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