Rural Synergies: Combined Heat and Power Systems at Dairy Farms and Ethanol Plants

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1 Rural Synergies: Combined and Power s at Dairy Farms and Ethanol Plants Presented at: 2010 ACEEE Forum on Energy Efficiency in Agriculture Madison, Wisconsin February 8 th, 2010 Presented By: Dr. Steffen Mueller & Cliff Haefke University of Illinois at Chicago U.S. DOE Midwest Clean Energy Application Center

2 Topics to be Covered Rural Delivery Issues and Concerns Concept of Combined and Power () on Farm and Ethanol Facility Co-location & Integration of Farm & Ethanol Facility 2010 The Trustees of the University of Illinois 2

3 U.S. DOE Midwest Clean Energy Application Center Located at University of Illinois at Chicago Originally established in 2001 by US DOE to support DOE Challenge Today the center promotes the use of, District Energy, and Technologies Strategy: Provide a technology outreach program to end users, policy, utility, and industry stakeholders focused on: Targeted Education Unbiased Information Technical Assistance Midwest 2010 The Trustees of the University of Illinois 3

4 2010 The Trustees of the University of Illinois 4

5 Rural Delivery Concerns Inadequate service lines Unable to attract larger businesses Higher electricity prices to build grid infrastructure Unstable electricity delivery (momentary power interruptions) Increased chance of electric outages (lower amount of utility support due to lower population) 2010 The Trustees of the University of Illinois 5

6 What is Combined and Power ()? A More Efficient Way of Delivering Energy A Form of Distributed Generation An Integrated Located At or Near a Building/Facility Provides at Least a Portion of the Electrical Load and Recycles the Thermal Energy for Space ing / Cooling Process ing / Cooling Dehumidification Domestic Hot Water 2010 The Trustees of the University of Illinois Picture Courtesy of UIC 6

7 Q in (fuel input) 100% Natural Gas Propane Digester Gas Landfill Gas Others 15% Prime Prime Mover Mover Q out Exchanger Exchanger Q out Thermal Thermal 50% thermal Defining Concept W out 35% electricity Generator Generator Prime Prime Mover Movergenerates mechanical mechanical energy energy (reciprocating (reciprocating engines, engines, turbines, turbines, fuel fuel cells) cells) Generator Generator converts converts mechanical mechanical energy energy into into electrical electrical energy energy includes includes one one or or more more heat heat exchangers exchangers that that capture capture and and recycle recycle the the heat heat from from the the prime prime mover mover Thermal Thermal Utilization Utilizationequipment converts converts the the recycled recycled heat heat into into useful useful heating, heating, cooling, cooling, and/or and/or dehumidification dehumidification Operating Operating Control Control s sinsure the the components components function function properly properly together together 2010 The Trustees of the University of Illinois 7

8 What are the Customer Benefits of? does not make sense in all applications, but where it does make technical and economic sense, it will provide: - Lower Energy Costs - Reduced Energy Consumption - Increased Electric Reliability - Standby Power - Improved Environmental Quality - Public Relations Benefits 2010 The Trustees of the University of Illinois 8

9 Example #1: Hunter Haven Farms Pearl City, Illinois 800 dairy cows Plug flow anaerobic digester 260 kw generating capacity 1.5 MMBtu/hr hot water heat recovery Began operation: 2005/ The Trustees of the University of Illinois 9

10 Example #2: Adkins Energy LLC Lena, Illinois Ethanol facility 47.5 million gallons per year Natural gas-fired system 5.0 MW system recovery: 125 psi pressure steam Began operation: The Trustees of the University of Illinois 10

11 Proximity of Dairy Farm to Ethanol Plant 2010 The Trustees of the University of Illinois 11

12 Typical Farm and Ethanol Plant Natural Gas Lagoon Dryer Feed 1/3 hay 1/3 corn silage 1/3 gluten + protein mix + corn DDG 2010 The Trustees of the University of Illinois 12

13 on Farm Bedding Biogas Natural Gas Digester Effluent (fertilizer) Dryer Feed 1/3 hay 1/3 corn silage 1/3 gluten + protein mix +corn Corn/ Silage DDG 2010 The Trustees of the University of Illinois 13

14 on a Farm and in an Ethanol Plant Bedding Digester Biogas Effluent (fertilizer) Natural Gas WDG Dryer Feed 1/3 hay 1/3 corn silage 1/3 gluten + protein mix +corn Corn/ Silage DDG 2010 The Trustees of the University of Illinois 14

15 Integration of Farm and Ethanol Plant Bedding Digester Biogas Effluent (fertilizer) Natural Gas Dryer Feed 1/3 hay 1/3 corn silage 1/3 WDG + gluten + protein mix + corn Corn/ Silage WDG DDG 2010 The Trustees of the University of Illinois 15

16 Closed Loop Energy Synergies Synergy #1 Bedding Digester Biogas Effluent (fertilizer) Natural Gas Dryer 1/3 hay 1/3 corn silage Corn/ Silage WDG DDG Feed 1/3 gluten + WDG 2010 The Trustees of the University of Illinois 16

17 Closed Loop Energy Synergies Synergy #2 Bedding Digester Biogas Effluent (fertilizer) Natural Gas Dryer 1/3 hay 1/3 corn silage Corn/ Silage WDG DDG Feed 1/3 gluten + WDG 2010 The Trustees of the University of Illinois 17

18 Closed Loop Energy Synergies Synergy #3 Bedding Digester Biogas Effluent (fertilizer) Natural Gas Dryer 1/3 hay 1/3 corn silage Corn/ Silage WDG DDG Feed 1/3 gluten + WDG 2010 The Trustees of the University of Illinois 18

19 Closed Loop Energy Synergies Synergy #4 Bedding Digester Biogas Effluent (fertilizer) Natural Gas Dryer 1/3 hay 1/3 corn silage Corn/ Silage WDG DDG Feed 1/3 gluten + WDG 2010 The Trustees of the University of Illinois 19

20 Closed Loop Energy Synergies Synergy #5 Bedding Digester Biogas Effluent (fertilizer) Natural Gas Dryer 1/3 hay 1/3 corn silage Corn / Silage WDG DDG Feed 1/3 gluten + WDG 2010 The Trustees of the University of Illinois 20

21 Closed Loop Energy Synergies All Identified Synergies Bedding Digester Biogas Effluent (fertilizer) Natural Gas Dryer 1/3 hay 1/3 corn silage Corn / Silage WDG DDG Feed 1/3 gluten + WDG 2010 The Trustees of the University of Illinois 21

22 Closed Loop Synergy Descriptions #1 (red) biogas from the digester produces electricity in the system and reduces rural electric load; the heat recovered from the engine maintains the temperature of the digester #2 (yellow) the liquid effluent (high in NPK) from the digester is utilized as fertilizer to grow corn/corn silage for feed to the cows; cow waste is recovered into the digester #3 (brown) the solid effluent from the digester is used as bedding for the cows, increasing cow health The Trustees of the University of Illinois 22

23 Closed Loop Synergy Descriptions #4 (green) heat recovery at the ethanol plant s system increases energy efficiency and reduces electric load on the rural grid #5 (blue) the WDG that is not dried into DDG at the ethanol plant is shipped to the local farm for animal feed. Cows turn animal feed into more biogas for more electricity production and reduced rural electric load 2010 The Trustees of the University of Illinois 23

24 Farm Energy Savings and Optimization Free electricity from biogas system Average generation 170 kw/hr Total 1,489,200 kwh per year Free from hot water heat recovery Maintain temperature of digester In-floor heating of barn and holding areas Farm hot water needs Reduced animal feed cost Corn silage from digester produced fertilizer (high NPK) WDG from ethanol plant Animal bedding from digester effluent (happy cows = more milk) 2010 The Trustees of the University of Illinois 24

25 Ethanol Plant Energy Savings and Optimization provides more efficient method of delivering energy to a facility when compared to standard method of electricity from utility and thermal energy from boilers Baseline Ethanol Plant No 0.71 kwh/gal* from utility Adkins Energy Self-generation <0.1 kwh/gal from utility Adkins Confirmed Reduced Power Outages *Source: Mueller and Copenhaver An Analysis of Modern Corn Ethanol Technologies Reduced energy consumption due to shipping WDG to area farmer (drying WDG is energy intensive operation) 2010 The Trustees of the University of Illinois 25

26 Summary provides a solution to increasing reliability of rural electric grid by reducing grid electric demand provides process efficiency for both farm and ethanol plant (closed loop synergies) Ethanol plants can provide valuable feedstock for farmers more farmers = more shipping of WDG and less DDG less DDG = lower energy consumption at ethanol plant Co-locate several farms in close proximity to a single ethanol plant for synergistic benefits 2010 The Trustees of the University of Illinois 26

27 Questions / Discussions Contact Information Steffen Mueller Cliff Haefke 312/ / muellers@uic.edu chaefk1@uic.edu Energy Resources Center University of Illinois at Chicago US DOE Midwest Clean Energy Application Center Promoting, District Energy, and 2010 The Trustees of the University of Illinois 27