A Guide for Distillers

Transcription

1 Future Energy Opportunities: A Guide for Distillers Published by: The Scotch Whisky Association 20 Atholl Crescent Edinburgh EH3 8HF Tel: [email protected] September 2012 The text of this guide was written by WSP on behalf of the SWA and Carbon Trust.

2 Introduction The Scotch Whisky industry plays a significant role in the Scottish and UK economies. The aspiration is to stay at the forefront of the drive to deliver long term economic, environmental and social sustainability. Scotland has one of the most ambitious renewable energy strategies in the world, aiming to produce the equivalent of 100% of electricity needs from renewable sources by 2020 with renewables targeted to provide 11% of Scotland s heat demand by The Scotch Whisky industry has set its own, equally tough, environmental targets and by 2020, 20% of the industry s energy should come from non-fossil fuel sources, rising to 80% by The Scotch Whisky industry s determination to make these goals a reality is impressive with exceptional investment going into green energy and other renewable projects at a time of some economic uncertainty. Renewables are already a reality for many of the Scotch Whisky Association s members. A number of sites have demonstrated how low and zero carbon energy for the sector can be delivered. William Grant & Sons anaerobic reactor at their grain and malt distilleries in Girvan, Ayrshire and Diageo s anaerobic digester (AD) and biomass conversion at Cameronbridge Distillery in Fife remain the biggest investments in renewables in Scotland outside of the utilities sector. The North British Distillery in Edinburgh is using AD to fire its boilers and the collaboration of energy and distillery companies that form Helius CoRDe (Combination of Rothes Distillers Ltd) in Morayshire will convert distillery by-product into 7.2 MW of energy enough to power a town the size of Elgin. Diageo s new Roseisle Distillery in Morayshire uses biomass and AD to provide heat and power to the distillery and also the heat to adjacent maltings. These commendable projects are all of scale. Significant developments on a smaller scale on the Isle of Islay are underway. The challenge is for more of these smaller and medium-sized and distilleries to identify where their renewables potential lies. With this publication, the Association is striving to help make the Scotch whisky industry s non-fossil fuel target a reality for smaller and medium sized distilling facilities, though the principles set out here will be applicable to companies of all sizes. This guide offers an introduction to the future energy options and opportunities from established technologies available to distillers both in their distillery and ancillary sites, such as packaging facilities and warehousing. It provides an overview of each available technology, its technical characteristics, how it works, key conditions, planning, relative costs, feasibility for distilleries, case studies and real examples. It also offers information about technologies, some of which are at the forefront of cutting edge innovation. It aims to demystify technologies and identify the relevance of each type to the Scotch whisky industry. This report can be used as a stand-alone guide but it also complements the online Distillers Renewables Tool which is freely available to all. That tool provides a specific overview of how each of the technologies works. It will allow individual sites to be assessed in terms of energy yield and analyse the commercial business case. The industry s energy goals are demanding but companies are on track to meet the challenge. This publication and the associated tool help our Association members and others in the industry focus their efforts appropriately. We would like to thank Carbon Trust Scotland for its financial support in developing this guidance, WSP Environmental for drafting the report and the following companies who assisted in the development and testing of the Distillers Renewables Tool: Beam Inc; Chivas Brothers, Diageo, Edrington, Glenmorangie and Morrison Bowmore Distillers Paul Wedgewood Manager, Carbon Trust Scotland Julie Hesketh-Laird Director of Operational and Technical Affairs Scotch Whisky Association 1 Future Energy Opportunities: A Guide for Distillers

3 CONTENTS Introduction 1 SECTION 01 Natural Resources & Current Distilling Energy Mix 3 SECTION 02 Available Low & Zero Carbon Technologies 6 Wind Power 7 Solar PV 12 Solar Thermal 19 Anaerobic Digestion 23 Biomass Heating 29 Biomass CHP 33 Hydroelectric 37 Ground Source Heat Pumps 41 SECTION 03 Alternative Renewable Technologies 45 Wave and Tidal 45 Hydrogen/Fuel Cells 49 2 Future Energy Opportunities: A Guide for Distillers

4 01 Natural Resources and Current Distilling Energy Mix When reviewing renewable technologies for a particular site or region it is important to have a clear picture of the existing local conditions starting with the availability and accessibility of the resources available for energy generation. Key elements to consider are: Availability of oil and natural gas or other fossil fuels Grid connection and capacity Established renewable installations or district heating network Natural energy resources (sun, wind, draff and other by-products etc.). The energy mix in Scotland Power in Scotland is supplied by a combination of large base-load plants, including nuclear, coal and gas-fired units, hydro generation, both conventional hydro and pumped storage, and a number of other renewable sources. The energy mix in Scotland is composed as shown below. Scotland generates over 25% of its energy from renewable sources, and with the current level of projects under construction and consented this would provide around 50% of Scotland s electricity. Renewable heating has doubled since July Scotland has set a challenging target of meeting 100% of the country s electricity demand equivalent from renewables by 2020 and 30% overall energy demand, meaning 11% of heat should come from renewable sources. Nuclear 20% Coal 30% Other Renewable 17% Gas & Oil 16% Hydroelectric 17% The Electricity Generation Mix in Scotland, Routemap for Renewable Energy in Scotland, Scottish Government, July Future Energy Opportunities: A Guide for Distillers

5 Overview of energy supply in distilleries Both heat and power are required in distilleries. Heat Gas is used directly for heating and oil typically for process heating, firing the stills or space heating. Natural gas has been the fuel of choice to raise steam. Where distilleries are not connected to the gas grid it is normal practice to use heavy or medium fuel oil to generate steam which is the main source of energy required for the whisky production process, from malting to distilling. Usually, space heating demand is low and mainly for site offices and visitor centres. This can be provided by electric heaters and sometimes heat pumps or off-grid gas/oil boilers. Power Although heat remains the principal type of energy required in distilleries, electricity, mainly used for lighting, pumps and fans, represents 10-20% of the total energy needs. Electricity from the national grid is normally used to power distilleries. Some distilleries are buying their electricity from green energy suppliers where the electricity is typically generated from renewable sources, such as wind farms. Natural Resources Solar Energy Solar radiation is one of the most versatile and plentiful sources of renewable energy at our disposal. In one year each square metre in the UK on average receives about 950 kwh of solar radiation and the peak solar irradiation is around 1 kw/m 2. This is approximately 50% of the annual solar radiation received at the equator which is mainly caused by the higher latitude and cloud cover. Scotland is generally cloudier than England, although some parts of Scotland get an average of over 1,400 hours of sunshine per year. There is a significant potential for solar technologies in Scotland despite the lower number of sunshine hours. 4 Future Energy Opportunities: A Guide for Distillers

6 Wind Energy Scotland has some of the best wind resources in the world accounting for 25% of Europe s wind energy potential. At present, 10GW of electricity potential has been leased offshore in Scotland to exploit the significant offshore wind potential. Annual mean wind speed at 25m above ground level (m/s) Tidal Due to a large tidal range which is further exacerbated by the rugged coastline with narrow sounds, this presents a viable consideration for many coastal installations. Britain has access to a third of Europe s wave and half of Europe s tidal power resources and the technology is largely at prototype and proving stage. As a result of this vast resource, Scotland has established the European Marine Energy Centre on Orkney to test various wave and tidal devices and linking them directly to the National Grid. Marine Scotland is a maritime nation with a history linked to the seas. Scotland s seas continue to be developed through the evolution of offshore renewable energy installations and the exploitation of oil and gas reserves in deeper water towards the edge of the continental shelf. Geology? km 25 0 Wave 125 km UK Wind Map: wind speed at 25m about groud levels Within Scottish waters, the wave climate is mainly influenced by conditions in the North Atlantic Ocean, where the fetch (i.e. distance the wind has blown over) is long enough to establish large, regular waves known as swell. The north and west of Scotland are most exposed to these conditions. On the east coast of Scotland, conditions in autumn and winter may also be rough in the North Sea because the wind direction can lead to large swells with significant energy. Did you know that. shallow ground sources of heat such as soils, ponds, shallow boreholes etc. extracted using heat pumps could make a very significant contribution to meeting targets for renewable heat. Scotland has a rich diversity of geological formations, some of which may host useful geothermal resources. Its geology is quite varied especially considering the country s size - around 78,780 Km 2. Scotland, with its highly varied geology, has the potential to exploit ground source energy as a sustainable and near-zero carbon source of heat and power. Geothermal energy and ground source energy are currently very minor sources of energy globally, nonetheless, important considerations when selecting alternative sources of clean (emission-free) energy. In this report we have considered, in particular, two forms of geothermal energy sources that are most appropriate for the temperature required to heat distilleries and the location where this source is available in close proximity to a distillery. These are: Hot sedimentary aquifers (HAS) Hot dry rocks (HDR). 5 Future Energy Opportunities: A Guide for Distillers

7 Available Low & Zero Carbon 02 Technologies This section highlights a number of low and zero carbon energy technologies that can be considered for energy generation in distilleries. These are: Wind power Solar PV Solar thermal Anaerobic digestion Hydropower Biomass Biomass CHP Ground source heat pump This list includes renewable technologies that have been widely installed in Scotland and elsewhere in UK. The technology review identifies how the different technologies could be applied to distillery processes and explores their relative costs and technical complexity. While actual costs for all installations vary, this document shows costs for each of these technologies, presented in order to aid comparisons. Each technology section is divided in the following subparagraphs: 1. Technical characteristics 2. How it works 3. Key conditions 4. Planning 5. Relative costs 6. Feasibility for distilleries 7. Examples of applications 8. Worked example The review also highlights if special skills would be required locally for some of the technologies or if conventional skills are sufficient. 6 Future Energy Opportunities: A Guide for Distillers

8 Onshore Wind By the end of 2010 there was just over 3.5GW of wind energy installed in Scotland, with a further 8.9GW in construction, awaiting planning determination, or at pre-application stage. The introduction of Feed-in Tariffs, which guarantees a set index-linked payment per unit of electricity produced for 20 years, has also seen an increase in small scale turbines and one or two large turbines installed on smaller sites or on industrial locations. Wind technologies can be considered as an option to generate on-site power for distilleries. 1. Technical Characteristics Wind turbines produce electricity by using the natural power of the wind to drive a generator. Wind turbines typically have three blades which rotate around a horizontal hub at the top of a steel tower. Other designs do exist including 2 blade versions and so called vertical devices which rotate around the vertical mast similar to those seen at the Olympic Park in London. Most wind turbines start generating electricity at wind speeds of around 3-4 metres per second (m/s), generate maximum rated power at around 15 m/s; and shut down to prevent storm damage at 25 m/s or above (50mph). Turbines range in size and application from micro wind turbines (<50kW) mounted on buildings or boats to large scale (>1MW) turbines up to 198m high. Building-mounted wind turbines are considerably smaller than free standing. They are appropriate in certain rural applications but performance in the built environment is greatly reduced by turbulence and lower wind speed caused by surrounding buildings and/or trees. As the wind is variable, the probability that it will not be available at any particular time is high. Wind energy has a load factor than can vary between 20 and 40% and this is compared to the maximum power the turbine can generate. Wind power technology is experiencing considerable annual growth in both the UK and worldwide with an increase of 75% in electricity generated by wind in the UK in 2010, at over 73,200kWh per year total operational onshore wind energy installed in Scotland, accounts for 63% of the UK total installed onshore (Renewable UK, Statistics). 2. How they work Wind passes over the blades exerting a turning force. The rotating blades turn a shaft inside the nacelle (the housing for all the generating components of the wind turbine), connected to a gearbox. The gearbox increases the rotational speed and the generator converts the rotational energy into electrical energy. The power output is converted by a transformer to the right voltage for the distribution system, typically between 11 kv and 132 kv. A wind turbine typically lasts around 20 years. During this time, some parts may need replacing. 7 Future Energy Opportunities: A Guide for Distillers

9 3. Key Conditions When calculating the output (e.g. electricity generation from the turbine) and the feasibility for wind it is important to take all the factors below into inconsideration. Wind speed: The key factor when considering a wind development is the average wind speed at the site over a year. For a larger installation it is recommended that wind speed is measured at the site over a year in order to get a more accurate indication of the wind resource. Micro wind applications are extremely site specific and require a minimum mean wind speed of 5m/s. Generally an average wind speed of >5m/s is used as a threshold below which wind turbines are not considered viable. Existing land uses: The existing uses of the land should be carefully considered to determine whether and how the wind energy project can best integrate with these existing uses. Ground conditions: The ground conditions at the site should be examined to consider construction of the foundations for the wind turbines, the erection of the machines and the provision of access roads is practical and economic. Features which may not appear on maps, such as fences, walls, streams and pipelines will need to be taken into account in the design and layout of the project. Grid connection: It is essential to have a suitable grid connection or the ability to connect to the grid. This is discussed in more detail later in this report. 4. Planning Large-scale turbines are generally not permitted to be located within 500 metres of buildings or residential properties due to disturbance. Planning is a significant issue to be considered when developing a wind power installation; approximately half of planning requests are refused due to local opposition. Location: Wind turbines should ideally be located in exposed areas away from built up areas or obstructions such as trees or buildings. Turbines should ideally be located at the highest topographical point available and not in the lee of hills or other terrain. Site Accessibility: The construction of a wind energy project requires access by heavy goods vehicles to the site. Access to the site must be assessed to determine the suitability of existing public and private roads and what improvements may be required to serve the development. There should also be sufficient access to the site to allow for development and access by maintenance staff. A study of the local road network will give an idea of the likely access constraints to the proposed site. Wind turbines could also impact on radar and radio frequency and thus additional studies are required to ensure that the impact of this technology is negligible. The installation must not be sited on safeguarded land or close to airports and bird reserves. This also depends upon the size of wind turbines; small scale wind turbines are unlikely to affect television and radio reception. Noise, vibration, flicker, safety issues like ice throw and tower topple are all carefully considered before a turbine is installed as well as considering land designation. Did you know that. a survey of residents living around Scotland s ten existing wind farms found high levels of acceptance and overwhelming support for wind power, with support strongest amongst those who lived closest to the wind farms. Those who live closest to wind farms are three times more likely to say it has a positive impact on their area than not.? 8 Future Energy Opportunities: A Guide for Distillers

10 5. Relative costs Wind power is now economically viable with short payback periods as a result of state support schemes such as the Feed-in Tariff and Renewables Obligations Certificates (ROCs). The price of small wind turbines depends on the size and type of a model. A typical small system (70kW) costs are 2,500-5,000 per kw. The cost of large, megawatt scale, wind turbines is today about 1,500 per kw capacity. 6. Feasibility for distilleries Because of land restriction or other constraints at some sites, it may not be possible to install on-site turbines and off-site option might be considered. There are already proposed sites for developing wind projects in Scotland, some of these have obtained planning permission and are under construction. Distillers may wish to consider investing in such projects. No distillery site has, to date, opted to install a single wind turbine, though this is a technically feasible option for power generation. Visual impacts are a key consideration, particularly at distillery visitor centres. There are a few examples of wind turbines installed in small scale industry applications that are shown in the next section. 7. Examples of Application Hobson s Brewery, Shropshire England Sustainability has become an increasingly important part of brewing processes and green technologies have been introduced to reduce their environmental impact, such as: the installation of an 18m high wind turbine that provides a third of the brewery s electricity requirements; a ground source heat pump system that chills the cellarage and heats the offices; and, a rainwater harvesting system which is then used in flushing and cleaning down ancillary processes. An innovative solution was created for this brewery. To simultaneously heat their bottle store and cool the barrel store a ground source heat pump system was designed so that the system could recover heat from the cold store well. Four boreholes were sunk providing a constant 11ºC of water that is then compressed for heat or cooling or both. To enhance the efficiency of the ground source heat pump an 11 kw wind turbine was installed to power about a third of the brewery s requirements. When the turbine is used to power the compressors that provide heating/cooling from the boreholes a highly efficient system is created. GlaxosmithKline, Montrose Angus, Scotland GSK is seeking to achieve carbon neutrality at its pharmaceutical manufacturing facility in Montrose. An initial study to assess various energy efficiency and renewable energy options was delivered and it was established that industrial-scale wind turbines would be the most effective means of generating the required amount of electricity. Following a detailed assessment and Environmental Impact Assessment, a planning application was submitted for a 5MW installed system. The project: 2 x 2.5 MW wind turbines Delivers approximately 13,000MWh 134% of the total electricity demand for the site Aspiration to be independent of the electricity grid. A good site for wind. 8. Introduction to the example project This is an example project for onshore wind installation to generate a percentage of the electricity demand of a typical small-medium scale distillery. Input Data High wind speed Close proximity to available grid capacity Compliance with government guidelines on noise limits Near motorway: ideal to minimise impact relating to construction traffic Grid connection It is assumed that the distillery is located in the west of Scotland which has been deemed feasible with a >7m/s wind speed. The site has land available, approximately 2,300m 2 Site energy demand is 10.2 GWh per annum, of which 4% is for electricity. 9 Future Energy Opportunities: A Guide for Distillers

11 Parameters Used The parameters used to assess this technology are: Wind speed on site: Type of site: Open agricultural areas Wind turbines size: Medium scale (330kW) Number of turbines: 3 turbines 4.0% Electricity generation 91.9% Overall energy generation How are the wind conditions on your site? The table below shows the wind potential at your site. Each square represents 1km area around your site. The wind speed for neighbouring areas has been given in order to show the general wind speed for your region. 10 Future Energy Opportunities: A Guide for Distillers

12 RESULTS GENERATION POTENTIAL All figures are estimates. Detailed analysis is needed for the technology to be developed Estimated pow er generation 406,440 kwh/year Installed capacity 675 kw % of on-site electricity consumption 91.9% % on-site of total energy consumption 4.0% % contribution to energy target 79.2% Warning: Investigation into the local grid capacity is required; refer to grid guidance below GENERAL GUIDANCE For safety and structural concerns the w ind turbine/s chosen must be at least at 32.5m from nearest building and 500m from domestic building to minimise noise impact. Minimum turbine distance from buildings 163 m Minimum land area recommended if more than 1 w ind turbine is installed 3.28 ha This analysis shows that 4 wind turbine/s of the chosen type are required to generate 100% of electricity demand. CO2 EMISSIONS REDUCTION Annual tco 2 e Saved tco 2 e/year % CO 2 e Reduction 0.01% Contribution to CO2 emissions reduction target 0.23% COST SAVING Capital investment 1,350,000 Maintenance 27,000 /year FiT Level /kwh Total annual revenue 116,531 /year Unlevered IRR 6.2% Simple payback 16.0 years 11 Future Energy Opportunities: A Guide for Distillers

13 Solar Photovoltaic Another alternative to generate power on site is to install solar panels on roofs (warehousing sites offer potential) or on the ground where space is available. 1. Technical Characteristics Photovoltaic (PV) systems convert solar radiation into electricity. PV cells consist of one or two layers of a semiconductor material, usually silicon. When the sun s rays hit the cell, an electric field is generated across the layers. PV cells do not necessarily require direct sunlight in order to operate, as they will still work with the diffuse light of a cloudy day. However, the greater the intensity of the sunlight hitting the cells, the greater the flow of electricity. The three most common cell types used for buildings (all based on silicon cells) are: Mono-crystalline: most efficient (15-17%) but highest cost; Poly-crystalline: cheaper than mono-crystalline but slightly less efficient (12-15%); Thin-film amorphous: considerably cheaper but about half the efficiency of mono-crystalline. Because of its flexibility, this type is best used for integration into building elements, light weight roofs or irregularly shaped surfaces. 2. How they work The majority of PV systems are grid-connected so that any electricity generated in excess to demand can be exported to the distribution network. A typical gridconnected system contains: an array of photovoltaic panels for generation of direct current (DC); a power-conditioning unit (PCU), i.e. an inverter, that converts the DC power to alternating current (AC) synchronised with the grid and at the correct voltage and frequency. The PV system can be connected to the electrical supply system of the building via the standard building wiring and the mains switch distribution board, and to the utility grid via import and export metering. Example of thin film application from WSP library 12 Future Energy Opportunities: A Guide for Distillers

14 3. Key Conditions Tilt and Orientation: In order to maximise the output of PV panels their position must be optimised. Panels should always be orientated to the south and at the optimum angle of between Mounting frames can be used to achieve the optimum angle if roof pitch is not ideal. Overshadowing: Shading from adjacent elements, both big or small, is a significant issue for PV installations and can greatly reduce output. Overshadowing from nearby obstructions such as trees or buildings or adjacent panels should be avoided where possible. Structural concerns: Roofs should be structurally sound although panel load is negligible compared to standard loading calculations; light panels should be considered for metal/laminated roofs. In the case of building integrated PV the structural integrity of the building may have to be assessed by a qualified engineer. 4. Planning The key considerations related to planning are: Roof mounted PV: these are generally permitted under planning conditions. Large ground mounted installations: they require planning permission and an environmental impact assessment. Listed buildings: planning permission is required for these buildings and the application might not be successful in some heritage areas. Solar cells are inert solid state devices; the systems therefore produce virtually no noise and no emissions. The panels do not give rise to any emissions which will impact on air quality. Because there are no adverse environmental impacts, planning considerations tend to focus on the physical and visual impacts of solar systems. Security should be considered; PV panels are expensive and should be protected from theft and damage (especially if located at ground level where the area is not gated). Decline in cost of PV installations 13 Future Energy Opportunities: A Guide for Distillers

15 5. Relative Cost Initial capital costs for PV installations range between 1,800 and 3,600 per kwp installed, although there is evidence of a drop in market prices in the past 5 years. This steady decrease in price of PV modules is due to the improving financial attractiveness of PV installations. The graph highlights the regular decline in PV pricing as global production capacity has increased to supply demand. Photovoltaic developments receive state support across Europe and are eligible under the Feed-in Tariff system in the UK which guarantees a set index linked rate per unit of electricity generated and exported for 25 years. These types of revenue together with the saving on energy bills allows for an attractive return. 6. Feasibility for distilleries A building mounted photovoltaic installation can make a highly visible statement about a business commitment to sustainability. The installation can also be interactive with a main display placed at the entrance of the building which displays graphically the levels of electricity generated and carbon abated per day, month, year, etc. Roof mounted photovoltaic PV panels are suitable for development in the distillation industry due to the presence of large structures and warehouses on site providing large areas often not shaded and at suitable angle of inclination. The electricity generated could also be either used on the site or sold back into the grid. began in Lots of time was spent in administration for approval and government grants. Works started in April 2009 and the system was connected to the grid in September The owner considers this a good investment - he signed a 20 year contract with EDF that will buy the electrical generated from the distillery roof at 60 Eurocent/kWh making the investment viable and after one year the overall production is higher than the predicted. PV Solar Farms UK The UK solar industry has been and is still going through a turbulent time with the short-term outlook still looking uncertain. Despite the climate of uncertainty in 2011, WSP worked on two solar farm projects and in early 2012 started work on a third. Two successful examples of ground mounted PV installations UK are for example the Durrants and Ebbsfleet solar farms. Size wise, Ebbsfleet solar farm (4.9MWp) has been developed in Kent and Durrants solar farm (4.9MWp) on the Isle of Wight. They were both constructed before the July 31st cut-off date in 2011, just in time to receive the higher tariff from the Feed in Tariff incentives scheme. An additional 500kW was then constructed at the Durrants Solar Farm before the October 18th (deadline for another change in the tariffs). In case of land availability ground mounted PV can be also considered. 7. Examples of Application PV Distillery Roof, Cognac France Having considered the economics and the outbuildings available, photovoltaic panels were the natural choice for this French distillery s energy project. With a large, south facing distillery roof, approximately 465m 2, and solar irradiation adequate for solar power generation it was decided to equip half for this roof with PV panels. The overall cost was 310,000 Euros and grants were available from regional government (18.5%) and European funds. The process was relatively long and Ebbsfleet Solar Farm, Kent from WSP Library PV for Retail Shed, Purley Way UK This project involved the construction of two retail units on a trading estate in Croydon, South London. The units were required to provide 10% of their energy from renewables. A photovoltaic system was deemed to be the simplest and most cost-effective method of achieving this. A system of 31kWp was installed at a cost of 113, Future Energy Opportunities: A Guide for Distillers

16 The system is predicted to provide 29MWh per annum. This should give a payback period of approximately 12 years based on the electricity savings and Feed in Tariff. The area of PV costs, efficiencies and incentives available is fast moving and particular consideration is required of when the system will actually be commissioned to consider the financial implications. 8. Introduction to the example project (PV roof mounted) This is an example project for Solar PV roof-mounted installation. Input Data Assumed that a small distillery located in Southern Uplands has been deemed feasible due to a solar irradiance index of 900kWh/m 2. The site has suitable roof space available of approximately 2,250m 2. Site energy demand is 500MWh per annum for electricity; that is about 10% of the total energy demand. Parameters Used The parameters used to assess this technology are: Roof type: pitched Orientation: south-east Roof tilt: 30deg Panel type: Mono-crystalline Shading: very little Solar output from Photovoltaics (PV) is directly proportional to panel area. The first step to size a PV system is select the roofs that are adequately oriented and not shaded. 44.5% Electricity generation 15 Future Energy Opportunities: A Guide for Distillers

17 RESULTS GENERATION POTENTIAL All figures here are estimates. Detailed analysis is needed for the technology to be developed. Estimated pow er generation 222,491 kwh/year Installed capacity 265 kwp % of on-site electricity consumption 44.5% % on-site of total energy consumption 4.2% % contribution to energy target not applicable Warning: Data input complete, but please ensure shading and proportion of electricity consumed on site are correct. GENERAL GUIDANCE Grid Guidance Grid Connection is a crucial aspect of any renew able energy installation. Connecting to the grid involves many considerations including; distance (from grid), cost of connection, securing access to the netw ork from the District Netw ork Operator (DNO), and the capacity of local grid. There is also guidance that should be follow ed (G83 and G59). Contact w ith the relevant DNO should be made w hen planning any connection to the grid, particularly w hen considering larger systems CO2 EMISSIONS REDUCTION Annual tco 2 e Saved tco 2 e/year % CO 2 e Reduction 0.01% Contribution to CO2 emissions reduction target % COST SAVING Capital investment 529,412 Maintenance 1,853 /year FiT Level /kwh Generation Tariff Revenue 19,802 /yr Export Tariff Revenue 0 /year Value of Electricity saved 17,799 /year Revenue 35,748 /year Unlevered IRR 6.5% Simple payback 13 years 16 Future Energy Opportunities: A Guide for Distillers

18 Introduction to the example project (PV ground mounted) This is an example project for Solar PV ground mounted installation. Input Data Assumed that a small distillery located in the South East of Scotland been deemed feasible due to a solar irradiance index of 903kWh/m2. The site has suitable land available of approximately 3,000m 2. Site energy demand is 350MWh per annum for electricity; that is about 8% of the total energy demand. Parameters Used The parameters used to assess this technology are: Land area for PV installation Orientation: south Panel inclination 35deg Panel type: poly-crystalline Shading: none 17 Future Energy Opportunities: A Guide for Distillers

19 RESULTS GENERATION POTENTIAL All figures here are estimates. Detailed analysis is needed before investing in any technology Pow er generation 314,309 kwh/year Installed Capacity kwp % of on-site electricity consumption 90% % of total energy generation 6.6% No energy target set for the distillery % GENERAL GUIDANCE Grid Guidance Grid Connection is a crucial aspect of any renew able energy installation. Connecting to the grid involves many considerations including; distance (from grid), cost of connection, securing access to the netw ork from the District Netw ork Operator (DNO), and the capacity of local grid. There is also guidance that should be follow ed (G83 and G59). Contact w ith the relevant DNO should be made w hen planning any connection to the grid, particularly w hen considering larger systems CO2 EMISSIONS REDUCTION Annual tco2e Saved % CO 2 e Reduction 0.02% No carbon target set for the distillery Not Applicable COST/SAVINGS Capital investment 285,000 Maintenance 1,050 /year FIT level /kwh Generation Tariff Revenue 27,973 /yr Export Tariff Revenue 0 /year Value of Electricity Saved 25,145 /year Revenue 53,118 /year Unlevered IRR 20.0% Simple payback 5.3 years 18 Future Energy Opportunities: A Guide for Distillers

20 Solar Thermal 1. Technical Characteristics Solar thermal collectors comprise of fluid filled panels that collect solar energy to heat water. These can be either flat plate or evacuated tube. The key element of both flat plate and evacuated tube collectors is the absorber. This is the surface, usually flat, on which the solar radiation falls and which incorporates tubes or channels through which the heat transfer fluid can circulate. A dark coloured, matt surface coating absorbs more radiation than light to reduce the emission of thermal radiation. This technology is relatively mature with installations first occurring in the 1920s, and many installations from the 1970s are still in use today. 2. How they work Flat plate: Glazed flat plate collectors comprise of a metal absorber in a rectangular metal frame. The absorber is made of copper or aluminium and is coated in black to improve absorption of solar energy and enhance solar transfer. The heat transfer medium (typically water) is contained and circulates in copper tubes, which are attached to the absorber. The collectors, insulated on their back and edges and glazed on the upper surface, supply heated water to an indirect coil located in a hot water cylinder. Flat plate collectors are mainly used in domestic properties and are most common in northern latitudes. Typically these are 3-5m2 collector panel installations tilted to face the sun. Evacuated tubes: Evacuated tube collectors are generally more efficient than flat plates, although more expensive as they are more sophisticated devices. Their increased efficiency results from mounting the absorber in an evacuated and pressure-proof glass tube, which reduces conductive and convective losses. They work efficiently at low radiation levels, with high absorber temperatures and can provide higher output temperatures than flat plate collectors. Dedicated solar storage is necessary, as solar energy input may not coincide with the actual hot water demand. For large installations, the system can be designed with two or more pre-heat and/or storage tanks in series, with sensors set to measure the return temperature of the water in the first tank and either re-circulate it through the collector or pass it on to the next tank. SOLAR COLLECTORS ON ROOF Solar Electric Panel Powering Circulating Pump COLD WATER Solar Preheated Water HOT WATER TO LOADS Mixing Valve Prevents Scalding Antifreeze to Solar Collectors Heated Antifreeze from Solar Panels Circulator SOLAR STORAGE TANK AUXILIARY WATER HEATER BOILER Diagram of solar collectors system linked with hot water tank and/or solar storage tank. 19 Future Energy Opportunities: A Guide for Distillers

21 3. Key Conditions Solar evacuated tubes Tilt and orientation: Solar thermal collectors are not overly sensitive to orientation or tilt and can thus be faced anywhere from south-east to south west (making an estimated 50% or more of the current building stock applicable for development Solar thermal panels are sensitive to inclination and work effectively from Shading: Panels should ideally not be shaded throughout the day therefore overshadowing of development area by trees, chimneys or higher buildings should be investigated. This can be done with solar modelling for new builds and site visits for existing. Allowance for the future growth of nearby trees should be also considered. Structural concerns: Considerations include allowance for thermal expansion, differential negative lifting on adjoining components, sufficient (over)lap of roof components, and the ability of the roof structures (i.e. rafters, purlins, trusses) to withstand the loadings. The structural integrity of the roof will have to be assessed by a qualified engineer. Location and equipment: Solar thermal collectors will be linked to a hot water cylinder ideally within a close distance in order to reduce heat loss and design complexity. If the panel is installed on a flat roof a metallic frame can be used to achieve optimum positions. The build-up of dust on the collector surfaces is another element to consider: a nominal 5 per cent loss of energy yield is expected in all conditions without cleaning. This will increase at pitches of less than 20 degrees. In areas where high build-up is expected i.e. from sea salt, high density traffic or tree sap, the problem will be exacerbated with collectors set at a low pitch. 4. Planning In general roof mounted solar thermal applications are looked on favourably by local authority planners, therefore in some cases these are regarded as permitted development and deemed not to require formal planning permission unless on a listed building or when located in a conservation area. If the system is considered to be a significantly large development then issues considered by the planning authority will include the visual impact, and a broken roof scape which concerns whether the height of the system will exceed the roof height. Solar thermal installations have an attractive payback when offsetting fossil fuel consumption and when there is a high hot water demand. The Renewable Heat Incentive (RHI) is contributing to making these generators of solar hot water more affordable and attractive in order to grow the UK solar thermal market. 6. Feasibility for distilleries Whisky distilleries have a great need for hot water however the temperatures required for the whisky production process are between approximately 60 o C and 90 o C. At these temperatures solar systems are less efficient and therefore, although the system can generate free thermal energy, there is only partial contribution to the overall energy needed. Further investigations are recommended to establish if this technology can be combined with others in order to generate energy more efficiently e.g. pre-heating. Another element to consider is the way solar systems work. The energy output is strictly dependent on the roof space available and most of the time the amount of heat required is in excess of the potential output from the site roofs. Solar panels are nevertheless an ideal option to provide on-site hot water for offices and visitor centres reducing the dependence on fossil fuel or as contributor to preheating. Low grade solar hot water probably can t be used in any of the distillation processes, but as mentioned earlier could be intended as pre-heating stage to reduce the overall energy demand and the dependence on fossil fuel. 20 Future Energy Opportunities: A Guide for Distillers

22 Solar thermal systems can greatly contribute to energy savings during the production processes in the beverages sector. For example, for processes that require temperature below 80 o C (bottle washing, cleaning, etc.) the hot water produced by the solar collectors can also be used for pre-heating the water entering the installation s steam boiler. In this case, the energy contribution of the solar system is relatively small both in comparison with the total energy demand, as well as in absolute figures. 7. Examples of Application Solar Systems Applications in the Dairy Industry (Greece) This example is to show the capability of a solar thermal system, to generate heat for industrial process such as dairies. Process hot water requirements Factory operation hours: 24/7 Hot water consumption: m 3 /day Temperature of process water: a) Industrial processes: C b) Example washing machine C Installation Description The hot water from the closed-loop hydraulic circuit of the solar collectors heats (via an internal heat exchanger) the water in two 2,500 litres storage tanks. The hot water leaving the solar storage tanks is then used for preheating the water entering the steam boilers. 8. Introduction to the example project This is an example project for solar thermal collectors, mounted on south facing roofs. Input Data Assumed that a small distillery located in Southern Uplands has been deemed feasible due to a solar irradiance index of 900kWh/m2. The site has suitable roof space available of approximately 2,250m2. Site energy demand for hot water is 150MWh per annum for natural gas; with an overall consumption for energy of 12GWh/year. Parameters Used The parameters used to assess this technology are: Flat roof: 336m2 it is recommended by the tool Orientation: south-east Panel tilt: 30deg Shading: modest 50% Hot water generation 1.2% Overall energy generation Did you know that...installing? 1,300m2 of solar collector can heat more than 20,000 litres of water at 63.5 o C and save approximately 70,000 litres of gas oil. ROOF ORIENTATION Please tick the box (ONE ONLY) corresponding to the main roof orientation ROOF INCLINATION Please tick the box (ONE ONLY) corresponding to the angle of tilt of the roof. 21 Future Energy Opportunities: A Guide for Distillers

23 22 Future Energy Opportunities: A Guide for Distillers

24 Anaerobic Digestion 1. Technical Characteristics Anaerobic Digestion (AD) involves the creation of biogas (60% methane) through the breakdown of an organic feedstock in the absence of air. The biogas can then be combusted in a combined heat and power (CHP) boiler to create heat and power or through a straight forward gas engine for electrical generation. More recently, biogas has been used in fuel cell applications. Alternatively the biogas potentially could be exported into the gas grid. AD is a viable option for large producers of organic byproducts such as brewing and distilling by-products (e.g. pot ale) and wastes from local councils, water utilities, farms and food producers. AD is well established in Europe and is becoming increasingly popular in the UK. The by-product of this process is digestate that can be used as a fertiliser depending on the original feedstock. At present this is an immature market but as a valuable source of such as Nitrogen, Phosphorous, Potassium, & Magnesium. It can have a value > 100/ha for a single 30m 3 application. A key driver of the AD industry has been a suite of policy instruments. The European Landfill Directive 1999 requires a 65% reduction in the amount of organic waste entering landfill by 2020 together with restrictions on inputs to energy from waste plants and mandatory source separation of waste and aims to reduce carbon emissions. Currently a large amount of waste from food processing is being sent to landfill or pumped at an elevated cost per tonne into the sewage system. Resource Use Distillers by-products e.g. pot ale CHP / electricity Anaerobic digestion Biogas On-site heat Other (optional) inputs e.g. manure, local food, waste Biogas to grid Digestate for fertiliser use Anaerobic Digestion Transport fuel 23 Future Energy Opportunities: A Guide for Distillers

25 2. How it works Anaerobic digestion occurs in an insulated sealed and heated (37 o C 40 o C) container. Before the four-stage process of hydrolysis, acidification, acetogenisis and methanogenisis. Input material is usually shredded and wetted to increase its surface area and to speed up the breakdown process. This feedstock is then broken down in the digester. The residence time depends on the feedstock and can be anywhere from 6-60 days. An energy yield of 10GJ/tonne from organic waste can be obtained with full utilisation of all gases and residues and recovery of low and high temperature heat. 3. Key Conditions Location: The key consideration in assessing the viability of AD on site is the availability of a regular and sizeable supply of suitable organic feedstock. In order to produce biogas sustainably the feedstock should ideally be produced on site or within a very short distance; long distance haulage of feedstock is not advised. AD systems are most suited to sites with a readily available organic based feedstock, either as a by-product of manufacturing or from a waste source, such as food back hauled to depots from supermarkets. In addition, other locations which are proving to be a rich vein for AD development are within the agricultural community. Energy Yield/Gas output: In order to gain sufficient gas from the digestion process it is necessary to have a feedstock with sufficient organic content to obtain a level of biogas that is economic to extract and to burn. It is typical for every kg of COD in effluent to contribute 0.245m 3 of methane gas (80%) and the heat potential value of each kg COD in terms of gas is 2.4kWt per kg COD. This translates to approximately 1kWe assuming a conversion efficiency of 40%. To improve the viability of an on-site AD plant it is beneficial to have a heat load present as biogas is not easily fed into the grid. It is more appropriate to combust on site in a CHP installation. If there is a large flow of material through the digester an on-site technician may be required in order to ensure optimum performance. Noise levels: In an AD plant the main source of high noise levels is the engine generator set. Actual decibel (db) levels produced at an AD facility will differ due to varying acoustical settings, but a generator set can produce between db (Fenton, 2011). However 24 Future Energy Opportunities: A Guide for Distillers

26 this issue can be easily mitigated by supplying noise protection devices, such as earplugs, to employees and visitors who are exposed to high noise levels and ensure the plant is at an adequate distance from a residential area. 4. Planning Development of an AD plant will require planning consent from the local authority and also consent from the environmental regulator in most cases. Consideration needs to be given to the proximity of neighbouring properties as AD plants can often release odour emissions. However, modern package/containerised systems have substantially improved this and installations are now regularly odour free and experience little in the way of complaints. 5. Relative costs AD plants are typically quite capital intensive at a small scale, with costs ranging from 5-10,000 per kwe installed for a kW size scheme. Above this size >500kW we would expect to see installed capital costs in the region of per kw. 6. Feasibility for distilleries The AD industry is more mature on the continent with Germany and Denmark having extensive experience in the field. The technology is just beginning to grow in the UK, and developing an installation remains a lengthy process. AD is established in a number of grain distilleries already in Scotland and the sector has much experience of the length of time needed to deliver AD installations and dealing with issues that arise from funding models, interventions during the planning process by the planning authorities, Environmental Health Officers, Scottish Environmental Protection Agency (SEPA) etc. as well as technical and process issues. Distilleries are well placed to profit from the ability to generate renewable energy from by-products and waste streams such as effluents. Sites where substantial volumes of feedstock are available have the potential for a dedicated anaerobic digestion plant to create energy and revenue, though revenue loss from the sale of byproducts should be taken into account in any financial calculations. Account should also however be taken of any savings made by avoiding drying and compounding of by-products in animal feeds plants. For example, pot ale from the distillation process can be converted into methane gas, which could be burned to make energy for the distillery. Even the smaller sites can sustain such an approach as by-products which are currently sold (e.g. for animal feeds) may be more valuable if converted to energy, or sites can import wastes from other distilleries nearby, or other sources, to make a project viable. Whisky has two main by-products: spent cereals and pot ale, which could, through AD processes, be used to produce methane or other gasses. 7. Examples of Application The North British Distillery The Edinburgh-based The North British Distillery Company Ltd embarked on its sustainability project at the end of The Gorgie grain distillery, the second largest in the industry, is a joint venture between Edrington and Diageo. The key objectives of the project were to reduce the energy profile of the business and to reduce the environmental footprint and impact of spirit production. The project is being managed in a staged manner and each stage verified on its technical capability and efficiency of operation before further stages re embarked upon. Subsequent stages are only progressed where clear future economic benefits can be realised. The North British Distillery AD plant under construction Stage 1 has involved the installation of an anaerobic digester to convert evaporator condensate from the distillers dark grains process, grey water and spent wash centrate into biogas. A dedicated biogas boiler burns the gas to produce process steam. Stage two will see the expansion of the new anaerobic digestion plant and the installation of a new water treatment plant to process effluent from the digester. The water treatment plant will improve effluent quality and provide clean water which can be recycled back into the process. 25 Future Energy Opportunities: A Guide for Distillers

27 The project seeks to produce up to 1MWe of renewable electrical energy, save 1MWe through less intensive energy use of the existing evaporation plant and recycle 40% of the effluent produced by the distillery back into the process. Implementation of the project will reduce CO 2 emissions by 9,000 tonnes per year. The distillery s aspiration is to expand its anaerobic digestion and electrical generation capacity to 3MWe so that it will be a non-importer of electrical energy. The AR plant allows the residual organic matter in the distillery by-products to be converted into biogas by the presence of microbes. This gas is burned in turbines to produce renewable energy in the form of 25MWh of heat and 60MWh of electricity per day. This significantly reduces the site s reliance on fossil fuels. The scheme has the added benefit of improving the quality of the site s effluent, with the chemical oxygen demand of the site s effluent discharge being significantly reduced. William Grant & Sons multimillion investment in anaerobic technology and the combined heat and waste power plant was recognised in May 2010 when it was highly commended by the Carbon Trust s Energy Efficiency in Manufacturing Award. Diageo s Roseisle Distillery, Moray, Scotland. Diageo s newest malt whisky distillery at Roseisle in Moray was formally opened in October The anaerobic reactor at William Grant & Sons, Girvan William Grant & Sons, Girvan, Scotland William Grant & Sons produce some of the world s best known brands of Scotch whisky, including Glenfiddich, The Balvenie range of handcrafted single malts and Grant s. The family-owned premium spirits company was the first Scotch Whisky producer to generate energy from whisky by-products at its Girvan site. The site is strategically important to William Grant & Sons, producing grain whisky that forms the heart of the popular Grant s blended whisky, Ailsa Bay Malt Whisky and Hendrick s Gin. It also houses offices, a cooperage and over 40 warehouses. The ground-breaking energy initiative, commissioned in 2009, produces power in the form of steam and hot water for use on the 380 acre site and electricity, some of which is exported to the grid. The 2009 anaerobic reactor (AR) plant forms part of the company s five year energy management plan which includes annual targets for site energy reduction. Roseisle was constructed using a combination of modern environmental technologies and traditional distilling techniques. The majority of the by-products are recycled on-site in a bioenergy facility (AD to convert the carbohydrates in the distillery by-products into methane and clean warm water), helping the distillery to generate most of its own energy and reduce potential CO 2 emissions by approximately 13,000 tonnes (equivalent to 10,000 family cars) through direct savings on fuel use for steam-raising. The distillery is sited next to Diageo s existing Burghead maltings, which allows the warm water produced in the bioenergy plant to be piped for use at the maltings, again minimising fossil fuel use and CO 2 emissions from raw material transport. Building the biomass burner at Roseisle Distillery The 3,000m² distillery was constructed on time and on budget, with work starting on site in October 2007 and 26 Future Energy Opportunities: A Guide for Distillers

28 completed in Spring Diageo worked closely with its partners for the development of the distillery. Austin- Smith: Lord (ASL) were the architects commissioned for this project. The lead designer and structural engineers were AECOM and Rok were the main contractors. The 14 million bioenergy facility was developed in conjunction with Dalkia. The plant has been built to the BREEAM standard, which is recognised as best practice in sustainable design. Adnams Brewery, England Adnams Brewery, through a subsidiary Adnams Bio Energy Limited, has developed an anaerobic digestion (AD) plant which is the first in the UK to use brewery and local food waste to produce renewable gas for injection into the national gas grid as well as providing gas for use as a vehicle fuel. Developed in partnership with British Gas and the National Grid, the facility is designed to inject renewable gas into the grid and to generate up to 4.8 million kilowatt-hours per year enough to heat 235 family homes for a year or run an average family car for 4 million miles. In the future, the facility will produce enough renewable gas to power the Adnams brewery and run its fleet of lorries, while still leaving up to 60% of the output for injection into the National Grid. The Adnams Bio Energy plant consists of three digesters sealed vessels in which naturally-occurring bacteria act without oxygen to break down up to 12,500 tonnes of organic waste each year. The result is the production of biomethane as well as liquid organic fertiliser. Source: Centralised Anaerobic Digestion and Farms and Distilleries in Denmark A common model used in Denmark is centralised anaerobic digestion which consists of one large plant that sources its feedstock from various local sources within 10km. The feedstock sources range from farm waste products such as slurry, to waste material from food processing plants. Operating in a centralised manner improves the economic performance due to economies of scale and the regularity and increased levels of organic feedstock. Distilleries within a local area could combine their organic by-products (e.g. pot ale) with liquid waste with livestock and arable farmers. 8. Introduction to the example project This is an example project for an AD system for a distillery with 500,000litre/year production. Input Data Assumed a small distillery located in the one of the Hebrides Islands has land available for an Anaerobic Digester Site energy demand is 20GWh/year of which 700MWh are for electricity. Parameters Used The parameters used to assess this technology are: Annual discharge at the distillery: 16,425,000litres/ year COD (chemical oxygen demand) 3,520mg/litre Fuel displaced: heavy fuel oil System selected: CHP 27 Future Energy Opportunities: A Guide for Distillers

29 2.9% Electricity generation 0.3% Overall energy generation 28 Future Energy Opportunities: A Guide for Distillers

30 Biomass Heating 1. Technical Characteristics Biomass heating systems typically replace either oil or gas fired boilers. Due to the nature of biomass fuels the boilers tend to be physically larger than those for oil or gas, they require more space and need to be located in a position that is easily accessible for fuel delivery vehicles. Biomass can include forestry waste, untreated wood, energy crops and short rotation coppice (SRC) e.g. willow, miscanthus (elephant grass) etc. and residues from food and drink production. To ensure that the biomass fuel is sustainable and economic it is recommended that biomass is locally sourced from suppliers within a 20/30 mile radius. Performance Issues The performance, efficiency and reliability of biomass boilers are strongly affected by the choice of fuel. It should be noted that some appliances may be capable of burning more than one form of biomass fuel. For example, reliable wood chip boilers have efficiencies between 88-90%. Wood pellets are a compact form of wood, which have low moisture content and high energy density. Although, these are currently more expensive than logs and wood chip, they are easier to handle and are ideal for automated systems. 2. How it works Biomass refers to organic materials which were produced recently through the process of photosynthesis and are still present in unaltered form. Energy contained within organic material, from straw to wood chip, is released through combustion generating heat (and electricity if used in a combined heat and power application). Biomass boilers are similar to fossil fuel fed boilers and incorporate timers, thermostats and Building Energy Management Systems (BEMS) that would be used in an identical way to fossil fuel based systems. Despite the good compatibility of this technology, future availability of biomass fuel is not guaranteed due to a rapid increase in demand. This can be overcome if biomass can be grown locally. 3. Key Conditions Storage: Biomass typically takes up significant space, so a site will require a dedicated dry covered area to maintain sufficient fuel stocks between deliveries. Delivery: Typically, most sites are only accessible by road, so access to the site by large articulated lorries is essential. Some sites benefit from access to railheads for delivery of fuels but these are currently rare. In addition to delivery, it is important to consider site transfer. In many cases the fuel will need to be transferred within the facility from a storage area to the boiler system. This maybe in the immediate facility but in some cases storage and boiler installation areas may be some distance apart depending on site space. Careful consideration needs to be given to conveying systems, such as screw augers systems, gravity feed, pneumatic/vacuum feed, as each approach has a suitability based on the plant scale. Fuel type: Buildings that currently use wood chip boilers include blocks of flats, visitors centres, office buildings and airport terminals. It is very important to ensure that wood chip boilers are supplied with the appropriate type of fuel. This will vary between boiler types and sizes. The two most important variables are particle size and moisture content. Wood chips that are too large or too wet for example, can jam the fuel feed system, reduce the efficiency and reliability of the boiler or cause the control system to trip out. ( org.uk) The site also needs to be accessible for a delivery lorry. Wood pellets can be delivered loose and blown into a hopper, or in bags. You will need space nearby where the boiler is sited to store the fuel. 4. Planning Planning permission is usually required for biomass boiler installations. Exceptions to this normally relate to the replacement of existing fossil fuel systems with some types of smaller biomass boiler. If planning permission is required, the main issues that need to be taken into account in designing the site and obtaining planning permission are traffic, emissions to air, noise, visual impact and compliance with legislation and regulations. 29 Future Energy Opportunities: A Guide for Distillers

31 5. Relative costs Biomass boilers are covered in the UK Government s Renewable Heat Incentive (RHI) programme. The RHI guarantees regular tariff payments for 20 years for heat generated by renewable means. 6. Feasibility for distilleries Distilleries produce a significant amount of biomass by-products which can be used for energy. Wood chip boilers are most appropriate for medium and large scale installations. They can be considered for both low grade heat generation, therefore small scale boiler for space heating and hot water provision. Alternatively, steam boilers can be fed with biomass reducing the load of existing boilers that are generally fuelled with gas oil or similar fuels. 7. Examples of Application Diageo s Cameronbridge Grain Distillery, Fife, Scotland. In 2008, Diageo announced plans for a bioenergy plant at its largest grain distillery. The bioenergy facility will generate renewable energy from spent wash a mixture of wheat, malted barley, yeast and water - produced during distillation. The spent wash is separated into liquid and dried solids. The liquid is then converted, via anaerobic digestion, into biogas and the dried solids form a biomass fuel source. Around 90,000 tonnes of co-products, which would have required transport off-site by road, will be turned into bioenergy in the form of electricity and steam for use at the distillery. The facility will also recover almost a third of the site s water requirements. It will reduce annual CO 2 emissions at the site by approximately 56,000 tonnes - equivalent to taking 44,000 family cars off the road. It will cut dependence on fossil fuels at the site by 95 per cent. Integrated sustainable technologies - including anaerobic digestion and biomass conversion are being deployed at the site and Diageo believes 98 per cent of the thermal steam and 80 per cent of electrical power used at the distillery will be provided by the plant. Biomass Energy Centre, HMP Guys Marsh Prison, Dorset HMP Guys Marsh has revolutionised its energy provision by installing a biomass fuel energy centre which has been operational for over a year and is demonstrating exciting benefits for the establishment. HMP Guys Marsh is located near Shaftesbury in Dorset and can accommodate up to 578 people. The majority of the prison campus was heated from a single energy centre using heavy oil boilers dating from The heat was distributed to the building via underground heat mains. An appraisal was undertaken to evaluate the technical and economic viability of constructing a new energy centre compromising of a single wood chip boiler system to act as the lead boiler with natural gas boilers providing standby and peaking capacity. A new pre-insulted heat main was installed to connect into the existing heat main system. The design settled on a single 1.2MW wood chip boiler (from Australian supplier, Binder GmbH) with 2 gas boilers each rated at 2400kW of capacity. The biomass boiler is able to operate at 20% of the boiler maximum rated capacity while still offering high efficiency. The load profile of the site indicated that there was sufficient base load demand that an accumulator tank would not be required. A key challenge for the project was the fuel storage and logistic arrangements for fuel delivery. A below ground fuel store was discounted due to a high water table which would have presented technical difficulties and high civil costs. The wood fuel solution, therefore, was an above ground walking floor (5m by 8m) and a fast wood chip distribution system. This design enables a tipped delivery of wood chip into a hopper which is then elevated by a fast vertical auger and distributed evenly onto the walking floor. The wood chip distribution system is capable of moving 120m³ of wood chip per hour, which means a 60m³ wood chip delivery can be emptied in half an hour. 30 Future Energy Opportunities: A Guide for Distillers

32 Biomass Boiler, Falmer Academy, Brighton The Academy is adjacent to the South Downs National Park and to Brighton University and the Brighton Health and Racquets Club. The project includes an Energy Centre which houses the main heating, hot water, rainwater and electrical incoming high voltage equipment that serves the Academy and Sports Hall facilities. Heating is provided by a 450kW biomass boiler and all services are routed through a services tunnel linking the Energy Centre with the Academy buildings. The plant has been appropriately sized to deal with the varying use of the connected buildings and to take account of peak and base load conditions to minimise energy consumption. All incoming and outgoing services have been fully coordinated and the design of the underground woodchip storage bunker has been developed closely with the local delivery company to ensure that the required minimum quantity of fuel storage is accommodated. 8. Introduction to the example project This is an example project for biomass boilers to replace or reduce the energy load of the existing boilers in a medium size distillery in Speyside. Input Data The site has available land for development, approximately 5,000m2. Site energy demand for heating is 9GWh/year. Parameters Used The parameters used to assess this technology are: Quantity of draff produced: 750t/ year Type of biomass for co-firing: woodchip Fuel displaced: gas oil 40% Hot water generation 36.6% Overall energy generation 31 Future Energy Opportunities: A Guide for Distillers

33 32 Future Energy Opportunities: A Guide for Distillers

34 Biomass CHP 1. Technical Characteristics CHP (Combined Heat and Power) is not a renewable source, unless it is powered by biofuels. CHP systems offer the potential for considerably improved generation efficiency with implicit carbon and cost savings benefits. Generating electricity in a CHP plant is typically only 40% efficient, almost all of the other 60% is dissipated in the form of heat at the generator before any power whatsoever is delivered to the distribution system, such as the national grid, from where further losses are incurred. Overall, national electricity generation and distribution is only about 35% efficient. CHP is effectively a small scale power station with heat reclamation and minimal distribution losses due to its close proximity to the load. In contrast to gas fuel, the use of biomass as a heat source for CHP systems has hitherto been restricted to large units (of several megawatts). 2. How it works There are three main technologies available for biomass CHP: 1. Grate combustion, which is the traditional approach for burning solid fuels. 2. Fluidised-bed combustion. Both these approaches use the heat to produce power from a steam turbine. 3. Gasification where combustible gases are extracted from the biomass source. The extracted gas can be used to fuel a range of prime movers including internal combustion engines. Performance Issues Large scale (>2 MWe) biomass CHP usually uses conventional steam turbine generating technologies, however below this size more exotic technology is required to achieve good efficiency. Many technologies are under active development but not mature yet therefore the market for sub 1MW biomass CHP is not currently commercially mature. Small scale biomass gasifiers exist that convert biomass into flammable product gas. Following suitable clean up and cooling, this can be used to run a 1-2 MWe gas turbine internal combustion engine. Once plant installation is completed, the required levels of performance and availability, and the associated economic benefits, can only be achieved and optimised if the plant is correctly operated and maintained. 3. Key Conditions For good quality CHP, achieved by utilising all the useful heat produced, the size of the CHP installation is determined by the heat base load of the site (domestic hot water). This also ensures that the CHP unit is running for as many hours as possible. Monitoring must be used as a means of evaluating the most economical way of using the plant, taking into account its performance and efficiency, its maintenance costs, and the costs of external energy sources such as electricity and gas. One typical scenario arising from this is that, during the overnight period, it may be cheaper to supply electricity from external sources and to use back-up heat supply plant, than to operate the CHP plant. Staff training could be required to ensure that the system operates efficiently and correctly. As the site already contains large boilers, the maintenance and operational requirements imposed by a larger unit will have little impact. Biomass Storage: The on-site biomass storage facility may need to hold considerable volumes of fuel depending on the CHP unit capacity and rate of use. The main purpose of the store will be to keep the biomass dry and protected from rain and groundwater. Typical storage facilities include bunkers or silos. Ventilation will be required in order to keep the biomass dry and possibly to aid further drying. Large stores of biomass will require regular turning. Drainage should be provided within the store to allow the removal of water (inadvertent ingress of water and water used for cleaning purposes). Biomass delivery: The amount of biomass material to be delivered and the delivery mechanism will depend on the size of the biomass facility. Convenient and safe access for delivery vehicles is required. 33 Future Energy Opportunities: A Guide for Distillers

35 4. Planning Economic benefit to fuel suppliers Construction impact of the plant and fuel storage area Visual impact of the plant Noise from plant operations Effects of airborne and water borne on health or ecology Impacts of increased traffic required to bring biomass fuels to site and take away by-product including noise, congestion and impacts on air quality and climate change Impacts on Heritage Assets. 5. Relative costs The cost of CHP systems based on wood-fuel is significantly in excess of that for those systems based on conventional fossil fuel. The capital cost per kw installed is detailed in the table. Energy Output Conversion Technology Cost per kw Installed Woodfuel CHP Combustion (<500kWe) 2,000/kW Woodfuel CHP Gasification and Pyrolysis 1,500/kW Woodfuel CHP Steam/Gas (Large Scale) 1,200/kW Gas CHP Gas Turbine 500/kW 6. Feasibility for Distilleries As distilleries produce a significant amount of biomass by-products and low-grade rejected heat, biomass fuelled systems should be considered and can be a key opportunity to address both industrial and domestic heat use. CHP fuelled by biomass, as explained in this chapter, is viable although it is only tested above 1MW. Most of the time this is not technology feasible for a distillery because, if on one hand the heat demand dominates, the electricity need is considerably lower, therefore the CHP size is often below 1MW. Furthermore if there is interest for generating surplus electricity this system can be considered and the electricity can be sold to the grid or to a neighbouring site. Biomass availability as mentioned in the key condition section is a very important factor for selecting biomass fuel systems. 7. Examples of Application Helius Corde, Speyside, Scotland In August 2009 a joint venture (JV), Helius CoRDe Ltd, was formed with the Combination of Rothes Distillers, comprising of a number of major distillers of Speyside. The JV was formed to take forward a 50m, 7.2MWe biomass combined heat and power plant at Rothes that by 2013 will use the by-products of the whisky-making process for energy production. Draff from participating distillers will be burned together with woodchips to generate enough electricity to supply 9,000 homes. Excess energy will be sold to the National Grid. All the draff will be sourced locally. Biomass Waste CHP, Mid UK Recycling, Lincolnshire Mid-UK Recycling is an independent company which works with businesses and councils to achieve a genuine 100% landfill diversion. Input: low-grade life expired timber (wood) MDF, chipboard, plywood, painted wood, laminated wood etc. as well as clean timber such as old pallets and offcuts from timber manufacture. Production: 3MW or 20,000MWhr per annum. Fuel Source: - Over 30,000 tonnes per annum of lowgrade life expired timber (wood) ROCS compliant 1.5 ROCS per MW hour AvedØre 2 CHP Plant, Denmark Around 7% of district heating in Denmark comes from biomass-fuelled systems, including straw, wood and pellets (usually from processed wood waste). One example is the AvedØre 2 CHP plant that came on-line in The project claims to be the world s largest multifuelled CHP unit, able to burn combinations of biomass, pellets, coal heavy fuel oil and gas. Electric power output from the plant will meet 20% of power demand in Eastern Denmark. The plant will also supply 485MWe of electricity and 570MW of heat to Greater Copenhagen s district heating system. This is sufficient to supply district heat to about 180,000 homes and provide electricity consumption for 800,000 households. 34 Future Energy Opportunities: A Guide for Distillers

36 CHP Biomass Gasifier, University of East Anglia (UEA), UK The construction of a Combined Heat and Power (CHP) biomass gasifier at the University of East Anglia has been completed. The Biomass used by the plant consists of woodchips from sustainable forestry in Norfolk. Once it is fully operational, the gasifier will reduce UEA s carbon emissions by over 30%, or more than 8,000 tonnes. Furthermore, the plant will generate a by-product of tonnes of biochar per annum, which the Low Carbon Innovation Centre (LCIC), based at the University, will be investigating for use as a carbon sequestration agent. As is appropriate for such a new technology, the gasifier has been undergoing rigorous testing. The first commissioning phase was completed in autumn 2010 and since then several modifications and adjustments have been made. The gasifier is now entering its second commissioning phase, after which UEA expects the plant to be fully operational. When coupled with the savings on gas and electricity imported to the site, the gasifier s payback period is expected to be in the region of four years. Though gasification processes are historically well known, the scale and type of the UEA gasifier is new. It is the first working plant of its kind in the UK and is already attracting a lot of attention, particularly as the UK requires much more renewable energy. On 13 April 2011, Helius announced financial close for this project, bringing in additional equity investment from Rabo Project Equity BV and debt funding from Lloyds TSB Bank plc and the Royal Bank of Scotland plc, enabling the project to progress into construction 8. Introduction to the example project This is an example project for biomass fuelled CHP system to reduce the on-site energy load for electricity and steam. Input Data Assumed distillery is located in Highlands. The site has available land for development, approximately 700m 2. Site energy demand is 7.2GWh/year. Parameter Used The parameters used to assess this technology are: Quantity of steam generated by CHP: 80% Type of biomass: pellets It is assumed that surplus energy generation is sold to the grid. 80% Hot water generation 89.2% Overall energy generation 35 Future Energy Opportunities: A Guide for Distillers

37 36 Future Energy Opportunities: A Guide for Distillers

38 Hydroelectric 1. Technical Characteristics Hydroelectric power involves converting flowing water into electrical energy by allowing it to pass through a turbine connected to a generator. Hydroelectric turbines are a mature technology however there has been a resurgence in Micro Hydro (<100kW) applications in recent years. Hydroelectric installations are highly site specific and may include civil works. Once installed civil works and electrical plant can last for several decades. There were over 17 new hydro installations in 2010 in UK (DECC). 2. How they work When the water flows downhill towards sea level it releases the stored energy (retained solar energy or from precipitations) into kinetic energy. Electricity is generated by passing the flowing water through hydrological turbines. Hydro-turbines convert water pressure into mechanical shaft power, which can be used to drive an electricity generator, or other machinery. The vertical fall of the water, known as the head, is essential for hydropower generation; fast-flowing water on its own does not contain sufficient energy for useful power production except on a very large scale, such as offshore marine currents. Hence two key quantities are required: a flow rate of water (volume of water passing per second m3/s) and a head (maximum available vertical fall in the water from upstream to downstream level). Hydro turbines have the benefit of availing of a predictable energy source that is usually continuously available. Maintenance is limited, no fuel is needed, and systems have a long life of up to 50 years. A short description of the different type of hydro-power technologies and applications follows. Pelton: The Pelton Turbine consists of a wheel with a series of split buckets set around its rim; a high velocity jet of water is directed tangentially at the wheel. The jet hits each bucket and is split in half, so that each half is turned and deflected back almost through 180º. Nearly all the energy of the water goes into propelling the bucket and the deflected water falls into a discharge channel below. The Pelton turbine has an excellent part flow efficiency curve that shows its ability to operate at high efficiency through a full range of flow rates. This makes it an ideal turbine to be used in an installation, which encounters seasonal variation in flow rate. Turgo: The Turgo turbine is similar to the Pelton but the jet strikes the plane of the runner at an angle (typically 20 ) so that the water enters the runner on one side and exits on the other. Therefore the flow rate is not limited by the discharged fluid interfering with the incoming jet. As a consequence, a Turgo turbine can have a smaller diameter runner than a Pelton for an equivalent power. Cross Flow: The Cross Flow turbine has a drum-like rotor with a solid disk at each end and gutter-shaped slats joining the two disks. A jet of water enters the top of the rotor through the curved blades, emerging on the far side of the rotor by passing through the blades a second time. The shape of the blades is such that on each passage through the periphery of the rotor the water transfers some of its momentum, before falling away with little residual energy. Francis Turbine: The Francis turbine is essentially a modified form of propeller turbine in which water flows radially inwards into the runner and is turned to emerge axially. For medium-head schemes, the runner is most commonly mounted in a spiral casing with internal adjustable guide vanes. Archimedes Screw: The Archimedes Screw is made up of a helix shaped blade mounted on a central shaft. Water enters the top of the cylinder or screw and the weight of the water on the screw causes water to fall to a lower level causing the shaft to rotate in the process. Archimedes screws are ideal at low head sites of 1.5m and above, but are limited to a max head of approximately 8m. The Archimedes screw is one of the most fish-friendly as they can pass through the turbine without interference. 37 Future Energy Opportunities: A Guide for Distillers

39 3. Key Conditions/ characteristics Site Layouts: Hydro installations are highly site dependent as they require access to a nearby river or burn. The river or burn has to be nearby and have a head of at least 3 metres. A detailed assessment to gauge the flow rate of the river is essential. The most common layouts of suitable location for hydropower installation for medium and high-head schemes are: Canal-and-penstock layout. Penstock layout without the use of a canal, applicable where the terrain would make canal construction difficult or in an environmentally-sensitive location where the scheme needs to be hidden and a buried penstock is the only acceptable solution. For low head schemes, there are a number of typical layouts: Lade or mill Leat. An old powerhouse or watermill or traditional distillery can often still have a lade or canal that was part of the old scheme or that might still be in use. A barrage is built and more cost-effective when the existing lade is sized for a lower flow with a barrage development, the turbine(s) are constructed as part of the weir or immediately adjacent to it, so that almost no approach lade or pipe-work is required. A final option for the location of new mini-hydro turbines is on the exit flow from water-treatment plants or sewage works. This application is growing in popularity with UK water companies. engineering cost. Cost of machinery for high head schemes is generally lower than for low head schemes of similar power. Civil works depends on site layout and might be significant for pipelines, water intake, screens and channel. The connection cost is set by the local electricity distribution company. The introduction of Feed-in-Tariffs has made smallmedium scale hydroelectric installations financially attractive with a relatively short payback period when conditions are right. 6. Feasibility in distilleries Traditionally distilleries have been located in close proximity to a water source or burn making hydro power a suitable technology for many of these sites. Finding the right location is a first and essential step however other elements can affect the implementation of this technology as mentioned in this section such as water flow, distance between distillery and water source, availability of the required volume of water, reliability of the water source and flow rates/volumes plus access to the grid connection and access for engineering such as civil works. 7. Examples of applications Deanston Distillery, Doune, Scotland Deanston Distillery in Doune, which is part of Burn Stewart Distillers, combines Scotland s engineering heritage with industrial re-invention, showing that renewable energy and sustainability are not new to the Scotch Whisky making process. 4. Planning/Environmental Concerns Micro hydro schemes require planning permission and have to obtain a range of environmental licenses which will depend on the nature of the scheme and turbine type. Licences may include water abstraction if water is diverted from stream or river or land drainage consent if work is carried out in a main channel. 5. Relative costs Small hydro cost can be splits in four segments: machinery, civil works, and electrical works and other The River Teith at Deanston 38 Future Energy Opportunities: A Guide for Distillers

40 Established in 1966, Deanston Distillery, producer of the hand-crafted Deanston Highland Single Malt Scotch Whisky, occupies a former cotton mill on the banks of the River Teith. It has achieved the rare status of being self-sufficient in electricity, with power generated by the on-site hydro-energy facility. The system, driven by the fast running water of the Teith, was introduced in the 18th Century to drive the world s first water-powered spinning frame - an invention by the mill s original designer, Richard Arkwright. At 36 ft 6 in diameter and 11 ft wide, Hercules, one of four colossal waterwheels powering the mill from 1833, was the largest waterwheel in Europe and the second largest in the world. The wheels were replaced with two turbines in 1937 which produce a combined output of 400kW. By 1965, changes in the world market for cotton forced the closure of the mill but it was converted for use as a distillery, reopening nine months later in Burn Stewart Distillers bought Deanston in 1990 and committed to retaining and developing the hydro-energy capacity of the distillery. The original turbines are still fully functioning. Modern switchgear equipment was installed but the original 1937 switchgears remain. They may be viewed as part of Deanston s new Visitor Centre experience charting the social and industrial history of the site from 1785 to present day. The two turbines produce on average 48,000kWh a week. Depending on production levels, the distillery uses 10 14,000kWh a week with the surplus energy being exported to the national grid. On average, Deanston delivers 1,300,000kWh pa of hydro-generated electricity to the national grid every year. This is enough energy to power 394 homes all year, based on average usage. The hydro-energy project at Deanston Distillery is managed by the Wemyss Development Company. Burn Stewart Distillers Limited is a fully integrated Scotch whisky producer and brand owner with three single malt whisky distilleries and a strong portfolio of Scotch whisky brands. 90kW Farm based Micro-Hydro Scheme, Devon A farmer based in Dartmoor National Park designed and developed a 90kW micro-hydro scheme at his site. This involved diverting water from a nearby river 500m away and building a channel along the side of the valley. The water then flows down a 100m penstock to a 90kW turbine. The turbine house is built of local wood and is surrounded by two acres of planted woodland. Power cables connect the site to the mains grid. The scheme now generates the energy consumption of about 90 homes, and avoids about 220 tonnes per year of CO 2. The hydro site has also become an attraction within local area, as owners regularly give talks and tours. 8. Introduction to the example project This is an example project for Hydropower generation in a medium distillery located near a river. Input Data The site has an annual demand for electricity that is about 300MWh/year. Site is located by a river that has a head of more than 3 metres. Parameters Used The parameters used to assess this technology are: River characteristics: Head 3.5m Burn section 5x5 m 2 River flow rate 11.3 m 3 /s Type of bed river surface: smooth Capacity factor: excellent Farm scale AD Credit: Biogen Future Energy Opportunities: A Guide for Distillers

41 96.1% Electricity generation 4.1% Overall energy generation 40 Future Energy Opportunities: A Guide for Distillers

42 Ground Source Heat Pumps 1. Technical Characteristics Both air source heat pumps (ASHP) and ground source heat pumps (GSHP) can be considered for the provision of space heating in winter and cooling. Ground source heat pumps provide a more efficient solution since they use low temperature latent heat, which exists naturally below ground. ASHP have not been considered for the study. In the UK, soil temperature below a depth of 5 metres stays at a constant temperature throughout the year of around o C; this being the annual mean air temperature. The soil at this depth is effectively a huge thermal store: storing heat absorbed from the sun in the summer and releasing it during the winter. GSHP take this low temperature energy and concentrate it into more useful, higher temperature, energy to heat water or air inside a building. Types of GSHP loop include: Horizontal Vertical Spiral or slinky 2. How it works A horizontal closed loop is composed of pipes that run horizontally in the ground. A long horizontal trench is dug typically at metres below ground level and U-shaped coils are placed horizontally inside the trench. These are ideal for smaller systems but they require significant land. A vertical closed loop field is composed of pipes that run vertically in the ground. A hole is bored and pipe pairs joined with a U-shaped cross-connector at the bottom of the hole creating a loop. Boreholes are typically spaced 5-6 metres apart and drilled to a depth of between metres. Vertical loop fields benefit from higher ground temperatures than trenches, are more efficient and require less land. Performance issues The first step in the design of a GSHP installation is the accurate sizing of the heat pump system. This is particularly important as over-sizing can significantly increase the installed cost with little operational saving and means that the period of operation under part load is increased. Conversely, if the system is undersized design conditions may not be met and the use of top-up heating, usually electric heating, will reduce the overall system efficiency. The selection of refrigerants is also a key element when sizing the system. A large quantity of low-grade energy absorbed from the ground is transferred to the refrigerant. This causes the temperature of the refrigerant to rise changing it from a liquid to a gaseous state. 3. Key Conditions Electrical energy supply for the heat pump: The heat pump uses the evaporation and condensing cycle of a refrigerant in order to transfer heat from one place to another. This is just like the operation of a refrigerator where heat is extracted from inside the fridge and expelled at higher temperature via the condenser on the back. A compressor is used to move the refrigerant around the system and to compress the refrigerant in order to raise the temperature at which it condenses to that required in the building. It is the compressor which consumes the electricity required by the system. Coefficient of performance: The coefficient of performance (CoP) is the ratio of the primary energy (usually electricity) to total heat out. The energy transferred out includes most of the primary energy too because the compressor power is ultimately turned into heat and collected. For this reason, the CoP of a refrigeration plant used as a heat pump is one higher than when it is used for cooling and sometimes called CoPH to differentiate it. 41 Future Energy Opportunities: A Guide for Distillers

43 Typically a ground source heat pump will produce a CoP of about 4, i.e. for each 1 kw of electrical energy in; 4kW of useful heat is transferred. Heat pumps are available in a range of installed capacities from several kw right up to several MW (large enough to provide all of the building s heat needs). Borehole cooling (or heating) is effectively an open loop system which uses the ground water temperature directly. The ground water is pumped to the surface and used for heat extraction and/or heat rejection before it is pumped back into the aquifer via a second (recharge) borehole. The capacity of the system is limited by the amount of water that can be extracted and the allowable rise/fall in temperature of the water before discharge. A geotechnical survey can be used to ascertain the thermal conditions at the site, aiding in assessing the viability of the installation. 4. Planning The use of boreholes is subject to approval by planners and the environmental regulator (SEPA), and the feasibility depends on local geology, the available water yield, and the presence of other boreholes in the area. The risk of the underground pipes/boreholes creating undesirable hydraulic connections between different water bearing strata is a potential concern. Pollution of groundwater that might occur from leakage of additive chemicals used in the system could also be of concern. 5. Relative Costs For all types of ground collector, setting up costs (design, equipment mobilisation and commissioning) are a significant part of the total cost therefore the capital cost measured in /m of borehole or /m of trench will fall as the collector size increases. Running costs are dependent on the electricity costs as electricity is still required. These solutions can often play a role as part of the wider solution incorporating other renewable technologies. 6. Feasibility for distilleries In many buildings ground source heat pumps provide an efficient solution for heating and cooling. This solution can be applied to a distillery for example to generate the space heating and cooling (if required) for the distillery s office area, toilets and visitor centres and other facilities. It could also be used to provide cooling at times of need. The size can vary considerably and is often driven by the space available or the installation cost for the distribution pipes and or the drilling of boreholes. Because of the temperature of the ground is largely constant GSHP are a very effective way to provide heat, however if used for process heating additional energy input is required by a boiler or the heat pump itself making this solution less effective. 7. Examples of applications Gloucestershire Police HQ, England The design team for the Gloucestershire Police new four storey 8,500m2 HQ took an innovative approach and specified a heat pump using ground source energy believed to be the largest of its type in the UK - instead of a conventional boiler and chiller solution. The use of geothermal energy was seen by the project team, as an innovative way of reducing long-term carbon emissions and hence assist in achieving compliance with Part L of the Building Regulations (England). The energy taken from the ground represents approximately three times the energy required by the heat pump compressor, therefore three quarters of the useful energy can be considered to be free and clean. The heat pump, capable of delivering a temperature range of between 7-50 o C, is expected to achieve energy savings for heating and cooling of between 30-40% compared to conventional air conditioning. To utilise the ground source energy, 150 boreholes were drilled to a depth of 98 m. The boreholes were connected into two separate fields to provide some resilience and maximise energy storage. Treated water in a closed loop is circulated down the boreholes where the energy is exchanged. In the summer, the energy will be stored and later recovered. To make the most effective use of the temperatures, an under floor heating and cooling system was specified for the ground floor areas. Meanwhile, the heat produced by the main IT equipment (approx. 100 kw) is also recovered by the heat pump system and delivered elsewhere in the building or stored. 42 Future Energy Opportunities: A Guide for Distillers

44 Consider that.heat pumps have a low maintenance requirement when compared to a conventional boiler and chiller system therefore considerable savings * on maintenance can be expected over the whole building life cycle with this system. IKEA Store, Corsico Milan, Italy A system was installed at the IKEA store in Corsico, Milan, with the need to provide some 1.4 MWth and covering thermal energy demand in the range from 40 to 100%. The closed loop system is expected to save IKEA over 500 tonnes/year in CO 2 emissions. Payback time was calculated in 7 to 10 years depending on climate conditions. After this period, capital costs will be recovered and only running costs (maintenance and management) will be required. Christies Garden Centre, Fochabers, Scotland This example is for a GSHP for a heating and cooling system. 8. Introduction to the example project This is an example project for a vertical Ground Source Heat Pump system for a distillery in Orkney Input Data The site has available land for development, approximately 2.600m 2. Site energy demand for heating is 5GWh/year. Parameter Used The parameter used to assess this technology are: Land available for boreholes: 450m 2 Fuel displaced: heavy fuel oil This system was designed to provide both heating and cooling to a garden centre, restaurant and shop on the Moray coast in North East Scotland. It is a horizontal ground loop extraction installation using a 37kW HGL heat pump unit. Some of the ground source pipe work was also run through the large green houses to enhance system efficiency. The heat pump also provides cooling to the restaurant and shop when required. 43 Future Energy Opportunities: A Guide for Distillers

45 100% Hot water generation 2.6% Overall energy generation 44 Future Energy Opportunities: A Guide for Distillers

46 Alternative Renewable 03 Technologies Wave & Tidal 1. Technical Characteristics Wave and tidal energy generators convert the kinetic energy stored within waves and tidal flows into mechanical then electrical energy. Despite the proximity of the European Marine Energy Centre on Orkney and several support structures in place to encourage the sector, there are only a handful of functioning grid linked installations throughout Scotland. 2. How they work Waves: Waves are created by the passage of the winds over the surface of the sea and the energy inherent in the wave is shown by its height and movement. Wave energy devices are designed to absorb this energy and convert it into electricity in as number of ways: for example by pushing a hinged door, linked to a hydraulic pump, open and closed. A number of devices are being developed to convert wave energy into electrical energy. These wave power devices, depending on type, are located off shore, near shore or shore-based. Types include the oscillating water column, hinged contour device, buoyant moored device, attenuators and overtopping device. Credit: European marine energy centre (EMEC) Tidal: Tidal energy, or tidal power, is a little known and little used energy source. Yet it is a very old energy source, dating back to the middle ages in Europe. Tidal energy is created by the relative motion of the earth, moon, sun, and the gravitational interactions between them. Every coastal region has two high and two low tides in each approximate 24-hour period. Tidal energy systems generate energy from the ebb and flow of tides using a turbine function in a similar way to wind turbines except for the density of the medium (water) is denser. This means that the energy potential of per cubic metre is higher. 3. Key Conditions/ characteristics Predictability: the size and time of tides can be predicted very efficiently. It is possible to predict the output of a tidal energy device decades in advance. Location: in order for electricity to be generated, differences between high and low tides must consistently reach 16 feet. There are few regions in the world where this occurs. There are eight main sites around Britain where tidal power stations could usefully be built, including the Pentland Firth, Severn, Dee, Solway and Humber estuaries. Only around 20 sites in the world have been identified as possible tidal power stations. Marine conditions: wave and tidal energy are highly dependent on the local marine conditions. Tidal energy is particularly focussed in areas with a high tidal flow density such as Pentland Firth. Practicability: although the tidal energy supply is reliable and plentiful, converting it into useful electrical power is not easy. Access to grid: access to the local grid is also a concern for developing remote marine installations as developer may have to incur cost of extending grid to site. Few technologies are suitable for deep applications therefore all installations need to be near shore. There has yet to be a commercially available wave or tidal technology offered to market as yet. However, some systems may become deployable within the medium term, in particular for sites located close to an exposed coastline. 45 Future Energy Opportunities: A Guide for Distillers

47 4. Planning The Crown Estate has possession of the majority of land off the coast of the UK. They are the key project partner in developing marine energy installations. It may prove that much less visible tidal stream and wave devices will encounter fewer objections when going through the planning application process. Environmental Impacts: Wave energy devices produce no gaseous, liquid or solid emissions and hence, in normal operation, wave energy is virtually a non-polluting source. However, the deployment of wave power schemes could have a varied impact on the environment. Some of the effects may be beneficial and some potentially adverse. Wave energy converters may have a variety of effects on the wave climate, patterns of vertical mixing, tidal propagation and residual drift currents. Hydrodynamic Environment: Wave energy converters may have a variety of effects on the wave climate, patterns of vertical mixing, tidal propagation and residual drift currents. The most pronounced effect is likely to be on the wave regime. A decrease in incident wave energy could influence the nature of the shore and shallow subtidal area and the communities of plants and animals they support. Noise: Some wave energy devices are likely to be noisy especially in rough conditions. Noise travels long distances underwater and this may have implications for the navigation and communication system of certain animals principally seals and cetaceans. It is thought unlikely that cetaceans would be affected as much of the noise likely to be generated is below the threshold hearing level (frequency) for dolphins. Device Construction: Other major impacts of wave energy conversion on the natural environment would result from the construction and maintenance of devices and any general associated development. Navigational Hazards: Wave energy devices may be potential navigational hazards to shipping as their low freeboard could result in their being difficult to detect visually or by radar. Several of the areas proposed for wave energy devices around European coasts are in major shipping channels and hence there is always an element of risk that a collision may occur. Conversion and Transmission of Energy: Transmission lines are required to transfer the electricity generated to the places it is required. Initially cables are likely to run on the seabed and, although lying underground may be possible on particular shorelines, the cost implications suggest that overhead lines may be required with the consequent problems of visual intrusion in areas of high landscape value. On certain shorelines overhead transmission lines can have an effect on the mortality of certain species, especially large migratory species which have limited manoeuvrability. Most collisions appear to occur where lines intersect flyways between roosting and feeding grounds. Visual Effects: In some areas, the water depth required by the near shore devices might be attained only a few hundred yards offshore. Such schemes and shoreline devices would have a visual impact. Such schemes may be particularly sensitive in areas of designated coastline and those used for recreational purposes. Considerable work is now being done within the UK, by the Department of the Environment, local authorities and voluntary organisations, to examine the issue of coastal zone management and it may be necessary to plan for the future inclusion of wave power in management plans developed. 5. Relative costs There are challenging technical and logistical problems to be solved and, at this stage of development, it is not clear that these can be overcome at an acceptable price. A study was commissioned by DECC and Scottish Government to provide an assessment of the current generation cost for wave and tidal generation projects in the UK. Further information can be found in this document 2. The data in the report suggest a wide range of costs at present based in the variety of technologies across the broad categories of wave, tidal range, tidal stream shallow and deep. It has been estimated that improving technology and economies of scale will allow wave generators to produce electricity at a cost comparable to wind-driven turbines. 2 Cost of and financial support for wave, tidal stream and tidal range generation in the UK. A report for DECC and the Scottish Government, Oct Future Energy Opportunities: A Guide for Distillers

48 6. Feasibility for distilleries There is still a long way to go in terms of commercial realisation of both wave and tidal power stations. Different technologies are at different stages. Tidal barrage technology is essentially mature whilst tidal stream technology a bit less mature; nevertheless devices are now being refined by world class major companies in the UK and elsewhere. Wave energy is the least mature, but Scotland appears to be well advanced in terms of construction and testing at full scale. 7. Examples of Application Oyster Wave Energy, European Marine Energy Centre, Orkney The Oyster 1 was activated on the 20th November 2009 and demonstrated the feasibility of using wave energy to pump high pressure water to an onshore hydroelectric turbine to create electricity. The device remained in the water for up to two winters and provided generation 24 hours a day. As the device was a prototype it was removed from service after two years in order to study the impact of two years at sea on the device. The Oyster concept utilises a wide buoyant bottomhinged oscillator (or flap) that completely penetrates the water column from above the surface to the seabed. The wave forces on the oscillator, and drives hydraulic pistons that pressurise water and pump it to shore through pipelines. The onshore hydroelectric plant converts the hydraulic pressure into electrical power via a Pelton wheel, which turns an electrical generator. The water passes back to the device in a closed loop via a second low pressure return pipeline. The Oyster 1 concept design has received 6.2 million in funding from SSE and has been deployed at the European Marine Energy Centre on Orkney. Oyster wave energy converter in operation at Orkney Credit: Aquamarine Power 47 Future Energy Opportunities: A Guide for Distillers

49 Tidal Turbines, Sound of Islay It was announced in January 2012 that ten tidal turbines, will be installed on the seabed in the Sound of Islay, the channel between the islands of Islay and Jura. It is envisaged that the electricity it will produce ten MW enough to power the whole of Islay, including the distilleries. The project will use HS1000 tidal turbines developed by the Norwegian company Hammerfest Strøm AS, partly-owned owned by Iberdrola. Seen as one of the world s most advanced tidal turbine designs, a prototype device has been generating electricity in Norway for over 6 years. The company is currently constructing the first HS1000 device that will go into waters off Orkney later this year. Tides to power whisky distilleries from TheIndipendent. co.uk 31 January2012. Limpet Wave Power Plant, Islay, Scotland LIMPET stands for Land Installed Marine Powered Energy Transformer. It is specifically the name given to the research and test facility developed on the island of Islay by Voith Hydro Wavegen; an Inverness based company. This wave installation involves a partially submerged chamber which encloses a column of water called an Oscillating Water Column (OWC). In LIMPET the chamber is set into the rock face on the shore although more recent plants have been built with the chamber incorporated into a breakwater structure in the near shore environment, such as Mutriku in the Basque Country in Spain. The rising wave causes the air in the chamber to compress forcing it through a Wells turbine. The falling wave draws air back through the turbine enabling the turbine to generate power in both compression and decompression cycles of the wave. It is a feature of the Wells turbine that it continues to rotate in the same direction, irrespective of the direction of the air flow. Being a research and test facility the output of this plant varies depending upon the equipment under test however it has continued to provide electricity to the grid on the Island of Islay off the west coast of Scotland for over ten years. This is an example of how this technology can be used to meet small-scale local needs. Since wave energy is a linear front it is clear that scaling up to larger capacity power plants lies not in large capacity units but in installing many small ones, such as these, along the incoming wavefront. Voith Hydro Wavegen s LIMPET facility on Islay Images courtesy of Voith Hydro Wavegen Limited Mutriku Power Plant in the Basque Country utilising Voith Hydro Wavegen s technology 48 Future Energy Opportunities: A Guide for Distillers

50 Hydrogen/Fuel Cells 1. Technical Characteristics Using an electrochemical process discovered more than 150 years ago, fuel cells began supplying electric power for spacecraft in the 1960s. Fuel cells convert chemical energy into electrical energy through electromechanical reaction, just like a battery; the only difference is that the fuel is supplied from outside; thereby making the fuel cell feel like an engine converting fuel into electricity without burning it. 2. How they work An electrical potential is applied to the metal plates of the fuel cell to begin splitting water molecules. Electrons are stripped from the H 2 O molecules on the cathode side and are pumped to the anode plate. This leaves a positive charge on the cathode and creates a negative charge on the anode. Protons (hydrogen) are attracted to the negative charge and repelled by the positive charge forcing them to diffuse through the proton exchange membrane to the anode. Lower energy hydrogen bonds are formed on the anode side and oxygen bonds are formed on the cathode side. Energy is now stored in a gas form and can be released in the reverse process. A motor connected between the anode and cathode will provide a path for the electrons to return to the cathode, energy will be released in the form of mechanical torque from the motor. 3. Key Conditions/ characteristics Fuel cells are used in a range of applications from stationary electricity generators for back-up power, but are most commonly used in combined heat and power production in order to utilise the heat generated by the fuel cell. Fuel cells have been used successfully in a wide range of applications including space craft, submarines, boats, domestic and business premises (providing heat as well as power) and of course in cars and small vans. There are a number of possible combinations of fuel and oxidant available but perhaps the most familiar is the hydrogen fuel cell that uses hydrogen as the fuel and oxygen (from air) as the oxidant. Fuel cells require access to a plentiful supply of natural gas, biogas, or hydrogen. An electrolyser can be used to create hydrogen if there is electricity generated on site. Producing hydrogen using clean, renewable electrical sources such as wind or tidal is also a way of storing that energy for later use or to use when the renewable source isn t available. Electrolysis is a method of injecting direct electric current (DC) into H20 to drive an otherwise non-spontaneous chemical reaction that results in the release of hydrogen. 4. Planning There is currently no transparency around the criteria that applies to this technology and still a lack of clarity in the policy. The main key challenges are around: Hydrogen production, including the availability of green hydrogen (from organic material or other renewable resource) Underdeveloped hydrogen infrastructure Storage Delivery 5. Relative costs Site-specific economic analysis is critical for evaluating if a particular site is suitable for installation of a fuel cell system. Key factors include grid electricity costs, delivered fuel costs (typically natural gas), site load profiles, and availability of financial incentives. Two of the most important drivers for economic viability are: 1) the premium placed on backup and reliable power for a given facility, and 2) the spread in cost between natural gas provided to a facility and the cost of electricity purchased from the grid, otherwise known as the spark spread. For locations with relatively low natural gas costs and relatively high electricity costs, fuel cell systems will have a faster payback period and may provide a substantial additional revenue stream when net metering applies. 49 Future Energy Opportunities: A Guide for Distillers

51 6. Feasibility for distilleries The fuel cell market has growing steadily worldwide with shipments growing by 132% from 2007 to The global fuel cell market is currently worth 400 million and will grow to 950 million by Uptake of fuel cell CHP within the UK is increasing rapidly. Projects such as the Transport for London emergency response centre at the Palestra building selected fuel cell CHP on commercial merit, and other commercial buildings have selected fuel cell CHP in preference to solar PV arrays as the most cost effective option for meeting on-site power generation and carbon reduction targets. This is a technology that can be feasible for distilleries in generating power and heat in a very efficient and clean manner, this should be considered in the near future where some of issues related to hydrogen availability, delivery and storage will be resolved. 7. Examples of Application Fuel Cells, Gussing, 100% Renewable Energy Development Austria. The town of Güssing in Austria selected ClearEdge to assist in meeting its target of producing 50 MW of clean distributed energy generation from fuel cells in the Republic of Austria by The agreement will see Güssing sell, install and service the fuel cells with 8.5 MW to be installed in the next three years with a further 41.5 MW installed by Transport for London (TfL) Palestra Building, London, UK The 200KWe fuel cell, supplied by Logan Energy, is part of a 2.4m combined heat and power (CHP) plant at the Palestra building in Southwark. The hydrogen fuel cell, funded by the 25m TfL climate change fund, will provide electricity, heat and cooling to the London building. The building s hot water supply will also be heated by the fuel cell. At times of peak energy use, the building will generate a quarter of its own power, rising to 100% off-peak. The waste heat from power generation will be pumped into a unit on the roof which will work to keep the building cool and supplement the building s six electric chillers. The project is part of efforts by TfL and the London Development Agency (LDA) to cut carbon emissions from head office buildings and cut 400,000 off its energy bills. TfL commissioned the project in As of mid- March 2010, the system had been operational for 5,860 hours and delivered 969MWhrs of electrical energy. The building is shared by 2,800 TfL and LDA staff. Tfl estimates the fuel cell and power plant will cut carbon emissions by up to 30% and generate 90,000 cost savings per year. Source: news.asp?id=7178&title=uk s+biggest+hydrogen+fu el+cell+sited+at+tfl+hq Headquartered in the Austrian town of Güssing, Güssing Renewable Energy offers instantly usable carbon-neutral solutions that help communities produce clean, reliable energy. These solutions include proven anaerobic technology that can convert organic mass into high-purity biogas that can be used to cleanly and cost-effectively generate electric power and heat in fuel cells like the ClearEdge systems. Under the agreement with ClearEdge Power, Güssing Renewable Energy has agreed to sell, install and service ClearEdge systems in Austria and also has the opportunity to foster adoption within Western European markets. The agreement is designed to support the installation of 8.5 MW of fuel cell systems in Austria over the next 36 months, which will then rise to 50 MW by Source: 50 Future Energy Opportunities: A Guide for Distillers

52 Beyond Traditional Renewables Innovative options to be considered in planning a future energy supply strategy for the distilleries manufacturing sector are discussed below. 1. Innovative energy solutions: examples from distilleries Algae and biofuel from draff (prototype) Scottish Bioenergy Ventures has successfully completed the first phase of a trial at one of Scotland s oldest working distilleries in which algae converts carbon dioxide into biofuels. Phase one of the trials involved an innovate process of capturing CO 2 from the distillery s boiler exhaust and percolating the gas through algae reactors, converting it into oils and protein which can be used as fuel for the distillery. The algae reactors also successfully eliminated chemicals and captured copper from the wastewater, reducing even further the environmental impact of the distilling process and reducing costs. Biofuel using pot ale and draff Using samples of by-product from distilleries, researchers at Edinburgh Napier University are developing a method of producing biofuel from two main by-products of the whisky distilling process. The new method aims to produce biobutanol, which gives 30% more power output than the traditional biofuel ethanol. The team has adapted this to use whisky by-products and has filed for a patent to cover the new method. It has created a spin-out company to commercialise the invention. 2. Innovative energy solutions: examples from the world WindFloat WindFloat is a floating support structure for offshore wind turbines with a simple, economic and patented design. The innovative features of the WindFloat dampen wave and turbine induced motion, enabling wind turbines to be sited in previously inaccessible locations where water depth exceeds 50m and wind resources are superior. Further, economic efficiency is maximized by reducing the need for offshore heavy lift operations during final assembly deployment and commissioning. Multiple projects are in development for the installation of commercial Wind float units in both European and US offshore wind farms. Solar Cogen/PV syst Traditional solar photovoltaic (PV) systems convert approximately 15% of the sun s energy into usable electricity, discarding the remaining energy as waste, mostly in the form of heat. Solar cogeneration captures this waste heat and transforms it into real value hot water. This cogenerative solution not only generates further savings, it also cools the PV components, enhancing their efficiency and boosting the system s electricity generation and lifetime. Cogenra Solar captures up to 75% of the sun s delivered energy and converts it into both electricity and hot water within a single solar array. This approach yields five times the energy of traditional PV systems. To achieve these efficiency gains, Cogenra integrates advanced silicon PV cells, concentrating optics with single-axis tracking and an innovative thermal transfer system in a low-cost and scalable design. The Gravity Head Energy System (GHES) The GHES, as shown in the following sketch, is a unique application of the traditional Organic Rankine Cycle (ORC) currently used in conventional industry standard binary cycle geothermal power plants today. GHES is an innovative technology designed by GeoTek Energy resulting in improved plant efficiency and a significant reduction in environmental impact. It also contributes in elimination of costly geothermal brine field gathering system and a simplified wellhead based power plant versus the traditional central power plant concept. 51 Future Energy Opportunities: A Guide for Distillers

53 Other Energy Infrastructure considerations 1. Energy Transmission & Distribution The electricity transmission network in Scotland is currently undergoing significant reinforcement work and upgrades. The system was designed for a different era with concentrated centralised energy generation. With the increasing amount of renewable energy being developed in Scotland the need to upgrade and reinforce the networks is paramount. In Scotland the transmission system owners are investing heavily in the necessary reinforcements required. In addition, the Scottish Government, together with Ofgem is working to change the charging system current in place for transmission, where Scotland faces some of the highest costs in the UK but at the same time, has the greatest renewable energy resource to be exploited. One of the key steps in any development will be to understand the grid capacity at site and to understand the issues that may arise with any renewable energy technology you might wish to connect to the grid. As part of your study you will need to ensure the following issues are covered: Distance to nearest connection point e.g. an existing substation. The current network capacity. Most local or remote area systems are 11kv or 33kv and designed for distribution rather than transmissions. The current status of on-site transformers. Are these able to deal with the proposed generation capacity from DC/AC conversion? Planning issues could be onerous depending on the options considered for connection. Above ground will be cheaper but may not be allowed, below ground could be a permitted development but will be expensive and more time consuming. All grid connections need to be negotiated with the local DNO and dialogue should be had at the earliest stage. This will also need to think about DNOs future plans and when you can get connected. Timing of the connection will have a serious impact on the timing of your development. Key things to consider for all developments: You will need to have a grid capacity study completed. This can be delivered for you by consultants with expertise in this area, or through the Distribution Network Operator. 52 Future Energy Opportunities: A Guide for Distillers

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