SYNERGISTIC MECHANICAL SOLUTIONS:MAXIMIZING PLANT ENERGY EFFICIENCY

WAEE ENERGY EXPOMay 17, 2018

Presentation by:Mike Rohde, President

OVERVIEW1.Traditional Approach

2. Synergistic Approach

3. How to Identify Synergistic Solutions

4. Ammonia Refrigeration Alternative Example

TRADITIONAL SYNERGISTIC

VSREFRIGERATION

• Separate mechanical systems• Low first cost• Energy efficiency at component level• Energy waste in individual systems

• Integrated mechanical systems• Life cycle cost consideration• Energy efficiency at component level• Energy shared between systems

SYNERGISTIC APPROACH

• Heat pump to convert low grade ammonia waste heat• Share energy between systems• Utilized waste heat from ammonia refrigeration system to offset

natural gas requirement for water heating• Increased efficiency of ammonia system by 20%• $178,000 per year energy savings• 1.7 year simple payback after Focus on Energy incentive

Project Distinction Award2011AMMONIA WASTE HEAT USED FOR CLEANING WATER HEATING

• Shuttle Kiln waste heat – 65,000 lbs/hr at 700°F• 660 MBTU heat recovered at 80% efficiency• 250°F hot water heats 18,000 gallons of water to 120°F and

portion of shuttle dryers process• 254,000 therms per year or $178,000 per year savings• 50% of project cost provided by Focus on Energy• Simple payback of only 2.5 years

SYNERGISTIC APPROACH

KILN STACK HEAT RECOVERY

HEAT RECOVERY HEAT PUMPS

SYNERGISTIC APPROACH

• $2,100,000 HVAC system for a new LEED Silver manufacturing facility and office.

• Most sustainable feature – heating office space with the 300hp worth of air compressors.

• Heating 75-80% with heat pumps for a 75,000 sq ft. office.

• Significantly dropped the hours of operation for the boiler.

• Other heat pump installations have used waste heat from plastic injection molding, hydraulics and refrigeration equipment.

SYNERGISTIC APPROACHENGINE TESTING – PROCESS AND HVAC• Central chilled and hot water systems• Engine, chiller and Dyno heat recovery• Thermal storage – highly variable process load• Low temperature hot water – 120°F supply, high delta T • Waste cooling water used for cooling makeup• Integrated controls with Allen Bradley PLC and Honeywell Tridium “Head End”• $83,000 annual energy savings, 5.5 year simple payback on upgrades

HOW TO IDENTIFY SYNERGISTIC SOLUTIONS

Look beyond the obvious and simple:• Process loads and modes of operation• Is steam necessary?• Can steam support cogeneration or trigeneration?• Are cooling and heating loop temperatures correct?• What’s on the roof? • Waste heat recovery / recycling / thermal storage• Make-up air, filtration and industrial ventilation• Automatic controls and energy IT• Is there a pond?

SYNERGISTIC SOLUTION CASE STUDY NEW FOOD PLANT REFRIGERATION, HVAC AND PROCESS

SYNERGISTIC SOLUTION CASE STUDY NEW FOOD PLANT REFRIGERATION, HVAC AND PROCESS

Ammonia Refrigeration HVAC Process

Traditional Approach• Multiple Systems• Multiple Bids• Multiple Contractors• Multiple Headaches

SYNERGISTIC SOLUTION CASE STUDY NEW FOOD PLANT REFRIGERATION, HVAC AND PROCESS

Customer Goals and Wishes• No ammonia• Ease of maintenance• Standard components• Chilled water• Energy efficient and sustainable

SYNERGISTIC SOLUTION CASE STUDY NEW FOOD PLANT REFRIGERATION, HVAC AND PROCESS

Central Chilled Water System• Needed to have operation cost

close to ammonia• Partially accomplished this

through ice storage and off peak operation

• Met remaining goals by creating a separate higher temperature system for HVAC

SYNERGISTIC SOLUTION CASE STUDY NEW FOOD PLANT REFRIGERATION, HVAC AND PROCESS

Low Temperature Water Loop • Chiller condenser cooling• Air compressor cooling• Hydraulic power unit cooling• Office HVAC heat pumps• Geothermal pond heat sink

SYNERGISTIC SOLUTION CASE STUDY NEW FOOD PLANT REFRIGERATION, HVAC AND PROCESS

Thermal Storage• Ice-making chiller with ice slush

storage silo• Chilled water storage buffer tank

Benefits of R134a refrigerant instead of R717 (ammonia)

• Lower first cost with comparable energy consumption

• Negates process safety management needs

• Eliminates emergency ventilation requirements