/h2>\n

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SACOME<\/strong> has designed and manufactured<\/strong> an important number of corrugated tube heat exchangers<\/span><\/a> for the most important distilleries in Scotland<\/strong> and, in all cases, these units are working nowadays at full capacity<\/strong>.
\nIn this particular project, a cooling from 63 \u00baC to 20 \u00baC was required prior to the fermentation process<\/strong> in different operating conditions and the process was divided into 4 sections<\/strong> according to the media used to cool the product (in this case: tower cooling water, fresh water and chilled water).<\/p>\n

The system basically works with the worts circulating by the corrugated inner<\/strong> tubes along 4 sections, while the different cooling media circulate by the shell tubes<\/strong> of the heat exchangers<\/strong>. It is important to comment that the design of the heat exchanger allows the connection of the shells of the sections 1, 3 and 4, with the intention to avoid the use of chilled water in those seasons when the environmental temperature allows it, which means an important economical relief<\/strong>.<\/p>\n

We have also to emphasize the important advantages of using multitubular heat exchangers with corrugated inner tubes<\/strong> for this kind of products as the increase of turbulence<\/strong> as a consequence of the corrugation results in a lower fouling<\/strong>, an increase of the heat transfer velocity<\/strong> and a better homogeneity of the product<\/strong> at the end of the cooling process<\/strong>.<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”3.0.47″ background_size=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;initial&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"” background_position=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;top_left&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"” background_repeat=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;repeat&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"”][et_pb_column type=”1_3″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2017\/11\/Placa-tubular-en-enfriadores-de-malta.jpg” alt=”Worts Coolers for Whisky Production” title_text=”Flange detail in worts coolers” _builder_version=”3.16.1″ animation_duration=”500ms” animation_intensity_slide=”10%” animation_direction=”left” \/][\/et_pb_column][et_pb_column type=”1_3″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2017\/11\/Inspeccion-de-los-equipos-en-fabrica.jpg” alt=”Shell and tube heat exchangers for worts cooling in whisky production” title_text=”Inspection and tests at SACOME factory” _builder_version=”3.16.1″ animation_duration=”500ms” animation_intensity_slide=”10%” animation_direction=”left” \/][\/et_pb_column][et_pb_column type=”1_3″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2017\/11\/Detalle-de-los-equipos-en-planta.jpg” alt=”Worts Coolers for Whisky Production” title_text=”SACOME Worts Coolers in the client’s distillery” _builder_version=”3.16.1″ animation_duration=”500ms” animation_intensity_slide=”10%” animation_direction=”left” \/][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section bb_built=”1″ fullwidth=”off” specialty=”off” prev_background_color=”#000000″ next_background_color=”#000000″][et_pb_row _builder_version=”3.0.47″ background_size=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;initial&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"” background_position=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;top_left&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"” background_repeat=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;repeat&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"”][et_pb_column type=”4_4″][et_pb_text _builder_version=”3.17.6″]<\/p>\n

Worts Coolers Thermal Calculation<\/h2>\n

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On the other side, our technical staff took into account the existing restriction in the outlet temperature of the fresh water<\/strong> as it is used in different processes and in case of do not meet this requirement the result would be a high energy loss.
\nIn the same way, when doing the thermal calculation of the heat exchanger<\/strong><\/a>, we considered that this heat exchanger<\/strong> should be working in production cycles of 30 to 45 minutes. Every 2 or 3 cycles, we made water at 85\u00b0C run through the inner tubes for cleaning and 2 or 3 times a week we repeated the same process with a hot cleaning solution.<\/p>\n

This tubular heat exchanger<\/strong> has been designed to process worts flows between 150 and 250 m3\/h and to reach final temperatures of 20 to 22\u00b0C. Flows and temperature of the water also vary (for example, for fresh water between 120 and 150 m3\/h with temperatures between 5\u00b0C and 19\u00b0C).<\/p>\n

These variations involve a major difficulty in the calculation of the necessary number of modules (we checked more than 20 different operating conditions). Finally, this cooler consisted of 16 modules assembled in one frame<\/strong> with the objective to obtain an easy drainability<\/strong> (we included a system of drain valves). Other key element was the\u00a0design of the expansion joints<\/strong><\/a> included on the shell of each module as we did a fatigue analysis of all the elements for 20 years.<\/p>\n

To do the thermal calculations of the heat exchanger<\/strong> we used the last updated version of HTRI<\/strong><\/span><\/a>, in which association we are registered as a member. Regarding the mechanical design, we considered the BRITISH STANDARD 5500 Category 2<\/strong><\/span> for the design pressure of 16 barg.<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section bb_built=”1″ _builder_version=”3.0.47″ custom_padding=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;0px|0px|3px|0px&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"” prev_background_color=”#000000″ next_background_color=”#000000″][et_pb_row _builder_version=”3.0.47″ background_size=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;initial&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"” background_position=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;top_left&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"” background_repeat=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;repeat&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"”][et_pb_column type=”4_4″][et_pb_text _builder_version=”3.21″ background_size=”initial” background_position=”top_left” background_repeat=”repeat” background_layout=”light” text_orientation=”left” border_style=”solid”]<\/p>\n

Process: basic stages in the whisky production<\/h2>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”3.0.47″ background_size=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;initial&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"” background_position=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;top_left&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"” background_repeat=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;repeat&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"”][et_pb_column type=”1_2″][et_pb_toggle title=”Preparation” _builder_version=”3.0.63″]<\/p>\n

For the manufacture of whisky, the main distilleries prefer the new species of barley grown in Scotland, since they contain a lot of starch and are low in protein. Once the grain is dried, it is collected and stored to dry the product, before its subsequent malting .<\/p>\n

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The ground malt is placed in a circular soaking kettle, called “mash tun”. Then, it is mixed with hot water to cause the enzymes of the malt to transform the starch into a sugary liquid, (worts) which is removed from the tank to the fermentation. The waste material is called hops.<\/p>\n

[\/et_pb_toggle][et_pb_toggle title=”Fermentation” _builder_version=”3.0.63″ background_size=”initial” background_position=”top_left” background_repeat=”repeat”]<\/p>\n

The must is pumped into large barrels (fermenters) where the yeast is added. A strong fermentation transforms the sugar into alcohol, where the resulting liquid is known as fermented must or “wash”.<\/p>\n

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The must is distilled twice in large copper stills, to produce “high wines” or “new whisky”. The first distillation in the stills causes the alcohol to evaporate and separate from the water, forming a liquid called ‘low wines’. This distillate is then transferred to the ‘low wines’ stills to produce brandy.<\/p>\n

[\/et_pb_toggle][et_pb_toggle title=”Aging” _builder_version=”3.0.63″ background_size=”initial” background_position=”top_left” background_repeat=”repeat”]<\/p>\n

After distillation stage, the liquor produced or “high wine” is added water and aged in white oak vats. The duration of aging can vary, but in general it is usually between 2 and 5 years, and can reach up to 10 and 15 years.<\/p>\n

[\/et_pb_toggle][et_pb_toggle title=”Bottling” _builder_version=”3.0.63″ background_size=”initial” background_position=”top_left” background_repeat=”repeat”]<\/p>\n

After the aging phase, the whiskey is reduced to the desired alcohol content by the addition of soft water. The whiskey is then carefully filtered and bottled with automatic machinery in bottles that are sealed and labelled.<\/p>\n

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The worts cooler is required between the mashing and fermentation stages.<\/h4>\n<\/blockquote>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row][et_pb_column type=”1_3″][et_pb_divider _builder_version=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;3.0.63&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"” divider_style=”solid” divider_position=”top” height=”10″ hide_on_mobile=”on” disabled_on=”on|on|off” color=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;#ffffff&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"” show_divider=”"&quot;&amp;quot;&amp;amp;quot;&amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;off&amp;amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;amp;quot;&amp;amp;amp;amp;quot;&amp;amp;amp;quot;&amp;amp;quot;&amp;quot;&quot;"” \/][et_pb_image _builder_version=”3.16.1″ src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2017\/11\/Enfriador-de-mosto-para-produccion-de-whisky.jpg” alt=”Tubular Heat Exchangers for worts cooling” title_text=”Worts Coolers” animation_duration=”500ms” animation_intensity_slide=”10%” animation_direction=”left” \/][\/et_pb_column][et_pb_column type=”2_3″][et_pb_text _builder_version=”3.17.6″]<\/p>\n