HomeMy WebLinkAboutEnergy Case studies est 2010Case Stiulfes
Ketchikan,Alaska
Clean energy lands at airport
/=GED ENERGY AUTHORITY
'J
Ketchikan Airport is one of a growing number of
public facilities on Gravina Island in Ketchikan which
has installed a commercial sized pellet boiler for space
heating.The new boiler replaces a 43-year-old oil-
fired boiler that was at the end of its useful life.Before
deciding on a pellet boiler,the project team received
two quotes to replace the oil boilers with similar units
along with an electric boiler back-up,and the quotes
ranged from $700,000 to $800,000.With a 700 gallon
thermal storage tank incorporated into the installation,
the new pellet system will save the Ketchikan Gateway
Borough at least $12,000 annually,even when the price
of heating fuel is low.
This boiler,however,has been installed as an
ambassador of biomass energy in the Southeast city.
The building that houses the boiler has a viewing
window into the boiler room.The hope is to showcase
this boiler as a model of how biomass systems can
be both clean burning and clean operating,as well as
using locally produced wood pellets.
'Objectives |
The borough laid out three key objectives for this
project,1)to replace the aging oil-fired boilers with a
renewable heating source,2)to work with local wood
fuel suppliers to promote economic development and
encourage further wood energy conversion,3)to build
an excellent project to showcase modern wood energy
technology.
Desigit aiid product Baléction!
The system designers were selected for their unique fo-
cus on biomass installations.The Viessman boiler was
chosen due to the high quality manufacturing,the long
expected service life,and the proven performance in
other installations.
Total Project Costs:$1,100,000
Project Funding:
Renewable Energy Grant Funds $620,000
Woody Biomass Utilization Grant $143,363
Local match $47,878
State of Alaska (remainder)$188,000
Capital Costs
Equipment Costs:$202,611
Design and Engineering:$184,159
Installation Costs:$620,000
Equipment
Make:Viessman
Model:Vitoflex 300-RF
Output:500 MBTU/hr
Thermal storage:700 gallons
Pellet Silo:stores 30 tons
Operational Expenses
Pellets:$300/ton ($4.80 fuel cost equivalent)
O&M:$500 annually
Wood Fuel Use
150 tons annually
Diesel Fuel Offset
20,000 gallons annually
Fuel Savings
$30-50,000 savings annually
Jobs Created
Duties rolled into existing position
an insight into a local industry.Photo by Karen Petersen.
Howwasthé boilersized?
The designers collected the building's historical heat
data and ran it through their proprietary energy model
to determine the optimal boiler size.The new boiler
replaces the largest quantity of oil while covering the
building's base heat load,and leaving the peak heat load
for the new back-up oil-fired boiler.This model found
the existing oil-fired boilers were grossly oversized.
noose pellets?i
A local pellet mill already existed in Ketchikan and had
been supplying pellets to other commercial buildings.
Using a local fuel instead of imported heating fuel can
save up to 40%on heating costs.
Why'is this installation import J
This installation is an example of how a regional
economy can be created by an energy resource.The
boiler will be seen by everyone who visits Ketchikan by
air,and will hopefully encourage others in Southeast
Alaska to investigate pellets as a heating fuel.
A local furniture manufacturer investigated using
residual sawdust and wood shavings to manufacture
wood pellets.When contracts to supply a few local
commercial buildings with pellets were signed,it
proved that a local wood pellet economy could be
created.The addition of new commercial and private
pellet boilers is growing demand for the local product.
ctsbbjettives metzy __|Weretheprojeé
The boiler was installed in June,2016 and the objectives
of using a local fuel supply,promoting biomass energy
and saving money are ontrack.The Ketchikan Gateway
Borough has already started looking to install a pellet
boiler in Ketchikan High School.Once funding has
been identified,that project will move forward.
2 p C
Freight time to Alaska can often take longer than
expected.Building more time into the project timeline
for boiler and silo delivery will ensure the project can
continue at the expected progress rate.
Locally available equipment and supplies are often
far more expensive than when sourced outside of
Alaska.This can unnecessarily drive up project costs.
Modularization and containerization can help reduce
these higher costs.
The new Viessman boiler can be viewed by the public through a view-
ing window.Photo by Karen Petersen.
Project Points of Contact:
Airport Director:Mike Carney
Ketchikan international Airport
1000 Airport Terminal Building,
Ketchikan,AK 99901
System Designer:Andrew Haden
Wisewood,Inc.
2409 N Kerby Avenue
Portland,OR 97227
(503)608-7366
Schmolck Mechanical
Dave Trudeau
110 Jarvis St,Sitka,AK 99835
907 747 3142
Installer:
Boiler Supplier:Fink Machine
124 Old Vernon Rd
Enderby,BC Canada VOE 1V0
Author:Amanda Byrd
Alaska Center for Energy and Power.
Email:agbyrd@alaska.edu.
(907)888 2516
Ketchikan,Alaska
Library stimulates local pellet market/Ga ENERGY AUTHORITY
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The new 16,250 sq ft Ketchikan Public Library building,
maintained by the City of Ketchikan,was built in 2012.
In place of electric heat,a pellet boiler was added to the
building design as a way to reduce electricity demand
on the limited local hydro resources.The library serves
the City of Ketchikan and the Ketchikan Gateway
Borough.
The objectives of installing a pellet boiler in the new
library were to 1)reduce the electricity demand on
the local hydro resource (many homes have installed
electric boilers increasing demand on the already
limited grid);2)to create a local wood pellet market;
3)to stimulate the economy by keeping the heating
expenses within the community with a local fuel.
The ACT Bioenergy system was chosen for its price,
automated fuel handling,and the potential to use
locally available renewable resources.In addition,an
ACT boiler had recently been successfully installed in
the nearby GSA Federal Building.A local pellet mill
had been established at Tongass Forest Enterprises
using a waste product from milling to generate an
energy product.Installing a pellet boiler at the library
would reduce hydro demand while increasing demand
for pellets and stimulating the local industry.
The premium quality pellets,sourced from the local
pellet mill in Ketchikan have gone through some
changes since the library's construction.The mill
reduced the bark content of the pellets,creating a
premium grade pellet.The library's fuel storage system
also underwent some modifications.Initially the inner
wall pitch of the 40 ton concrete bunker was not steep
Total Project Costs:$489,913
Capital Costs
Equipment and Installation Costs:
$234,000
Pellet storage bunker:$206,600
Design Costs:$49,313
Equipment
Make:ACT Bioenergy ™)
Model:CP500 Pellet Boiler
Output:510 MBTU/hr
Pellet storage:40 ton capacity underground
concrete bunker
Thermal storage:500 gallons
Operational Expenses
Pellet Fuel:$305/ton delivered
O&M:2 man-hours per week in an
existing maintenance position
Pellet Fuel Use
60 tons (2013/14)Tongass Forest Enter-
prises
Electricity (and supplemental diesel)Offset
$40,000 for heating in 2012/13 (part of
this time coincided with the island being
heated by diesel.)
Fuel Savings
Up to 5094 gallons @$4.26/gallon -$21,700
(5,100 gallons of fuel =40 tons pellets when burned
efficiently)
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Pellet supply access at the Ketchikan Public Library.Photo by Steve
Hofstedt,City of Ketchikan.
enough to allow the pellets to travel to the auger for
efficient fuel movement.Another issue was that the
springs on the auger arms had insufficient strength to
push against the weight of the pellets piled on top of
them.Both of these issues are now resolved and are
now working well.
How wag the'pellefboil
The boiler was sized for the design load of the building
which is the peak heating load of the building during
the coldest day of the year.This is standard practice
for sizing an oil fired boiler,but results in an oversized
biomass boiler that operates inefficiently.A 135 kW
electric boiler is installed as a back-up to the pellet
boiler,and for when the pellet boiler is not in use.The
pellet boiler is set to run between 180°F and 155°F,and
performs best with an outside temperature of 40°F.The
electric boiler is set to run when the thermal storage
tank drops to 140°F.
Was there"any.iraining J
aaaeottteamedérsized3]
Basic training was provided by the boiler manufacturer
including a video recording detailing the major parts
of the boiler.However,a series of instructional videos
detailing common problems and showing solutions
would have been very handy.
Boiler performance |
During the first year the boiler ran infrequently due to
three main problems that caused frequent shutdowns.
The first was too much oxygen entering the burn
chamber,which was causing inefficient performance
and creating large clinkers.This was resolved by
installing two missing screws from the air intake panels
in the combustion chambers.The second issue was low
water pH in the boiler water that caused corrosion of
seals.The third was a burn-back of fuel up the stoker
auger triggered the water deluge fire suppression system.
This deluge turned the pellets concrete hard.This was
resolved by an ACT technician.Since the issues have
been resolved the boiler has been performing well.
The utility bill for the first year of heating system
operation was 163%over budget due to high use of
electricity and diesel fuel for heating the building during
pellet boiler shutdowns.The electricity use for heating
has started to decrease with the pellet boiler running
optimally (when the outside temperature is below
4OF).In the summer,the electric boiler is used,which
adds increased pressure on the local hydroelectric grid
supplying the local fish processing plants and other
summer electric users.
Wag The local pelletmarkef$timulated
Yes.One other local pellet boiler installation in the
Ketchikan GSA Building also purchases pellets from
the local supplier.The Ketchikan Airport has installed
a pellet boiler,which is using the local product as well.
Demand is expected to grow at a manageable level.
stimulated?|
Yes.The money spent on heating with pellets is kept
within the community.Approximately $18,300 is used
to purchase local fuel.
J
¢Plan fora pellet boiler prior to building construction
to allow an appropriate boiler size for optimal year-
round efficiency.Increasing the thermal storage capacity
may allow more use in warmer temperatures.
¢Provide hands-on,on-site technical training for
the boiler operators and maintenance staff prior to and
during system start-up.
e Reach out to other pellet boiler users in the area to
share experience and support
Project Contact information
Owner/Operator:City of Ketchikan.Contacts:Steve
Hofstedt,steveh@city.ketchikan.ak.us;Linda Lyshol lindal@
firstcitylibraries.org
System Designer:Welsh Whiteley Architects,LLC.
Contact Tim Whiteley,(907)225 2412,ext:#2
Installing contractor:Ketchikan Mechanical,Inc.(907)
225 9466,
Case Study Author:Amanda Byrd Alaska Center for
Energy and Power,Ph:(907)888 2516,agbyrd@alaska.edu
Coffman Cove,Alaska
Students and teachers energized by biomass
/=Game ENERGY AUTHORITY
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Located on Prince of Wales Island in Southeast Alaska,
Southeast Island School District manages 8 schools
including the K-12 Howard Valentine School in
Coffman Cove.
In a community of 200 residents,the Coffman Cove
school has an enrollment of 14 students (2015/16).
Two 325,000 BTUh Garn boilers were installed at the
school and heating costs were reduced from $40,000
to $28,000 annually.The school has also installed a
6,500 square foot greenhouse using excess heat from
the biomass boilers to heat the water in the aquaponic
system.
The project was so successful that the school district
installed biomass boilers and greenhouses in Kasaan,
Thorne Bay,and Naukati Schools with projects also
underway at Hollis and Whale Pass Schools.
The installation of these cordwood boilers had three
distinct objectives.The first was to save money on
heating,the second was the use a renewable energy
resource,which is abundant on Prince of Wales Island,
and the third objective was to create jobs.
Wha bidmase boiler?
In 2010,after an Alaska Energy Authority report stated
that the school district could reduce heating costs by
changing from diesel to biomass energy,SISD installed
two Garn 2000 cordwood boilers at the school.The
annual heating was reduced,and the community and
school district both benefited from the installation.
Total Project Costs:$424,000
Capital Costs
Equipment Costs:$270,210
Installation Costs:$50,000
Project management and other:$116,553
Equipment
Make:Garn
Model:2000 cordwood Boiler
Output:325,000 BTU/hr
Wood storage building:75 cord storage
Operational Expenses
Cordwood:$200/cord
O&M:$10,000
Cordwood Fuel Use
50 Cords per year
Diesel Fuel Offset
2,900 gallons
Fuel Savings
$11,165 at 3.85/gallon.
Pre-cut cordwood that has been dried for at least one year is loaded into
the Coffman Cove Garn boilers.
{How.was thisSystem sized?
The boilers were sized based on initial oil-fired boilers
and additional heating was added to account for future
building additions.
These additions include a 6,500 square foot greenhouse
and a 4000 square foot teaching housing unit.The
aquaponic greenhouse is operated by the students
and staff and the vegetables produced are added to the
school lunch program and sold across the island
The biomass system has created a market for cordwood
and local jobs for high school students or community
members to feed the boilers.
Did it ncet the projectsobjectives?1
The project initially intended to save money,but also
added benefits of employment,student involvement .
and numerous educational opportunities.The trickle
down effects of the savings into the community was
a further benefit.Profits from the greenhouse can
generate up to $50,000 a year to fund student travel
and activities.
This project has been so successful that SISD is
continuing to plan boiler installations in other
communities.Garn boilers are already operational
in Thorne Bay,Kasaan,and Naukati.Greenhouses
have been included in these sites providing food and
educational opportunities in each location.
Léssons Learned.
A small amount of wood is stored for daily use in the
boiler building.The remaining cordwood is stored and
dried in a purpose-built adjacent building.Having
more wood storage room in the boiler building would
making loading the boilers more efficient.
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Wood storage building at Coffman Cove.Photo by Amanda Byrd/ACEP.
Project Points of Contact:
Boiler Operator:Jonathan Fitzpatrick
Southeast Island School District
1010 Sandy Beach Rd,
Thorne Bay,AK 99919
System Designer:CE2 Engineers
Paul Weisner
PO Box 232946
Anchorage AK 99523
Marble Construction
355 Carlanna Lake Road Set #100
Ketchikan,AK 99901
Installer:
Boiler Supplier:Dectra Corporation
3425 33rd Ave NE
St.Anthony,MN 55418
Garn (http://www.garn.com/)
School Contact:Lauren Burch,SISD Superintendent
P.O.Box 19569
Thorne Bay,AK 99919
Author:Amanda Byrd
Alaska Center for Energy and Power.
Email:agbyrd@alaska.edu
(907)888 2516
FELINDSIS Kasaan,Alaska
Green Energy to Greenhouses
Located on Prince of Wales Island in Southeast
Alaska,Southeast Island School District (SISD)
manages 8 schools including the K-12 Barry Craig
Stewart School in the village of Kasaan.
Kasaan,a community of 49 residents and a local
school enrollment of 14 students (2015/16),became
a focus in 2012 for SISD to increase local food
production.
In an effort to increase fresh produce for the district's
school food program,SISD proposed to install a
biomass boiler and build a greenhouse near the
Kasaan school building.In 2015 this became a realitywithalegislativegrantof$90,000.A Garn 2000
boiler was installed to heat the school,a teacher
housing unit,and greenhouse totaling 5,000 square
feet.Heating costs were reduced by $2,464 annually
making a heated greenhouse economically viable.
Objéctives}
Total Project Costs:$128,622
Capital Costs
Boiler Equipment Costs:$60,820
Boiler Installation Costs:$20,000
Greenhouse Equipment Costs:$32,802
Greenhouse Installation Costs:$15,000
Equipment
Make:Garn (Dectra)
Model:2000 cordwood Boiler
Output:325,000 BTU/hr
Wood storage building:22 cords
Operational Expenses
Cordwood:$200/cord
Biobricks:$200/ton
O&M:$500
Wood Fuel Use
15-20 cords annually
12 tons biobricks
Diesel Fuel Offset
Around 600-1000 gallons per academic year
Fuel Savings
$2,464 annually
The main objectives for this project were to reduce
dependence on heating fuel and reduce energy costs
by using locally harvested cordwood and processed
wood bricks.A consequence has been production
of fresh vegetables to supplement the school food
program,and fundraising opportunities through the
growth and sale of fruits and vegetables.
Reasong forjustallingthis system
A very wet climate and high costs of transporting
food to the schools in SISD has created limited access
to fresh fruits and vegetables.Installing a year-round
greenhouse means that the school and the community
have access to fresh food and the opportunity to
learn about agriculture,food production,energy,and
business management.
Kasaan greenhouse planted with lettuce varieties offers fresh produce to
school students and excess is made available to the community.Photo by
Karen Petersen.
i J
In 2012,after an Alaska Energy Authority report
stated that the school district could reduce heating
costs by changing from diesel to biomass energy,
SISD installed a Garn 2000 cordwood boiler at the
school.The annual heating cost was reduced,and the
community and school district both benefited from
the installation by using locally available cordwood
and biobricks.
Kasaan high school students are hired to feed the
boiler.Both the boiler and the greenhouse provide
endless opportunities for learning and on-the-job
training.
|q The SISD students have created a fresh produce business on Prince of
The cordwood is cut,split,and stacked in the Wales Island,including designing their own logo.
boiler building.The biobricks are also stored in the
building.
Project Points of Contact:
r |Boiler Operator:Jonathan Fitzpatrick
The installation of the boiler and the greenhouse not Southeast Island School District
1010 Sandy Beach Rd,only met but exceeded the expectations.The students Thorne Bay,AK 99919arelearningboileroperationandloadingskills,
business management,agriculture,healthy eating System Designer:Southeast Island School Districthabits,and are raising money for their own student 1010 Sandy Beach Rd,travel and activities.And,the use of biomass over Thorne Bay,AK 99919dieselissavingmoneyinadditiontokeepingmoney
in the local community.Installer:Jonathan Fitzpatrick
Southeast Island School District
1010 Sandy Beach Rd,
L 4 Thorne Bay,AK 99919
SISD is moving forward to install biomass boilers in Boiler Supplier:.
';pplier:Dectra Corporationotherschoolsontheisland.In 2016 Naukati school 3425 33rd Ave NEhadaboilerinstalled,and in 2017 installments are St.Anthony,MN 55418currentlyinprocessinthecommunitiesofHollisandGarn(http://www.garn.com/)
Whale Pass.Garn boilers are already operational in
Thorne Bay and Coffman Cove.Hydaberg School School Contact:Lauren Burch,SISD Superintendent
District,also in Prince of Wales Island is in the P.O.Box 19569
process of installing a Garn boiler.Thorne Bay,AK 99919
Author:Amanda Byrd
Alaska Center for Energy and Power.L J Email:agbyrd@alaska.edu.Increasing wood storage space would allow for more (907)888 2516cordwoodtodrycompletelybeforeburning.
CASE SINUIDNY
Ketchikan GSA Building
300 kW,1000 MBTU Wood pellet fired boiler
General Services Administration (GSA)Region
10 installed the system at the federal building in
Ketchikan,Alaska and submitted the project to
the Green Proving Ground (GPG)program.GSAs
GPG program contracted with the National Re-
newable Energy Laboratory (NREL)to assess the
installation and the technology.The system serves
as a demonstration to assess actual system effi-
ciencies,as well as operating characteristics and
financial benefits.In addition to installation and
operational issues,the project team/researchers
examined other issues,including fuel transpor-
tation costs,building energy savings,and overall
economics.
The installation of this pellet boiler had two distinct
objectives.The first was to demonstrate that a bio-
mass boiler system can be installed in an existing
building in a turnkey fashion with reliable,cost-ef-
fective performance.
The second aspect of the project was to understand
the lessons learned from this single installation and
use them to assess additional deployment potential
at other GSA facilities.
The GSA is interested in biomass heating technol-
ogies as conventional fuel prices are high in remote
locations;biomass fuel is abundant in many re-
mote areas;and they are interested in supporting a
biomass fuel market in Alaska and the Northwest.
This ACT biomass boiler can burn pellets or wood
chips,is generally low maintenance,and boasts
Total Project Costs:$450,000
Capital Costs
Equipment Costs:$193,000
installation Costs:$260,000
Building retrofitting:$4.247 Million (not
included in this study)
Equipment
Make:ACT Bioenergy '™)
Model:1000 Pellet BoilerOutput:1,000 MBTU/hr 7 0 4er Seal ke )Pellet storage:23 ton capacity silo
Operational Expenses
Pellet Fuel:$250/ton
O&M
Pellet Fuel Use
60 tons in 2013
Diesel Fuel Offset
4,000 gallons (of possible 9,000 gallons)
Fuel Savings
-$6,830*(*first year run at 44%capacity)
in
Ketchikan GSA Federal Building.Photo credit http://www.schmolckmechani-smooth fuel delivery through an auger,and an au-cal.com/ketchikan-fedral.htmltomaticashremovalsystemavoidsinterruptions.
The initial proposal request stipulated a US-made
boiler system identically sized to the previous
steam-boiler's BTU output.After the heating distribu-
tion retrofits,it may have been uncertain the heat-
load required for the building.An oversized pellet
boiler,with a capacity factor of 13%was installed,in
addition,an efficient oil-fired boiler was installed for
back-up.The ACT 1000 system emits 1000 MBTUs
per hour undera full pellet load.The system ran at
a partial load of 256 MBTU per hour.Generally,a
boiler meeting 60%of the peak load,(60%capacity),
would be installed and an oil-fired (or other fuel)
furnace remain in-line to make up the remaining load
requirements during peak heat loads.
|Payback Period
Due to the oversizing of the boiler,and the low capac-
ity factor of the system,the payback period is around
30 years.A smaller system could have been installed
meeting 60%of peak load and having a shorter pay-
back period of around 5 years.The payback period
is further increased when heat distribution systems
must be upgraded.
The goal of this demonstration project was to show
that a biomass boiler system can be successfully
installed in an existing building with reliable perfor-
mance.The system worked well,needed very little
maintenance or attention,and performed within the
vendor specified efficiencies.A second goal was to
use the lessons learned in this project for potential
biomass boilers system deployments in other GSA
facilities.
Yes,but future biomass boilers should be installed
where a hot water heating system is already in place,
in facilities under new development,where low-cost
natural gas is unavailable,and in very cold climates.
High Boiler Efficiency:Ketchikan boiler performed
at 45%of operational load but maintained 85%
efficiency.Adjustments to system size will result in
higher operational efficiency.
Favorable Payback:Payback for the Ketchikan boiler
is 30 years.This boiler is capable of generating 8,760
MMBTUs annually,estimated use in 2011 was 1,150
MMBTUs,or 13%of full capacity.Appropriate boiler
sizing,and more favorable environmental conditions
could see the simple payback as low as 5 years.
Low Operational Costs:Automatic fuel handling,
feeding,and cleaning enables small scale operations
to keep operational costs low.
Target Hydronically Oil-heated Buildings:Wood
pellet fired boilers should be considered at all hydron-
ically heated facilities where natural gas is unavailable
and heating seasons are extended.
Project Points of Contact:
Boiler Operator:Ketchikan GSA
Ketchikan Federal Building
648 Mission
Ketchikan,AK 99901-6534
System Designer:RSA Engineering
Warren Williams
570 W.Fireweed Rd,
Anchorage,AK 99503
Schmolck Mechanical
Dave Trudeau
110 Jarvis St,Sitka,AK 99835
Installer:
Boiler Supplier:ACT Bioenergy
30 Commerce Park Dr
Schenectady,NY 12309
Resources:Tomberlin (2014)Wood Pellet-Fired
Biomass Boiler Project at the Ketchikan
Federal Building,NREL Report
Author:Amanda Byrd
Alaska Center for Energy and Power
agbyrd@alaska.edu