Chartered Consulting Engineers Cost & Carbon Saving Opportunities in the Food & Allied Industry Doug...

CharteredConsulting Engineers

Cost & Carbon Saving Opportunities

in the Food & Allied Industry

Doug Marriott BSc CEng CSci FIEE FIET FInstR MInstPet MEI FIFST FRSA

Chartered Engineer - Chartered Scientist

Director

Doug Marriott Associates LtdEmail [email protected] Tel +44(0) 1227 730912 Mob +44(0) 7860 331834

mailto:[email protected]


Agenda

Waste StatisticsCo- Tri Polygeneration GQCHP – Good Quality CHPCommercial Considerations for use of CHPApplications Some Examples and Site DetailsSorption SystemsCommercial Example ~ Funding Grants Concluding Remarks


Some Food Industry Statistics

Major user of energy ~ 100TWh which is equivalentto 11% of energy use by business 7.9 Million tonnes Carbon p.a.Significant waste stream ~ accounting for 10% industrial & commercial wasteRefrigeration is a significant polluter in terms of refrigerant leakage (Can be >25% energy CO2

equivalent in some sectors)Landfill waste costs rising annually -current cost typically £93/t overall


Waste Figures in the UK

19 million tonnes food waste (+/- 5%)6.7 million tonnes household food waste 4.1 m t / p.a. food manufacture3.0 m t / p.a. food service & restaurants1.6 m t / p.a. retail food3.6 m t / p.a. remainder ~ horticulture, agriculture, schools, hospitals.

Source http://www.wrap.org.uk/retail/food_waste/nonhousehold_food.html


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 >100Mtonnes of organic waste (90 M tonnes from manure)

• 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 byproduct


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.


Grid Power Conventional

Embedded Power Trigeneration?

Why Trigeneration


Grid Supply Energy Efficiency Limitations

Grid electrical efficiency use on site is limited to thepower station efficiency minus distribution losses e.g. 40% - 4% = 36% (Max Available)The waste heat from the power stations have historically not been captured / used waste energy.CHP has opportunities to use this waste energy and can accordingly improve the thermal efficiencyon applications compared to grid electrical supplyreaching efficiencies of =>80%


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


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 !


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 ( My Rule of thumb)Index = 200 Electrical Efficiency + 125 Thermal Efficiency > 100

GQCHP Avoids payment of climate change levy (CCL)


CHP the Success Criteria

Continuous and matched heat & electrical supply & demand Suitable ratio of energy demand/supplyCurrently Spark Gap (electrical cost / fuel cost) > 3.0 CO2 emission reduction – Tax advantagesImproved security of supplyInterruptible energy supply cost savings - supply security Suitable relative capital incentive – mains supplyRelative maintenance costs not a significant penalty Projected life cycle costs are attractive comparedto conventional.


Some Applications of CHP The plant electrical or part load supply plus Water/Fluid heating – Process industry, adjacent heating, space heating, food cooking/ pasteurisationSteam raising – district heating, process heatingCO2 + electricity + heat for horticulture

Drying - direct – milk, process - indirect – waste sludge, - secondary processes


Actual Deliveries of CHP Systems by a Leading Supplier


Commercial Considerations for Successful CHP 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 supplies


The Prime Movers There is a variety of available systems thatcan be applied as the electrical primary energySupply devices. E.g.

Reciprocating EnginesMicroturbinesGas TurbinesSteam TurbinesSolar ORC (Organic Rankin Cycle)Fuel Cells


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


Zero or Negative Cost Fuels


An Example of a CHP applicationWaste Reprocessing plant 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 with the crates are transported 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 !


Typical Life Cycle Costs

FuelCapitalO&MMisc.


Trigeneration CHCP & CHRP Reasons for use over CHP

Improve Thermal Efficiency + 20%Reduce Emissions ~ Direct & IndirectLife Cycle Cost reductions Security of supply Refrigeration Simplified


Applications of Trigeneration CHCP A simultaneous demand for heat,

cooling/refrigeration and power

• Food & Food Retail Industry• Manufacturing and Process Industries• Hotels• Hospitals• Leisure Centers• Office and Residential Buildings• Schools and Domestic Residences


Trigeneration ~ Combined Heat Cooling/Refrigeration & Power


Sorption• Absorption is the incorporation of a substance into another of a different state.

e.g. Liquids into Solids or Gases into Liquids

Absorption 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


• 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

Simplified Silica Gel Schematic


Simplified Lithium Bromide - Li/Br• Water – Refrigerant

• Evaporator • Pumps weak Sol’n• Rectifier

concentrates the solution

• Vapour driven off• Liquefied –

condensed • Evaporates • Care to avoid triple

point solidification

DRIVING HEAT SOURCE


Simplified 2 Stage Li/Br Compared with Single Stage

• Higher Generator temperature input req’d• Resultant higher COP

DRIVING HEAT SOURCE


Li / Br Gauge Pressure (kg/cm2 G)

Absolute Pressure(kg/cm2 G)

Temp(oC)

Remarks

Pressure

10 11 183.2Driving pressure fordouble effect type

Driving pressure forsingle effect type

8 9 174.5

5 6 158.1

1 2 119,6

0.5 1.5 110.8

1 atm. 760 mmHg 100 Atmospheric Pressure

Vacuum

650.0 95.5High Temp. GeneratorPressure

Condenser Pressure

Evaporator Pressure

525.9 90.0

167.6 62.6

92.5 50.0

61.0 41.5

31.8 30.0

29.4 28.6

9.2 10.0

6.54 5.0

5.68 3.0

Pressure & Temperature Relationships Li/Br


Simplified Ammonia Absorption Refrigeration Plant (AARP)

• 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


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


• Generally food process where CHRP is needed• Ideal consideration on new investment • Retrofit when considering time expired plant needing / or environmental upgrade • It needs planning from conception

Food Industry Applications for Trigeneration


Trigeneration Industrial Applications

Food & PharmaceuticalsFreeze DryingFood RefrigerationCold StorageDairiesIce Making Plants / Ice Storage.Ice Cream PlantsMeat ProcessingFish Processing Industries.Blast Freezing / Cold StoresSolvent RecoveryIndustrial Processes


AMMONIA ABSORPTION REFRIGERATION PLANTS (AARP)

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.


Ammonia Absorption Refrigeration Plant


Polygeneration Dairy Complex in Govind Dairy India with Integral Block Ice Making Plant

• Fuel waste sugar cane husk, coal, wood, other waste fuel

• Steam @ 21 bar G

• Steam driven electrical turbine

• Steam exhaust powers AARP

• Complete cooling services

• Integral ice making plant


Example of Relative Payback/ Cost Conventional vis CHRP


Chilled Food Application at 1 Tonne/hr Dairy Produce Chilling Yogurt


Assumptions for Comparisons

Tri-gen plant producing at 80kWeProcess heating Hx2 = 71 kWRegenerative Hx1 = 45 kWSpiral cooling duty = 55 kWr6000 hrs p.a. production plan


Conventional Plant Tri-generation Plant

Capital cost £ 35k (Refrigeration plant + heating)

£110k (Based on MGT)

Electrical requirement 52.5 kWe (Imported Main Grid)

25 kWe (to drive the fans, lights etc). (From the 80 kWe CHP plant)

Exported electricity 0 kWe 55 kWe

Gas consumption 88.75 kWf 285.7 kWf

Running cost p.a. £ 38,513 £ 42,855

Equivalent exported energy cost p.a.

0 £26,400

Net running cost p.a. £ 38,513 £ 16,455

Relative maintenance similar for both installations

Capital cost difference + £ 75,000

Net running cost difference -£ 22,058

Pay back on the difference 3.4 Years

Economic Comparison of Conventional ~ Tri-generation


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


We acknowledge with thanks the Co-Funding Provided by Defraunder the Advanced Food Manufacturing Food Link Programme. The project is directed by Prof Savvas Tassou Brunel University.

The Consortium in the AFM project in addition to the above is:Tesco, Somerfield - Co-op, A&N Shilliday & Co Ltd, Cambridge

Refrigeration Technology, Bond Industries Ltd, BockKaltenmaschinen GmbH, ACDP, Apex Air Conditioning Ltd, CSA,

Bowman Power Group Ltd, Danfoss Ltd, George Barker& Co (Leeds Ltd) - part of the Elfi Group, Cogenco Ltd &

Doug Marriott Associates Ltd

Acknowledgements


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 7 Renewable Heat Incentive http://www.decc.gov.uk/en/content/cms/meeting_energy/renewable_ener/incentive/incentive.aspx

Alternative

● Option 8 Waste heat generation of Electricity 15-20% recovery

http://www.eon-uk.com/source



http://www.eca-water.gov.uk/

http://www.shellspringboard.org/

http://www.defra.gov.uk/erdp/schemes/res

http://www.grantsforindustry.co.uk/business-grants/eligibility-check


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/renewa

bles/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

http://www.therenewableenergycentre.co.uk/grants/

http://www.bwea.com/you/funding.html

http://www.renewableenergyfocus.com/view/8384/small-business-captures-largest-share-of-renewable-energy-grants/

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

http://webarchive.nationalarchives.gov.uk/+/http:/www.dti.gov.uk/energy/sources/renewables/business-investment/funding/r-and-d/page19363.html

http://www.google.com/aclk?sa=l&ai=CFt4Nim9sTt6fPMGZgQexl_TiDpva5O0C-7Sqni2IvsEICAAQBSCVi5oCKAZQyJL77Pn_____AWC75pmD0AqgAbXu1NgDyAEBqQJ2XY5LG526PqoEIk_Q5mVUUexkB5MAJQNL0hcxUT-dgPwEOIkYlYtSwKqpi4w&sig=AOD64_1d8DTWDMGXbXX2_GzSg-LUVGpdKg&adurl=http://www.edfenergy.com/products-services/interstitial-business.shtml?9gtype=search&9gkw=business%20electricity&9gad=12039207707.1&9gag=3333295907





http://webarchive.nationalarchives.gov.uk/+/http:/www.berr.gov.uk/energy/sources/renewables/business-investment/funding/page19360.html

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



Site Photos


Doug Marriott Associates Saving Saving Business Energy

A Packaged 500kW CHP



18 Cylinder 1500 kWe Genset



Retrofit CHP with existing Boilers


Saving Your Business Energy Worldwide

Doug Marriott BSc CEng CSci FIEE FIET FInstR MInstPet MEI FIFST FRSA

Chartered Engineer - Chartered Scientist

Director

Doug Marriott Associates LtdEmail [email protected] Tel +44(0) 1227 730912 Mob +44(0) 7860 331834



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