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ONION DEHYDRATIONONION DEHYDRATION WITH GEOTHERMAL WITH GEOTHERMAL ENERGY IN THE USAENERGY IN THE USA
John W. LundJohn W. Lund
Andrew Chiasson, Toni BoydAndrew Chiasson, Toni Boyd
Geo-Heat CenterGeo-Heat Center
Oregon Institute of TechnologyOregon Institute of Technology
Klamath Falls, OR, USAKlamath Falls, OR, USA
PROCESSINGPROCESSING
Creoloe, Southport Globe and Hybrid Southport Creoloe, Southport Globe and Hybrid Southport types usedtypes used
White in color and process a higher solid content White in color and process a higher solid content which yields a more flavorful and pungent onionwhich yields a more flavorful and pungent onion
Continuous belt conveyor usedContinuous belt conveyor used Proctor & Schwartz dehydrator single line Proctor & Schwartz dehydrator single line Special silica gel – Bryair desiccation often used Special silica gel – Bryair desiccation often used
for the final dryingfor the final drying $1,500,000/yr in fuel used (180 days) $1,500,000/yr in fuel used (180 days) Geothermal saves 116 million cubic feet of NGGeothermal saves 116 million cubic feet of NG
InsulationFeed Conveyor
Feed
Section A-A’
Geothermally HeatedHot Water Coils
Insulation
AirDistributionGrating
Conveyor Belt
To Stack
A
A’Product
Fan
Basic dehydration operation
PROCESSING 2PROCESSING 2
Dehydration – basic stepsDehydration – basic steps– HarvestingHarvesting– TransportingTransporting– Curing - 100Curing - 100ooF heated air used – ease of peeling and F heated air used – ease of peeling and
processing – 48 to 72 hoursprocessing – 48 to 72 hours– Washing and chlorinated to reduce bacteriaWashing and chlorinated to reduce bacteria– SlicingSlicing– Dehydration – in 3 to 4 stages – high air volumesDehydration – in 3 to 4 stages – high air volumes– Milling (powdered, granulated, ground, minced, Milling (powdered, granulated, ground, minced,
chopped or sliced)chopped or sliced)– PackagingPackaging
AGRICULTURAL DRYING 1AGRICULTURAL DRYING 1
Two large geothermal onion and garlic Two large geothermal onion and garlic dehydrators are located in NW Nevadadehydrators are located in NW Nevada
These units can each process 5 - 7 tons of wet These units can each process 5 - 7 tons of wet onions/hr – drying them from 83% to 4% moisture onions/hr – drying them from 83% to 4% moisture (output = 0.9 – 1.2 tons/hr dried product)(output = 0.9 – 1.2 tons/hr dried product)
0.15 therms/lb used = 500 million Btu/day or 76 0.15 therms/lb used = 500 million Btu/day or 76 billion Btu/yr (22 GWh) (150 days period)billion Btu/yr (22 GWh) (150 days period)
Product used in soups, baked goods, salt, & Product used in soups, baked goods, salt, & seasoning as powders to slicesseasoning as powders to slices
AGRICULTURAL DRYING 2AGRICULTURAL DRYING 2
Single-line, continuous-belt dryer useSingle-line, continuous-belt dryer use– 12.5 ft wide12.5 ft wide– 190 to 212 ft. long190 to 212 ft. long– 3 to 4 sections (A to D) –210 to 1203 to 4 sections (A to D) –210 to 120ooF– Processing 5 to 7 tons/hr of wet onionsProcessing 5 to 7 tons/hr of wet onions– Using 86,500 ftUsing 86,500 ft33/hr of air/hr of air– 26 million Btu/hr26 million Btu/hr– Onions 2 inches to 6 feet deepOnions 2 inches to 6 feet deep– Bryair desiccation unit required in final stageBryair desiccation unit required in final stage
Exhausts
InletA-1
A-2
A-3
B-1
A-4
209 ft 8 in
B-2
DIntakes
C
Outlet
A-1
5.0 x 106
1600F
500 gpm
2100F
2100F2300F
900 gpm
400 gpm
2300F
A-2
Preheatbryair
A-4
2100F
2000F
- 3000F
3.6 x 106 BTUhr.
5.9 x 106 BTUhr.
4.9 x 106
Productionwells (2)
400F
1800F
1750F
500 gpm
400 gpm
1950F 1920F
400 gpm
A-3
Gasheater
1950F
0.5 x 106 BTUhr.
400 gpm
Space heatergreenhouses
0.5 x 106
1900F
500 gpm - 1800F
500 gpm
2300F
B-1 B-2 C D Curingdocks
1800F 1650F
1450F
1610F
1300F
1590F
1200F
1.0 x 106 BTUhr.3.6 x 106 0.4 x 106 0.6 x 106
1560F
1000F
1540F
1710F900 gpm
500 gpm
Reinjectionwell (1)
(assumed outside temperature is 400F)
AGRICULTURAL DRYING 3AGRICULTURAL DRYING 3
Brady’s Hot Spring plant – first in U.S. - 1978Brady’s Hot Spring plant – first in U.S. - 1978– 270270ooF geothermal fluidF geothermal fluid– Only has 3 stages (A thru C)Only has 3 stages (A thru C)– 6-months operation season - 65 employees6-months operation season - 65 employees– 25,000 tons of wet onions are processed during season – producing 25,000 tons of wet onions are processed during season – producing
5,000 tons of dry product5,000 tons of dry product– 190-ft. long dryer by 12.5 ft. wide190-ft. long dryer by 12.5 ft. wide– Uses 190 to 120Uses 190 to 120ooF air in various stagesF air in various stages– Has also processed celery and carrots to extend seasonHas also processed celery and carrots to extend season– Product trucked from S. California to S. Oregon (300 to 600 miles)Product trucked from S. California to S. Oregon (300 to 600 miles)
AGRICULTURAL DRYING 4AGRICULTURAL DRYING 4
Empire Foods plant – constructed 1994Empire Foods plant – constructed 1994 CapacityCapacity
– 37 tons/day onions; 42.5 tons/day garlic37 tons/day onions; 42.5 tons/day garlic– 7 tons/yr (60% onions and 40% garlic)7 tons/yr (60% onions and 40% garlic)
900 gpm of geothermal fluid @ 266900 gpm of geothermal fluid @ 266ooFF 45 million Btu/hr – discharge at 16045 million Btu/hr – discharge at 160ooFF Cold storage warehouse allows year-round operation – 2Cold storage warehouse allows year-round operation – 2ndnd
line being consideredline being considered Geothermal energy also used for four ORMAT 1.5-MWe Geothermal energy also used for four ORMAT 1.5-MWe
binary units – net output 3.6 MWebinary units – net output 3.6 MWe Now shut down due to garlic imports from China Now shut down due to garlic imports from China
Empire 6.0 MWe binary plants (3.6 MWe net)
CONCLUSIONS 1CONCLUSIONS 1
A survey in the U.S. found that of 108 industrial A survey in the U.S. found that of 108 industrial processes surveyed (representing 80% of U.S. processes surveyed (representing 80% of U.S. industrial energy usage), 97% of all processes industrial energy usage), 97% of all processes required heat input in the form of steam at 250required heat input in the form of steam at 250ooF or F or higher.higher.
An examination of geothermal wells in 8 western An examination of geothermal wells in 8 western U.S. states reveals that 99% are 250U.S. states reveals that 99% are 250ooF or less.F or less.
High load factor important (0.44 to 0.68 in 2000)High load factor important (0.44 to 0.68 in 2000) Wells above 250Wells above 250ooF would normally be used for F would normally be used for
electric power generation, however ----electric power generation, however ----* * source: K. Rafferty, GHC Bulletin Vol. 24, No. 3 (Sept., 2003)source: K. Rafferty, GHC Bulletin Vol. 24, No. 3 (Sept., 2003)
0
500
1000
1500
2000
Num
ber o
f w
ells a
t or a
bove
110 120130140150160170180190200250
Well Temperature in F
Geothermal Well TemperaturesOR, ID, NV, UT, CO, AZ, NM, MT
Cost of Energy
02468
10
0.1 0.15 0.2 0.25 0.3 0.4
System Load Factor
Co
st o
f E
ne
rgy
$/M
M B
tu
CONCLUSION 2CONCLUSION 2
Consider: Power plant vs dehydration plantConsider: Power plant vs dehydration plant AssumptionsAssumptions
– 300300ooF resourceF resource– 20 MW net binary power plant20 MW net binary power plant– US$0.07 per kWh power sales priceUS$0.07 per kWh power sales price– 10-month dehydration operation10-month dehydration operation– 15,000 tons annual production (2 lines)15,000 tons annual production (2 lines)– US$1.00/lb dried product wholesale priceUS$1.00/lb dried product wholesale price
CONCLUSIONS 3CONCLUSIONS 3
Power plant vs dehydration plantPower plant vs dehydration plantPowerPower DehydrationDehydration plantplant plantplant
Capital ExpenditureCapital Expenditure $50 mill. $15 mill.$50 mill. $15 mill.Gross RevenueGross Revenue $11 mill.$11 mill. $30 mill. $30 mill.Resource require. 12,000 gpmResource require. 12,000 gpm 1,200 gpm 1,200 gpmEmployeesEmployees 15 15 75 75**source: D. Mendive,source: D. Mendive, Geothermal Development Assoc., Reno, NVGeothermal Development Assoc., Reno, NV
RefrigerationPlant
Food Processing
Power Plant
ApartmentBuilding
Greenhouse
Fish Farm
2000C
1000C
RESOURCE EVALUATIONRESOURCE EVALUATION
Initial search of data baseInitial search of data base– Ontario, Lancaster, Vale, Nyssa , Harper and Ontario, Lancaster, Vale, Nyssa , Harper and
AdrainAdrain– 42 by 36 mile area42 by 36 mile area– 9 springs9 springs– 270 wells identified270 wells identified– 68 to 23968 to 239oF – high temp. at Vale– Most below 200oF– One “dry well” – 10,052 ft at 334oF - Ontario
41 42 43 44 45 46 47
16
17
18
19
20
21
Ontario
Vale
Lancaster
Harper
Nyssa
68 -131 F
Adrain7 wells
4 springs1 well
8 wells3 wells1 well
7 wells15 wells9 wells9 wells10 wells1 spring
8 wells1 spring
13 wells6 wells59 wells1 spring
5 wells1 well2 springs
2 wells
8 wells5 wells3 wells5 wells
2 wells1 well2 wells13 wells1 spring
14 wells
98 -1345 ft
68 -174 F
26 -249 ft
77 F
459 ft
68 -79 F
239-698 ft
72 -84 F
256 -443 ft
68 F
105 ft
84 -183 F
19 -1568 ft
68 -84 F
449 -885 ft
70 -100 F
213 -695 ft
68 -115 F
121-1259 ft
68 -158 F
151-718 ft
68 -129 F
128 -508 ft
75 -334 F
19 -10052 ft
68 -79 F
55 -876 ft
68 -239 F
23 -1017 ft
68 -75 F
98 -459 ft
70 -190 F
190 ft
81 -84 F
462 -475 ft
68 -84 F
23 -689 ft
70 -82 F
383 -771 ft
75 -77 F
410 -607 ft
70 -124 F
278 -1214 ft
68 -72 F
52 -144 ft
185 F
1374 ft
75 -145 F
272 -1489 ft68 -90 F
200 -1004 ft
PROPOSED SCOPE OF WORKPROPOSED SCOPE OF WORK
1.1. Determine source and market of productDetermine source and market of product2.2. Estimate size of developmentEstimate size of development3.3. Determine temperature and flow rate neededDetermine temperature and flow rate needed4.4. Review literature and determine resource Review literature and determine resource
available to meet requirementsavailable to meet requirements5.5. Recommend site(s) for resource (well)Recommend site(s) for resource (well)6.6. Perform economic analysisPerform economic analysis7.7. Make recommendation(s) Make recommendation(s) 8.8. Write final reportWrite final report
THANK YOUTHANK YOU
GHC
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