4-C Foods CHP PlantNYSERDA Demonstration Project

June 24, 2004

William Cristofaro P.E.Energy Concepts Engineering PC

Rochester, NY585-272-4650

www.nrg-concepts.com

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Project Summary:Modular 380 Kw CHP plantHeat recovery to space heating, cheese process and absorption cooling.Total project cost $1,120,000.Net-net savings of $ 200,000 per year.NYSERDA grant of $558,000.Status: plant built within budget and now operating, some commissioning still under way.

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4-C Foods, Brooklyn, NY

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4-C Foods Project TeamOwner – 4-C foods, Wayne Celauro Owner engineer – Joe OrieroDesigners – Energy ConceptsCogen units – Coast IntelligenElectrical – All Services/Interphase Mechanical – Richtech IncControls –Integrated Controls (Automated Logic)Electric Utility – ConedGas Utility - KeyspanNYSERDA rep – Dana Levy

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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.

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First Step – Engineering AnalysisPreliminary 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.

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4-C Foods Heat Recovery Plant Layout

DG-1

DG-2

DG-3

Future

Building Heating

Cheese Process Dryer

Air Conditioning Absorption Chiller

Electric Power to Building

Heat

Recovery

Loop

Modular Cogen Assembly

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Thermal Effect With Absorber

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2,000

4,000

6,000

8,000

10,000

12,000

14,000

Jul-00 Aug-00

Sep-00

Oct-00 Nov-00

Dec-00

Jan-01

Feb-01

Mar-01

Apr-01

May-01

Jun-01

HEAT LOADincludingdeductions(Therms)

THERMALLOAD OFABSORPTIONCHILLER(Therms) TOTALUSABLE LOAD(Therms)

COGEN HEATOUTPUT(Therms)

Added thermal load of absorber achieves year long thermal balance.

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Electric Utility Arrangement, 4-C Foods

150 Kw

150 Kw

80 Kw

Modular Cogen Assembly

Electric Panel Xfrmr

To Building Loads

Simultaneous Power From Utility and CHP Plant, Split Service.

Electric Panel Xfrmr

To/From Utility

Common Heat Recovery Loop All Three Units

Service 1

Service 2

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4-C Foods, Electric Savings

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20,000

40,000

60,000

80,000

100,000

120,000

140,000

Jul-00

Aug-00

Sep-00

Oct-00

Nov-00

Dec-00

Jan-01

Feb-01

Mar-01

Apr-01

May-01

Jun-01

ON-PEAK +SHLDR

ON PEAKELECTRICITY

CHILLERELECTRICSAVINGS

Total ElectricSavings

Facility load

Generated

Load following parallel plant. Summer chiller electric savings is added to power generated savings.

Total

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Main System in C-Tainer Package

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Top of C-Tainer, Catalytic Converters

3-Way catalytic converter

Drycooler

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Heat Recovery to Cheese Dryer

Hot water coil added to air stream ahead of existing coil

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Ceiling Units for Heating/Cooling

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4-C Foods, Cogen Unit Controller

Coast Intelligen microprocessor controller and relays.

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C-Tainer Cogen Packaging

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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.

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Thermal Effect With Absorber

0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

Jul-00 Aug-00

Sep-00

Oct-00 Nov-00

Dec-00

Jan-01

Feb-01

Mar-01

Apr-01

May-01

Jun-01

HEAT LOADincludingdeductions(Therms)

THERMALLOAD OFABSORPTIONCHILLER(Therms) TOTALUSABLE LOAD(Therms)

COGEN HEATOUTPUT(Therms)

Added thermal load of absorber achieves year long thermal balance.

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Absorber Air Conditioning

Small to Large Chiller PlantsFlexible Location, Just Get Hot WaterUses Waste Heat From PlantLittle Electric UseCleanest Available RefrigerantComplete Elimination of Ozone DepletingGood for Low Temp Chilled H2O

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Max Use of Waste Heat

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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 1,000 kw rule”

On-site power less than 1,000 kwClean emissions (Lean or CAT Conv.)Min total energy efficiency of > 60 %.Exempt from standby tariffs – or owner choice of best tariff.

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Value Engineering/Lessons LearnedConsolidating electric services should be weighed economically with split-service 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.

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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.

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4-C Foods: Project Recap$ 1,120,000 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.