Doef’s Greenhouses CO2 and Heat Capture

Project Overview

Funded through ERA’s Food, Farming and Forestry call in 2021, Doef’s Greenhouses and Horseshoe Power planned to construct a tri-generation plant that utilizes natural gas from surrounding natural gas fields and generates electricity, heat, CO₂ and water for a 13-acre greenhouse. While the team did not complete all the initial milestones, the project presents an opportunity for Albertans to invest in a sustainable, multi-industrial, integrated business, made in Alberta. 

Reducing Emissions from Greenhouses Using Tri-Generation 

Commercial-scale greenhouses in Alberta face high energy costs, making locally grown produce less competitive than imports. However, Alberta’s abundant natural gas reserves and deregulated power market offer a unique advantage for year-round food production. This project aimed to lower emissions and delivery costs by integrating greenhouses with power, heat and CO₂ generation, as well as water treatment within natural gas fields. In this system, waste heat is recovered and used to heat the greenhouse and treat water for plant irrigation. Exhaust CO₂ from the power plant is captured, cleaned and injected into the greenhouse to optimize photosynthesis and plant growth. Additionally, more energy-efficient grow lights and advanced vegetable inspection to reduce spoilage will be implemented. Emission reductions from the project are estimated at approximately 10,000 to 50,000 tonnes each year, depending on the electricity market. These reductions are achieved by capturing and utilizing CO₂ and detecting spoiled produce to avoid the CO₂ emissions associated with return haul trucking and the decomposition of wasted produce. Additionally, utilizing waste heat and replacing traditional lighting systems with white LED grow lights reduces energy consumption and the associated emissions.

Understanding How Flexibility and Proactivity Can Support Future Success

Overall, the team integrated and installed certain aspects of the project and validated some of the technologies. Notably, the implementation of Full Spectrum LED lights significantly decreased the greenhouse’s electricity consumption, decreasing electricity demands in the crop area by 40 per cent compared to the conventional system. This change did not affect crop production levels, demonstrating the economic and environmental sustainability of the Full Spectrum LED lights. This reduction in electricity consumption has not only resulted in cost savings but has also contributed to a reduction in our carbon footprint, aligning with our commitment to sustainable practices. In addition to the energy-efficient lighting system, the team also integrated a mould detection system. This system serves as a valuable secondary defence mechanism against potential mould contamination, representing a proactive approach to quality control. 

Despite these successes, the project faced several challenges, which led to delays. During the project, the ownership of the co-located tri-generation unit changed. Horseshoe Power, the original owner, transitioned to new ownership under the company BTG Power. This ownership change added another layer of complexity to the project, requiring adjustments in communication and operational protocols. The transition has necessitated a review and potential renegotiation of existing agreements, as well as the establishment of new relationships with the BTG Power team. Additionally, Alberta’s electricity pricing has been volatile, significantly impacting the operations. The CO₂ reactor units, CO₂ cooling units, and waste heat capture system were successfully installed and commissioned; however, fluctuating prices have made it commercially unviable to operate the tri-generation co-located units for electricity production. The current soft market prices do not cover the operational costs, forcing the team to adopt traditional operating strategies. Although the current energy market has impacted the organization’s operational strategies, it maintains a significant competitive edge due to its ability to rapidly optimize and fully utilize existing on-site equipment. This strategic advantage allows Doef’s Greenhouses to maintain flexibility and respond swiftly to changes in market conditions. Additionally, this proactive approach will enable the organization to navigate the challenges of the current market while positioning for future success.

What’s next?

At project completion in 2025, Doef’s Greenhouses is poised to capitalize on new opportunities as they arise, aiming to remain at the forefront of the industry. The company states that its team will continue to monitor Alberta market pricing indicators, and when the pricing is favourable, the co-located tri-gen units will run consistently, and they will be able to extract energy and CO₂ to further reduce operating costs. Doef’s Greenhouses states it remains committed to optimizing its operations and exploring innovative solutions that enhance efficiency, sustainability and profitability.