Source: RUTGERS, THE STATE UNIVERSITY OF NEW JERSEY submitted to NRP
COMMERCIAL GREENHOUSE PRODUCTION: COMPONENT AND SYSTEM DEVELOPMENT
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
HATCH
Reporting Frequency
Annual
Accession No.
0215808
Grant No.
(N/A)
Cumulative Award Amt.
(N/A)
Proposal No.
(N/A)
Multistate No.
NE-1035
Project Start Date
Oct 1, 2008
Project End Date
Sep 30, 2013
Grant Year
(N/A)
Program Code
[(N/A)]- (N/A)
Recipient Organization
RUTGERS, THE STATE UNIVERSITY OF NEW JERSEY
3 RUTGERS PLZA
NEW BRUNSWICK,NJ 08901-8559
Performing Department
Environmental Sciences
Non Technical Summary
Topic 1: Energy conservation and alternative energy sources Justification: As oil prices approach $100 per barrel, rising energy costs are clearly a concern for greenhouse growers. Strategies to reduce energy consumption, particularly for heating, include management, maintenance and, where justified, investment for upgrades of facilities and equipment. Topic 2: Water and nutrient solution management Justification: Optimizing the management of nutrient delivery systems, through control of electrical conductivity, can ensure plants are only provided the fertilizer concentration needed for healthy growth, without risk of nutrient deficiencies or the potential for nutrient toxicities and fertilizer runoff that result from fertilizer over-application. Topic 3: Sensors and control systems Justification: It is important to accurately measure and interpret the greenhouse environment in order to provide an optimum environment throughout a cropping cycle. Growers use a range of sensors and control systems, from manual control all the way to sophisticated computer control. Topic 4: Environmental effects on plant composition Justification: Research conducted by team members has the potential to make contributions to the fields of genetic engineering and human health. By manipulating the plant environment, it may be possible to stimulate specific gene expressions in plants, or increase the production and/or the quality of compounds important for the nutritional value of specific plants. Topic 5: Natural ventilation design and control Justification: Natural ventilation of greenhouses involves the use of sidewall and/or roof vents to cool the air and reduce humidity. Reducing heat stress and diseases caused by high temperature and humidity have a direct effect on the profitability of the greenhouse operation. Outcomes/Impacts: 1. Evaluation of biomass as a replacement fuel for propane and natural gas. 2. Optimized Argus Nutrient Delivery System. 3. Improved measurement and control techniques for using soil moisture sensors for crop irrigation. 4. Improved nutrient delivery systems that effectively incorporate recycling of nutrient solutions while maintaining optimum plant health and quality. 5. Improved grower investment advice for energy efficient use of heating fuels, including alternative fuels. 6. Improved understanding of greenhouse water use to allow for a reduction in water use as an input to crop production, including in semi-arid regions. 7. Improved natural ventilation models using CFD techniques, resulting in real-time control of natural ventilation of greenhouses. 8. Improved collaboration and information exchange with commercial greenhouse manufacturers represented by the NGMA (National Greenhouse Manufacturers Association). In addition, commercial growers will have economic data on which to base decisions regarding: 1. Switching to various energy conservation measures and alternative energy sources. 2. Adopting improved nutrient deliver systems. 3. Using natural ventilation systems.
Animal Health Component
(N/A)
Research Effort Categories
Basic
(N/A)
Applied
(N/A)
Developmental
(N/A)
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
4012410202030%
4022410202030%
4042410202040%
Knowledge Area
401 - Structures, Facilities, and General Purpose Farm Supplies; 404 - Instrumentation and Control Systems; 402 - Engineering Systems and Equipment;

Subject Of Investigation
2410 - Cross-commodity research--multiple crops;

Field Of Science
2020 - Engineering;
Goals / Objectives
Evaluate biomass derived fuels for greenhouse heating Develop decision support systems for alternative fuel heating systems Develop protocols for irrigation that maximize water use efficiency while maintaining crop growth and quality Develop irrigation protocols and filtration or sterilization methods for nutrient solution recirculation that minimize the effects of pathogens or toxic metabolites Improve volumetric water content sensor efficacy Improve sensor control of the greenhouse aerial environment (light, carbon dioxide, temperature, and moisture) Develop greenhouse design and management protocols to maintain high nutrition values of vegetable crops grown under various environments Develop greenhouse design and management protocols to maximize production of beneficial compounds such as phytochemicals and biopharmaceuticals To continue our efforts to use CFD techniques to evaluate greenhouse natural ventilation systems Continue efforts to improve the efficiency and effectiveness of greenhouse fog cooling systems Improve control strategies as an alternative to existing vent control systems
Project Methods
Topic 1: Energy conservation and alternative energy sources Objective 1. NE will be the lead station. NJ will contribute information pertaining to switchgrass and landfill gas. PA will provide information pertaining to shelled corn. NE will determine the combustible energy contents of various biofuels using bomb calorimetry tests, and contribute to improvements to burner efficiency through sensors and controls. NE will maintain a web site on use and availability of biofuels for greenhouse heating, along with webinars on this topic. Objective 2. NJ will be the lead station. PA will contribute information pertaining to waste plastic as an alternative fuel source. CT will contribute information about wood as an alternative fuel source. NE will assist in the decision support system development. Topic 2: Water and nutrient solution management Objective 3. CT will be the lead station. GA will contribute information pertaining to the use and effectiveness of volumetric water content sensors. ME will contribute information pertaining to the use of VWC sensors in automated irrigation systems, and depends on work done in GA. OH will contribute information pertaining to single nutrient dosing systems, as well as non-contact plant water status monitoring techniques. Objective 4. CT will be the lead station. NY will contribute information pertaining to root exudates. OH will contribute information pertaining to the dissolved oxygen concentration of the nutrient solution. NJ will provide information pertaining to its experiences with a recirculating ebb and flood floor irrigation system. Topic 3: Sensors and control systems Objective 5. ME will be the lead station and will work closely with GA. OH will contribute information pertaining to its experience with different volumetric water content sensors. Objective 6. NY will be the lead station. AZ and NJ will contribute information pertaining to greenhouse cooling. NE will provide information pertaining to greenhouse moisture control through the evaluation of non-contact infrared temperature sensors to monitor dew point temperatures on interior surfaces of the glazing, floor, and plant canopy. Topic 4: Environmental effects on plant composition Objective 7. AZ will be the lead station. CT will contribute information pertaining to the changes in nutrient solution composition during continuous recirculation. In addition, CT will contribute information pertaining to seasonal, environmental, and nutrient solution composition effects on plant metabolites. Objective 8. NY will be the lead station. NJ and AZ will contribute information pertaining to their efforts to improve the quantity of antioxidants in fruits and vegetables. Topic 5. Natural ventilation design and control Objective 9. AZ will be the lead station. NJ will contribute information pertaining to its experience with CFD techniques for greenhouse floor heating. Objective 10. AZ will be the lead station. NJ will contribute information pertaining to fog cooling systems for orchid production. Objective 11. AZ will be the lead station. NY will contribute information pertaining to its efforts using pressure differences to control ventilation inlet openings.

Progress 10/01/08 to 09/30/13

Outputs
Target Audience: Cooperative Extension Personnel, Greenhouse Growers, Greenhouse Industry Supply Companies, Agricultural Industry Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided? A graduate student completed his Ph.D. dissertation and an undergraduate student was trained in environmental data acquisition and analysis, as well as sensor technology and installation. In addition, two more graduate students (1 Ph.D., 1 M.S.) at other institutions were advised during the completion of their greenhouse related research projects. How have the results been disseminated to communities of interest? Information and research activities related to energy use and consumption by commercial greenhouse operations has been distributed and shared through fact sheets, trade journal articles, growers presentations and publications in scientific journals. Growers who implemented conservation strategies have been able to realize energy savings between 5 and 30%. What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? IMPACT Objective 2. Develop decision support systems for alternative fuel heating systems. A decision support system for a landfill-gas fired microturbine systems was developed. While not every greenhouse will be located near a source of landfill (methane) gas, a regular (natural) gas-turbine can similarly be operated as a CHP Combine Heat and Power) system, making our approach more universally applicable. CHP systems generates both electricity and heat (by converting the ‘waste’ heat in the exhaust system into a usable form of energy such as hot air or hot water).The overall conversion efficiency of a CHP system is 20-30% higher compared to an installation with separate heating and power generating systems. Hence, using a microturbine for greenhouse applications can be an economic improvement if the initial investment and operating costs can be kept at acceptable levels. Objective 6. Improve sensor control of the greenhouse aerial environment (light, carbon dioxide, temperature, and moisture). Information about the environmental parameters measured in a research and demonstration greenhouse was shared with the greenhouses grower and adjustments were made to the greenhouse computer control system in order to provide a better plant environment and to reduce the cost of maintaining that environment. ACCOMPLISHMENTS Objective 2. Develop decision support systems for alternative fuel heating systems. Research was conducted to investigate the most economical strategy to use the output of a 250 kW microturbine system located at the NJ EcoComplex Research and Demonstration Greenhouse, near Columbus, NJ. The generated electricity and waste heat can be used in the greenhouse (in particular to operate the supplemental lighting system), exported in to the local electricity grid, or some combination of the two. A former Ph.D. student (Ariel Martin) developed a decision support system that helps the system operator to optimize the economic return, while ensuring that the greenhouse crops will be ready for processing on their intended harvesting/shipping dates. Objective 6. Improve sensor control of the greenhouse aerial environment (light, carbon dioxide, temperature, and moisture). Sensors and a datalogger were installed in a greenhouse section of the EcoComplex greenhouse that is used for orchid production. Temperature, PAR, relative humidity, wind speed, and wind direction are recorded to better characterize the indoor environment.

Publications

  • Type: Theses/Dissertations Status: Published Year Published: 2013 Citation: Martin, A. 2013. Development of a decision support system to operate the greenhouse lighting and shading systems powered by a distributed generator. Ph.D. dissertation. Rutgers University Libraries. 182 pp.
  • Type: Book Chapters Status: Published Year Published: 2011 Citation: Both, A.J. 2011. Horticultural engineering. In Encyclopedia of Life Support Systems, Developed under the auspices of the UNESCO, Eolss Publishers, Oxford ,UK, [http://www.eolss.net].
  • Type: Book Chapters Status: Published Year Published: 2008 Citation: Both, A.J. and D.R. Mears. 2008. Building and maintaining greenhouses for energy savings. In Horticulture: Principles and Practices, 4th ed. by G. Acquaah; included in Chapter 12 Controlled-Environment Horticulture. Prentice Hall, Inc. Upper Saddle River, NJ. pp. 406-417.
  • Type: Journal Articles Status: Published Year Published: 2012 Citation: Blanchard, M.G., E.S. Runkle, A.J. Both, and H. Shimizu. 2012. Greenhouse energy curtains influence shoot-tip temperature of new guinea impatiens. HortScience 47(4):483-488.
  • Type: Journal Articles Status: Published Year Published: 2011 Citation: Zinati, G.M., J. Dighton, and A.J. Both. 2011. Fertilizer, irrigation and natural ericaceous root and soil inoculum (NERS): Effects on container-grown ericaceous nursery crop biomass, tissue nutrient concentration, and leachate nutrient quality. HortScience 46(5):799-807.
  • Type: Journal Articles Status: Published Year Published: 2009 Citation: Mears, D.R., A.J. Both, L. Okushima, S. Sase, M. Ishii, and H. Moriyama. 2009. Some alternatives to burning fuels for greenhouse heating (in Japanese). Journal of Agricultural Meteorology. 65(3):303-308.
  • Type: Journal Articles Status: Published Year Published: 2008 Citation: Lefsrud, M., D. Kopsell, C. Sams, J. Wills, and A.J. Both. 2008. Dry matter content and stability of carotenoids in kale and spinach during drying. HortScience 43(6):1731-1736.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2011 Citation: Both, A.J., T.O. Manning, A. Martin, D.R. Specca, and E. Reiss. 2011. Operating a 250 kW landfill gas fired microturbine at a 0.4 hectare research and demonstration greenhouse. Acta Horticulturae. 893:397-404.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2009 Citation: Brumfield, R.G., A.J. Both, and G. Wulster. 2009. How are greenhouse growers coping with rising energy costs? Southern Nursery Association Research Conference Proceedings. Georgia World Congress Center, Atlanta, GA. February 12-13, 2009. pp. 304-307. Available at: http://www.sna.org/content/Economics and marketing 2009_1.pdf
  • Type: Other Status: Published Year Published: 2011 Citation: Runkle, E. and A.J. Both. 2011. Greenhouse energy conservation strategies. MSU Extension Bulletin E-3160.
  • Type: Other Status: Published Year Published: 2010 Citation: Manning, T., A.J. Both, and J. Rabin. 2010. Understanding on-farm utility costs and billing (FS1128).
  • Type: Other Status: Published Year Published: 2013 Citation: Both, A.J. and T. Manning. 2013. Powering up: Utilizing solar and wind energy can help balance the costs of production in your greenhouse facilities. American Nurseryman Magazine. March issue. pp. 16-20.
  • Type: Other Status: Published Year Published: 2012 Citation: Both, A.J., R. Hansen, and M. Kacira. 2012. Hydroponics give growers control. Article is part of the Water Wisely series in Greenhouse Grower Magazine. May issue.
  • Type: Other Status: Published Year Published: 2012 Citation: Mitchell, C.A., A.J. Both, C.M. Bourget, J.F. Burr, C. Kubota, R.G. Lopez, R.C. Morrow, and E.S. Runkle. 2012. LEDs: The future of greenhouse lighting! (feature article) Chronica Horticulturae 52(1):6-12.
  • Type: Other Status: Published Year Published: 2008 Citation: Both, A.J. and T. Manning. 2008. Solar and wind energy for greenhouses. OFA Bulletin No. 910. September/October issue. pp. 1, 6-7.
  • Type: Other Status: Published Year Published: 2011 Citation: Both, A.J. 2011. Maintaining the optimum environment. Greenhouse Management and Production (GMPro). June issue. pp. 20-22, 24.
  • Type: Other Status: Published Year Published: 2009 Citation: Both, A.J. 2009. How does sustainability fit into your plan? Greenhouse Management and Production (GMPro). May issue. pp. 26, 28-29.
  • Type: Other Status: Published Year Published: 2008 Citation: Both, A.J. 2008. Energy efficiency: Learning to conserve. Greenhouse Grower 25th Anniversary Issue. December issue. pp. 56, 58.


Progress 10/01/11 to 09/30/12

Outputs
OUTPUTS: Research was conducted to investigate the most economical strategy to use the output of a 250 kW microturbine system located at the NJ EcoComplex Research and Demonstration Greenhouse, near Columbus, NJ. The generated electricity and waste heat can be used in the greenhouse (in particular to operate the supplemental lighting system), exported in to the local electricity grid, or some combination of the two. A PhD candidate (Ariel Martin) developed a decision support system that helps the system operator to optimize the economic return, while ensuring that the greenhouse crops will be ready for processing on their intended harvesting/shipping dates. PARTICIPANTS: Nothing significant to report during this reporting period. TARGET AUDIENCES: Nothing significant to report during this reporting period. PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.

Impacts
While not every greenhouse will be located near a source of (landfill) methane gas, the same technology can be operated on natural gas, making it more universally applicable. Because the installation operates as a combined heat and power system, the overall conversion efficiency is higher compared to the situation with a separate heating system and power generator. Hence, using a microturbine for greenhouse applications can be an economic improvement if the initial investment and operating costs can be kept at acceptable levels.

Publications

  • Both, A.J., R. Hansen, and M. Kacira. 2012. Hydroponics give growers control. Article is part of the Water Wisely series in Greenhouse Grower Magazine.


Progress 01/01/11 to 12/31/11

Outputs
OUTPUTS: The installation of a 250 kW microturbine and associated gas cleaning system was completed at the EcoComplex Research and Demonstration Greenhouse. Early on, the system experienced several technical glitches ranging from a malfunctioning gear box, a defective recuperator, and a broken dryer. Scheduled and non-scheduled maintenance is covered by a service maintenance agreement with the vendor (Ingersoll Rand). The microtubine system passed inspections for exhaust characteristics and proper grid connectivity. The system generates electricity for use in the greenhouse and export to the grid, and the waste heat contained in the exhaust gasses is captured using a heat exchanger and delivered to the greenhouse for heating purposes. Research is under way to investigate the most economical strategy to use the generated electricity (and waste heat): use it in the greenhouse (in particular to operate the supplemental lighting system), export in to the local electricity grid, or some combination of the two. A PhD candidate (Ariel Martin) is developing a decision support system that would aid the system operator to optimize the economic return, while ensuring that the crops grown inside the greenhouse will be ready for processing on their intended harvesting/shipping dates. PARTICIPANTS: Nothing significant to report during this reporting period. TARGET AUDIENCES: Extension educators, greenhouse industry, researchers, students PROJECT MODIFICATIONS: Not relevant to this project.

Impacts
While not every greenhouse will be located near a source of (landfill) methane gas, the same technology can be operated on natural gas, making it more universally applicable. Because the installation operates as a combined heat and power system, the overall conversion efficiency is higher compared to the situation with a separate heating system and power generator. Hence, using a microturbine for greenhouse applications promises to be an economic improvement if the initial investment and operating costs can be kept at acceptable levels.

Publications

  • Both, A.J., T.O. Manning, A. Martin, D.R. Specca, and E. Reiss. 2011. Operating a 250 kW landfill gas fired microturbine at a 0.4 hectare research and demonstration greenhouse. Acta Horticulturae. 893:397-404.
  • Zinati, G.M., J. Dighton, and A.J. Both. 2011. Fertilizer, irrigation and natural ericaceous root and soil inoculum (NERS): Effects on container-grown ericaceous nursery crop biomass, tissue nutrient concentration, and leachate nutrient quality. HortScience 46(5):799-807.


Progress 01/01/10 to 12/31/10

Outputs
OUTPUTS: The installation of a 250 kW microturbine and associated gas cleaning system was completed at the EcoComplex Research and Demonstration Greenhouse. Early on, the system experienced several technical glitches ranging from a malfunctioning gear box, a defective recuperator, and a broken dryer. Scheduled and non-scheduled maintenance is covered by a service maintenance agreement with the vendor (Ingersoll Rand). The microtubine system passed inspections for exhaust characteristics and proper grid connectivity. The system generates electricity for use in the greenhouse and export to the grid, and the waste heat contained in the exhaust gasses is captured using a heat exchanger and delivered to the greenhouse for heating purposes. Research is under way to investigate the most economical strategy to use the generated electricity (and waste heat): use it in the greenhouse (in particular to operate the supplemental lighting system), export in to the local electricity grid, or some combination of the two. A PhD candidate (Ariel Martin) is developing a decision support system that would aid the system operator to optimize the economic return, while ensuring that the crops grown inside the greenhouse will be ready for processing on their intended harvesting/shipping dates. PARTICIPANTS: Not relevant to this project. TARGET AUDIENCES: Greenhouse growers, Cooperative Extension personnel PROJECT MODIFICATIONS: Not relevant to this project.

Impacts
While not every greenhouse will be located near a source of (landfill) methane gas, the same technology can be operated on natural gas, making it more universally applicable. Because the installation operates as a combined heat and power system, the overall conversion efficiency is higher compared to the situation with a separate heating system and power generator. Hence, using a microturbine for greenhouse applications promises to be an economic improvement if the initial investment and operating costs can be kept at acceptable levels.

Publications

  • Both, A.J., T.O. Manning, A. Martin, D.R. Specca, and E. Reiss. 2010. Operating a 250 kW landfill gas fired microturbine at a 0.4 hectare research and demonstration greenhouse. Presented at the 2009 GreenSys meeting in Quebec City, Canada. Submitted for publication in Acta Horticulturae (in press).


Progress 01/01/09 to 12/31/09

Outputs
OUTPUTS: The installation of a 250 kW microturbine and associated gas cleaning system was completed at the EcoComplex Research and Demonstration Greenhouse. The system has been operational intermittently due to several non-related technical glitches ranging from a malfunctioning gear box, a defective recuperator, and a broken dryer. Scheduled and non-scheduled maintenance has so far been covered by a service maintenance agreement with the vendor (Ingersoll Rand). The microtubine system passed inspections for exhaust characteristics and proper grid connectivity. When operational, the system has generated electricity for use in the greenhouse and export to the grid and the waste heat contained in the exhaust gasses was captured using a heat exchanger delivered to the greenhouse for heating purposes. Research is under way to investigate the most economical strategy to use the generated electricity (and waste heat): use it in the greenhouse (in particular to operate the supplemental lighting system), export in to the local electricity grid, or some combination of the two. A PhD candidate (Ariel Martin) is developing a decision support system that would aid the system operator to optimize the economic return, while ensuring that the crops grown inside the greenhouse will be ready for processing on their intended harvesting/shipping dates. PARTICIPANTS: Tom Manning (NJAES Project Engineer), David Specca (NJ EcoComplex), Ariel Martin (PhD Candidate), amd Eugene Reiss (former Rutgers employee and greenhouse manager) have all made significant contributions to this work. TARGET AUDIENCES: Nothing significant to report during this reporting period. PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.

Impacts
While not every greenhouse will be located near a source of (landfill) methane gas, the same technology can be operated on natural gas, making it more universally applicable. Because the installation operates as a combined heat and power system, the overall conversion efficiency is higher compared to the situation with a separate heating system and power generator. Hence, using a microturbine for greenhouse applications promises to be an economic improvement if the initial investment and operating costs can be kept at acceptable levels.

Publications

  • Both, A.J., T.O. Manning, A. Martin, D.R. Specca, and E. Reiss. 2009. Operating a 250 kW landfill gas fired microturbine at a 0.4 hectare research and demonstration greenhouse. Presented at the 2009 GreenSys meeting in Quebec City, Canada. Submitted for publication in Acta Horticulturae (under review).