Most of us now agree that climate change is all too real and we therefore all need to do something about it, sooner rather than later.
However, some impulsive political changes in the past 18 months, like unilaterally banning all new offshore oil and gas exploration, can be environmentally counter-productive. For example, NZ coal usage in 2018 was the highest for a decade! Undoubtedly, this is a decision our political leaders didnt want to see happen.
Wood biomass however is a great renewable resource and therefore represents an important and growing energy solution.
At this time, NZ needs a genuine cross-party accord on the best way to tackle climate change, much like the superannuation accord back in the 1990’s. The superannuation accord worked well and served to de-politicise a potentially highly contentious area. A similar approach is needed now.
Richard Gardiner – Managing Director of Total Utilities
The following was a recent press release from Azwood Energy. biomass
Azwood Energy welcomes the Interim Climate Change Committee’s “Accelerated Electrification” report, which investigated the potential of electricity in greenhouse gas reduction. Azwood Energy agrees with the Committee’s view: “The challenge is clear – it is not so much about reducing emissions from the generation of electricity in a narrow sense, but it is about using low or zero-emissions energy to fuel the economy.”[1]
Whilst we find its investigation into electrifying our vehicle fleet commendable, we question whether the Committee’s reliance on the wholesale electrification of process heat is an outcome that truly promotes carbon neutrality and greenhouse gas emission reduction.
Azwood Energy is of the view that the increased utilization of woody biomass, a renewable, carbon-neutral energy source, in the transition from fossil fuel use in process heat makes sense, both economically and environmentally.
Energy expert, Dr. Martin Atkins,[2] has noted that “Biomass will play a vital role in providing process heat, particularly in producing process steam for medium to high process temperature demands. Biomass will be the lowest cost fuel switching option by a large margin when compared to electricity.”[3] He notes that complete electrification of process heat demand is not economically feasible.
Process heat needs are highly-situationally dependent and site-specific. However, from an operational and Capex perspective, high temperature hot water and steam requirements are best met using biomass as a fuel source in place of coal or diesel.
It seems big players in the industry agree. A video was released for the Climate Leaders Coalition showcasing Fonterra Brightwater’s switch to co-firing with biomass.[4] Speaking, in May, at the New Zealand Minerals Forum, Tony Oosten, Fonterra’s Energy Manager, noted that capital outlay and fuel costs for new wood versus coal boilers are now the same, and the viability of wood fuel has been proven in their Brightwater pilot.[5]
He explained Fonterra’s cheese plants use lower temperatures and can be run on electric technologies. Oosten says milk-drying plants prove more complex, (given their mixed high-heat requirements), but indicated new plants will be designed to meet their low heat energy requirements with electricity, allowing biomass-fueled boilers to be used for higher temperature requirements. Oosten says electrode boilers may be used for peak loads as they are more responsive than wood boilers, but they are twice as expensive to run as current systems.
Oosten raised issues of wood fuel supply, however, stating, based on the locally available supply in each region, Fonterra could access 15 megawatts of wood into each of its 32 manufacturing sites. Given Fonterra has now put a stop to installing any new coal boilers or increasing capacity to burn coal,[6] their energy requirements, 40% of which is currently met by coal, are set to supercharge demand for wood fuel.
More recently, French multinational food-products corporation Danone announced they would invest $40 million to convert their Balclutha milk drying plant to 100% biomass, cutting CO2 emissions by 96% or 20,000 tones per year.[7]
Brook Brewerton, General Manager of Azwood Energy, welcomes this, stating that the current constraint in demand is at the heart of stated perceptions of constrained supply. He says there is ample forestry residue left unutilized on hillsides and the commercially unproven fixation on industrial electrification is hampering the switch to biomass fuel and confusing the low-emission messaging.
Azwood Energy sees key areas of this report’s findings as an exacerbation of the problem. The ICCC should encourage thermal heat plant users to firstly reduce energy demand, secondly reduce the low-temperature heat demand on boilers and then encourage the feasibility of fuel switching to biomass for high-temperature water and steam.
Biomass for high-temperature water and steam is the most cost-effective option, at about one-quarter of the cost to produce steam, when compared with electricity, and does not require a huge investment in electrical networks and infrastructure.
Until increased demand ramps up the supply chain logistics, however, the perception of scarcity will continue. Azwood Energy is poised to scale their operations at viable sites across New Zealand and has been commercially supplying biomass to large heat plant systems for almost 20 years.
Scion has reported that there is sufficient biomass in New Zealand to replace in the order of 15PJ of coal consumption with its associated GHG emissions reductions.[8] The Bioenergy Association states there is potentially enough biomass available from plantation forestry to replace 60% of coal used in existing heat plant over the next 30 years. It notes that the biomass fuel market is under-developed because the current demand for wood fuel is low, but that “there are enough suppliers with commercial and technical capability to expand supply if demand for wood fuel increases consistently and in an orderly manner”. [9]
Brewerton notes that the recoverability of wood energy in the scenarios underpinning the Scion and Bioenergy Association data is conservative, and not based on 17 years of residue recovery and methodology improvement. “There is far more out there if the market is willing to pay for it. Recoverability modeling is on the low side, but it is a good place to start.”
Azwood Energy eagerly awaits the PHiNZ report due to be released later this year by MBIE, which addresses process heat directly. It is hoped the regulatory and policy settings changes it advocates will provide the priority for wood fuel it deserves, as a proven, economically viable local energy source with both up and downstream environmental benefits.
[2] Dr Martin Atkins, Senior Research Fellow with Waikato University’s Energy Research Group, has advised some of New Zealand’s most iconic companies on their path towards lower emissions, from dairy giant, Fonterra, to pulp and paper processor, Oji.
“A society grows great when people plant trees whose shade they know they will never lie in.” – Greek Proverb
I spent the best part of Saturday planting trees, flaxes, and ferns along a stream bank with my son, Tom, and his best mate. The task was “wholesome” according to Tom, as the plantings should facilitate the recovery of a stream that was once badly polluted but now runs mostly clear following positive steps by my dairy farmer neighbor to abide by the Fonterra clean stream accords.
As I patted my own back for my newly enhanced green credentials, I turned my thoughts to the wider question of how governments wrestle with the challenge of leaving behind a better place for our grandchildren.
As part of its efforts to reduce emissions, the Government asked the Interim Climate Change Committee to provide advice on planning for the transition to 100 percent renewable electricity by 2035. The Government has also set a target for New Zealand’s economy to produce net-zero emissions by 2050.
Admirable goals, for sure, but does this approach stack up? When I run the numbers it is questionable whether going after more renewable energy is even worth it beyond a certain point.
Hang on a minute
At current rates of clean energy build, New Zealand should reach around 93 percent renewables by 2035, well short of the target set by the current Government. Going faster towards renewables would come with an uninviting economic burden. It is unlikely we will see much public demand for more hydro dams, so we are likely to be building out solar, wind and geothermal sources of energy. This would prove very costly on a national scale.
The closer we get to a reliance of 100 percent renewable energy, the more expensive it becomes to generate each unit of additional power. It’s a law of diminishing returns. The net result is that the consumer will end up paying ever-increasing energy prices as we strive for ecological nirvana.
The Government could, in this scenario, tax fossil fuels at an ever-increasing rate to keep electricity competitive, while passing laws that force consumers to switch. In the end, this would be political suicide and a market-distorting approach that could yield all sorts of unintended consequences.
Light bulb moment
On the other hand, fossil fuels used in transport and process heat offer a sensible, more economic option for change. These activities account for six times the greenhouse gas emissions of electricity production. Under this scenario, electricity prices would remain affordable and the emissions savings would be substantially higher from day one.
It was with this in mind that the Commission recommended that the Government amended its 100 percent renewal electricity future vision for the more realistic and attainable transport and process heat transformation approach. It is telling to note that this approach also offers incremental benefits, with every new electric vehicle or process heat facility reducing emissions on day one and into the future.
There are three major initiatives recommended by the Commission that, as I see them, make economic sense and deliver positive results in the short-, medium- and long-term. Those sensible recommendations are:
Phase-out of fossil fuels for process heat by deterring the development of any new fossil fuel process heat, and setting a clearly defined timetable to phase out fossil fuels in existing process heat facilities.
Set a target and develop incentives to reduce emissions from transport by converting to electric vehicles.
Investigate the potential for pumped hydro storage to eliminate the use of fossil fuels in the electricity system.
Meanwhile, I am off to plant another tree or two. My great-grandchildren might enjoy it’s shade one day.
New Zealand has set a target under the Paris Agreement to reduce its greenhouse gas emissions by 30% below 2005 levels by 2030, and to adopt increasingly more ambitious targets in the future.
Per capita, New Zealand’s emissions are one of the highest in the world with an output of <1% of the total world’s emissions.
Business New Zealand recently released a report which concluded that “opportunities to improve our performance in productivity and renewable penetration lie in every part of the energy supply chain. While productivity and renewables are not necessarily mutually exclusive, we need to consider the best policy balance. Our country is richly endowed with resources so should our focus be primarily on economic growth with a reliance on carbon prices to guide renewable penetration, or do we need stronger policy support for low-carbon economic output? With an economy heavily driven by trade, the cost of our choices has direct consequences for our international competitiveness. And, since our future is uncertain, how do we remain responsive and resilient to changes in the world around us?”
There is no doubt that the current Government’s policy strategy is being geared to meet the targets under the Paris Climate Accord.
The Insights Behind Sustainable Business Growth
Centrica recently published the following survey of businesses in 10 countries (UK, Ireland, Germany, Italy, France, Hungary, Belgium, Netherlands, USA and Mexico) and across 7 verticals (manufacturing, retail/ wholesale trade, healthcare/ medical, education/schools/universities, construction/ trades/ property development, travel/tourism/hospitality and property/real estate).
The survey identified some interesting trends:
Customers are driving change
Perceived risks are growing
Energy is an increasingly vital part of an overall business strategy
Yet only 1 in 8 businesses are doing it successfully
They concluded that in today’s fast-changing world, businesses need to find an innovative way to balance their financial performance and environmental policies using the following key focus areas.
What does this mean for your business?
Becoming a supportable business isn’t something that can be achieved overnight, and the journey can be challenging. Many successful businesses are complementing their internal expertise by engaging a third party, like Total Utilities, to help them understand the energy market and associated technologies, build business cases and engage stakeholders.
I lit my first fire at home for the year on the unusual date of May 31, just one day before the official beginning of winter.
I live in the sunny north side of Auckland, but I would have expected to see my dog sleeping in front of the fire by around late April.
There are some of us who believe that to the detriment of future generations the planet is suffering from global warming and others who feel that the scientific consensus is still a long way from being agreed. Either way, I do believe there is a general accord that we can’t keep consuming the planet’s resources at the rate we are, without very dire consequences.
Whether it is to save the planet or to drive efficiency, businesses are now using technology to reduce their carbon footprint. Some of these are unexciting and some are just plain cool. Either way, I describe below a few to pay attention to.
Tech to reduce the footprint
Methane co-generation
Very few people realize that Auckland’s largest landfill is also an energy park. The rubbish that goes into Waste Management’s Redvale Landfill captures more than 95 percent of the methane gas that is generated from the waste, which is then used to generate up to 14MW of electricity. Last year this meant it generated enough electricity to power 12,000 homes, making it the largest producer of renewable electricity in the Auckland region.
Heat recovery
Energy-intensive businesses, supported in some cases by subsidies from the Energy Efficiency and Conservation Authority (EECA), are now placing increased emphasis on the reuse and reinjection of heated water and steam in their industrial processes. We at Total Utilities have, as a result, seen excellent improvements in energy efficiency at factories and larger campuses.
Heat recovery is also used for go-generation where energy is converted to electricity and put back on the national grid.
Sensors, monitoring and the Internet of Things (IOT)
There is a difference between managing and monitoring business activities. A simple analogy is parents in the park: one couple hovers over their beloved children, constantly checking and rechecking their safety while exhausting everyone in the process; meanwhile, over at the park bench, another couple enjoys the sun, chats and drinks coffee while watching their young ones interact safely with the world and only interfering when they observe a real problem.
In the past, businesses used product-specific sensors to monitor equipment and processes. These sensors tended to be expensive, proprietary and clunky in their outputs (think: complex graphs on green screens).
Today an edgy new cousin has turned up, reducing the cost of monitoring, and providing rich insights via web-based applications that run on almost every device. This is called the Internet of Things (IOT). These simple, useful sensors provide streams of meaningful data about electricity consumption, temperature, process efficiency, humidity and more.
Artificial intelligence
While the Internet of Things sounds a bit like Nirvana, it does have one significant flaw: complexity. In theory, we could provide an IoT connector to every grain of sand on Earth without consuming all the available capacity.
Making sense of all the data it reports is the big problem. This is where Artificial Intelligence (AI) comes in. Capable of analyzing billions of bits of data from multiple data sources, AI is being used by many businesses to sift huge data pools and deliver the insights and activities that deliver competitive advantage and reduce wastage.
In the electrical industry, Power Factor is widely known as a bit of a dark art. Over the last few years, advances in technology have brought new types of correction systems to the market along with a range of off the shelf cheap products that can be ordered online and promise the world but deliver little.
The below paper was written by Allan Ramson (NZCE, BEng, MBT), General Manager of kVArCorrect Ltd and provides an insight into the pros an cons of active versus passive power factor correction for different applications. For a full copy of this paper please click here.
History of Static VAr Generators (SVG) Technology in New Zealand
Metalect Industries combined with the Engineering School at Canterbury University to fund and direct research into Active Systems for 3 phase applications in 1996-1998. This culminated in publication of a PhD thesis by Edward Arnold Memelink in 1999. From there, single phase prototypes were built and tested. Metalect Industries and a technical team from Canterbury then extended the design to 3 phase, obtained government research grants, and units were built and site tested, notably on the Queenstown Gondolas. Whilst successful in electrical terms, the systems could not be economically manufactured due to component limitations of the time and by 2006, the projects were abandoned. Several related products were spun off as ongoing products for Metalect Industries and several of the ZVX units (Zero Crossing By-Pass units) have been installed in many sites around New Zealand.
Conventional Capacitor Based Power Factor Systems
Benefits
Proven technology when correctly designed
Larger switchboard builders and specialist companies know what they are doing
Utilises available switchgear
Contactors, MCB’s, fuses
Simple to maintain
Ensure air flow as designed, capacitor current within specifications, temperature within specification
Simple to repair
Replace contactors, capacitors, MCB’s, fuses, etc. All done by any Electrician without system shutdown (if designed correctly)
Low cost test equipment
Current meter, temperature measurement. Capacitance meter not required (if the current is correct, so is the capacitance)
Easily expanded
Add more capacitance in very small lumps as site grows
Reliable
Capacitor failure does not take whole system offline. Saves customer money in penalties by continuing to partially operate
Deficits
Cannot control leading power factor
There are very few sites where this is required.
Can be slow to react (but not always)
Often not required. However, there are capacitor-based systems that are specifically designed to response sub-second
Old capacitors may be prone to leaking
Modern capacitors are optionally fire-retardant resin filled.
Generate significant heat
True, but active systems generate even more. If the available cooling cannot handle a capacitor system, it absolutely cannot cool an active system
Can produce system resonance issues
This is so rare; we have only ever documented one case in NZ (but can be easily fixed)
Considered to be Old Fashioned
A matter of image only
Risk of fire in the event of capacitor failure
Modern capacitors, combined with correct design, completely mitigate this.
Active Power Factor Systems (SVGs)
Benefits
Fast and accurate correction of power factor (leading or lagging)
When working as designed, there is no doubt that the power factor correction delivered is excellent
Often physically smaller than capacitor systems
Wall mount options are lower cost than the rack mounted large SVGs
More reliable than poorly designed conventional systems
Certainly not true for properly designed capacitor-based systems
Deficits
Higher cost of installation than conventional capacitor-based systems
Made up of unit purchase price plus 3 x CT’s (and may require air conditioning.) Even without air conditioning in the switch room, the cost of SVGs is higher
Expensive to expand because the units come in big lumps. EG: if the system is 5kVAr short of achieving target, minimum step is 30kVAr at >$5-7k installed
Contrast a capacitor-based system where an extra 5kVAr may be a few hundred dollars only
All the eggs are in one basket, causing potential large penalty tariffs to the user
If the unit has a fault and goes ‘off- line’ all power factor correction is unavailable. If a capacitor fails in a conventional system, then the rest can continue
Generates almost twice the heat as a capacitor-based system and is specified for lower ambient temperatures to start with.
Capacitor based systems have a higher ambient temperature specification. This is critical in non-air conditioned rooms over summer months
Usually very high MTTR (mean time to repair) times – recommend 100% complete spare system backup to avoid 0% power factor control to the site (maximum exposure to penalties)
When the whole system is offline, the full penalty tariffs will be incurred by the end user. One way around this is to use multiple 30kVAr units rather than a single larger unit, although this is a huge cost disadvantage
Units have more capacitance internally than conventional systems. Worse, these capacitors are electrolytic type with corrosive acids inside
True, and the lifetime of electrolytics is known to be significantly less than high quality MPP caps as used in capacitive type power factor systems. See kVArCorrect’s papers on Design Problems in Power Electronics
More susceptible to dusty and humid environment compared to capacitor-based systems
Modern capacitor-based systems can fail too, but the MTTR is significantly lower and can be fixed by local electricians without ‘return to base’ or very specific skill sets
A Combination of the two Technologies – THE HYBRID SYSTEM
Potentially, a Hybrid system that combines the two technologies can mitigate the cons of both technologies whilst accentuating the pros. The scenario would be, for a 100kVAr requirement, to provide 70kVAr of capacitor based modules with a 30kVAr SVG. In every case where the author has investigated the case for control of leading power factor, it has been found that the amount of leading kVAr required is less than 30% of the total requirement. For example, we’ve documented sites with 20-50kVAr leading at certain times and 200-300kVAr lagging at other times. This Hybrid system is undoubtedly more cost effective than a full 300kVAr of SVG, in addition to not having all of the negative points shown in the tables above. The system will produce far less heat and will not be completely off-line due to an SVG electronic malfunction, as there would be significant capacity in the capacitor based section of the system to avoid the bulk of penalties.
Summary
The comparative pros and cons of the three technologies are summarised in the following table – the third column relates to kVArCorrect’s Hybrid system, which was developed specifically to overcome the limitations of both capacitor-based systems and active systems. It uses a traditional capacitor-based approach for bulk power factor correction, with a smaller active system to handle high speed as well as leading power factor requirements. The Hybrid system is designed to have the best of both technologies whilst offering superior reliability.
While fully active systems can provide exact kVAr requirements for both leading and lagging power factor in near- to real time, they can be extremely expensive, and are normally return-to-base in the event of electronics failure. Clients are often shocked to discover the cost of expanding a fully active system could be as high as the original installation.
Hybrid systems only rely on the active electronics for less than 25% of the overall available corrective kVAr’s, meaning 75% or more of the power factor correction is still available to mitigate the potential penalties, should the electronics require repair or servicing. Hybrid systems combine the speed and control benefits of a fully active system, with the maintainability and reliability of a capacitor-based system.
About the author
Allan Ramson is the owner of kVArCorrect Limited and has worked extensively in the Australasian Power Factor market for over ten years. Allan and other engineers at kVArCorrect are ex-employees of Ampcontrol and Metalect Industries in Rotorua, and have been involved with Active System technology in New Zealand for many years.
Also having been closely associated with few hundreds of power factor correction systems installed, it is with significant experience in the market that this document has been written. kVArCorrect designs and manufactures capacitor based power factor systems, Hybrid Capacitor/SVG systems, a range of power quality controllers, and SVG add-ons. Additionally, kVArCorrect sells SVG systems in 30kVAr, 50kVAr, 100kVAr and above sizes.
