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 Cost Carbon Saving Opportunities in the
Food Allied Industry Summary Presentation

• Doug Marriott
• BSc CEng CSci FIEE FIET FInstR MInstPet MEI FIFST
  FRSA
• Chartered Engineer  - Chartered Scientist
• Doug Marriott Associates Ltd
• Email marriottuk_at_aol.com Tel [phone]
  730912 Mob 44(0) 7860 331834

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Agenda

• Anaerobic Digestion
• Polygeneration Justification Some Applications
  
• GQCHP Good Quality CHP Success Criteria
• Other prime movers fuel sources
• Commercial Considerations for use of CHP CHRP
• An Actual Applications for Heat and Power
• Some Examples and Site Details
• Sorption Systems
• Commercial Example
• Concluding 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 gt110 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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Why Trigeneration Not Blue Sky
Embedded Power Trigeneration?
Grid Power Conventional
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Conventional Systems

• ? Power station 40-45
• ? transmission - 3
• ? Power to site 37- 42
• ? 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 ( Rule of thumb)
• Index 200 Electrical Efficiency 125 Thermal
  Efficiency gt 100
• GQCHP Avoids payment of climate change levy (CCL)

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CHP CHRP - the Success Criteria

• Continuous and matched heat electrical supply
  demand
• Suitable ratio of energy demand/supply
• Currently Spark Gap (electrical cost / fuel cost)
  gt 3.0
• CO2 emission reduction Tax advantages - Carbon
  Tax
• Improved security of supply
• Interruptible energy supply cost savings - supply
  security
• Suitable relative capital incentive mains
  supply
• Relative maintenance costs a potential advantage
• Projected 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 /kWh
• Rule of thumb Spark Gap gt 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
• Upgrading time expired refrigeration plant

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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

• 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 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 CHP
• Heating load 600kWh effective
• Electrical 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 Indirect
• Life Cycle Cost reductions
• Security of supply
• Refrigeration Simplified

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Sorption Refrigeration Systems

• 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)
• .

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Simplified Silica Gel Schematic

• 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

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Simplified Lithium Bromide - Li/Br

• Water Refrigerant
• Evaporator
• Pumps weak Soln
• Rectifier concentrates the solution
• Vapour driven off
• Liquefied condensed
• Evaporates
• Care to avoid triple point solidification

DRIVING HEAT SOURCE
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Simplified 2 Stage Li/Br
Compared with Single Stage Higher Generator
temperature input reqd Resultant higher
COP
DRIVING HEAT SOURCE
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Pressure Temperature Relationships Li/Br
Li / Br Gauge Pressure (kg/cm2 G) Absolute Pressure (kg/cm2 G) Temp (oC) Remarks
Pressure 10 11 183.2 Driving pressure for double effect type Driving pressure for single effect type
Pressure 8 9 174.5 Driving pressure for double effect type Driving pressure for single effect type
Pressure 5 6 158.1 Driving pressure for double effect type Driving pressure for single effect type
Pressure 1 2 119,6 Driving pressure for double effect type Driving pressure for single effect type
Pressure 0.5 1.5 110.8 Driving pressure for double effect type Driving pressure for single effect type
1 atm. 760 mmHg 100 Atmospheric Pressure
Vacuum 650.0 95.5 High Temp. Generator Pressure Condenser Pressure Evaporator Pressure
Vacuum 525.9 90.0 High Temp. Generator Pressure Condenser Pressure Evaporator Pressure
Vacuum 167.6 62.6 High Temp. Generator Pressure Condenser Pressure Evaporator Pressure
Vacuum 92.5 50.0 High Temp. Generator Pressure Condenser Pressure Evaporator Pressure
Vacuum 61.0 41.5 High Temp. Generator Pressure Condenser Pressure Evaporator Pressure
Vacuum 31.8 30.0 High Temp. Generator Pressure Condenser Pressure Evaporator Pressure
Vacuum 29.4 28.6 High Temp. Generator Pressure Condenser Pressure Evaporator Pressure
Vacuum 9.2 10.0 High Temp. Generator Pressure Condenser Pressure Evaporator Pressure
Vacuum 6.54 5.0 High Temp. Generator Pressure Condenser Pressure Evaporator Pressure
Vacuum 5.68 3.0 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 gt30 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 _at_
-500C 43 COP _at_ -400C Various
cooling solns - industrial brines etc
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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 _at_ 21 bar G
• Steam driven electrical turbine
• Steam exhaust powers AARP
• Complete cooling services
• Integral ice making plant

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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 Emissions12.6 t/day

• Tri-generation System
• Overall Efficiency 73 (COP0.35)
• 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 lt30 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 lt 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/filelib
  rary/LCBP2E/LCBP2E_Guidance_Notes_new_v1.0.pdf
• ? Option 7 Renewable Heat Incentive
• 
  http//www.decc.gov.uk/en/content/cms/meetin
  g_energy/renewable_ener/incentive/incentive.aspx
• Alternative
• ? 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/smal
  l-business-captures-largest-share-of-renewable-ene
  rgy-grants/
• http//www.energysavingtrust.org.uk/business/Busin
  ess/Local-Authorities/Funding
• http//www.sungiftsolar.co.uk/grants.htmlhttp//ww
  w.r-e-a.net/info/links/funding-links
•  http//webarchive.nationalarchives.gov.uk//http
  //www.dti.gov.uk/energy/sources/renewables/busines
  s-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/busines
  s-investment/funding/page19360.html   
•  http//www.scotland.gov.uk/Topics/Business-Indust
  ry/Energy
• Dougs Em marriottuk_at_aol.com Tel 44(0)
  1227 730 712 Mob 44(0)7860331834
• www.spiral-freezers.co.uk