{"id":7677,"date":"2011-07-14T21:23:53","date_gmt":"2011-07-14T21:23:53","guid":{"rendered":"http:\/\/prairieswine.com\/rsc\/?p=7677"},"modified":"2011-07-14T21:23:53","modified_gmt":"2011-07-14T21:23:53","slug":"controlling-energy-costs-in-the-barn","status":"publish","type":"post","link":"http:\/\/prairieswine.com\/rsc\/controlling-energy-costs-in-the-barn\/","title":{"rendered":"Controlling energy costs in the barn"},"content":{"rendered":"

\u00a0As we approach winter in tight financial times in the swine industry, producer\u2019s thoughts are turning to how to best manage their heating and ventilation systems to keep their utility and energy expenses in line.<\/p>\n

There are few publicly available production cost summaries. \u00a0One of the best is the information from the Center for Farm Financial Management at the University of Minnesota (www.finbin.umn.edu<\/a>). \u00a0For the 4 year period of 2004-2007, wean-to-finish cooperators in this record program reported an average fuel and oil expense of $1.43 per pig and a utilities expense of $1.04 per pig. \u00a0Fuel and oil includes both propane and any diesel and gasoline charged to the swine unit for such items as tractors, lawn mowers, power washers, generators, pickups, etc. \u00a0Utilities include electricity and telephone\/internet. \u00a0Surprisingly, both fuel and oil and utilities varied little for the 4 year period. \u00a0There was no indication in the data set of what the mix is of curtain sided versus tunnel wean-finish facilities.<\/p>\n

Finishers of feeder pigs reported fuel and oil expenses of $0.71\/pig and utility expenses of $0.62\/pig. \u00a0For farrow-weaning cooperators (average inventory of 950 sows), the fuel and oil expense was $0.49 per pig weaned while utilities were $1.03\/pig weaned.<\/p>\n

Once facilities are tightened for winter operation and have the appropriate insulation in the ceiling and side walls, the major causes of excessive heating expenses are:<\/p>\n

    \n
  1. improper minimum ventilation rates<\/li>\n
  2. improper furnace sizing<\/li>\n
  3. improper temperature selection<\/li>\n<\/ol>\n

    \u00a0<\/p>\n

    As I work with a large number of different types of facilities and production systems in the upper Midwest and Canada, I continually find that producers have a very limited knowledge of their ventilation system. \u00a0In most situations, they don\u2019t have any idea of the capacity of their system, nor do they fully understand the impact of small ventilation mistakes on propane usage.<\/p>\n

    The MWPS (Midwest Plan Service) recommends the following minimum ventilation rates for moisture control in swine facilities:<\/p>\n

    \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 Weaning \u2013 30 lb (13.6 kg)\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 2 cfm\/pig<\/p>\n

    \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 30-75 lb (13.6- 34 kg)\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 3 cfm\/pig<\/p>\n

    \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 75-150 lb (34-68 kg)\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 7 cfm\/pig<\/p>\n

    \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 >150 lb (> 68 kg)\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 10 cfm\/pig<\/p>\n

    \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 Gestating female\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 12 cfm\/female<\/p>\n

    \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 Farrowing\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 20 cfm\/crate<\/p>\n

    These numbers don\u2019t mean much to most producers until you add in the approximate capacity of various sized fans. \u00a0While such items as shutters, discharge cones, hoods, etc have an impact on the capacity of exhaust fans in negative pressure systems, the following rough estimates are valuable starting points for producers trying to understand their ventilation systems:<\/p>\n

    \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 Fan blade diameter, in.\u00a0 Approximate CFM<\/span><\/p>\n

    12\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 1200<\/p>\n

    14\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 2000<\/p>\n

    16\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 2500<\/p>\n

    20\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 4500<\/p>\n

    24\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 6000<\/p>\n

    36\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 12000<\/p>\n

    Suppose that you have a 300 head weaned pig room, and there is a 12\u201d fan running as the minimum fan. \u00a0This fan has the capacity for 4 cfm per pig, which is twice the recommended minimum ventilation rate. \u00a0Either this fan needs to be replaced with a smaller fan, or it needs to be connected to a variable speed controller and set to operate at 50% of its rated output. \u00a0Notice that I didn\u2019t say 50% of its rated speed or 50% on the controller. \u00a0Generally small variable speed fans achieve 50% of their rated output at approximately 65-70% of their rated rpms. \u00a0Twenty four (24) in. diameter fans often achieve 50% of their rated output at 60-65% of their maximum rpms.<\/p>\n

    There is quite a bit of variation between ventilation controllers on how they control variable speed fans. \u00a0Depending on the controller specifics, a 50% setting as the minimum speed may or may not be anywhere close to the intended 50% operating performance.<\/p>\n

    \"\"<\/a>Improper furnace sizing is usually the result of installation of a furnace that is too large for the facility. \u00a0A furnace is large enough if is shuts off occasionally on the coldest day of the year. \u00a0When furnaces are too large, the end result is rooms that have large temperature variations when the furnace operates. \u00a0Many times this results in the temperature at the controller temperature probe rising beyond the room set point, resulting in the ventilation system increasing the ventilation rate to remove the extra heat, which means the room cools and the process starts again.<\/p>\n

    Most ventilation controllers log the high and low temperature for the last day or since the controller was last reset. \u00a0Using the controller\u2019s temperature logs, the high, low and set point temperatures should recorded on a daily basis. \u00a0When the facility is operating in the heating mode, the daily high temperature should never be at or above the set point temperature. \u00a0If the high gets to or above the set point, this suggests that the ventilation system responded by exhausting the heat just added to the room with the furnace. \u00a0To prevent this from happening, as a starting point, set the furnace to shut off at 2o<\/sup>F (1o<\/sup>C) below the room set point temperature.<\/p>\n

    Many producers make the mistake of assuming that the set point temperature for the controller will be the room temperature at the temperature probe. \u00a0This is not the case. \u00a0In cold weather, if the furnace is set to turn off 2o<\/sup>F below the set point, the room temperature should be 2o<\/sup>F colder than set point as the furnace \u2018OFF\u2019 temperature is the control point for the room.<\/p>\n

    As pigs grow and produce increasing amounts of heat, the ventilation system responds by increasing the ventilation rate. \u00a0If stage 1 is variable speed and has a 2o<\/sup>F bandwidth, when stage 1 is operating at 100% speed, the room must be 2o<\/sup>F warmer than set point. \u00a0This is because the controller is set to not attain 100% speed unless the room is 2o<\/sup>F warmer. \u00a0Set point is just the decision point from which the controller makes decisions as to which devices to operate in the ventilation and heating system.<\/p>\n

    Photo caption:<\/span>\u00a0 Nursery heater-1 \u2013 Having more furnace or heater capacity than required leads to more variable temperatures and higher energy bills<\/em><\/p>\n","protected":false},"excerpt":{"rendered":"

    \u00a0As we approach winter in tight financial times in the swine industry, producer\u2019s thoughts are turning to how to best manage their heating and ventilation systems to keep their utility and energy expenses in line. There are few publicly available production cost summaries. \u00a0One of the best is the information from the Center for Farm 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