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Optimizing Greenhouse HVAC and the
Growing Environment for Maximum Yield
with Minimal Energy Waste
May 8, 2018
Jim Leidel
DTE Gas, Major Accounts
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• The Potential for Greenhouses
• What do plants need to grow and thrive?
• Elements of indoor, controlled growing
environment
– Envelope, Heating, Ventilation, Cooling, Dehumidf.
• Lighting: Extra attention is given artificial lighting
options
• Case Studies
Outline
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Title
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The Netherlands is a small agricultural powerhouse. It is the
second largest exporter of food by dollar value after the U.S.A.
using only a very small area of, by use of greenhouses.
Top 20 Tomato Producing Nations (2014)
Legend Green bar = yield per area
Red circle = total production
Grey square = land area
Source: “A Tiny Nation that Feeds the World”, National Geographic, Sept 2017
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The Netherlands
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Source: “A Tiny Nation that Feeds the World”, National Geographic, Sept 2017
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TEMPERATURE
HUMIDITY
WIND
SOLAR
ENERGY
NUTRIENTS
Elements for
Healthy
Plant Growth
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6CO2 + 6H2O + solar energy 6O2 + glucose
Glucose = C6 H12O6
Photosynthesis – chemical reaction
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Nearly all life on the planet is supported by this reaction.
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Controlled Environment Agriculture
• Provide Light Energy
– Solar or Artificial
• Macro Nutrients – CO2 and H2O
• Micro Nutrients: N, P, K, other Minerals
– Soil or Hydroponics
• Suitable Environment – Temperature, Humidity, Wind
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Elements of a Greenhouse • Building envelope
– Weatherization / air infiltration,
– heat insulation,
– light transmittance
• Lighting
• Heating
• Ventilation
• Cooling
• Humidity control
• Delivery of nutrients
– CO2, water, fertilizer (N,P,K and minerals)
• Supply of electricity: utility, renewables, CHP
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Structure Envelope • Reduce Air Leaks
– Weatherstrip doors, vents and fan openings
– Service louvers frequently to close tightly
– Repair broken glass or holes in the plastic
– Seal and weatherize foundation
• Double Coverings – Cover "inside" sidewalls and end walls inside with poly or bubble wrap
– Install double wall polycarbonate panels to get insulation effect and reduce recovering labor.
– Use poly with an infrared inhibitor on the inner layer for 15% savings
– Use single or double layer of plastic over older glasshouses to reduce infiltration and heat loss
• Energy Conserving Curtain – Install a thermal curtain for 20%-50% savings. An energy curtain can significantly reduce
nighttime heat loss from a greenhouse. Payback within 1 to 2 years.
• Foundation and Sidewall Insulation – 1-2" extruded polystyrene board to 18-24" below ground to reduce heat loss. This can increase
the soil temperature near the sidewall as much as 10 degrees during the winter.
– 1-2" board insulation on kneewall or sidewall up to bench height.
• Site Location – Locate greenhouses in sheltered, reduced wind areas (but not shaded)
– Windbreaks on the north and NW exposures with rows of conifer trees or plastic snow fencing.
• Space Utilization – Optimize space utilization: movable benches, multi-level racks for low light crops, try addition of
hanging baskets, and roll-out bench system can double growing space, where top level plants
are moved outside during the day.
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Source: Stephanie Burnett, Roberto Lopez, and Neil Mattson, “Evaluate Your Greenhouse to
Save Energy”, Greenhouse Management and Production magazine (Sept 2009)
.http://msue.anr.msu.edu/uploads/resources/pdfs/Energy_Evaluations.pdf
Properties of Glazing Materials
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Glazing Classifications
• Plastic Thin Films
– 2-8 mills .002 - .008” inch
– Polyethylene, EVA, PVC films, and polyester
• Flexible Plastics
– FRP, polycarbonate, acrylics, plastic fused to
glass
• Rigid Glass
– float glass, tempered class, rolled glass
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Automated Night Thermal Curtains
Photo: John Bartok, Jr., University of Connecticut
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Heating Options • Consider Thermal Storage
• Direct fired unit heaters (CO2 + heat)
• Indirect fired unit heaters
– High efficiency condensing unit heaters (90%+)
• Natural gas boiler
– Radiant piping heat
– Radiant floor heat
• Combined Heat and Power (CHP)
• Ground source heat pumps
• Renewable options
– Solar thermal
– Biomass (wood chips)
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Condensing
Unit
Heaters
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An under-bench forced air heating
system with polyethylene air duct
to evenly distribute heat
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An under-bench radiant heat
can be fintue or bare pipe
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Seasonal Energy Storage
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Ventilation Options
• None: sealed environment
• Automated roof vents
• Sidewall electric fans
• Need to control interactions with CO2
supplementation systems
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Natural ventilation from
proper venting
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Cooling Options
• Natural ventilation only
• Side wall evaporative cooling
• Ground source heat pumps
• Conventional refrigeration cooling
• Shading
– Shade curtains
– Exterior spay on white-wash
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Humidity Control
• Ventilation with outdoor air
• Active refrigeration based dehumidification
• Desiccant dehumidification with thermal
reactivation (new concept for grow-rooms)
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Delivery of Nutrients
• Fertilized Soil
• Hydroponics
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CO2 Supplementation
• Yields can increase ~33% if CO2 doubles
• Supplementation sources
– Liquid CO2 (relatively inexpensive)
– Combustion of natural gas or propane
• Direct fire burners
• Boiler exhaust
• CHP exhaust
BOILER CHP
Conventional
natural
gas
Cogeneration
HW
CO2
H2O
Electricity
HW
CO2
H2O
natural
gas
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Am
bie
nt (A
pril 2018)
CO2 vs Photosynthesis
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Natural Gas Combustion
HEAT
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Direct Fired
CO2 Burners
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Carbon Dioxide Fertilization
• Ambient CO2 ~410 ppm (April 2018)
• During daylight hours CO2 may be rapidly
depleted during crop production
• Depletion may be exacerbated during
winter production when there is less
ventilation
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CO2 Greenhouse Levels
• 1,000 ppm or more have shown to increase tomato yields economically
• However, you must adjust based on plant maturity and environmental conditions
• Bright, sunny weather 1000 ppm
• Cloudy weather 750 ppm
• Young plants 700 ppm
• During moderate ventilation 350-400 ppm
• Less needed as temperature and ventilation
rates increase
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Supply of Electricity
• Utility company
• Renewables
– Solar PV
– Wind turbines
• Combined Heat and Power
– Special case for greenhouse application
– It is a heating source (boiler)
– It is a distributed generation source
– It is the best “Energy Efficiency” technology
– It is also a source of CO2 and H2O
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Combined Heat and Power
• Use Condensing waste heat recovery
• Gas treatment is required
– Oxidizing catalyst
– SCR urea based NOx scrubber
– Test for NOx and ethylene
• Inherently CHP is:
– a heating source: HW boiler
– a source of electric power
– the best “Energy Efficiency” technology
– a source of CO2 and H2O
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Lighting
• Natural light
• Artificial light sources
– HPS
– MH
– LED
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Full Spectrum of Solar Radiation
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Full Spectrum of Solar Radiation
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Rela
tive L
ight
Inte
nsity
Photosyntheticly Active Radiation
400nm to 700nm
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Photosynthesis Activity
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Natural Daily Light Integral (DLI)
First and foremost,
maximize the use
of free, natural
solar energy!!
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Efficiency of Vertical Farming?
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Source: Vertical Farming, Bruce Bugbee, Dept. of Plants Soils and Climate, Utah State University (Sept 2015)
Less than
20%
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Light Measurement Terminology Full Solar Spectrum
Radiation Power, P [units: watt / m2]
300 to 3000 nm Solar Radiation
380 to 780 nm Human Vision
Illumination or luminous intensity for the human eye
Luminous power (in 360o) [unit: lumen] [or candlepower]
Illuminance or illumination intensity = Lux [unit: lumen / m2]
or Footcandle [unit: lumen / ft2]
Light for plant growth
400 to 700 nm Photosyntheticly Active Radiation (PAR)
Quanta = number of photons [unit: mole]
Mole = the quantity of 6.02 x 1023 of anything
Photosynthetic photon flux (PPF) [unit: mmole / s
Photosynthetic photon flux density (PPFD) [unit: mmole / (s m2)
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E = photon’s energy [Joules]
h = Planck constant [6.626×10−34 J sec]
c = speed of light [3.0×108 meters / sec]
λ = photon’s wavelength
Energy in Light
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E = photon’s energy [Joules]
h = Planck constant [6.626×10−34 J sec]
c = speed of light [3.0×108 meters / sec]
λ = photon’s wavelength
= frequency [hertz]
Energy in Light
and
Planck–Einstein
EQ
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Solar radiation – Rochester Hills, MI on April 26, 2018 6:00pm
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Cloudy day, 4-27-2018, Detroit, MI downtown 2:45pm
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70 Watt HPS (82 watts on meter)
Y axis: Absolute spectral irradiance (mW /cm2 / nm)
X axis: Wavelength (nm)
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70 Watt MH (98 W on meter)
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250 W halogen incandescent (251 W on meter)
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(qty 4) 3500K CFL’s at 42 watt total
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(qty 4) 3000K LED’s at 34.5 watt total
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(qty 4) 5000K LED’s at 60 watts total
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Typical LED spectral power distributions normalized
for constant luminous intensity.
Source: http://www.ledsmagazine.com/articles/print/volume-12/issue-
10/features/street-lights/light-pollution-depends-on-the-light-source-cct.html
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(qty 4) grow light LED at 20 watts
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0
1
2
3
4
5
6
7
8
9
10
300 350 400 450 500 550 600 650 700 750 800
light wavelength (nm)
sp
ectr
al
inte
nsit
y (
mic
roW
/ c
m2 /
wavele
ng
th)
(1) 70 W HPS (1) 70 W MH (1) 250 W halogen incand. (4) 3500K CFL
(4) 5000 K 15 W LED (4) 3000k 9W LED (4) grow LED
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Lighting Type Watt PAR mW / cm2 PAR mW/Welect/cm2
(1) 70 W HPS 82 838 10.2
(1) 70 W MH 98 1,578 16.1
(1) 250 W halogen 251 3,182 12.7
(4) 3500K CFL 40 343 8.6
(4) 5000 K 15 W LED 60 4,430 73.8
(4) 3000k 9W LED 34.5 1,938 56.2
(4) grow LED 20 552 27.6
Light Source PAR Efficacy
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Two Case Studies
• Howling Tomatoes – California
• Great Northern – Kingsville, Ontario
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Houweing Tomatoes
• 125 acre greenhouse
• Camarilo, California (north of Los Angeles)
• Three reciprocating natural gas engines
– Over 40% electrical efficiency
– Over 90% overall efficiency
• 13 MW total with excess power exported to grid
– condensing waste heat exchanger
• Natural Gas CHP: four products utilized
– electricity
– heating
– CO2 exhaust (treated for use)
– Condensed H2O (treated for use)
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Houweling Tomatoes - California
Image: Southern California Gas
Reciprocating
Engines
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• Kingsville, ONT, Canada
• 50 acres of hydroponics tomatoes
• 5 acres under HPS lighting
• 12 MW electric CHP system – Sells electricity to Ontario Power Authority
• Uses mainly heat and CO2 on-site
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Conclusions
• Maximize use of solar lighting,
• Fully indoor grow environments have different load profiles and energy use requirements,
• LED lighting is maturing and will be the most efficient option for artificial light,
• Conventional efficiency measures in weatherization and HVAC apply,
• The balancing of heating, dehumidification, CO2 supplementation is complex but can be optimized.
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