If you ferment a beer at 65°F and atmospheric pressure, it will contain 0.88 volumes of carbonation at the end of fermentation. If you want to carbonate to 2.5 volumes, you will need to add 2.5 - 0.88 = 1.62 volumes of additional CO2. 1 volume of CO2 is equal to 1.977 g/L or 0.264 oz/gal. Therefore, to add 1.62 volumes of CO2 to 5 gal of beer requires:
CO2 added for Carbonation = 5 gal * 1.62 volumes * 0.264 oz/(gal*volume) = 2.14 oz
To maintain 2.5 volumes at 40°F serving temp, you need to set the CO2 pressure to 12 psi. At 12 psi the vacated keg volume will contain (12 + 14.7) / 14.7 = 1.82 volumes of CO2. Therefore, to push 5 gal of beer requires:
CO2 to push = 5 gal * 1.82 volumes * 0.264 oz (gal*volume) = 2.4 oz
So, to carbonate and push 5 gal of beer requires 2.14 oz + 2.4 oz = 4.54 oz of CO2. So, 5 lb of CO2 can carbonate and push 5 lb * 16 oz/lb / 4.54 oz/keg = 17.6 kegs. This does not allow for any CO2 use for purging kegs, leakage, or any other use, and any such use will lower the number of kegs carbonated and served.
To avoid having to purge kegs with bottled CO2, you can
use fermentation CO2 to purge kegs. This requires a fermenter that will hold at least a couple of PSI pressure without leaking -
so not a plastic bucket. You also need to do closed transfers that do not expose the beer to any air, or allow any air to enter the keg during the filling process.
Using CO2 for purging will significantly reduce the number of kegs you can carbonate and serve with a given amount of CO2. Also, very often CO2 cylinders are not filled to rated capacity.
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