NYSERDA / Byrne Dairy, Energy Evaluation and Report, Syracuse, NY

O’Brien & Gere was retained to perform an energy study and evaluation as part of NYSERDA’s Flexible Technical Assistance Services for the Byrne Dairy’s Oneida Street Facility in Syracuse NY.

This study evaluated the facility to assess the potential for implementing various efficiency improvements to reduce energy use and costs. The focus of the study was on major end uses in the facility, consisting of refrigeration systems, compressed air systems, thermal processes and boiler loads.

As a first step, a baseline for energy use and cost was developed utilizing existing utility data and on-site sub-metering data. Based on this data, numerous energy conservation measures (ECMs) were identified. An initial screening identified six ECMs as the most promising.

The six ECMs identified as most promising for the facility totaled an annual energy savings of 1.2 million kWh and 27,500 therms. This equates to a total energy cost savings of approximately $134,000 per year. A total investment of $250,000, for implementation, results in an average simple payback of approximately two years for the six ECMs identified.

• Reduce minimum saturated condensing temperature from 82°F to 70°F. Annual savings 253,632 kWh / $21,559, simple payback 0.2 years
• Increased saturated suction temperature to 15°F on new refrigeration system. Annual savings 235,100 kWh / $19,984, simple payback 0.2 years
• Increased saturated suction temperature to 15°F on old refrigeration system. Annual savings 105,2770 kWh / $8,949, simple payback 0.6 to 2.2 years
• Install 200 HP variable speed, single-stage air compressor, additional storage and controls. Annual savings 630,720 kWh / $53,611, simple payback 3.0 years
• Heat recovery from new water-cooled air compressor. Annual savings 105,2770 kWh / 16,669 therms / $18,933, simple payback 1.5 years
• Heat recovery from reciprocating compressors on old refrigeration system. Annual savings 10,895 therms / $10,895, simple payback 3.7 years