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CharteredConsulting Engineers
Cost & Carbon Saving Opportunities in the Food & Allied Industry
AgendaAnaerobic DigestionPolygeneration Justification & Some Applications GQCHP – Good Quality CHP & Success CriteriaOther prime movers & fuel sourcesCommercial Considerations for use of CHP & CHRPAn Actual Applications for Heat and Power Some Examples and Site DetailsSorption SystemsCommercial ExampleConcluding Remarks Trigeneration & Food Engineering Funding and some Grant options
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Defra Backs Anaerobic Digestion
• Organic Materials - Manure Slurry Food waste - could be source of 2 MWhe Source UK Gov. - Jane Kennedy Farming & Environment Minister
• Defra indicate the UK produces >110 M tonnes of organic waste (90 M tonnes from manure + 20 M tonnes Waste Food Defra launching Task force - To Assist sectors such as Farming Water Industry, Food Industry to produce biogas
• NFU target to have 1,000 on farm units by 2020 to power farms and have fertilisers as a by product
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Definition of Polygeneration
CHP is the simultaneous production of Heat & Power derived from a single or multiple source of fuel/energy.
Polygeneration is the use of multiple energy inputs to create multiple energy outputs.
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Grid Power Conventional
Embedded Power Trigeneration?
Why Trigeneration Not Blue Sky
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Conventional Systems
• ή Power station 40-45%• ή transmission = - 3%• ή Power to site = 37- 42%
• ή Loss = 63% – 58%
2/3 energy is lost Energy Act - 80% reduction in energy use by 2050How can we achieve it !
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The key design Good Quality CHP (GQCHP)
The target energy usage should ideally have a ratio of heat/power requirements, which are as closely in phase with the ratio of heat and power delivered by the CHP plant through all the production capacities / demand.
The Measure is Good Quality CHP ( Rule of thumb)Index = 200 Electrical Efficiency + 125 Thermal Efficiency > 100
GQCHP Avoids payment of climate change levy (CCL)
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CHP & CHRP - the Success CriteriaContinuous and matched heat & electrical supply & demand Suitable ratio of energy demand/supplyCurrently Spark Gap (electrical cost / fuel cost) > 3.0 CO2 emission reduction – Tax advantages - Carbon Tax Improved security of supplyInterruptible energy supply cost savings - supply security Suitable relative capital incentive – mains supplyRelative maintenance costs a potential advantageProjected life cycle costs are attractive compared with conventional
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Commercial Considerations for Successful CHP / CHRP Applications
e.g. Electricity £0.010/kWh : Gas £0.030 /kWhRule of thumb Spark Gap > 3.0 Relative cost of power / fuel ~ Electricity to GasCost of electricity - gas ~ Price Gap = 7.0 p/kWCost of electricity / gas ~ Spark Gap = 3.3Electricity Connection Charge and agreements Gas Connection charge and agreement Potential to manage interruptible gas suppliesUpgrading time expired refrigeration plant
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The Prime Movers There is a variety of available systems thatcan be applied as the electrical primary energySupply devices. E.g.
Some fuels used in prime movers • Natural Gas (including interruptible supplies, CNG)• Wellhead Gases • LPG (liquid and gaseous)• Naphtha• Landfill and Sewage Gas• Mines Gas (Coal Bed Methane)• High Hydrogen Gases• Coke oven gas• Synthetic Gases from biomass, coal and wastes • Gasified (‘wood & waste food gas’) • Diesel, Kerosene & biofuels• Crude Oil• Waste solvents e.g. ethanol, methanol hydrocarbon based solvents • Permits are potentially an issue to consider
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Zero or Negative Cost Fuels
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An Example of a CHP applicationWaste Reprocessing plant with tray washing Washing Plastic Food Crates Uses a submersible conveyor with direct gas fired heaters (effective heating water to 700C in a tank through which the conveyor belt carries crates cleaned and strerilised and dried with an air knife) – replaced with a CHPHeating load 600kWh effectiveElectrical site load 400kWe +/- 150 kWe
Note the balance of supply and demand !
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Payback 2 years
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Trigeneration CHCP & CHRP Reasons for use over CHP
Improve Thermal Efficiency + 20%Reduce Emissions ~ Direct & IndirectLife Cycle Cost reductions Security of supply Refrigeration Simplified
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Sorption• Absorption is the incorporation of a substance
into another of a different state.e.g. Liquids into Solids
or Gases into LiquidsAbsorption is basically where a material takes in another substance.
• Adsorption is the physical adherence or bonding of ions and molecules onto the surface of another phase
( e.g. reagents adsorbed to solid catalyst surfaces).
Sorption Refrigeration Systems
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• Water refrigerant • Vacuum Vessel• H2O evaporates• Chilled Water formed• Silica Saturates• Heat Regenerates Silica• Cycle commences• Adjacent chamber – typically 2 chambers• Adjacent chamber with external thermal storage necessary
• Temp +5oC down to -60oC• NH3 refrigerant /H20 absorbent • Flexible and rapid temp adjustment/ start up • Only one moving part (pump)• No refrigerant losses • Low Maintenance • No Triple point issues • Long Life >30 Years• Performance a function of plant temperatures • Fuels Cost Low Zero Negative Carbon/Cost – opportunity
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Operation of Ammonia Absorption Refrigeration Plant (AARP)
• Evap +5 – 600C • Gen heat +95 to 1800C • Various heating media - steam - hot oil• Condenser low temp e.g. + 56% COP @ -500C +43% COP @ -400C • Various cooling soln’s - industrial brines etc
Steam / Heat DrivenWide refrigeration temperatures from + 5oC to –60oC.Accepts Heat source of ≥ 85oC.No moving parts, except a robust centrifugal pump.High availability reliability, low maintenance.Fully automatic. No running attention required.Outdoor / rooftop installation possible.Long life even beyond 40 years.Best efficiency up to 30% of rated capacity.Oil-free refrigerant, no fouling problems.
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Ammonia Absorption Refrigeration Plant
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Polygeneration Dairy Complex in Govind Dairy India with Integral Block Ice Making Plant
Chilled Food Application at 1 Tonne/hr Dairy Produce Chilling Yogurt
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Comparison Between Conventional and Tri-generation System
Conventional System
• Overall Efficiency: 51 %
• Running Cost: £800 p.w.
• CO2 Emissions:12.6 t/day
Tri-generation System
• Overall Efficiency 73 % (COP=0.35)
• Running Cost: £440 p.w
• CO2 Emissions: 5.3 t/day
Note: Efficiency and environmental performance of tri-generation system will increase significantly when low temperature absorption refrigeration systems with COP (Coefficient of Performance) close to 1.0 are achieved.
Doug Marriott Associates Saving Business Energy
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Some Grants and Funding & Options Option 1 Community & Charitable Grants <£30 K www.eon-uk.com/source • Option 2 ECA 100% first year Energy Saving www.eca.gov.uk / Low Carbon/Water Conservation www.eca-water.gov.uk● Option 3 Shell Springboard < £40 k www.shellspringboard.org ● Option 4 Defra - Rural Enterprise Scheme www.defra.gov.uk/erdp/schemes/res
● Option 5 Collaborative Research TSB http://www.grantsforindustry.co.uk/business-grants/eligibility-check
● Option 6 Low Carbon Building Programme http://www.lowcarbonbuildingsphase2.org.uk/filelibrary/LCBP2E/LCBP2E_Guidance_Notes_new_v1.0.pdf
● Option 8 Waste heat generation of Electricity 15-20% recovery
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Other References and Web Access • http://www.therenewableenergycentre.co.uk/grants/• www.bwea.com/you/funding.html • http://www.renewableenergyfocus.com/view/8384/small-business-captures-largest-share-of-renewable-energy-grants/• http://www.energysavingtrust.org.uk/business/Business/Local-Authorities/Funding• http://www.sungiftsolar.co.uk/grants.htmlhttp://www.r-e-a.net/info/links/funding-links• http://webarchive.nationalarchives.gov.uk/+/http://www.dti.gov.uk/energy/sources/renewables/business-investment/funding/r-and-d/
page19363.html• www.edfenergy.com/Business-Electricity • http://webarchive.nationalarchives.gov.uk/+/http://www.berr.gov.uk/energy/sources/renewables/business-investment/funding/page19360.html • http://www.scotland.gov.uk/Topics/Business-Industry/Energy• Doug’s Em [email protected] Tel +44(0) 1227 730 712 Mob +44(0)7860331834 • www.spiral-freezers.co.uk