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 Ltd
Email marriottuk@aol.com
Tel +44(0) 1227 730912
Mob +44(0) 7860 331834
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Agenda
Waste Statistics
Co- Tri Polygeneration
GQCHP – Good Quality CHP
Commercial Considerations for use of CHP
Applications
Some Examples and Site Details
Sorption Systems
Commercial Example ~ Funding Grants
Concluding Remarks
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Some Food Industry Statistics
Major user of energy ~ 100TWh which is equivalent
to 11% of energy use by business
7.9 Million tonnes Carbon p.a.
Significant waste stream ~ accounting for 10%
industrial & commercial waste
Refrigeration 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
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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 manufacture
3.0 m t / p.a. food service & restaurants
1.6 m t / p.a. retail food
3.6 m t / p.a. remainder ~ horticulture,
agriculture, schools,
hospitals.
Source http://www.wrap.org.uk/retail/food_waste/nonhousehold_food.html
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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 >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
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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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Why Trigeneration
Embedded Power Trigeneration?
Grid Power Conventional
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Grid Supply Energy Efficiency
Limitations
Grid electrical efficiency use on site is limited to the
power 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 efficiency
on applications compared to grid electrical supply
reaching efficiencies of =>80%
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Conventional Systems
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ή Power station 40-45%
ή transmission = - 3%
ή Power to site = 37- 42%
ή Loss = 63% – 58%
2/3 energy is lost
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Conventional Systems
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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 2050
How 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 ( My Rule of thumb)
Index = 200 Electrical Efficiency + 125 Thermal Efficiency > 100
GQCHP Avoids payment of climate change levy (CCL)
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CHP the Success Criteria
Continuous and matched heat & electrical supply & demand
Suitable ratio of energy demand/supply
Currently Spark Gap (electrical cost / fuel cost) > 3.0
CO2 emission reduction – Tax advantages
Improved security of supply
Interruptible energy supply cost savings - supply security
Suitable relative capital incentive – mains supply
Relative maintenance costs not a significant penalty
Projected life cycle costs are attractive compared
to conventional.
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Some Applications of CHP
The plant electrical or part load supply plus
Water/Fluid heating – Process industry, adjacent
heating, space heating, food cooking/
pasteurisation
Steam raising – district heating, process heating
CO2 + electricity + heat for horticulture
Drying - direct – milk, process
- indirect – waste sludge,
- secondary processes
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Actual Deliveries of CHP Systems by a Leading Supplier
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Commercial Considerations for
Successful CHP Applications
e.g.
Electricity £0.010/kWh : Gas £0.030 /kWh
Rule of thumb Spark Gap > 3.0
Relative cost of power / fuel ~ Electricity to Gas
Cost of electricity - gas ~ Price Gap = 7.0 p/kW
Cost of electricity / gas ~ Spark Gap = 3.3
Electricity Connection Charge and agreements
Gas Connection charge and agreement
Potential to manage interruptible gas supplies
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The Prime Movers
There is a variety of available systems that
can be applied as the electrical primary energy
Supply devices. E.g.
Reciprocating Engines
Microturbines
Gas Turbines
Steam Turbines
Solar
ORC (Organic Rankin Cycle)
Fuel Cells
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Some fuels used in prime movers
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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 application
Waste 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 CHP
Heating load 600kWh effective
Electrical site load 400kWe +/- 150 kWe
Note the balance of supply and demand !
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Typical Life Cycle Costs
Fuel
Capital
O&M
Misc.
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Trigeneration CHCP & CHRP
Reasons for use over CHP
Improve Thermal Efficiency + 20%
Reduce Emissions ~ Direct & Indirect
Life Cycle Cost reductions
Security of supply
Refrigeration Simplified
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Applications of Trigeneration CHCP
A simultaneous demand for heat,
cooling/refrigeration and power
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Food & Food Retail Industry
Manufacturing and Process Industries
Hotels
Hospitals
Leisure Centers
Office and Residential Buildings
Schools and Domestic Residences
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Trigeneration ~ Combined Heat
Cooling/Refrigeration & Power
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Sorption Refrigeration Systems
Sorption
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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.
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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)
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Simplified Silica Gel Schematic
• Water refrigerant
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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
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Simplified Lithium Bromide - Li/Br
DRIVING
HEAT
SOURCE
• Water – Refrigerant
• Evaporator
• Pumps weak Sol’n
• Rectifier
concentrates the
solution
• Vapour driven off
• Liquefied –
condensed
• Evaporates
• Care to avoid triple
point solidification
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Simplified 2 Stage Li/Br
Compared with Single Stage
DRIVING
HEAT
SOURCE
• Higher Generator
temperature input req’d
• Resultant higher COP
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Pressure & Temperature Relationships Li/Br
Li / Br
Pressure
1 atm.
Vacuum
Gauge Pressure Absolute
(kg/cm2 G)
Pressure
(kg/cm2 G)
Temp
(oC)
Remarks
10
11
183.2
8
9
174.5
5
6
158.1
1
2
119,6
0.5
1.5
110.8
Driving pressure for
single effect type
760 mmHg
100
Atmospheric Pressure
650.0
95.5
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
Driving pressure for
double effect type
High Temp. Generator
Pressure
Condenser Pressure
Evaporator Pressure
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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
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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
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Food Industry Applications for
Trigeneration
• 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
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Trigeneration Industrial Applications
Food & Pharmaceuticals
Freeze Drying
Food Refrigeration
Cold Storage
Dairies
Ice Making Plants / Ice
Storage.
Ice Cream Plants
Meat Processing
Fish Processing Industries.
Blast Freezing / Cold Stores
Solvent Recovery
Industrial Processes
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AMMONIA ABSORPTION REFRIGERATION PLANTS
(AARP)
Steam / Heat Driven
Wide 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
• 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
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Example of Relative Payback/ Cost
Conventional vis CHRP
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Chilled Food Application at 1 Tonne/hr
Dairy Produce Chilling Yogurt
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Assumptions for Comparisons
Tri-gen plant producing at 80kWe
Process heating Hx2 = 71 kW
Regenerative Hx1 = 45 kW
Spiral cooling duty = 55 kWr
6000 hrs p.a. production plan
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Economic Comparison of Conventional ~ Tri-generation
Capital cost
Conventional Plant
Tri-generation Plant
£ 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
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Comparison Between Conventional and
Tri-generation System
Conventional System
Tri-generation System
• Overall Efficiency: 51 %
• Overall Efficiency 73 %
(COP=0.35)
• Running Cost: £800 p.w.
• Running Cost: £440 p.w
• CO2 Emissions:12.6 t/day
• 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.
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Doug Marriott Associates
Saving Business Energy
Acknowledgements
We acknowledge with thanks the Co-Funding Provided by Defra
under 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, Bock
Kaltenmaschinen 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
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Some Grants and Funding & Options
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Option 1
Option 2
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Option 3
Option 4
Option 5
Option 6
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Community & Charitable Grants <£30 K
www.eon-uk.com/source
ECA 100% first year Energy Saving
www.eca.gov.uk /
Low Carbon/Water Conservation
www.eca-water.gov.uk
Shell Springboard < £40 k
www.shellspringboard.org
Defra - Rural Enterprise Scheme
www.defra.gov.uk/erdp/schemes/res
Collaborative Research TSB http://www.grantsforindustry.co.uk/business-grants/eligibility-check
Low Carbon Building Programme
http://www.lowcarbonbuildingsphase2.org.uk/filelibrary/LCBP2E/LCBP2E_Guidance_Notes_new_v1.0.pdf
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Option 7
Renewable Heat Incentive
http://www.decc.gov.uk/en/content/cms/meeting_energy/renewable_ener/incentive/incentive.aspx
Alternative
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Option 8
Waste heat generation of Electricity
15-20% recovery
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Other References and Web Access
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http://www.therenewableenergycentre.co.uk/grants/
www.bwea.com/you/funding.html
http://www.renewableenergyfocus.com/view/8384/small-business-captures-largest-shareof-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/renewa
bles/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/renew
ables/business-investment/funding/page19360.html
http://www.scotland.gov.uk/Topics/Business-Industry/Energy
Doug’s Em marriottuk@aol.com Tel +44(0) 1227 730 712 Mob +44(0)7860331834
www.spiral-freezers.co.uk
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Site Photos
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Doug Marriott Associates
Saving Business Energy
A Packaged 500kW
Saving
CHP
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18 Cylinder 1500 kWe
Genset
Doug Marriott Associates
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Saving
Retrofit CHP with existing
Boilers
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Doug Marriott Associates Saving Business Energy
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 Ltd
Email marriottuk@aol.com
Tel +44(0) 1227 730912
Mob +44(0) 7860 331834
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• End of slides
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