4-C Foods CHP Plant NYSERDA Demonstration Project June 24, William Cristofaro P.E. Energy Concepts Engineering PC Rochester, NY

Transcription

1 4-C Foods CHP Plant NYSERDA Demonstration Project June 24, 24 William Cristofaro P.E. Energy Concepts Engineering PC Rochester, NY

2 Project Summary: Modular 380 Kw CHP plant Heat recovery to space heating, cheese process and absorption cooling. Total project cost $1,120,0. Net-net savings of $ 2,0 per year. NYSERDA grant of $558,0. Status: plant built within budget and now operating, some commissioning still under way. 2

3 4-C Foods, Brooklyn, NY 3

4 4-C Foods Project Team Owner 4-C foods, Wayne Celauro Owner engineer Joe Oriero Designers Energy Concepts Cogen units Coast Intelligen Electrical All Services/Interphase Mechanical Richtech Inc Controls Integrated Controls (Automated Logic) Electric Utility Coned Gas Utility - Keyspan NYSERDA rep Dana Levy 4

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6 What Was 4-C Interest?, Needs? Product process is energy intensive and 4-C needed to reduce costs. Needed to upgrade HVAC systems for better plant conditions. Some aging chiller equipment needed replacement/service. Required an orderly project process. Remain competitive in future. 6

7 First Step Engineering Analysis Preliminary engineering study to determine electric and thermal loads, model sizes of CHP Plants. Figure out best uses for heat recovery specific to 4-C foods. Based on economic size do preliminary layout and project estimate. Provide owner with options. Apply for NYSERDA funding. 7

8 4-C Foods Heat Recovery Plant Layout Modular Cogen Assembly DG-1 DG-2 DG-3 Heat Recovery Loop Building Heating Cheese Process Dryer Air Conditioning Absorption Chiller Future Electric Power to Building 8

9 Thermal Effect With Absorber 14,0 12,0 10,0 8,0 6,0 4,0 2,0 HEAT LOAD including deductions (Therms) THERMAL LOAD OF ABSORPTION CHILLER (Therms) TOTAL USABLE LOAD (Therms) COGEN HEAT OUTPUT (Therms) 0 Jul- Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr- May- Jun- Added thermal load of absorber achieves year long thermal balance. 9

10 Electric Utility Arrangement, 4-C Foods Modular Cogen Assembly Simultaneous Power From Utility and CHP Plant, Split Service. Service Kw Electric Panel Xfrmr 150 Kw 80 Kw Electric Panel To/From Utility Xfrmr Common Heat Recovery Loop All Three Units To Building Loads Service 2 10

11 4-C Foods, Electric Savings 140,0 120,0 Facility load ON-PEAK + SHLDR 1,0 Total ON PEAK ELECTRICITY 80,0 60,0 40,0 Generated CHILLER ELECTRIC SAVINGS 20,0 Total Electric Savings 0 Jul- Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr- May- Jun- Load following parallel plant. Summer chiller electric savings is added to power generated savings. 11

12 Main System in C-Tainer Package

13 Top of C-Tainer, Catalytic Converters Drycooler 3-Way catalytic converter 13

14 Heat Recovery to Cheese Dryer Hot water coil added to air stream ahead of existing coil 14

15 Ceiling Units for Heating/Cooling 15

16 4-C Foods, Cogen Unit Controller Coast Intelligen microprocessor controller and relays. 16

17 C-Tainer Cogen Packaging 17

18 4-C, Yazaki Absorber Chillers Waste heat from DG plant used to drive Absorption air conditioning. Does not use electricity and eliminates use of ozone depleting refrigerants and hazards. 18

19 Thermal Effect With Absorber 14,0 12,0 10,0 8,0 6,0 4,0 2,0 HEAT LOAD including deductions (Therms) THERMAL LOAD OF ABSORPTION CHILLER (Therms) TOTAL USABLE LOAD (Therms) COGEN HEAT OUTPUT (Therms) 0 Jul- Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr- May- Jun- Added thermal load of absorber achieves year long thermal balance. 19

20 Absorber Air Conditioning Small to Large Chiller Plants Flexible Location, Just Get Hot Water Uses Waste Heat From Plant Little Electric Use Cleanest Available Refrigerant Complete Elimination of Ozone Depleting Good for Low Temp Chilled H2O 20

21 Max Use of Waste Heat 21

22 Regulatory and Tariff Issues Owner can choose CONED SC-09 or CONED SC-14 standby tariff. Economics similar for either tariff. Major NY PSC Under 1,0 kw rule On-site power less than 1,0 kw Clean emissions (Lean or CAT Conv.) Min total energy efficiency of > 60 %. Exempt from standby tariffs or owner choice of best tariff. 22

23 Value Engineering/Lessons Learned Consolidating electric services should be weighed economically with splitservice arrangement. Simplify heat recovery without compromising effectiveness. Take advantage of pre-packaging in high labor markets. Use digital control and automation to lower equipment cost and increase efficiency. 23

24 Lessons Learned - Issues Coordination of equipment vendors and technicians continues to be an important issue. Project scheduling more complex with CHP, team members may underestimate effects of decisions. 24

25 4-C Foods: Project Recap $ 1,120,0 Project completed within budget. Some schedule slippage due to certain coordination items. Electric and thermal recovery systems operating as expected. Some commissioning and controls work still underway. Increase in client loads will increase cost savings/avoidance. 25