CASE REPORTS ON RELEVANT MEASURES AND TECHNOLOGIES FOR

IMPROVED ENERGY EFFICIENCY AND RENEWABLE ENERGY SOURCES

IN GREENHOUSES

WITH A VIEW TO APPLICATIONS IN NORTHERN EUROPE

DR. RUHRMANN & PARTNERS

STUTTGART
RELEVANT MEASURES AND TECHNOLOGIES FOR IMPROVED ENERGY EFFICIENCY AND
RENEWABLE ENERGY SOURCES IN GREENHOUSES - WITH A VIEW TO APPLICATIONS IN
NORTHERN EUROPE

This report is presenting relevant and interesting examples and case reports from projects performed
mainly in the European greenhouse sector, in order to demonstrate the potential for energy efficiency
improvement and for implementation of renewable energy sources. The selection of case reports and
examples was made with a view to transferability of these experiences to the situation in Northern
Europe.

In addition to case reports, brief summary descriptions of specific experiences from Germany and from
The Netherlands are presented.

As an introduction and for better orientation on the various case reports, the following 2 tables present
an overview on the principle measures, with an indication of the case studies presented in the
corresponding fields.
TABLE: RELEVANT MEASURES AND TECHNOLOGIES FOR IMPROVED ENERGY EFFICIENCY AND RENEWABLE ENERGY IN GREENHOUSES

Heating System:

PRINCIPLE TECHNOLOGIES SPECIFIC OPTIONS AND TECHNIQUES ECONOMY CASE REPORT

MEASUR
ES
From Industrial Heat Sources Waste heat temperature 20 80 C A1 German Experience
Waste and Excess Heat From Thermal and Nuclear Up to 30 % A2 Hortitherm Project
Utilisation Power Plants Heat transmission: cost savings A3 Marion Project
From Waste Treatment - Private heating network or D6 D7 Integrated
- Public District Heating system Municipal Waste
Treatment
HEATING
SYSTEMS From Geothermal sources E1 E2
Large-scale centralized CHP Gas/diesel engine / gas turbine / B1 The Netherlands
system, run by public utility or steam turbine; with combinations: Situation
Combined Heat&Power by producers co-operative - Steam turbine /biomass boilers
Generation (wood chips, saw dust, straw);
Small-scale de-centralized - Gas engine with bio- B2: CHP with
systems gasification / utilisation of landfill Up to 60 % Uitilisation of Landfill
gas cost savings Gas
Public District Heating Utilisation of return water for
greenhouse heating
Biomass Boilers and Energy Wood boilers, CHP with D1 D4;
from Waste (RES) biomass;
Waste incineration with heat D6 D7
recovery
Solar-Thermal Systems (RES) Usually integrated with other F1
heating system
Other Measures on Energy Efficiency Improvement:
PRINCIPLE TECHNOLOGIES SPECIFIC OPTIONS AND ECONOMY CASE REPORT
MEASURE TECHNIQUES
MONITORING & Computerized integrated <= 12 % energy savings compared C1 Low cost controller
CONTROL Greenhouse Management to conventional systems
Systems
HEAT EXCHANGER Heat recovery from ventilation air C2
STORAGE SYSTEMS Soil Storage e. g. low cost tube heat exchanger; C3
Rain water tanks rock bed storage C4
HEAT PUMP Centralized / De-centralized C5 Project in Stavanger
APPLICATION Dutch Study on Heat
Pump Application
ENERGY EFFICIENT Optimisation by Computer New insulation techniques; Research objectives: C6
DESIGN Simulation Integrated passive solar heating; Energy consumption down to
Low Energy Greenhouse Root zone heating;.... 30 % of conventional, uninsulated
greenhouse
PROJECT EXAMPLES AND CASE STUDIES ON ENERGY EFFICIENCY IMPROVEMENT

A. Waste Heat Utilisation for Greenhouse Heating

1. Summary of German Experience With Waste Heat Utilisation for Greenhouse Heating

Low temperature waste heat utilisation was a major RTD issue in the eighties, when the oil price was
rather high (2.5 times more than today). Several large scale projects had been implemented in this
field. Most prominent projects are

- Marion Gartenbau in Saarlouis, utilising waste heat from a pit coal power plant at 40 60 C;
- Gustav Buhk Gartenbau in Hamburg, utilising waste heat from waste incineration plant at 60 C;
- Hortitherm near Cologne, utilising waste heat from a lignite fired power plant at 28 40 C.

The Marion and Hortitherm projects are described hereafter in detail.

It is obvious that expenditure for waste heat utilisation is least if waste heat temperature is similar to
conventional heating (60 70 C). Except for the heat transport, no other change in technical
equipment is necessary. But, waste heat of this temperature level will probably be not much cheaper
than conventional heating.

Waste heat of 50 60 C can also be used directly for greenhouse heating with relatively little
additional measures. The larger heaters which are then necessary can be easily built into the
greenhouse.

This is different if waste heat temperature is below 40 C. If waste heat is to be directly applied for
greenhouse heating, heaters have to be unproportionally enlarged or forced ventilation is necessary to
encrease the efficiency. Specially developed heating systems are then necessary. Another technical
option would be a heat pump installation to increase the temperature level.

On the other hand, low temperature waste heat is a more safe heat source than higher grade heat:
industrial processes with 60 C waste heat may change, or the temperature level may decrease due to
heat integration of the plant etc.

A general problem is the high investment cost for pipeline and heat exchangers compared to
conventional heating. It is therefor normally necessary that the waste heat is year round available and
utilized. Also, heat supply should be secured all over the week. This could also be a problem with
waste heat from industrial plants, if these are only operated during five or six days.

Several installations of waste heat utilisation implemented during the eighties have faced reduced
return on investment compared to original expectations due to drastically decreased oil and gas
prices. This circumstance practically stopped further development of waste heat utilisation. In addition,
the spreading of combined heat and power generation offered very viable options too.

Today, the sitution might have again changed:

On the one hand, technological innovation in pipeline systems, heat exchangers, heat pumps,
insulation techniques, and control equipment brought significant efficiency increase and cost
reductions of these systems. On the other hand, environmental constraints are forcing reduction of
CO2 emissions. Waste heat utilisation employing such advanced equipment might therefore become
again economical today.

(References: ITG Institut fr Technik im Gartenbau, University of Hannover and RWE Essen)
2. The Hortitherm Project

Another approach to utilize low temperature waste heat from power plants was made by RWE, the
biggest German electric utility company. RWE operates several large brown-coal fired power stations
in the area of Cologne. In 1983 RWE started a large project in order to utilize the low grade heat from
cooling towers of RWEs Niederaussem power station in a 270.000 m2 greenhouse park. The project
was carried with the assistance of the regional plant growers association.

For this project, RWE had the opportunity to buy a 60ha farming ground close to the Niederaussem
power station. Due to the low temperature of the waste heat (20 40 C), utilisation is only economic
within short distance from the heat source. Subsequently, RWE developed the 60 ha farm ground to
provide the infrastructure for greenhouse park of 270.000 m2 under glass. All necessary infrastructure
including heating and electric supply was provided. For the greenhouses, a flexible, and modular
concept was developed which allowed for company units from 10.000 m2 upwards. Based on long
term lease contracts (30 years) for the ground plus infrastructure installations, farmers could build
there own greenhouses on this park.

For heating the greenhouses, low grade heat from the cooling towers of four electric generator sets
was supplied. The waste heat of these four sets was around 2.000 MW. As this was a base load power
station, heat production was ensured year round. Waste heat temperature was max. 40 C in summer
and min. 28 C in winter. This is much less than the 70 C to 90 C water temperature of conventional
heating systems. Therefore, a special low-temperature heating system with efficient heat exchangers
had been developed and was very successfully tested before the project was started. The heating
system is known under its registered trademark Hortitherm.

The Hortitherm system consist of low temperature heat exchangers, with forced ventilation to
increase the efficiency, and with a light transmissive air tunnel. The heating system extends over the
full length of the greenhouse. It is divided in modules of ca. 3m length:

Hortitherm element
Length 2.93 m
Width 0.40 m
Heat exchanger surface 60 m
Heating power 9.95 kW
Air flow Max. 7.000 m / h
Water flow 1.4 m / h
Temperature difference feed water / return water Ca. 6 K
Ventilator power 0.46 kW

The side walls of the air box of one such element are made of glass. Each element contains one fan
located in the centre of the glass wall to the inside of the greenhouse. The heat exchanger is closing
the top side of the air tunnel (see picture).

Greenhouse temperature is controlled by changing eather the water flow or the air flow through heat
exchangers. Fans can be controlled with variable speed electric drives.

The system is planned to fully substitute conventional heating. For a 10.000 m greenhouse, this
means an energy saving of around 600,000 l of oil. Based on a full cost calculation, the cost
advantage of the system was estimated at 30 to 35 DM per m2 and year. This was under the condition
of 1983 oil prices of 0,75 DM / l, which meanwhile are less than half. Under these conditions, the
higher investment costs for the Hortitherm system (which were included in the lease) could have been
recovered within one year.
Experience during operation from 1988 to 1993:

The Hortitherm project started by setting up four greenhouse businesses during 1/88 2/89, with
41.000 m under glass. The energy performance of these four businesse was closely monitored during
1988 1993. The report covers also detailed description of the production systems.

The following cultures were produced:

Company A (15.000 m): Spathiphyllum Walisii, Chamaedora Elegans, Areca Lutescens,

Euphorbia Pulcherrima, Impatiens.
Company B (4.200 M): Hydrangea Macrophylla, Euphorbia Pulcherrima, Impatiens.
Company C (11.300 M): Kalanchoe Blossfeldiana, Euphorbia Milii.
Company D (10.900 m): Gerbera cut flowers (various kinds).

Security of heat supply:

Heating systems in all four greenhouse units are designed to cover a temperature difference of 30 K
(+18 C inside air temperature / -12 C outside air temperature). Worst weather conditions during
monitoring period were 14,3 C outside air temperature, low solar immission, relatively high wind
speed and snow fall. The system covered the heat demand under these conditions without any
problem; forced ventilation did not reach maximum volume. In one greenhouse unit, even a
temperature of 22 C was maintained without problem. This was due to high feed water temperature of
32 37 C, which could be provided by RWE through switching between generator sets, thus utilising
always the hottest waste heat source.

Average electric consumption was proved to be 5 % of heat demand. A further potential for efficiency
increase of 30 % through change in the control strategy was identified.

One problem was that the feed water is not clean. Heat exchanger efficiency therefore decreased after
three years due to blocking. Intens rinsing with fresh water was sufficient to clean the heat exchangers
and re-establish their high efficiency.

Economy:

RWE Energie AG operates and maintaines the whole greenhouse park. Production area is leased to
greenhouse businesses on long term conditions (30 years). Infrastructure investment has to be fully
paid by the greenhouse operators, but is financed by RWE over a 30 year period; operators have to
pay a fixed annual rate. Maintenance cost of RWE is an additonal cost item.

Cost overview:

DM / m per annum
Rent of production area (excluding infrastructure) 0.24
Investment cost for infrastructure (excluding Hortitherm 7.70
heating system) / 30 year financing rates
Maintenance and repair 0.75
TOTAL 8.69
90 % net production area (8.69 / 0.9) 9.65

For comparison with conventional heating, the following conditions have to be taken into account:

Investment cost of Hortitherm heating system is more expensive than conventional heating; the
excess cost for Hortitherm is about 30,- DM per m.
Annual capital cost, maintenance cost and depreciation are calculated at 15 % of the investment; this
leads to excess cost of 4.50 DM per m and per annum compared to conventional heating.
65 % of infrastructure cost of the greenhouse park is due to Hortitherm; excess cost for infrastructure
is thus 5.50 DM per m and per annum.
No extra cost for electric power arises.
Cost comparison overview:
DM per m and per annum
Annual excess cost for Hortitherm heating system 4.50
Annual excess cost for Hortitherm infrastructure 5.50
Annual excess cost for electric power 0.00 (-0.50)
Total annual excess cost for Hortitherm compared 9.50
to conventional heating system to 10.00
Energy cost of conventional heating system for 24.00
22 C, at an oil price of 0.40 DM / l (0.30 DM / l) (18.00)
[based on a consumption of 60 l / m * a]

Cost saving compared to conventional heating is therefore 8.00 to 14.50 DM / (m * a). Payback of
Hortitherm investment cost which are calculated at 30.00 DM per m, is thus achieved within 2 4
years. This calculation includes all interest rates on the investment.

Advantages / Disadvantages:

The high investment costs is the major disadvantage of the system. This was overcome in the project
through financing by the public utility. The advantages are:

Cost savings of 8.00 to 14.00 DM / m for heating from 14 C to + 22 C;

Heating costs become fixed costs;
Independance of fossil fuels;
Substantial reduction of CO2 emissions;
Low heating costs allow year round production (Germany) at high temperature level;
Good control of air humidity in the greenhouse;
Investors find production areas with full infrstructure;
Neighborhood of several greenhouse businesses allows for cooperations.

The greenhouse park is fully operational today. Further businesses have invested, although the full
size of 270.000 m is not utilized.
3. The Project at Company Marion Gartenbau, Saarlouis, Germany

The project was planned in the early eighties and was in operation in 1984. The objective was to
recover the waste heat available from the pit-coal fired power plant in Ensdorf.

A relevant feature of the energy recovery system in this specific project was to utilize the thermal
energy contained in the hot ashes gathered in the boiler combustion chambers. This should allow for
temperatures of the heating water of around 60 C which is well above the 40 C of water coming only
from the power plant cooling towers. The planned annual energy saving was 1.500 TOE.

At the power plant, the system involved the following main components:
- mixing of cooling water from the two electric generating sets of 120 and 300 MW and ash into 4
mm dia. granules;
- a basin for dis-charging and settlement of ash granules;
- circulation pump system;
- and a flow rate and temperature control system.

After passing the discharge basin, the waste water was directly transported via a pipeline to the
greenhouse complex, at a flow rate of 460 m3/h and and at a foreseen temperature of 60 C. The
greenhouse complex had a size of 25000 m2 and was located 3 Km from the power plant. Pipeline
diameter was 300 mm. The pipeline is owned by the greenhouse grower. The relatively high costs for
the pipeline due to this long distance was acceptable only because of the higher waste water
temperature.

At the greenhouse, the heat was transferred to the internal heating system via low temperature heat
exchangers. Additional heavy fuel oil burners supply heat to cover peak load and as stand-by reserve.

The economy was based on the oil prices at the beginning of the eighties. With 0,75 DM / l and an
annual saving of 1500 toe, the payback was expected within 4 5 years. This was reasonable
compared to an expected life time of the system of over 20 years.

In its operation, the project faced major problems which seriously reduced the economic viability:

- First of all, the oil price did not stay at the high level of the early eighties; already at the end of the
eighties it was much lower, and today the price is 0,30 DM / l. Although payback of the investment
had been achieved, the benefits later on were much less than expected.
- Also technical problems had been encountered over the years:
- the discharge basin did not completely remove all ash content in the feed water. Thus the water
supplied through the pipelines to the heat exchangers still contained abrasive particles which
caused increased fouling of heat exchangers and reduced their life time.
- The temperature level of 60 C of the feed water could also not be maintained. The average
temperature level today being only 45 48 C. This was due to better heat recovery measures
performed at the power plant.

Another problem was more accidental by nature: a new public water way was built right across the
pipeline route. Due to the fact that the ground was not owned by the greenhouse grower, this caused
additional costs for removing the pipeline and later on bridging the water way. During building of the
water way, the pipeline was not available. The company had to cover the heat demand completely with
heavy fuel oil at that time.

Later on, the company became connected to a new public district heating system, which today is
covering most of the companys heat demand. The low temperature waste heat is only an additional
supply which to a small extent lowers todays heating costs.
4. Surface-Heating Greenhouses with Power Plant Waste Heated Cooling Water

Another strategy to heat the greenhouses with waste heat was followed in a project at the Baldwin
Power Plant near St. Louis, USA:

The outside surface of this greenhouse was heated by letting power plant cooling water flow over it.
The feed water temperature was 20 30 C. The water was applied at the ridge and allowed to run
over the roof and sidewalls and into gutters where it was returned to the power plant's discharge
canal. Such experiments had first been carried out in the Fifties in Russia, but with little success.
Advantages of surface heating are for instance prevention of snow loads and low capital costs.

Tests were performed on a small experimental greenhouse of 1,000 m.

One season's heating performance data and resulting conclusions show that surface heating reduced
conventional heat requirements by one third on the test greenhouse.

When these results are projected to a commercial greenhouse, the heating energy costs can be
reduced by 67%. These cost savings would be 28% if 5C cooler water were used and 90% if 5C
warmer water were used. Walker developed simulation model to calculate energy and cost savings
which can be achieved by surface heating. The model takes into account the actual climate data,
greenhouse design data, greenhouse temperature and feed water temperature.

Savings are strongly depending on the water temperature and on greenhouse design (heat transfer
coefficient of the surface).
B. Combined Heat and Power Generation

1. The Situation in The Netherlands

Vegetables grown under glass account for 7.5 percent of total production value of the Netherlands
agriculture sector. Three quarters of this production is exported throughout the world. The Netherlands
is the largest greenhouse country in the world. Greenhouse vegetables in the Netherlands are mainly
grown by family businesses. Average greenhouse area of 9,600 square metres. The average
greenhouse area per holding is increasing and will soon exceed one hectare. Tomatoes (1,100
hectares), peppers (1,000 hectares) and cucumbers (800 hectares) are the major crops. Greenhouse
vegetables in the Netherlands are grown by specialist nurseries, usually growing just a single type of
vegetable. Most of the greenhouses are in the coastal areas. Close to the sea the climate is mild: the
winters are relatively warm and the summers cool.

Energy conservation issues

To conserve energy the greenhouse vegetable growers have signed an agreement with the
government to improve energy efficiency by 50 percent by the year 2000 compared with 1980. 37
percent has already been achieved. The agreement also contains an undertaking to reduce emissions
of carbon dioxide by 3 percent by the year 2000 compared with 1990.

Most greenhouses now use gas-fired central water-heating. A proportion of the exhaust gas is reused:
The carbon dioxide released by the combustion of the gas is channelled into the greenhouse and used
to stimulate assimilation and growth. Energy efficiency is improved either by increasing production per
square metre or by conserving energy. One way of conserving energy is to insulate the greenhouses.
Extra insulation is achieved using protective screens which are automatically unrolled along the walls
and over the crop at night.

More and more of the growers are using combined heat and power systems. For this purpose they
have a total energy installation which produces heat and electricity simultaneously. This gives a far
greater yield than separate generation of heat and electricity. Nurseries generally generate more
electricity than they need. The surplus is sent to the public electricity supply.

An increasing number of greenhouses are now also getting their heat from third parties. The heat
originates from industries which generate more heat than they themselves require. Six percent of the
heat required to heat greenhouses is now supplied in this way, the most of this coming from electricity
generation by utilities; these are to a large extent CHP plants in The Netherlands. This is more a
centralized CHP application with heat supply to the greenhouses through a public district heating
system.

In some areas, there are public utilities which deliver over 90 % of the energy produced to the
greenhouse sector. One such example is Nutsbedrijf Westland which produces electricity and heat
with CHP systems, and deliver 93 % to greenhouse farmers. Due to the dense population of
greenhouses, such centralized CHP production is most efficient. Total installed power of NBW is 89
MW, all generated by CHP systems. In recent years, average size of installed systems was around 1
MW (decentralized systems).

(Reference: Dutch Ministry of Agriculture, NBW)

2. Example: CHP and Utilisation of Landfill Gas

This is a most interesting concept. Landfill gas is mainly used in gas engine CHP systems directly at
the landfill site in order to generate electricity. Because of its high temeperature level, the engine
waste heat from cooling water and exhaust gases can be well used to heat greenhouses.

One interesting example is a greenhouse unit of 7.000 m in the region of Munich (Germany). It is
located close to a local landfill site. The gas of this landfill site is exploited by a private company which
is specialised in the manufacturing of gas engines. This company runs four of its gas engines at the
landfill site with a total power of 0,5 MW for electricity generation. The engine waste heat could not be
used otherwise.

Heating the greenhouses was therefore a cost efficient option. Through a heat exchanger, the waste
heat from the engines is transmitted in a closed water circuit to the greenhouses. Changing heat
demand is equalized by a 100 m storage tank. The temperature of the feed water is up to 70 C,
which allows to utilize the heat with conventional heating sytems.

As a standby, only a relatively small boiler was additionally installed. Direct firing of a boiler with landfill
gas was not realized because of a high risk of corrosion. Gas engines are better suited for landfill gas
utilisation.

Ownership of the systems was shared between the engine operator and the greenhouse company.
Each partner owned the part that he controlled; the cut was made at the beginning of the pipeline from
the engine station to the greenhouse.

The heat delivered is measured with a conventional sensor. Calculation and payment is done on a
monthly basis. The heat price is fixed at 1/3 of the current oil price. Due to an average boiler efficiency
of only 85 % at the time of installing the system, the overall heat cost is 35 % of a conventional oil
heating. This takes already into account the financing of the higher investment cost.

The actual data of the system were:

Total heat demand of the greenhouses: 2.870 MWH

Heat delivered from gas engines: 2.560 MWh
Energy saving: 330.000 l of light fuel oil
Cost savings: 58.000 DM per annum

This cost saving is calculated at a rather low oil price of 0,27 DM / l and including the interest on
investment costs. As the additional investment cost for the system wer around 100.000 DM, the full
payback of the system is achieved in less than two years.

A similar project is reported from the Netherlands: the Kragge landfill site of Bergen op Zoom
produces 1,300 cubic metres per hour of landfill gas. In this case, the heat produced could not be used
close to the landfill site. The CHP system was therefore not installed directly at the landfill site, but at
the site of six greenhouses instead. The gas was transported to the CHP units after compressing,
drying and sampling. The heat produced by the CHP units is fed to greenhouses; electricity is fed to
the national grid.

The CHP system produces 16.000 MWh per year of electricity and 13.900 MWh/year of heat.
The heat produced saves 1,550,000 m3/year of natural gas and the electricity production effectively
saves a further 4,790,000 m3/year. In all, an annual saving of 6,340,000 m3 of natural gas is possible.

With an extra investment of NLG 1,307,000 and gas savings on heat production (at NLG 0.20/m3) of
NLG 310,000/year the pay back period is approximately 4.2 years.

The proposed use of landfill gas reduces the national emission of carbon dioxide by about 14.000
t/year, 11.250 kg/year of which result from the savings in the production of electricity.
C. OTHER MEASURES ON ENERGY EFFICIENCY IMPROVEMENT

1. Low Cost Electronic Control Systems for Greenhouses (Quebec; Canada, 1995/96)

The objective of this project was to adapte a control system for greenhouse environments by verifying
if the control systems could adequately respond to the environmental control needs in small to large
area greenhouses. Night and day temperature control, as well as precise readings, are necessary
characteristics of a control device, in order to justify its purchase.

Two different systems were evaluated during this project with the following features:
- Temperature control (heating and ventilation);
- Humidity control (heating and ventilation);
- Internal clock permitting control of day time and night time environment settings;
- Optional (only one of the systems):
Data acquisition system;
Communications interface to adjust and visualize environmental settings (direct or modem
access).

Both systems function without any problems.

For greenhouses producing year round, energy savings are approximately 12,5%. This is based on
daytime and night time temperature control (20/18 C). Greenhouses producing from March to August,
would save 16,5% in energy consumption. The heating degree days for the region is 4575, based on
18 C.

The energy savings are due to the following aspects:

- decrease in night time temperature produces the most significative savings. A decrease of 2 C
generates savings of 7% for year round production (for greenhouses producing between the
months of March and August, savings of 11% are realized for a drop of 2 C);
- precision controllers permit the decrease in overall temperature. With conventional thermostats,
temperatures were kept higher to ensure a minimum temperature;
- interrelation of environment settings ensures control of the greenhouse environment by preventing
simultaneous heating and ventilation (except in dehumidification mode).

Profitability of the control systems depend on factors like the overall area of the greenhouse, period of
production and installation. Payback period around 2 years. Low cost controller systems are available
at a cost of 600 to 900 ECU.

2. Heat Exchangers to Recover Heat from Ventilation Air

Low cost air-to-air heat exchangers are available to recover part of the latent sensible heat from warm
and humid inside air and use it to heat cold and dry outside air:

One recent development at the Institut des Technologies Agro-Alimentaires in Quebec (CAN) consists
of five internal tubes which carry outside air for preheating, and the 300-mm outer sleeve evacuates
the warm and humid air. The heat exchanger is 24.3 m in length and has a transfer surface of 62.1
m2. The heat exchanger comprises two fans of 0.186 W (0.25 HP) each. Average efficiency is 84% for
an hourly air exchange rate of 0.5 and 78% for an hourly air exchange rate of 0.9.

The first prototype has been in operation since February 1996 in a test greenhouse. The results
obtained with the design prototype indicate an average efficiency of 81%, which corresponds to an
annual saving of 300 MJ / m2.

Similar heat exchangers have been tested and applied in Germany and the Netherlands. They are low
cost devices (around 700 ECU) which pay off within less than 2 years.
3. Soil Heat Exchanger - Storage System for a Greenhouse

Location : La Pocatire Quebec, Canada

The soil within a greenhouse represents an important thermal mass - one that can be utilized for
heating or cooling. By providing a suitable heat exchange surface, soil can become a relatively low-
cost storage material that could help to reduce the consumption of heating energy.

A soil heat exchanger system was installed in a commercial-type greenhouse. A heat exchanger-
storage system, made of 26 non-perforated, corrugated plastic drainage pipes, 102 mm in diameter,
was buried in the soil. Two rows of 13 pipes, 12 m long, were buried at 450 mm and 750 mm depths,
respectively. The pipes were parallel to the longitudinal axis of the greenhouse and were spaced 450
mm apart. A 0.75 kW blower circulated hot air collected in the greenhouse, through the pipes at a flow
rate of 0.91 m3/s. The heat stored was recovered both by convection at the soil surface and by forced
circulation through the exchanger pipes. A minimum temperature differential of 2C between the air
and the soil appears suitable for efficient operation.

Performance Data

Results indicate that an average coefficient of performance (COP) of 4.6 was obtained. The system
performance is more influenced by the greenhouse air temperature than by incident solar radiation.
Results indicated that solar energy contributed to 58% of the heating requirements from February to
June and from September to December 1986. This contribution approximately represents a 33%
energy saving.

The payback period for the system is from one to five years, depending on costs and crop productivity
improvements. In this case, costs of materials and installation were CAD 3,440 and savings were CAD
1,936. Payback is estimated to be within two years.

4. Environmental Control for Greenhouses Equipped with a Short Term Rock Bed Thermal
Storage

A ware-house operating at a setpoint of 12 deg. C had been constructed, equipped with a short term
thermal rock-bed storage. Black painted airconditioning ducts are placed in the ridges of the ware-
house above the thermal screens. Those low cost air collectors operate together with the thermal
screens, and with the ventilation control. Four storage units are placed in the soil of the greenhouse.
The air system is a closed loop system using only inside air. When the operation mode changes
(charge - discharge) there is flow inversion in the storage. Part of the classical (water) heating system
is replaced by an air heating system.

Technical data:

Floor area : 1120 m2 ;

Volume : 3349 m3
Collector area : 126 m2 ;
Storage : 192 m3 (4 units)
2 fans : max. 2 x 7000 m3/h at 2 x 2000 Watt / min. 2 x 3500 m3/h at 2 x 275 Watt
Heat loss coefficient : 9337 W/deg. C
Heat injection potential HRS = 50000 Watt
Maximum heat removal potential HRS : 62000 Watt

Air collectors operate (storage) when external horizontal radiation exceeds 225 W /m2. The air
collectors involve an extra air-temperature increase which fully compensates the exploitation cost
electrical consumption of the fans). The heat demand is 30 % lower than in a conventional system.
The heating cost is 40 % lower than in a conventional system. The operation hours are 28 % lower
than in a conventional system.
Achievements :

From the installed project and the following measurements, following conclusions can be taken :
the surface of the collector unit can be enlarged up to +/- 400 m2.
the rock bed can be reduced with 50% but by holding about the same passing section.
the debit of the ventilator can stay unchanged, but may possibly be operated with only 1 speed.

An improved construction has been proposed with following details:

- Greenhouse dimensions : 12.80 m wide x 32.30 m long

- Gutter height : 4.20 m
- The greenhouse will be equipped with rolling benches. Two benches will be
- fixed with the rock bed under these fixed benches.
- The rock bed has a section of about 2 m wide and 1 m high and will be digged in for 40 cm. The
bed has a U-form with leg length of 6 m and an air chamber in front of the two legs. The total stone
contents is 25.2 m3 porphyr.
- The debit of air will be 4500 m3/hour.
- The sun collectors are perforated air channels diameter 3500 mm, painted in black.
- The ventilation group will be equipped with a heating battery as volume heating if there
- was no suffisant storage.
- The benches will be equipped with a low temperature heating circuit at the bottom of the
- benches.

This construction has following advantages :

The rock bed will be placed for the largest part above ground, an expensive watertight cellar is thus
not necessary. Insulation of the rock bed with sandwich panels, or a brick wall is sufficient to close the
rock bed. This gives a real cost advantage.
The air system will be placed under the benches. By this way there will be no shadow.
The incorporated heating battery allows to work without the traditionally heating tubes, sothat the
collector tubes are not causing extra shadowing in the greenhouse.

Project implemented during 1987 - 1990

Contact: Serres Deforche NV, Gentseheerweg 108, BE 8700 Izegem (Region West-Vlaanderen);
Belgium. Tel: +32-51303701 / Fax: +32-51308361
5. Heat Pump Application

A successful heat pump installation in a greenhouse is being reported from Stavanger (Norway). The
greenhouse was built in 1979 and has a total area of 4000 m. 1000 m is heated during the winter to
18-20C, 2000 m is heated to 12C and the rest is kept above 3C. Four heat pumps were installed in
1987 and they provide 70% of the heat demand of the greenhouse.

The energy consumption has decreased from 2.274 MWh/year to 1.092 MWh/year.

The energy cost savings were NOK 277.900 / year. The total investment costs were NOK 760.000 and
the payback time was 2.7 years.

While the above described small scale system seems to have proved commercial viability of heat
pumps, a recent Dutch study Comparison of Heat Pumps for Greenhouses by O. Kleefkens showed
that payback period for large scale greenhouse heating is not yet so convincing.

For three different cultures, four process-models are evaluated. The models include a ground-source
electric heat pump, a gas engine driven heat pump, an absorption heat pump and an electric heat
pump with low temperature source from industrial waste heat. Payback periods were calculated for all
options. It was concluded that for the short term, absorption heat pumps seem to be the best solution.

Compared to gas fired boilers, the payback time is 6 9 years, based on the low Dutch gas tariff of
0,12 USD per m. A 25 % higher gas tariff would reduce payback time to 4 7 years.

Details:

The study included greenhouses for producing tomatoes, roses and freesias because of their high
energy-intensity. Basic energy and economy data for these crops were assumed in the study with the
following values:

Economy
CROP AREA INCOME PROFIT ENERGY COSTS
[ ha ] [USD/m2] [USD/m2] [USD/m2]
Tomato 1241 32 18 5
Rose 926 43 20 12
Freesia 282 20 12 2

Energy
CROP Gas consumption AssimilationLighting Ground cooling CO2 supply
[ m 3/ m 2 * a ] [kWh / m2 * a] [kWh / m2 * harvest]
Tomato 44,5 yes
Rose 43,8 0,0121 yes
Freesia 15,3 11

Heat pump system configurations

Configuration Technology Applications
Drive Energy Heat source Heat sink Heating Cooling CO2 supply Dehumidification
Electric compression Electricity Ground or Water Yes Only fresias No No
heat pump surface water (PE tubes)
Gas engine compression Gas Ground or Water Yes Only fresias Yes No
heat pump surface water (PE tubes)
Gas-fired absorption Gas Ground or Water Yes Only fresias Yes No
heat pumo surface water (PE tubes)
Electric heat pump with Electricity Low temperature Water Yes Only fresias No No
low temp. waste heat waste heat (PE tubes)
Calculation results
Configuration Primary energy savings [%] Investment [USD/kW] Payback period [years]
Tomato Rose Freesia Rose Freesia Freesia Tomato Rose Freesia
Electric compression 26 36 54 329 329 354 26 19 17
heat pump
Gas engine compression 34 50 64 623 623 575 21 13 12
heat pump
Gas-fired absorption 27 40 38 277 277 303 8 6 9
heat pump
Electric heat pump with 27 40 60 338 338 363 17 13 15
low temp. waste heat

If ground water aquifers are readily available without high developing costs, payback time for gas
absorption heat pumps can be reduced to four years. In this case the technology already represents a
profitable option.

6. Energy Efficient Design Strategy

Example: Development of Low Energy Consumption - LEC Greenhouse

(ongoing research project):

The scientific and technical objectives of this research project concern developing a new type of
greenhouse with a heat consumption of only 30% of normal consumption in traditional uninsulated
greenhouses. As far as this is published, the aim shall be reached through high insulating mobile
screens, passive solar heating with solar energy stored in rainwater reservoirs. Product is expected to
be available beginning of 2000.

Contact: Rosager & Larssen Radg. Ing. ApS., 85 Kroggardvej, DK-5270 Odense , Denmark
Contact Person : Mr. Dorn, Tel: +45 - 48 19 50 13
PROJECT EXAMPLES AND CASE STUDIES ON RENEWABLE ENERGY SOURCES
D. Biomass and Waste

1. Medium-Powered Chipped Wood Boilers in Kit

A 200 kW medium power wood-chip heating system prototype, the so called "Clorofil" system has
been designed and and demonstration prohects set up in 1989/90 by Applications Mecaniques, with
Metallerie Bayeusaine and Biomasse Normandie. Main system characteristics are: - the automatic
feed only formed by shunt systems driven by hydraulic jacks; - a dry wood burner fixed onto boiler,
containing two concentric envelopes, with a circular vortex; - a programmed control system directing
combustion and safety systems.

The plant, which is build from a kit, includes the following mechanical and thermal components:

1 - THE WOOD FEEDING SYSTEM

This compact, automaticfeeding system includes is only formed by pushing systems (descaler,
conveyors, injector piston) driven by jacks from a hydraulic group. Unlike other systems (endless
screw), this hydraulic process is very reliable, simple and easy to tune up. The feeding system
includes a silo of storage of 15 to 25 m3

2 - A DRY WOOD BURNER

This burner, mounted on a boiler, is constituted by two concentric envelops, which canalize primary air
(for drying and gasification) and secondary air (for gas oxydation). An excellent combustion is
obtained and the flame goes into the boiler. Its simple design (no heavy refractory walls) makes this
burner cheaper than other furnaces. A dust absorbing cyclone is fitted to the boiler.

3 - AN O2 EXHAUST GAS ANALYSER

For an optimal combustion, secondary air flows are regulated by a speed variator (on the extractor
fan), controlled by the 02 analyser. This is a good solution for a solid fuel which has an irregular
calorific value. This special control justifies the use of a programmable robot.

This system is well fitted for low size housings, common in rural areas: groups of houses or small
collective buildings public establishments (schools, old folks' homes, swimming pools...), as well as for
some agricultural (greenhouse farming, horticulturists) or industrial enterprises (joinery work shops...).
It allows a better utilization of wood wastes and at the same time, reducing environmental damages
and creating jobs. The product is marketed by Applications Mecaniques' Company.

Reported Achievements:

1 - IMPROVING THE PROTOTYPE INSTALLATION

Successive improvements have been brought to the design of the burner, in such a way as to assure
an excellent quality of combustion and at the same time, to stop the risk of escape of unburned
material and forming of slag.
2 - PUTTING INTO SERVICE TWO HEATING PLANTS
- School buildings of the commune of Jumieges (Seine-Maritime) : dry wood. The plant was put into
service at the end of 1992 and stopped for improvements.
- Retirement home of Chanu (Orne) : moist wood.
3 - UNDERTAKING OF A THIRD HEATING PLANT
- Heating network for the commune building at STE-MARIE-DE-CUINES (Savoie) : dry wood.

Technical Success:

"Clorofil" is now a reliable product, which supplies excellent combustion. The 3 heating plants operate
quite well. Furthermore, important work was done on the architectural integration of the heating plants,
wood supply and wood storage.
Economic Profitability:

The present energy price context is very hard on medium-sized operations; the Clorofil product,
made in a very small series, is still too expensive. This option can be profitable only for long, full load
uses, in establishements such as retirement homes, swimming pool, small district heating network...
Owing to the small difference in price between the chipped wood and the substituted fuel, and to the
strong competition with other energy sources, it has not been possible, up to present day, to develop
this product in France.

Project Start Date : 1991-01-01 / End Date : 1993-04-30

Programme: THERMIE 1 / Project Reference : BM/058/90

Contact:
Applications Mecaniques; Zone Industrielle Rue Armand Busquet 6, Bp 72; F-14404 BAYEUX;
Tel: +33-31921650 / Fax: +33-31-211175

2. Energy Development of Scrap Wood, sorted and conditioned by Sorting Centres

The objective of this project was the energy development of scrap wood, sorted conditioned and
produced by regional sorting centers for simple industrial waste.

The project implementation was foreseen in 6 sorting centers of Lyon, Grenoble, Annemasse/Geneva
and Faverges of a new fuel consisting of sorted scrap wood (category 1 wood as per German
legislation).

The heat was to be utilised by 4 local collective heating operations using wood for the energy
development of this fuel in:

Dardilly: 1.800 kW for a school building

Faverges: 5.000 kW in the local district heating system
Bossey (Switzerland - Annemasse and Geneva): 4000 kW in a horticultural greenhouse.
Grenoble: 12.500 kW in a cold fluidized bed coal-fired boiler district heating system.

Reduction in pollution levels by replacing fossing-fuel boilers with wood fuel plants which respect
German emission standards (Category 1) with even stricter standards for dust (50 mg/Nm3) by
installing suitable dust removal equipment was envisaged.

Innovation :
The production and utilization of a new fuel made from visually sorted scrap wood for automatic boiler
plants. Visual sorting allows the virtual 100 % elimination of soiled wood and provides category 1
heating wood as laid down by German legislation. To facilitate the introduction of wood boiler plants in
built-up areas, de-dusting systems will be set up to respect the toughest dust emission standards (50
mg instead of 1 50 mg/Nm3) . Trans-frontier organization of scrap wood management.

Context :
4 local collective heating operations using wood for the energy development are planned. These four
projects have a wide range of demonstration parameters (different power ratings, substitution of
different forms of energy) and so afford a finer analysis with a view to develop this process (about 250
000 tonnes of scrap wood are presently not being used in the Rhone-Alpes region).
Economic Aspects:
Annual turnover for sorting centers of Frs 3 050 K (ex VAT) andexcluding transportation, i.e an annual
financial appreciation of Frs 750 K compared with ongoing opportunities (corresponding to 23 500
tonnes of wood commercialized) for an extra overall outlay of Frs 3 000 K for the sorting centers.

Annual savings of FFR 3.604.000 on heating costs, with investment cost of FFR 28.148.000 for the
wood-fired boilers (all sums ex VAT). Substitution of 7.342 TOE of fossil fuels, thus permitting a
reduction in S02 emissions (54 t), C02 emissions(9.600 t) and NOx (10,5 t). Reduced transportation of
industrial waste (sorting centers in the vicinity).

Achievements :

Faverges: The 9000 kW district heating system has been achieved as planned, with 2600 kW heated
by wood boiler. There was no significant problem.
Grenoble: The modifications of the fluidized bed coal fired boiler of the district heating system of
Grenoble was achieved in December 1994. Their were no significant problems.
Bossey: (Greenhouse heating) The length of the network has been reduced without changing the
power of the wood boiler. Studies have been completed. The project was ought to be
carried out in summer 1995.

Start Date : 1993-01-01 / End Date : 1996-01-01

Programme: THERMIE 1 / Project Reference : BM/0348/93

Conttact: Rhonalp Energie; Rue de la Republique 69; F-69002 Lyon; France

Tel: +33-78372914 / Fax: +33-78376491

3. Waste-wood Combustion in Greenhouses

Location : Barendrecht; The Netherlands

In this project, combustion of wood chips is used to reduce the fuel oil consumption of a greenhouse.

Waste wood such as garden refuse, timber remnants, wooden beams from demolished buildings, is
cut into small chips, which are stored in a 30 m3 silo. From this silo they are fed to a furnace, heating a
2,330 kWth boiler. Between the furnace and the chimney a cyclone battery was installed to remove fly-
ash from the flue gas.
Operating wood combustion equipment requires some extra effort:
- machinery is needed to chip the wood;
- to transport chips to the furnace and to remove fly-ash and bed as the boiler has to be cleaned
more frequently than an oil or gas fuelled one;
- the 200 kW diesel engine driving the chipping machine has to be operated by specially trained
personnel.

Equipment of this type can be used in companies or factories with a constant hot water demand and
annual energy consumption of 500,000 m3 nge.

Technical Data

Wood chips stored in a 30 m3 silo, are fed by means of a conveyor to a 2.3 MW boiler producing
water at a maximum temperature of 110C to heat the greenhouse. Fly ash is removed from the flue
gases by cyclone filters. A 250 kW diesel generator drives the chopper.
Performance Data

Energy savings are related to the old situation. A comparison is represented below:

Old System New System Tonnes of Wood

(m3 nge*) (m3 nge*)
Energy demand 730,000 - 2,067
Electricity demand 9,000 26,800 -
Chipping - 78,200 -
TOTAL 739,000 105,000 2,067

* Natural gas equivalent: 31.6 MJ/m3

Economic Data

The total costs of operation, including investment costs, interest, maintenance, energy consumption,
ash disposal and personnel costs are given below: (Note: NLG is the Dutch guilder)

COSTS Gas/Oil Wood with pre- Wood without pre-

(NLG) 1987 processing processing
Installation 235,000 470,000 350,000

Running Costs:
Fuel 310,300 93,000 134,355
Maintenance 5,000 10,000 5,000
Electricity 5,200 15,500 10,000
Diesel Generator - 66,600 -
Ash Disposal - 6,000 6,000
Personnel Cost - 55,000 25,000
Total of Running costs 320,500 246,100 180,355

It was shown that a wood price of NLG 45/tonne the equipment could be operated economically; at the
market price of NLG l80/tonne a system without wood pre-processing is better.

Organisation: NOVEM; Contact: Somers, Francien, Mrs; Email: F.Somers@novem.nl

4. Combined Heat and Power Plant Fired Entirely by Straw

Location : Haslev; Denmark

Haslev Combined Heat and Power Plant (CHP) is built, owned and operated by the local electricity
company SEAS which is the distributor of electricity to Southeast Zealand and the nearby islands. The
plant supplies electricity to the grid and heating to about 2,000 customers of the local district heating
company.

This completely straw-fired CHP plant became commercially operational in September 1989. The plant
consists of a straw warehouse, boiler house, turbine house, heat storage tank, chimney and weighing
facilities.

The straw storage can hold 700 Heston bales in four layers which allows the plant to operate without
supplies over a weekend or adjacent holidays.

The boiler consists of a three-pass boiler with two superheaters as well as a boiler economiser, an air
preheater with a ball cleaning system, a district heating economiser, a slag conveyor and smoke
cleaning filters. Stoking is done into four parallel Voelund cigar-firing systems without any pre-
treatment. A crane places the bales on a feeding unit which conveys them into a closed tunnel, acting
as a fire sluice between boiler and storage. In the opening of the combustion chamber a number of
nozzles direct high-velocity combustion air at right angles to the bales. This cigar firing system
ensures that the bales are burned from front to back.

Slag deposit problems are minimised by limiting the superheater temperature to a maximum
temperature of 450C. The slag is dropped into two containers and returned to straw suppliers as
fertiliser.
The flue gas is cleaned in a bag filter. The plant complies with the latest environmental limits for
particulate emission.
In order to produce electricity during times with low district heating requirement the plant has a buffer
tank for storing surplus heat.

Technical Data

Straw storage 350 tonnes

Annual straw consumption (1996) 23,000 tonnes
Water content in straw 10-25 %
Ash content in straw 1.5-6.8 %
Feeding system Cigar firing
Nominal heat capacity 13 MJ/s
Nominal electric capacity 5 MJ

Boiler data:
Steam volume 26 t/h
Steam pressure 67 bar (working 65 bar)
Steam temperature 450 C (working 425C)
Straw consumption 5,300 kg/h

Flue gas filter: bag filter

Surface area 804 m
Max operating temperature 125 C
Flow max 9.9 kg/s

Turbine: Back pressure turbine (reaction turbine)

Speed 10,000 rpm
Steam volume 26 t/h
Steam pressure 65 bar
Steam temperature 430-450 C

Generator: 4 pole, air cooled, synchronous AC generator

Rated voltage 10,500 volts
Rated output 6.4 MVA

Heat storage tank Approximately 3,500 m3

Performance Data
The total net efficiency is about 86% of the calorific value of the straw. In 1996 the heating output was
228 TJ and the electricity output was 16 GWh.

Economic Data
The total investment was DKK 100 million. (Note: DKK is the Danish krone).

Environmental Data
Straw is considered to be a CO2 neutral fuel. When straw is burned in CHP plants the amount of CO 2
developed is the same as if the straw was burned after harvest or degraded after ploughing in the
fields. Consequently the energy produced from a straw-fired plant does not contribute to the
greenhouse effect.
The flue gas is cleaned in a bag filter in an electronically controlled pulsating cleaning process. The
emission of solids particles after the filter is measured as being lower than 35 mg/Nm3.

Project Implementation: 1988 - 1989

Contact: Mr Preben Thisgaard, Danish CADDET National Team

Tel. + 45 59 186 999 / Fax + 45 59 186 573 / Email novapro@inet.uni2.dk

5. Small-scale Straw-fired Combined Heat and Power Plant

Location : Slagelse; Denmark

The straw-fired Combined Heat and Power plant in Slagelse became operational in 1990. It was built
as a result of an agreement in 1986 between the Danish government and the Danish power suppliers.
They agreed on building small-scale CHP plants based on indigenous fuels and with a total capacity of
450 MW over a 10 year period. The fully automated plant is built and owned by the utility company SK-
Power. The electricity is supplied to Eastern Denmarks grid and the heat to Slagelse district heating
network.

A local association of farmers delivers about 20,000 tonnes of straw per year. The straw is delivered to
a 2,100 m straw storage with a capacity of 1,100 bales, corresponding to three days consumption at
full load. The other buildings are a boiler-house, a turbine and district heating building, a container and
workshop building, an accumulator tank and a 51 m high stack.

The bales are transported on a conveyor belt through a closed fire sluice system towards a scarifier.
The strings are removed before the loose scarified straw is pushed onto the grate system consisting of
a sloping, moving step grate and a short horizontal step grate. After combustion the ash/slag drops
into a water-filled slag section from which the wet slag is conveyed to a container. The farmers use
residual slag as fertiliser.

The boiler is connected in parallel (common steam supply to the same turbine) with a waste fired
boiler. The boiler consists of a large number of pipes containing water and steam. The pipes form the
walls of the boiler. At a temperature of 425C the boiler water is transformed into high-pressure steam
which is led to a turbine connected to a generator producing electricity. Some steam continues on to
district heat exchangers. A heat accumulator storage tank stores excess production of district heating
water. This gives a greater flexibility and allows electricity production at periods of low district heating
requirement.

The flue gas passes through an electrostatic ash precipitator before it is discharged from the stack.

Technical Data

Straw storage 2,100 m or 550,000 kg straw

Heat storage tank 3,500 m3
Annual straw consumption (1996) 28,000 t
Nominal electric capacity (straw and MSW) 12 MW
Nominal heat capacity 28 MJ/s

Straw-fired boiler:
Rated steam production 40.3 t/h
Steam pressure 67 bar (65 bar operating)
Steam temperature 450 C (425C operating)
Straw consumption 5.3 t/h
Annual MSW Consumption (1997) 66,000 tonnes
Waste-fired boilers:-
a) Hot water boiler: heats 230 t/h from 80 to 107 C
Nominal capacity 6.0 MW

b)Steam producing boiler

Rated steam production 18.0 t/h
Steam pressure 67 bar
Steam temperature 430 C

Steam turbine:
Speed 8,016 rpm
Steam consumption 57.6 t/h
Steam pressure 65 bar
Steam temperature 430 - 450 C

Generator:
Speed 1,500 rpm
Voltage 10.5 kV
Rated output 14.2 MVA

District heating system:

Supply temperature 90 C
Return temperature 55 C

Performance Data:
Annual electricity production in 1996 was 38,952 MWh (net). Heat production between December 96
and November 97 and sold to consumers in Slagelse was 588 TJ. The district heat production from
Slagelse CHP plant covers 85% of the annual district heat demand of Slagelse. The remaining 15% is
supplied by two gas-fired district heating plants in Slagelse which also operate as reserve for the CHP
plant.

In 1997 about 53% of the electricity and heat production was based on hot water and steam from the
waste incineration plant. The remaining 47% came from straw firing. 23% of the fuel energy (from
waste and straw) is utilised for electricity production and 73% for heat production, 4% is lost. The 4%
loss only derives from the straw-fired plant as the waste incineration plant delivers the energy as hot
water and steam.

Economic Data: The total investment was DKK 140 million. (Note: DKK is the Danish krone).

Environmental Data: Combined production of heat and power gives a better fuel economy than with
separate production of electricity and heat. The energy loss is decreased and less fuel is needed to
produce a certain amount of electricity and heat.

When simple boilers are replaced by small-scale straw fired CHP plants the environment benefits in
two ways. The decreased fuel consumption results in lower CO2 emissions of and straw is a CO2
neutral fuel. This means that straw gives off exactly the same quantity of CO2 during combustion as it
absorbed from the air during growth.

Project implementation 1986 1990

Contact: Mr Preben Thisgaard, Danish CADDET National Team

Tel. + 45 59 186 999 / Fax + 45 59 186 573 / Email novapro@inet.uni2.dk
6. Total Integration of a Municipal Solid Waste Treatment Plant through Heat and CO 2 Transfer
to Greenhouses (THERMIE Demonstration Project)

The project objective was to valorize the combustible, non-biodegradable fraction of sorted municipal
solid waste as process heat for greenhouse operation,complementing thereby the process heat
generated through bio-methanation and biogas burning of the biodegradable part of that municipal
solid waste.

The project concerns treatment of 26 000 tons of waste (including 85 % municipal solid waste and 15
% sewage sludge). The greenhouse has a size of 3 ha and is located at the city of Gueret, France.

The combustible, non bio-degradable fraction of sorted municipal solid waste is burned in a 2 325 kW
boiler, equipped with a post-combustion unit, a waterjacket, a neutralizing unit and a recovery unit, as
well as, upstream, a 100 m3 feedstock storage place and, downstream, a 100 m3 hot water storage
tank at 85 C.

Process heat is furnished to the greenhouses via 2500 kW high-Joule/low-Joule heat exchangers.

Yearly 25 000 MWh are needed in the plant:

80 % originates from the proposed combustion, 15 % from biogas and 5 % from city gas. The
complete system includes therefore 2 furnaces totalizing 8 700 kW to generate process heat from
biogas and from complementary city gas. The latter are not part of the present project. Safety will be
ensured by a set of air coolers totalizing 1988 kW.

32 % of the 25 000 MWh of the yearly produced process heat are needed for internal use, leaving 68
% for greenhouse operation and other uses. Heat and temperature at various places will be
continuously monitored. The colleted data are stored and regularly treated.

The economics of the system is based on a 20 years exploitation. The present system offers a simple
payback of 3.3 years when compared to a standard solution solely based on gas and not including this
combustion unit.

Project implementation was during 1987 - 1990

Contact : Valorga SA, Rue de Massacan 5, BP 56, F- 34740 Vendargues, France

Tel: +33-67870387

7. Urban and Rural Environmental Combustion System - Diversified Utilisation of Waste Heat
(Location : Toyohashi-shi, Aichi; Japan)

The Waste Treatment and Resource Recovery Centre of Toyohashi City, consists of an incineration
plant, a high-speed composting plant, a raw sewage treatment plant and a resource recovery plant. It
combines organic waste treatment with agriculture in the district and ensures effective reutilisation of
resources by integrating the treatment of municipal refuse, raw sewage and industrial and agricultural
wastes.

Waste heat from incineration is used for many purposes with priority given to the steam supply to a
group of greenhouses and a gymnasium and to the heat required for the integrated waste treatment
processes. The waste heat surplus is used to generate electric power to provide part of the electricity
consumed in the Centre. As for the integrated waste processing plant, the dewatered sludge
generated in the raw sewage treatment plant is mixed with refuse and manure in a high-speed
composting plant to produce better compost as fertiliser. The residues from the high-speed
composting plant together with screened residues from the raw sewage treatment plant and
combustibles from the resource recovery plant are sent to the incineration plant.
Technical Data

The facilities were designed to serve 400,000 people, with an incinerator with two units of capacity
each of 125 tonnes/day (t/d). Each has a waste heat boiler with a maximum evaporative capacity of 12
tonnes per hour. A total of 74,800 tonnes of waste were burned in 1990. The steam-turbine generator
has a output capacity of 1,500 kW.

Thirty-six greenhouses with a total area of 35,380 m were provided with steam from the Centre. An
additional 150 t/d incinerator was installed in 1991.

Performance Data

In 1990, the Centre supplied the greenhouses with 14,700 tonnes of steam, consumed 3,800 tonnes
of steam on the premises and, in addition, generated 5,826 kWh of electricity, satisfying one third of
the power required in the Centre.

Economic Data

After the operation and maintenance costs were taken into account, the expenditure of the city on the
power generating equipment, JPY 177 million, was recovered within four years by the savings in
electric power costs. (Note: JPY is the Japanese yen)

Environmental Data

In 1990, the composting plant processed 9,100 tonnes of waste and delivered 380 tonnes of compost
to farms and domestic vegetable gardens. The resource recovery plant disposed of 6,500 tonnes of
bulky wastes and industrial wastes and recovered 490 tonnes of reusable metal products. The raw
sewage treatment plant treated 85 million litres of raw sewage and waste water from the other plants.
The Centre used 16,000 tonnes of this processed water on the premises as service water and only
discharged the surplus into the river.

Organisation
Toyohashi City; Dept.Environmental Sanitation, 530 Aza Nishi Houei-cho
Toyohasi-shi, Aichi, 441-31, Japan , Tel. +81 532 46 5304 / Fax +81 532 46 7942
E. Geothermal Heat

1. Development of a Low Temperature Geothermal Acquifer Resource for the Heating of

Greenhouses, Dwellings and other Premises

The project objective was to introduce the use of low temperature (53 C) geothermal energy in a
range of applications, including greenhouses, grain drying, offices, retail and dwellings, by means of
innovative engineering techniques.

The process plant comprises a geothermal doublet (supply and reinjection wells); extraction and
reinjection pumps; chemical treatment facilities; heat exchanger; vapour compression and absorption
heat pumps; standby and back up boilers; CHP generator for the supply of process electricity; heat
distribution pumping equipment and pipelines and the central system for fully integrated operation.
The hot water from the geothermal/process will be distributed at two temperature levels:
- the first 50 deg. C to serve a 10-20 acre glasshouse which will be equipped with a forced
convention heating system designed to operate with a return temperature of 35 deg. C,
- and the second at 65-70 deg. C to serve dwellings and other premises to achieve a return
temperature of 40 deg. C.
A particular feature of the scheme is a visitor centre which includes a geothermal exhibition related to
the use of the geothermal resource, an engineering exhibition which describes and displays the
process techniques used and finally an exhibition on the uses of the energy in particular the
glasshouse.

Contact: Cleethorpes Geothermal Ltd.; Middle Reach Ridley Hill, TQ6 OBY, Kingswear; UK
Tel: +44-1803752851 / Fax: +44-1803752764

2. The Largest Geothermal Power Station and Effective Utilisation of Hot Water in Japan

Location : Kokonoe; Japan

Kokonoe-machi (Kokonoe town) in Oita, Kyushu, has the largest geothermal power generation in
Japan, having three geothermal power stations with a total output of 147.5 kW. They include the Otake
power station of 12.5 MW built in 1967, the Hacchobaru power station with No.1 unit of 55 MW built in
1977 and No.2 unit of 55 MW built in 1990 and the Takigami power station of 25 MW built in 1996. The
Hacchobaru station, the biggest in Japan with a total capacity of 110 MW, has increased its output by
20% by employing a double-flash system, the first anywhere in in the world.

After separating steam and water this system then generates secondary, low-pressure steam in
flashers to supplement the primary, high-pressure, steam for power generation. To ensure that the
community takes full advantage of the resource, the town government also exploits the hot water from
the geothermal reservoirs for such things as the development of agriculture and tourism. The
geothermal hot water is used to provide heat for the Sensui Rose Greenhouse, parks and many other
greenhouses growing flowers and vegetables and to supply hot water for bathing, space heating and
domestic hot water to 120 ordinary residences and nearly 60 lodgings, rest homes, health centres and
meeting rooms. The Kokonoe Bio Center also uses hot water supplied from the Otake Station to
produce virus-free seeds and seedlings for farmers in the town.

Technical Data

Compared to the single-flash systems which employ only steam separators, the double-flash systems
have higher equipment costs, but increase the output by 15 - 25%. Because the geothermal hot water
contains arsenic, heat exchangers are used to transfer the heat to water extracted from a river for
supply to users. In the case of the first Sensui Rose Park (10 greenhouses, 5,723 m), a heat
exchanger produces 26 tonnes/hour of hot water at 80C using geothermal hot water at a rate of 16
tonnes/hour at 96C and 3.4 tonnes/hour of steam from a well 1,073 m deep. Of this hot water, 7
tonnes/hour is supplied to a recreational lodge for boys and girls at 80C and 3 tonnes/hour to a
towns community centre at 75C. The remaining 16 tonnes/hour is supplied to the Rose Park at 73C
and discharged from there at 28C after heating the greenhouses.

Because the geothermal hot water supply is limited to 6.6 tonnes/hour, the Second Sensui Rose Park
(20 greenhouses, 19,278 m) receives hot water at 94C into a storage tank and then circulates the
water repeatedly through heating circuits, providing a flow through the greenhouses of 37 tonnes/hour
of water at 50C.

Performance Data
The annual changes of outdoor temperatures at the site of the Sensui Rose Parks are similar to those
in the cold Tohoku district. If the temperature in the greenhouses is to be kept at 18C throughout the
year,(based on 60,210 degrees hours, an average heating load coefficient of 17.2 kJ and a heat
saving ratio of 0.7), the annual heating load for the greenhouses with a total surface area of 39,953 m
amounts to 30,170 GJ. Hence, the use of geothermal energy saves 884 kilolitres/year of fuel oil
(heating value: 42,700 kJ).

Economic Data
The saving of oil in the Sensui Rose Parks is worth JPY 41.5 million/year at an oil price of JPY 47/litre.
(JPY is the Japanese yen)

Environmental Data
The use of geothermal energy mitigates the emissions of greenhouse gas emissions by amounts
corresponding to the savings of oil. The geothermal hot water, after transferring its heat to river water,
is re-injected deep into the ground to avoid environmental pollution.

Contact: Kyushu Electric Power Inc.; Hacchobaru Otake Power Station; Address: 601 Yutsubo,
Kokonoe-machi; Kusu-gun, 879 4912, Japan . Tel. +81 9737 9 2308 / Fax +81 9737 9 3221
F. Solar Heating

Project: Year-round Vegetable Cultivation in a Cold Region Using a Solar Plastic Greenhouse

Location : Kitami-shi, Hokkaido; Japan

Project Description:
Year-round vegetable cultivation using plastic greenhouses in Hokkaido is considered to be difficult,
due to the cold climate. The Kitami area, however, has relatively good sunshine, although the monthly
mean temperature during the coldest period reaches minus 10C. To investigate the feasibility of year-
round vegetable cultivation in greenhouses, field tests have been conducted since 1992, using a pair
of well-insulated solar greenhouses. Each greenhouse is 227 m in area and has a double skin
structure of two films of transparent PVC.

The solar greenhouse system has 20 panels of evacuated double glass tubular solar collectors
together with a kerosene-fired hot water boiler, as a heat source to provide hot air for heating the
greenhouse and hot water for warming the soil using underground hot water pipes.

The three-year trial cultivation established a year-round cycle of four croppings of three types of
vegetables comprising spinach (winter), melons and spinach (summer), and Welsh onions (autumn-
early winter). This provided the prospect of annually earning sales of JPY 1,500,000 and net profits of
JPY 500,000-700,000 (where JPY is the Japanese yen). On average during the three-year field tests
the collectors supplied 9.2% of heat for greenhouse heating and solar energy, including direct
insolation, covered 63.5% of the heat input into the greenhouses.

Technical Data:
The tube-framed greenhouse is 6.3 m wide, 3.6 m high, 36 m long and 227 m in area and has a
double skin structure formed by two films of transparent PVC. In winter, low tunnels covering
vegetables are formed in the greenhouse by heat insulated plastic films to reinforce the insulation.
Polystyrene foam insulation of 50 mm thick is buried vertically under the ground surrounding the
greenhouse to the depth of 600 mm, thus reducing heat loss underground through the soil. Hot water
from the collectors and the boiler is stored in a heat storage tank. When the water temperature in the
tank falls below a set point (35C), the boiler is automatically fired to maintain the temperature. The hot
water is then sent to heating pipes buried under the growing beds at a depth of 400 mm to warm soil
and to a heat exchanger in the greenhouse as a heat source for maintaining the indoor temperature.

Performance Data:
The share of the solar collectors in heat supply for greenhouse heating was 9.87% in 1992, 7.78% in
1993 and 9.98% in 1994. The collector efficiencies in each year were 38.40%, 40.10%, 39.06%
respectively. Solar energy including direct insolation covered 69.92% of the total heat input into the
greenhouses in 1992, 59.95% in 1993 and 61.47% in 1994.

Economic Data:
Cost reduction measures such as the change of the solar collectors from an evacuated double glass
tubular type to a flat plate type can decrease the construction costs of the solar plastic greenhouse
system to JPY 9 million.
Even with the expectation that the share of the collectors in the heat supply for greenhouse heating
could be increased to 24%, however, pay-back periods with an annual profit of JPY 700,000 and of
JPY 500,000 are estimated at 10 years and 13 years respectively. Thus, it is difficult to recover the
investments within the life of the plastic greenhouses under present oil price levels. However, a
subsidy covering 1/3 of the construction costs enables the pay-back within the lifetime by shortening
the pay-back periods respectively to 7.7 years and 8.6 years. (Note: JPY is the Japanese yen).

Start date November 01, 91 / End date: March 01, 95

Contact:
KIT Kitami Institute of Technology, Dept of Mechanical Engineering, Mr Kimio Kanayama
165 Koen-cho, Kitami-shi, Hokkaido, 090 Japan , Tel. +81 157 24 1010 / Fax +81 157 23 9357