啤酒厂糖化车间设计(论文).doc

啤酒厂糖化车间设计(论文)

———————————————————————————————— 作者：
———————————————————————————————— 日期：

2

个人收集整理 勿做商业用途
目录

题目······································································································································Ⅰ
摘要及关键词·······················································································································Ⅱ
1 总论·································································································································· 2
1．1 概述····························································································································· 2
1．2设计依据······················································································································ 2
1．2．1 根据在四平金士百啤酒有限公司实习一周所获的一些基础资料················· 2
1．2．2 参考资料············································································································· 2
1．2．3 吉林农业大学毕业设计任务书········································································· Ⅲ
1．3 主要技术经济指标··································································································· 2
1．4 问题与建议··············································································································· 3
1．4．1 本项目有以下问题与风险··················································································3
1．4．2 建议······················································································································ 4
1．5 结论···························································································································· 4
2 工厂总体设计·················································································································· 4
2．1 厂址概述····················································································································· 4
2．2 总平面布置················································································································· 4
2．2．1 工厂总平面布置设计原则··················································································· 4
2．2．2 车间布置设计原则······························································································· 5
3 生产工艺··························································································································· 6
3．1 原料及产品的质量标准····························································································· 6
3．1．1 理化指标··············································································································· 6
3。1.2 感官指标····················································································································· 6
3．2 生产工艺流程············································································································· 7
3．2．1 酿造啤酒的原料···································································································7
3．2．2 麦汁的制备··········································································································· 7
3．2．3 啤酒的发酵········································································································· 9
3．2．4 啤酒的包装与成品啤酒······················································································· 10
3．2．5 生产工艺流程简图·······························································································11
3．2．6 物料衡算···············································································································12
3．2．7 热量衡算···············································································································13
3．2．8 水衡算···················································································································16
3．2．9 主要工艺设备选型计算·······················································································16
4 环境保护及综合利用···································································································17
4．1环境保护························································································································17
4．1．1执行标准···················································································································17
4．1．2 污染物及治理方法·································································································17
5 职业安全卫生··············································································································17
5．1 职业安全·····················································································································17
5．2 劳动卫生·····················································································································18

6 消防·····························································································································18
6．1 消防遵循的原则········································································································18
6．2 消防依据····················································································································18
6．3 安全防护消防············································································································18
7节约能源·······················································································································19
7．1 概述······························································································································19
7．2 设计上的节约措施······································································································19
8 主要设备一览表··················································································································19
9 致谢·················································································································20

21

年产十六万吨啤酒工厂设计
——-糖化工艺的研究设计
学 生：
专 业:2003级生物工程
指导老师：
摘 要: 本设计书是对四平金士百啤酒有限公司进行实习后对年产十六万吨啤酒工厂外部空间布置及生产工艺流程进行设计研究，其主要包括生产工艺的各种指标、设备选形设计计算、物料衡算、水、电、汽的估算以及工艺流程图的设计。该设计成果主要采用形式为全厂总平面布置图（1张），工艺流程图（1张），设备布置图（2张），并编写详细数据说明书.
关键词：糖化：设计：流程：说明书
Yearly produces 160,000 tons beer plant design
— — Saccharification craft research design
Name：
Major： Bio-engineering
Tutor：
Abstract: This book of design is carries on the practice after JinShibai gentlemenhundred beer limited companies to yearly produce 160，000 tons beerfactories exterior space arrangement and the production technicalprocess conducts the design research,it mainly includes the production craft each kind of target，the equipment chooses the shapedesign calculation,material of the graduated arm of a steelyard calculation，the water,the electricity，the steam estimate as well as the flow chart design.this designachievement mainly uses the form for the entire factory totalfloor—plan（1），flowchat(1)，equipment general arrangement（2）,and compilation文档为个人收集整理,来源于网络文档为个人收集整理,来源于网络
particular data instruction booklet。
Key word: Saccharification:Design: Flow：Instruction booklet

1 总 论
1．1 概述
自上个世纪90年代初 外资看好蓬勃兴旺潜力无限的中国啤酒市场，50多家洋啤酒潮水般地涌入，使当时国内许多啤酒企业或外资控股或被收购.90年代中后期,因国内啤酒市场地方保护严重,价格大战硝烟弥漫等一系列恶性竞争，导致绝大多数外资啤酒“水土不服"，纷纷退出中国市场。
中国加入世贸组织后，游戏规则的改变，关税门槛的降低，特别是税制的改革，使地方政府实施地方保护的政策杠杆和财政手段大大削弱，由此带来的市场形势的变化，将使中国啤酒业逐步走向公平、公正、合理的发展方向发展.
更为重要的是，中国啤酒市场呈现了飞速发展的态势。已经超过了美国，成为世界最大的啤酒消费市场。
1．2设计依据
1．2．1 根据在四平金士百啤酒有限公司实习一周所获的一些基础资料
1．2．2 参考资料
《啤酒工业手册》
《发酵工厂工艺设计概论》
《化工原理》
《啤酒工艺》
《发酵设备》
《化工设计手册》
《AutoCAD2002应用程序》
1．2．3 吉林农业大学毕业设计任务书
1．3 主要技术经济指标
本项目主要技术经济指标见下表。
表1—1 主要技术经济指标表
Table1—1shows the major technology and economy quota

序号
指 标
单 位
数 量
备 注
1
生产规模
万吨/年
16

农大纯生啤酒
万吨/年
10

农大普通啤酒
万吨/年
6

农大各种精品啤酒
万吨/年
2

2
总投资
万元
25567。7

固定资产投资
万元
21346.5

建设期借款利息
万元

流动资金
万元
3940.3

3
投资指标
元/T产品

百元销售收入占用流动资金
元/百元
7。24

4
全厂定员总计
人
1356
不包括临时工

工人
人
866

工程技术人员
人
350

管理人员
人
140

序号
指 标
单 位
数 量
备 注
5
全年生产天数
天
340

6
主要原料、物料、燃料需用量

麦芽
t/a
15467

黑米 黑甜玉米、小黑麦、黑糯玉米
t/a

啤酒花
t/a
154.7

商标
万个/a
21564

瓶损
万个/a
17953

易拉罐
万个/a
6826

硅藻土
t/a
258

瓶装箱
万个/a
579

罐装箱
万个/a
799

瓶盖
万个/a
21564

水
t/a
2459206
全厂综合

电
kwh/a
2581
全厂综合

煤
t/a
47894
全厂综合
7
运输量
万t/a
37.89

运入量
万t/a
10。74

运出量
万t/a
17.83

8
全厂占地面积
立方米
450000

生产区占地面积
立方米
80000

生活区占地面积
立方米
37000

9
年总成本（100％负荷）
万元
39556
计算预期平均值
10
正常年生产品单位产品成本
元/t产品
3258.8
计算预期平均值
11
年销售收入
万元
69458
计算预期平均值
12
年利税
万元
27893
计算预期平均值
13
年利润
万元
20984
计算预期平均值
14
全员劳动生产率
万元/人。a
186.7
计算预期平均值
15
工人实物劳动生产率
t/人a
398

16
借款偿还期
a

17
投资回收期
a
3.83
税后
18
投资利税率
%
156.85

19
投资利润率
%
82。68

20
财务内部收益率
%
59。58
税后
1．4 问题与建议
1．4．1 本项目有以下问题与风险
（1）原料的供应不能确保,由于麦芽要进口的，且路程较远，因此不能完全保证。
（2）水灾，火灾等重大自然灾害造成损失的风险不能较大程度的避免 .
（3）由于是私营企业，在融资方面的不能及时,从而影响项目建设进度的问题。
（4)在产品外销时,受地域限制教明显，使得品牌在外地市场竞争力弱。

1．4．2 建议：
(1）对于原料供应问题,本项目啤酒生产主要原料有大米、麦芽、啤酒花，吉林省盛产大米,且品种优良，啤酒生产用大米货源充足，啤酒厂所需要原料大米供应有可靠保证。
啤酒生产所需要麦芽由新疆、辽宁级黑龙江等地麦芽厂供应，啤酒花主要产地在新疆,应该与原料商建立长期、稳定、良好的合作关系,可以保证材料的质量和数量，从而保证企业产品的质量。
（2）对于人类不可抗拒的重大自然灾害,项目应采取投保的方式进行解决，尽量减少损失.
（3）对于融资方面可能发生的商业贷款到位不及时问题,应加大公关协调力度，力争贷款，及时足额到位。同时建设单位要准备一定数量的资金，必要时进行垫付,确保本项目能按计划如期完成。
1．5 结论
本项目是充分利用当地的原料资源和劳动力资源，促进当地工业农业的发展的项目，是招商引资、提高人民生活水平，为国家创造财政收入的好项目。本项目采用的生产方法和生产工艺技术，选用的设备稳定可靠，先进可行,生产的啤酒质量高。项目建设完成投产后,正常年分创造产值68322万元，销售税金7658万元，所得税5151万元，税后利润14810万元，财政内部收益率52。88％，盈亏平衡点28。17％，投资回收期(包括建设期二年）所得税后3.52年，所得税前3.52年社会效益和经济效益明显，有一定的抗风险能力，项目是可行的.
2 工厂总体设计
2．1 厂址概述
金士百啤酒集团公司隶属于全国知名乡镇企业红嘴集团，是一家专业生产、销售啤酒产品的集体所有制企业。公司占地面积45万平方米,建筑面积8万平方米。拥有员工1300余人，年设计生产能力30万吨,资本总额5亿元，是吉林省单产规模最大，东北地区第三大啤酒企业。公司始建于1985年，1995至2000年与英国巴斯啤酒公司合资.2000年4月公司转为中方独资企业。仙马泉是金士百啤酒集团公司的取水地.仙马泉是经过国家地矿部坚定的天然矿泉水.天然纯净、品质优良、无污染，是酿制啤酒的绝好佳品。金士百啤酒集团公司是我国啤酒行业首家获得ISO9002国际质量保证体系的啤酒企业。
2．2 总平面布置
2．2．1 工厂总平面布置设计原则
(1） 满足生产要求，工艺流程合理 工厂总体布局应满足生产要求,符合工艺过程，减少物流量，同时重视各部门之间的-关系密切程度。具体布置模式有两种：
　①　按功能划分厂区，即将工厂的各部门按生产性质、卫生，防火与运输要求的相似性，将工厂划分为若干功能区段。如中、大型机械工厂的厂区，可划分为加工装配区，备料（热加工）区，动力区、仓库设施区及厂前区等.这种布置模式的优点是各区域功能明确,相互干扰少，环境条件好，但是，这种布置模式难以完全满足工艺流程和物流合理化的要求。
②　采用系统布置设计模式，即按各部门之间物流与非物流相互关系的密切程度进行系统布置,因此可以避免物料搬运的往返交叉,节省搬运时间与费用。
（2）适应工厂内外运输要求，线路短捷顺直 工厂总平面布置要与工厂内部运输方式相适应.根据生产产品产量特点，可以采用铁路运输、道路运输、带式运输或管道运输等。根据选定的运输方式，运输设备及技术要求等，合理地确定运输线路及与之有关的部门的位置。
厂内道路承担着物料运输，人流输送，消防通行的任务,还具有划分厂区的功能;道路系统的布局对厂区绿化、美化，排水设施布置，工程管线铺设,也有重大影响.
工厂内部运输方式，道路布局等应与厂外运输方式相适应，这也是工厂总平面布置应给予重视的问题.
（3)合理用地 节约用地是我国的一项基本国策.工业企业建设中，在确保生产和安全的前提下，应尽量合理地节约建设用地.在工厂总平面布置时可以采取如下措施：
①　根据运输、防火、安全，卫生、绿化等要求，台理确定通道宽度以及各部门建筑物之间的距离，力求总体布局紧凑合理。
　②　在满足生产工艺要求的前提下，将联系密切的生产厂房进行合并，建成联合厂房。此外,可以采用多层建筑或适宜的建筑物外形。
③　适当预留发展用地。
（4)充分注意防火、防爆、防振与防噪声 安全生产是工厂布局首先要考虑的问题,在某些危险部门之间应留出适当的防火、防爆间距。
振动会影响精密作业车间的生产，因此精密车间必须远离振源或采用必要的隔振措施.如机械厂的精加工车间及计量部门应远离锻造车间或冲压车间。
噪声不仅影响工作，而且还会摧残人的身体健康.因此，在工厂总平面布置时要考虑防噪声问题,一是可以采取隔音措施，降低噪声源发出的噪声级；二是可以采取使人员多的部门远离噪声源的方法.
(5）利用风象、朝向的自然条件,减小环境污染 生产中产生的有害烟雾和粉尘会严重影响工作人员的身体健康,并会造成环境污染。进行工厂总平面布置前,必须了解当地.全年各季节风向的分布和变化转换规律，绘制成风象图,拽出全年占优势的盛行风向及最小风频风向。如我国北方大部分地区春，夏季盛行东南风,秋，冬季盛行西北风。散发有害烟雾或粉尘的车间，应分布在两盛行风向间的最小频风向的上风侧。
另外,建筑物的朝向也是工厂总平面布置时应注意的问题,特别是对日照、采光和自然通风要求较高的建筑物，更应注意这个问题。
（6）充分利用地形、地貌、地质条件。
(7）考虑建筑群体的空间组织和造型，注意美学效果.
（8)考虑建筑施工的便利条件。
2．2．2 车间布置设计原则
（1)确定设备布置形式 根据车间的生产纲领，分析产品-产量关系，从而确定生产类型是大量生产、成批生产还是单件生产，由此决定车间设备布置形式是采用流水线式，成组单元式还是机群式.
(2）满足工艺流程要求 车间布置应保证工艺流程顺畅，物料搬运方便，减少或避免往返交叉物流现象.
(3）实行定置管理，工作环境整洁，安全。对车间布置时除对主要生产设备安排适当位置外，还需对其它所有组成部分包括在制品暂存地，废品废料存放地,检验试验用地、工人工作地，通道及辅助部门如办公室，生活卫生设施等安排出合理的位置，确保工作环境整洁及生产安全.
（4）选择适当的建筑形式 根据工艺流程要求及产品特点，配备适当等级的起重运输设备,进一步确定建筑物高度、跨度、拄距及形状.
（5）采光、照明、通风，采暖、防尘、防噪声。
(6）具备适当的柔性，适应生产的变化。
3 生产工艺
3．1 原料及产品的质量标准
我国啤酒的质量标准为GB4927—1991，实验方法 GB4928-1991
3．1．1 理化指标
表3-1 成品啤酒理化指标
Table3—1shows finished product beer of physics and chemistry quota

级别
项目
优级
一级
二级
酒精度％
18º
≥4.5
≥4.3
16º
≥4.4
≥4。2
14º
≥4。3
≥4.1
12º
≥3.7
≥3。5

11º
≥3.4
≥3.2
10º
≥3。1
≥2。9
8º
≥2。57
≥2。4
≥2。2
原麦汁浓度%
18º
18±0.3
16º
16±0。3
14º
14±0.3
12º
12±0.3
11º
11±0.3
10º
10±0。3
8º
8±0.3
总酸
ml/100
ml
18º16º
≤4。5
14º
≤3.0
12º11º
≤2.6
二氧化碳%
≥0。40
≥0。38
≥0.35
双乙酰
Mg/l
浅色
≤0.13
≤0.15
≤0.20
浓色
≤0。14
≤0.16
≤0。20
保存期（天)
≥120
≥120
≥60
3。1.2 感官指标
表3-2 成品啤酒的感观指标
Table3—2shows finished product beer of feeling quota

级别
项目
优级
一级
二级
外观
透明度
清亮透明,无明显悬浮沉淀物
尚清,较透明
浑浊度
≤1.0
≤1.0
≤2。0
形态
泡沫洁白细腻持久挂杯
泡沫较洁白细腻
较持久挂杯
泡沫尚洁白
较粗
泡沫性
瓶装
≥210
≥100
≥120
罐装
≥180
≥180

色度
14º
5.0—11.0
5.0—11。0
5.0-14.0
12º11º10º
5.0-9.5
5。0-11。0
5。0—12.0
8º

5.0—12。0
5。0-12。0
香气和口味
有明显的酒花香气，口味纯正,爽口，酒体谐调柔和，无异味。
有较明显的酒花香气，口味纯正,爽口，酒体谐调柔和，无异味
有酒花香气，口味纯正，无异味
3．2 生产工艺流程
3．2．1 酿造啤酒的原料
酿造啤酒的主要原料是大麦,水,酵母，酒花.
（1）大麦：大麦是酿造啤酒的主要原料,但是首先必须将其制成麦芽，方能用于酿酒.大麦在人工控制和外界条件下发芽和干燥的过程，即称为麦芽制造.大麦发芽后称绿麦芽，干燥后叫麦芽。
麦芽的制造主要分为四个阶段:
1、精选后的大麦浸泡在水中，使大麦吸收水分,达到能发芽的要求，此阶段称为浸麦.根据设备和工艺要求的不同，又有好多种方法,这里就不做详细介绍。
2、然后在人工控制的条件下进行发芽，利用发芽过程中形成的酶系,使大麦的内容物质进行分解，变为麦芽。
大麦发芽的主要目的：胚乳细胞壁的部分或全部降解,是干燥后的麦芽变得疏松，更易粉碎，内容物质更容易溶出。
3、发芽完毕的成为绿麦芽，利用热空气 进行干燥.
干燥的主要目的：使绿麦芽停止生长和酶的分解作用，除区多余的水分，防止腐烂,便于运输.使根部干燥便于初去，增加麦芽的色，香,味。
4、然后经过机械原理将麦芽的根除去。
（2）酿造水：啤酒的主要成分就是水，所以水的好坏对啤酒的影响很大，详见下表

水质内容:
颜色
透明度
味
总溶解盐
PH值
有机物（高锰酸钾耗氧量)
理想状态:
无色
透明，无沉淀
无味
150-200mg/L
6。8—7。2
0—3mg/L

水质内容：
铁盐（以Fe计)
锰盐(以Mn计)
氨态氮(以N计）
氯化物（以Cl计)
游离氯
理想状态：
〈0.3mg/L
〈0。1mg/L
0
20—60mg/L
〈0。1mg/L

（3）酵母：酵母的种类很多，用于啤酒生产的酵母叫做啤酒酵母。
啤酒酵母的学名：Saccharomyces cerevisiae
根据Loder分类，酵母有39属，350种。
根据发酵方式分为：上面发酵的酵母和下面发酵的酵母
啤酒酿造中酵母主要起的作用就是降糖，产生二氧化碳和酒精
（4)酒花：啤酒花(简称：酒花)作为啤酒工业的原料开始使用于德国。使用的主要目的是利用其苦味，香味，防腐力和澄清麦汁的能力。
3．2．2 麦汁的制备
其主要过程有原料粉碎,糖化，醪液过滤，麦汁煮沸，麦汁后处理等几个过程
（1） 原料的粉碎· 麦芽粉碎：麦芽粉碎的目的主要在于,使表皮破裂,增加麦芽本身的表面积,使其内容物质更容易溶解，利于糖化.按其粉碎类型来说，可以分为干粉碎和湿粉碎两种。
值得注意的是，对于表皮的粉碎要求破而不碎，原因是表皮主要组成是各种纤维组织，其中有很多物质会影响啤酒的口味，如果将其粉碎，在糖化的过程中，会使其更容易溶解，从而影响啤酒的质量，其次使是因为，在糖化过后的过滤中，可以将去其更容易的过滤掉，而且可以让其充当过滤层，达到更好的过滤效果。
人们通过测定麦芽某些性能，预示或指导后续工艺及控制啤酒质量,从而对麦芽质量作出正确评定
大米和玉米的粉碎:对于大米来说，粉碎的越细越好，越利于糊化.玉米要求先脱胚和壳，粉碎度不能超过要求。两种辅料粉碎后的时间不能超过24小时，防止发热结块。
（2）糖化：所谓糖化就是利用麦芽所含的各种水解酶，在适宜的条件下，将麦芽中不溶性高分子物质(淀粉,蛋白质，半纤维素及其中间分解产物），逐步分解成低分子可溶性物质,这个分解过程叫做糖化.
· 整个过程主要包括:淀粉分解，蛋白质分解， B—葡聚糖分解，酸的形成和多酚物质的变化。
· 糖化的主要方法：煮出糖化法，浸出糖化法，双醪糖化法，分级糖化法。见下表
温度℃
效应
35-37
酶的浸出,有机磷酸盐的分解
40-45
有机磷酸盐的分解,B-葡聚糖的分解，蛋白质分解，R-酶对支链淀粉的解支作用
45—52
蛋白质分解,低分子含氮物质多量形成，B—葡聚糖的分解,R-酶和界限糊精对支链淀粉的解支作用，有机磷酸盐的分解
50
有利于羧肽酶的作用，低分子含氮物质的形成。
55
有利于内肽酶的作用，大量可溶性氮形成