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Dairy Insight Project II: On Farm Energy Savings

Dairy Insight Project II: On Farm Energy Savings. K Hartman & Ralph E H Sims Centre for Energy Research, Massey University, Palmerston North R.E.Sims@massey.ac.nz Karl@dews.co.nz. Why Peak Reduction?. 3.85 million head 100w/hd 385 MW peak. $10,000/MWh $10/kWh $1/hd. The Big Question.

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Dairy Insight Project II: On Farm Energy Savings

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  1. Dairy Insight Project II:On Farm Energy Savings K Hartman & Ralph E H Sims Centre for Energy Research, Massey University, Palmerston NorthR.E.Sims@massey.ac.nz Karl@dews.co.nz

  2. Why Peak Reduction? 3.85 million head 100w/hd 385 MW peak $10,000/MWh $10/kWh $1/hd

  3. The Big Question How can I save energy? 2 sides of the “savings” coin: • Conserve energy • Reduce costs

  4. Finding the Answer • Where is energy used on the farm • How much am I using • Where can I conserve energy • How can I reduce energy costs • Case studies • Almost there… • What if… • Further assistance

  5. Where is Energy Used on the Farm Barrie, 2005 Proportion of energy inputs on the average farm surveyed

  6. Survey Results – kWh/day vs # head

  7. Survey Results – kWh/hd/day vs # head

  8. Comparison (kWh/hd/day)

  9. How much am I using Meridian Energy Calculators • Full Model • Mailed out to customers, CD based • Intensive • Mini-Calculator • On-line version (www.meridianenergy.co.nz) • Simple Model (3-5 minutes)

  10. WWW.Meridianenergy.co.nz/yourfarm

  11. Where can I conserve energy Major loads • Milking Machine (vacuum pump) • Milk Chilling • Water Heating • Irrigation (not on all farms) • Miscellaneous • Water and effluent pumping • Lighting • Other minor loads (is the kettle major or minor?)

  12. Vacuum Pump (non variable speed) • Constant load • Fully loaded – entire milking & cleaning • Size proportionate to # of clusters • More clusters - larger the load • Vacuum brakes provide reserve capacity • Not doing useful work - 0% efficiency

  13. Milk Chilling • Two parts • Initial cooling of the milk • Maintaining milk temperature <4 °C (10%) • Pre-cooling • Plate heat exchanger (35 – 20 °C) • Dependant on cooling water temperature • Bore vs surface water

  14. Water Heating • Electric (resistive) heating • Batch or Continuous heat • Initial and Maintenance heat (15%) Centralized thermal power plant • Fuel – electricity – heat • Can be less than 18% efficient at point of use • 3.5x the primary fuel use than if made onsite • 4x more heat wasted at power plant than developed at point of use

  15. Water Heating (B.V)

  16. Water Heating (A.V.)

  17. Irrigation / Pumping / Other • Individual farm dependant • Age/type/condition of pump • Pumping head (static vs dynamic) • Saving water saves energy • Other loads • Lighting (Natural vs artificial) • Incandescent Light bulb ~2% efficient fuel to light

  18. How can I reduce energy costs • Reduce usage • Waste heat recovery – preheat water to cylinder • Additional milk pre-cooling (1 °C ~ 6% cooling load) • Variable speed vacuum pump / pully size • Reduce vacuum demand ? (10/20/70) • Load Shifting / Peak Reduction • $/month per kW peak use charge (?) • Energy Storage (Hot Water, Ice Banks) • Rate schedules • Day / Night / Controlled Rates • Fixed daily charges (higher daily = lower per unit)

  19. Case Study – Almost there… • Smaller farm – 220 head • 20 bail herringbone • Day / Night rate (night = 1/3 day rate) • Timers on water heaters (batch w/pre-heat) • Ice bank • Used for morning and afternoon milking • Pre-cools milk to 4 °C into the vat • Low vacuum demand (~4 kW) • Short milk and vacuum runs • Enclosed milk vat, uninsulated

  20. Cumulative Energy Use (kWh)

  21. Case Study – What if… • Mid-sized farm – 550 head • 2x 20 bail herringbone pits • Anytime / Controlled rate • 15 kW vacuum demand • 2 hot washes per day • Uncovered, insulated milk vat • 15 psi artesian bore • 27 kW for effluent stir / pumping

  22. Total energy use (before) 25% 75%

  23. Hot Water (before) Vat Wash System Wash

  24. Hot Water (after)

  25. Milk Chiller (before)

  26. Milk Chilling (after)

  27. Vacuum Pump (before)

  28. Vacuum Pump (after)

  29. Total System (after) 55% 30% 70% Overall 50% cost savings Overall 33% energy savings 45%

  30. Further Assistance • Dairy Insight Phase II • Identify energy saving techniques and technologies • Demonstrate on-farm examples • Getting the word out • Process-specific information sheets • Water Heating • Milk Cooling • Milking Machine • Tractor Fuel Use (revisiting Tractor Facts from 80’s) • Lighting / Other

  31. Review • Big ticket items – in the shed • Water Heating • Milk Cooling • Milking Machine (vacuum pump) • Fast payback • Batch hot water vs constant feed • Day / Night rates • Timers – Lighting / Hot Water • Minimize water use

  32. Future Technologies • On-site co-generation (biofueled?) • Wind/Hydro/PV/solar thermal • Waste-to-energy (AD) systems • Enhanced thermal storage

  33. The Matrix

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