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“We Bring
Engineering
to Life”
Biological and Agricultural Engineering
Reducing Curing Costs and
Alternative Fuel Sources for
U.S. Flue-Cured Tobacco
Production
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Flue-Cured Energy Sustainability • Modern U.S. agriculture is heavily dependent on nonrenewable energy
sources
• Curing energy is still a substantial production input
• Significant increase in the cost of petroleum fuels in recent years and
continued uncertainty of future prices
• More growers continue to make energy efficiency improvements to
existing infrastructure and replacing older barns
• Any significant increase in U.S. production will require new curing
barns – 5 manufacturers made barns for 2013 season
• Energy efficiency improvements and energy conservation is the
quickest and cheapest new energy source
• Research continues to explore energy efficiency improvements and
renewable energy technologies that are economically feasible
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Efficient Grower Average Energy Use per Cure (10-box barn, 10 hp (7.5 kW) fan motor)
(Assumptions: $1.10/gal LP, $0.10/kWh, 3500 lb per cure season average)
Fuel
(gal)
Fuel Cost
($/barn)
Electricity
(kWh)
Electrical Cost
($/barn)
Total
$/Cure $/lb ($/kg)
300 (1,140 L) $330 1,500 $150 $480 0.14 (0.31)
• Curing energy efficiency is affected by many variables
− barn and heating system efficiency
− green leaf loading rate
− curing management
− weather
− quality of the green tobacco
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LP Gas and Natural Gas Price History
Source: U.S. Energy Information Administration (LP Gas – Wholesale/Resale; N.G. – Commercial)
*>80% of NC Producers use LP gas
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Source: U.S. Energy Information Administration (LP Gas – Wholesale/Resale; N.G. – Commercial)
LP and Natural Gas Present and Future Cost Comparison
Currently, NG provides a 30% cost savings
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Automatic Ventilation Control – Improving
Management and Energy Efficiency
Many automatic systems now
measure relative humidity directly,
but display dry-bulb and wet-bulb
temperature.
10-15% Fuel Savings
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Real-time Continuous Monitoring of the Curing
Environment
• Significant time management tool for growers
• Web-based monitoring system
• Audible alarm conditions to help minimize leaf damage during
equipment failures or power loss
• Capacity to store curing data (temperature, humidity, burner on
time) the entire season to assist with maximizing cured leaf quality
and other diagnostics
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2012 NC County Agent Survey Data (50% of total acreage reported) 20
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Fuel Cost ($/unit)
0.80 1.00 1.20 1.40 1.60 1.80 2.00
lb/gal $ / lb Cured
7 0.114 0.143 0.171 0.200 0.229 0.257 0.286
8 0.100 0.125 0.150 0.175 0.200 0.225 0.250
9 0.089 0.111 0.133 0.156 0.178 0.200 0.222
10 0.080 0.100 0.120 0.140 0.160 0.180 0.200
11 0.073 0.091 0.109 0.127 0.145 0.164 0.182
12 0.067 0.083 0.100 0.117 0.133 0.150 0.167
13 0.062 0.077 0.092 0.108 0.123 0.138 0.154
System Energy Efficiency and Estimated
Cost per Pound Cured Leaf (fuel only)
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On-Farm Energy Evaluation of New Curing Barns
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Energy Content and Cost Comparison of Fuels
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Hurst Boiler Biomass Fired Hot Water Heating System – 2012 20
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Woodchip Biomass System
and Automated Controls
Water to Air Heat
Exchanger mounted
in Return Air Plenum
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Hurst System Specifications
• System rated @ 3.4 MMBTU/hr (996 kW)
• Heat on demand modulating system
• PLC touch screen controller with real-time performance information
• 1000 gallon water storage
• Emission controls
• Manual ash removal
• Burns a wide variety of wood waste (fine saw dust to 2” chips)
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System Performance – 2012 Season • 300,000 to 350,000 BTU/hr (88 to 103 kW) @ 70 gpm
• 195 to 200oF (91 to 93oC) water temperature at the barn
• No change in cure duration
• 17 barns and 131 cures
• 250 tons @ $30/ton
• Primary fuel source chipped pallets (< 10% m.c.)
• 1.2 lb wood chips per lb cured leaf
• Fuel cost $55 to $65 per cure or 1.5 – 2.5¢ per lb cured (3.3 – 5.5¢/kg)
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Greenhouse Heating Applications w/Biomass Unit
Curing Barns and Greenhouse
Applications
Result in Extending System
Operation from July - March
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Max Ox Smaller Capacity Biomass Heating System –
10 Barns and 200’ Greenhouse Application (900,000 Btu/hr (264 kW))
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Automated Biomass Fired System • Advantages
– Reduced fuel cost (70 to 90%)
– Abundant renewable fuel
– High combustion and thermal efficiency
– Automated system (combustion controls, emissions, ash removal)
– TSNA NOx mechanism eliminated
• Disadvantages
– High initial investment
– More equipment maintenance
– Increased management
– Limited local service technicians
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Additional Technologies Evaluated to Improve
Barn Energy Efficiency
• Thermal and electrical energy load vary with time during curing
• Variable rate technologies can potentially improve load matching and
therefore decrease total energy usage
• Variable Frequency Drive (VFD) or Adjustable Speed Drive
technology utilized to change the speed of an electric motor
– Strategically reduce the fan electric motor speed and decrease electrical
energy usage
• Variable firing rate burner or modulating burner utilized to decrease
fuel consumption and heat exchanger thermal cycling
– Burner heat output adjusted automatically based on thermal load
– Reduction in thermal cycling to extend the heat exchanger longevity and
minimize TSNAs in the cured leaf
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VFD unit and Controller
Utilized to Automate the
Change in Fan Speed
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VFD Application Summary • Limited, if any, decrease in cured leaf quality observed
• Limited increase in curing time associated with fan speed reduction
• Typical seasonal electrical energy savings range 20% to 25% (300 to
400 kWh)
• Cost savings will depend on the electrical rate ($/kWh) and motor size
• At 25% energy savings simple payback is 4 to 5 years (10 hp)
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Modulating Burner Technology Summary
• Marginal fuel savings obtained at two locations
• Application may not be possible with all heat exchanger designs
• Some heat exchangers will not operate very efficiently at low firing rates
• Approximately a 35% reduction in the number of burner cycles compared
to a conventional burner
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Questions??
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