Proposals for Energy Efficiency Solutions in the RÍO NUEVO Agroindustry through Biogas, Solar Energy and Thermal Preheating

Abstract

The energy efficiency project developed at the RÍO NUEVO company in Jacona, Michoacán, whose main objective was to propose sustainable solutions using available resources to reduce the high energy costs of its broccoli and fruit processing, focused on three proposals after a plant visit. The first was the use of organic broccoli waste to produce biogas (with a minimum of 55% methane) to power a 70 kW motor-generator that would operate 10.48 hours a day using 440 m3 of gas. The second was the sizing of a photovoltaic system that, with 962 modules, could generate 30.48% of the total annual consumption, achieving savings of 143616.40 USD ($2872328.00 MXN). The third is the implementation of a solar water preheating system for the boiler, which, by heating from 22˚C to 90˚C, would save 48.3% in LP gas costs. While the study is valuable for integrating solar resources and agro-industrial waste to generate economic benefits and reduce fossil fuel consumption, its implications point out that biogas production is interrupted four months a year due to the seasonality of waste, and that photovoltaic generation is limited by available land.

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Vega, J. , Vera-Romero, I. , Reyes, J. , Nava, I. , Soriano, A. , Ábrego, V. and Martínez-Pérez, B. (2026) Proposals for Energy Efficiency Solutions in the RÍO NUEVO Agroindustry through Biogas, Solar Energy and Thermal Preheating. World Journal of Engineering and Technology, 14, 973-991. doi: 10.4236/wjet.2026.144058.

1. Introduction

The company RÍO NUEVO, located in Jacona, Michoacán 19˚58’09”N 102˚17’34”W (Figure 1), is dedicated to food processing, mainly cooked broccoli and seasonal fruits such as mango and berries. Broccoli is mainly processed during the months of March, April, September and October, coinciding with the peak production seasons in the region. On the other hand, mangoes are received and transformed between February and July, when the local harvest takes place. The process includes stages such as receiving, selecting, washing, cooking, cooling, packaging and cold storage, as can be seen in Figure 2, which requires significant amounts of thermal and electrical energy. Currently, the company operates under the GDMTH (Great Demand in Hourly Medium Voltage) tariff scheme [1], which reflects a significant electricity consumption profile throughout the day. Furthermore, it has a high consumption of LP gas, used primarily for the operation of the steam boiler, which is essential in thermal processes such as cooking broccoli. In this context, energy consumption represents a considerable portion of operating costs and environmental impact, due to the intensive use of fossil fuels and grid-connected electricity. This presents an opportunity and a need to implement energy efficiency measures that reduce costs and improve the sustainability of the production process.

Figure 1. Area and location. Google Earth 2025.

Figure 2. Path sketch. Sweet Home 3D software, open source 2025.

In the case of broccoli, anaerobic digestion can produce 22 L per kg of plant material with a retention time of 18 to 20 days, using a 2:1 ratio, i.e., two parts of broccoli to one part of water at room temperature with a minimum methane quality of 55% in the biogas and a PC = 15,350 kJ/kg [2].

For mango waste, anaerobic digestion produces 7.5 ml of biogas per gram of substrate with a retention time of 29 days using a 1:1 ratio at room temperature, with an elemental analysis of 43% = C, 6% = H, and 0.6% = N. Using a stoichiometric ratio, this yields a methane quality of 26.6% and a PC = 6300 kJ/kg [3].

Solar irradiation data were obtained from the NASA Prediction of Worldwide Energy Resources (POWER) Data Access Viewer using the geographic coordinates of the RÍO NUEVO processing plant (19˚58’09”N, 102˚17’34”W) [4]. The analyzed period extended from November 2024 to June 2025, corresponding to the operating period considered in this study. Monthly solar irradiation values provided by NASA POWER were used to calculate the average irradiation for the analyzed period, resulting in an average value of 5.76 kWh/m2·day.

2. Methodology

A plant visit was conducted at the RIO NUEVO food processing plant to learn about the processes and collect relevant data on electrical (Table 1) and thermal (Table 2) energy consumption. Historical consumption data from the last year will be obtained to identify energy demand and costs.

During the plant visit, operational information was obtained through meetings with personnel responsible for the plant’s maintenance and production areas. Electricity consumption data for the period from April 2024 to April 2025 were obtained from the historical billing records available through the Federal Electricity Commission (CFE) website, using a CFE electricity bill provided by the Industry, Head of Maintenance at RÍO NUEVO, as the reference for accessing the account information. The electricity consumption values reported in this study correspond to actual billing records rather than estimates.

Table 1. Consumption of the Rio Nuevo processor, May 2024 - April 2025. CFE.

Month

Demand kW

Total consumption kWh

Power factor %

Load factor %

MXN/kW h

MXN (Energy)

USD/kWh

USD (Energy)

May

858

320,055

94.92

50.14

$2.68

$857683.39

$0.13

$42884.17

Jun

1205

406,332

93.65

46.83

$2.54

$1031717.58

$0.13

$51585.88

Jul

1224

488,983

93.02

53.7

$2.49

$1219034.62

$0.12

$60951.73

Aug

1244

438,422

93.71

47.37

$2.54

$1115038.67

$0.13

$55751.93

Sep

668

228,279

95.8

47.46

$2.74

$625712.74

$0.14

$31285.64

Oct

403

141,847

98.54

47.84

$2.35

$333765.99

$0.12

$16688.30

Nov

617

134,140

97.67

30.2

$3.11

$417014.43

$0.16

$20850.72

Dec

561

175,254

96.76

41.99

$2.85

$499211.02

$0.14

$24960.55

Jan

826

239,475

93.62

38.97

$2.89

$692418.02

$0.14

$34620.90

Feb

741

220,923

91.57

44.37

$3.05

$674632.57

$0.15

$33731.63

Mar

1183

312,880

93.96

35.55

$2.69

$841647.20

$0.13

$42082.36

April

1196

389,957

92.5

36

$2.59

$1008038.85

$0.13

$50401.94

Min.

403

134,140

91.57

30.2

$2.35

$333765.99

$0.12

$16688.30

Ave.

894

291,379

94.64

43.37

$2.71

$776326.26

$0.14

$38816.31

Max

1244

488,983

98.54

53.7

$3.11

$1219034.62

$0.16

$60951.73

Total

3,496,547

$9315915.08

$465795.75

Table 2. Gas historical consumption per ton of broccoli (annual).

Months

t/day

t/month

L gas LP/T

MXN

USD

Nov

20

300

25

$82950.00

$4147.50

Dec

20

500

25

$138250.00

$6912.50

Jan

20

520

25

$143780.00

$7189.00

Febr

20

480

25

$132720.00

$6636.00

Mar

20

520

25

$143780.00

$7189.00

April

20

520

25

$143780.00

$7189.00

May

20

500

25

$138250.00

$6912.50

Jun

20

300

25

$82950.00

$4147.50

Total cost

$1006460.00

$50323.00

Based on knowledge of consumption and costs, sustainable strategies will be proposed to increase the plant’s energy efficiency by implementing power generation technologies, leveraging available resources to reduce energy bills over time. Process analysis revealed that broccoli and mango processing generates a large amount of organic waste, which can be used to produce biogas and harness it to supply part of the plant’s consumption, generating electricity through the use of a motor-generator. Due to the plant’s location, solar resources are available; therefore, photovoltaic generation and water preheating for steam generation are also feasible.

2.1. Biogas Production for Engine-Generator

Broccoli processing generates a large amount of organic waste; around 50% of the product is discarded in the form of stems, leaves, and vegetable grits. The 50% fraction of broccoli residues was established based on an operational relationship reported by Eng. Ramón Romero Campos, Head of the Plant, during the field data collection. According to the plant’s operating conditions, approximately 40 t of broccoli is processed per day. Of this amount, approximately 20 t corresponds to the usable finished product (florets), while the remaining 20 t consists mainly of stems and leaves, which are considered residual biomass. Therefore, a 50% residue fraction was used to estimate the available feedstock for biogas production. Since broccoli processing depends on seasonal raw material availability, the estimated 20 t/day of residual biomass represents the availability during peak production periods and was not assumed to be continuously available throughout the year.

Similarly, mango processing generates 46% of waste in the form of stems and pits. It should be noted that the processing of these foods is seasonal, so the waste is not constant throughout the year. To estimate biogas generation, literature on the production potential of the respective waste will be reviewed to understand technical aspects such as organic matter processing, retention days, volume of biogas obtained per kg of waste, and percentage of methane in the biogas [5]. In the case of broccoli, anaerobically digested, 22 L can be produced per kg of plant material with a retention time of 18 to 20 days using a 2:1 ratio, i.e., two parts broccoli to one-part water at room temperature with a minimum methane quality of 55% in the biogas and a PC = 15,350 kJ/kg [2]. For mango waste, anaerobically digested, 7.5 ml of biogas per gram of substrate are obtained with a retention time of 29 days using a 1:1 ratio at room temperature, with an elemental analysis of 43% = C, 6% = H, and 0.6% = N. Using a stoichiometric ratio, this yields a methane quality of 26.6% and a PC = 6300 kJ/kg [3]. Using the information obtained, biogas production will be estimated in each case, taking into account the amount of waste generated. Using the volume of biogas obtained, the biodigester and the engine-generator suitable for utilizing the fuel supply will be sized, and the energy generated will be calculated to meet the energy demand. Once the energy produced is obtained, the savings will be graphed and quantified using the average kWh cost in the tariff schedule during the hours the power will be on, as well as the investment cost and return on investment.

Operational Assumptions of the Biogas System

The biodigester start-up is considered using cattle manure from an operating biodigester as inoculum, occupying 20% of the useful working volume, while the remaining volume is initially completed with water [6]. Subsequently, the biodigester is fed daily with broccoli waste and water at a 2:1. From the first day of broccoli feeding, a retention time of 20 days is considered before biogas production is available for use.

The reference used for broccoli digestion does not report an additional biogas filtration process; therefore, no specific gas-cleaning stage was included in the present proposal. The selected motor-generator is sized to consume the volume of biogas produced daily, so no long-term gas storage is considered under normal operation.

The digestate resulting from anaerobic digestion is considered suitable for subsequent use as an organic soil amendment in agricultural land. Electricity generation is planned to complement the plant’s electricity consumption during the hours with the highest electricity cost. Since the plant does not operate on Sundays, this day is considered suitable for preventive maintenance of the motor-generator. In addition, during periods in which the biodigester is not producing biogas due to the absence of broccoli waste, general maintenance of the biodigester can be performed.

2.2. Power Generation Using a Photovoltaic System

To calculate the photovoltaic sizing, the average daily energy consumption (kWh/day), the power of the selected panel, the system efficiency, and the available peak solar hours in the region will be considered to quantify the number of photovoltaic modules required [7]. Various factors will be considered, such as the available area (5000 m2), coordinates and orientation (19˚58’09”N 102˚17’34”W). The module selected for the system is a 660 W “Vertex monocrystalline” module with an efficiency of 21.6%, a height of 2.38 m, and a width of 1.30 m. Considering the module dimensions, the appropriate quantity for the available area will be proposed, and the ideal distribution will be simulated to prevent the modules from being shaded and the system’s efficiency from decreasing. Using the number of modules and HSPs available throughout the year, the daily, monthly, and annual power generated will be calculated, and the inverter(s) for the system will be selected. Knowing all this data, the investment cost of the system will be estimated, considering modules, panel structure, wiring, and labor. Savings will be calculated based on the energy generated and graphed by comparing annual consumption and annual generation. The return on investment will be determined based on the investment cost and savings.

2.3. Preheating Water

LP gas fuel consumption is 500 L on an ideal work day, processing 20 tons of broccoli in a 16-hour workday. The boiler operates at 1205 HP = 898 kW with water supply at 22˚C and steam output at 134˚C for 17 hours. The daily water volume requirement can be calculated using data obtained from the boiler, where the volumetric flow rate can be easily obtained, and the total daily water volume can be estimated using the operating hours.

The fuel cost per ton of production per day, month, and year will be estimated. In this case, energy will be analyzed in terms of heat Q = kJ, where the energy supplied by the LP gas to heat the water from 22˚C to 134˚C will be calculated. The energy input for preheating using solar collectors, where the water temperature reaches 90˚C, will also be determined. Knowing the volume of water and the region’s irradiation = 5.76 kWh/m2 [4], the preheating system can be sized, therefore suitable equipment will be selected and the investment cost will be determined. Knowing the heat supplied by the solar heater, the equivalence in liters of LP Gas will be calculated. With these equivalent liters and considering the cost of LP Gas, the savings generated by preheating can be calculated. Finally, the return on investment will be estimated and the heat supply in both cases will be graphed.

3. Calculations and Results

3.1. Biogas Production for Engine-Generator

Biogas production from mango waste is ruled out due to the low methane content. For biodigester dimensions, the volume is calculated using the kilograms of broccoli waste and its water ratio (2:1) over the retention days.

k g substratum =k g waste +( L Water ∗ ρ Water )

k g Total =k g mix ∗20 days

L Total =k g Total ∗ 1 L/ 1 kg

According to the literature, the amount of Biogas per day and per month is calculated depending on the amount of waste after the first 20 days of retention.

L Biogas/day =k g waste ∗( 22 L/ 1 kg )

L biogas/month =k g waste ∗ ( 22 L )/ 1 kg ∗Day s month

m biogas 3 =1000 L

For the selection of the biodigester, the total volume of the mixture during the 20 days of retention is considered, as can be seen in Table 3.

Table 3. Mixing volume to Biodigestor sizing (20 days of retention).

Days

Month

kgwaste waste kg/day

kg water

kgTotalkg Total

LBiogas/daym3 day

Lbiogas/monthm3 Total

15

Nov

20,000

10,000

30000

30

600

25

Dec

20,000

10,000

30000

30

600

26

Jan

20,000

10,000

30000

30

600

24

Feb

20,000

10,000

30000

30

600

26

Mar

20,000

10,000

30000

30

600

26

Apr

20,000

10,000

30000

30

600

25

May

20,000

10,000

30000

30

600

15

Jun

20,000

10,000

30000

30

600

A continuous flow biodigester from JINGCHENG WEIYE company with a capacity of 650 m3 was selected.

With the available volume of biogas, its Heat Value (HV) = 15,350 kJ/kg, its density = 1.57 kg/m3, working hours, and 25% efficiency of a biogas engine, the potential for electrical generation will be obtained to then choose the engine-generator that adapts to the fuel supply.

H V m 3 =HV∗ρ=24,099.5  kJ/ m 3

Powe r electric =HV∗ m ˙ ∗ η engine

m ˙ =( 24099.5 kJ m 3 )( 0.25 )( 70 kJ s )=0.01166 m 3 s

Supply= Powe r electric ∗ h day ∗ day  month

Knowing the generation potential, a motor-generator is proposed that meets the daily fuel supply capacity, thus determining the engine’s operating hours and the energy generated at rated power. Motor-generator selection. Model TG7.IDG 70 kW, 15-year life. All this is done with the help of the engine’s technical data.

The generator motor requires a supply of 0.6 m3/kWh, so that it works at its nominal power of 70 kW (Figure 3), considering the volume of biogas produced per day to know how long it is able to keep the motor running and how much energy it generates (Table 4).

h supply = m day 3 0.6  m 3 ∗70 kWh

Energ y generated = h supply ∗70 kW

To calculate the savings, the average cost of kWh is calculated in the GDMTH tariff scheme (Table 5) and the schedule that the engine-generator is intended to be kept on, which is from 11:30 am to 10:00 pm.

Figure 3. Parameters and supply details for 70 kW Biogas Generator.

Table 4. Electric generation with biogas.

Month

Consumption (kWh)

Generation (kWh)

Saving (MXN)

(USD)

May-2024

320,055

18333.33

$38357.00

$1917.85

Jun-2024

406,332

11000.00

$23014.20

$1150.71

Jul-2024

488,983

0.00

0.00

0.00

Aug-2024

438,422

0.00

0.00

0.00

Sep-2024

228,279

0.00

0.00

0.00

Oct-2024

141,847

0.00

0.00

0.00

Nov-2024

134,140

11000.00

$23014.20

$1150.71

Dec-2024

175,254

18333.33

$38357.00

$1917.85

Jan-2025

239,475

19066.67

$39891.28

$1994.56

Feb-2025

220,923

17600.00

$36822.72

$1841.14

Mar-2025

312,880

19066.67

$39891.28

$1994.56

Apr-2025

389,957

19066.67

$39891.28

$1994.56

Annual

133466.67

$279238.96

$13961.94

The economic savings from biogas electricity generation were calculated according to the GDMTH tariff periods corresponding to the proposed operating schedule of the motor-generator. From Monday to Friday, 6.48 h/day of generation corresponds to the intermediate period at a cost of $2.006 MXN/kWh and 4 h/day to the peak period at $2.253 MXN/kWh, considering 155 operating days. On Saturdays, 8.48 h/day corresponds to the intermediate period and 2 h/day to the peak period, considering 32 operating days. Based on the 70 kW generator capacity, the weighted calculation results in an equivalent electricity cost of approximately $2.0922 MXN/kWh. Therefore, this value represents the weighted cost of the electricity displaced during the actual generation periods rather than a general average electricity tariff.

Table 5. Average cost per kWh during electricity generation hours.

$ Cost per kWh (GDMTH)

Monday - Friday 113708 kWh/day

Saturday 23475.2 kWh/day

Fee

Hours

Cost (MXN/USD)

kW

Days

Cost (MXN/USD)

Hours

Cost (MXN/USD)

kW

Days

Cost (MXN/USD)

Intermediate

6.48

$2.006/$0.100

70

155

$141037.85/$7051.89

8.48

$2.006/$0.1003

70

32

$38104.37/$1905.22

Tip

4

$2.253/$0.113

70

155

$97780.2/$4889.01

2

$2.253/$0.1127

70

32

$10093.44/$504.67

Total

238818.048/$11940.902

Total

$48197.81/$2409.89

Generation Total (kWh)

Total Cost (MXN/USD)

Average $/kW h (MXN/USD)

113708

$238818.048/$11940.902

$2.0922/$0.1046

23475.20

$48197.8112/$2409.891

Addition

137183.20

$287015.8592/$14350.793

Figure 4 shows the energy that can be generated by the biogas engine generator compared to the total energy consumption during the year. Knowing the savings and investment cost (Table 6) allows to estimate the return on investment and the economic benefit over time.

Figure 4. Consumption vs. electricity generation with biogas.

Table 6. Biogas engine generator investment costs.

Component

Unit Cost (MXN/USD)

Quantity

Subtotal (MXN/USD)

Biodigester 650 m3

$620,000/$31,000

1

$620,000/$31,000

Motor-generator 70 kW

$150,000/$7500

1

$150,000/$7500

Engineering and Installation

$500,000/$25,000

1

$500,000/$25,000

Shipment

$130,000/$6500

1

$130,000/$6500

Accessories

$100,000/$5000

1

$100,000/$5000

TOTAL

$1,500,000/$75,000

Payback= Inverment Anual savings = $1500000( $75000.00 ) $279238.96( $13961.95 ) =5.3 years

Sensitivity Analysis

The biogas production proposal was evaluated considering the main parameters involved in the calculation. The available data establish a biogas yield of 22 L/kg of broccoli waste, with a minimum methane content of 55% and a retention time of 18 - 20 days. For the design calculations, a retention time of 20 days was adopted.

The system considers 20,000 kg/day of broccoli waste mixed with 10,000 kg/day of water, resulting in a daily mixture volume of approximately 30 m3. With a 20-day retention time, the required volume is 600 m3, for which a 650 m3 continuous-flow biodigester was selected.

For electricity generation, 25% generator efficiency was considered. The proposed 70 kW motor-generator requires approximately 0.6 m3 of biogas per kWh generated.

The number of operating days varies according to broccoli availability, with the available records considering 15 days in November, 25 in December, 26 in January, 24 in February, 26 in March, 26 in April, 25 in May, and 15 in June. Therefore, annual biogas and electricity production are directly conditioned by the seasonal availability of broccoli waste and the actual operating days of the plant.

3.2. Photovoltaic Sizing

The sizing was based on the average daily energy consumption, Peak Sun Hours (PSH), power of the selected panel, and system efficiency. According to the guidance, the efficiency drops to 85%. Various estimates were made using minimum, average, and maximum consumption to determine the number of modules needed (Table 7) to cover the energy supply in each case (Table 8), and these were graphed along with the annual consumption (Figure 5).

Paneles= Consumo  kWh/ dia η sistema ∗Pot . panel ∗HSP

Table 7. Number of panel.

660 W

PSH

kWh month

kWh day

# Panels

Min

4.71

134,140

4471.33

1692.21

Intermediate

5.692

291,379

9712.63

3041.65

Max

7.42

488,983

16299.43

3915.67

Generatio n panels = η sistem ∗Pawer . panel ∗Num . panels ∗PSH

Table 8. Simulated photovoltaic generation for a typical local year.

Month

Min kWh/month

Intermediate kWh/month

Max kWh/month

Jan

168,344

302,483

389,290

Feb

188,267

338,281

435,361

Mar

237,276

426,339

548,691

Apr

248,729

446,918

575,176

May

242,125

435,053

559,905

Jun

195,430

351,150

451,924

Jul

187,049

336,092

432,545

Aug

186,357

334,848

430,943

Sep

166,266

298,749

384,484

Oct

186,357

334,848

430,943

Nov

170,959

307,181

395,337

Dec

163,149

293,147

377,275

Figure 5. Total consumption vs. photovoltaic generation: minimum, average, maximum.

For a real sizing, important factors were taken into account such as the available and optimal area for the installation of the system, in this case 100 m × 50 m, the dimensions of the photovoltaic module with a height of 2.38 m and 1.30 m wide and the optimal distance between panel sheets to avoid shadows and guarantee the efficiency of the system. The sizing for the optimal distribution of the panels was carried out with the help of the PVsyst software [8] that simulates the solar path as can be seen in Figure 6 and Figure 7, while the resulting monthly percentage values are compiled in Table 9.

Figure 6. Dimension and simulation (software PVsyst) [8].

The electricity generated from biogas is intended for on-site consumption during plant operation. As shown in Figure 6, the monthly electricity generation from biogas remains below the plant’s electricity consumption; therefore, no electricity export to the grid or generation curtailment is considered in the proposed operating scheme, integrated with the complete monthly photovoltaic yield performance detailed in Table 10.

Table 9. Efficiency losses due to shadows (Software PVsyst) [8].

Month

% losses

Jan

1.2

Feb

0.4

Mar

0

Apr

0

May

0

Jun

0

Jul

0

Aug

0

Sep

0

Oct

0

Nov

0.1

Dec

0.9

Table 10. Photovoltaic generation (PVsyst) [8].

962 modules

Days

PSH

Generation (kWh)

Consumption total (kWh)

Cost $/kWh

Saving (MXN/USD)

31

Jan

4.86

76,525

239,475

$2.8914/$0.145

$221,266/$11,063

29

Feb

5.81

85,582

220,923

$3.0537/$0.153

$261,342/$13,067

31

Mar

6.85

107,860

312,880

$2.69/$0.135

$290,143/$14,507

30

Apr

7.42

113,066

389,957

$2.585/$0.129

$292,277/$14,614

31

May

6.99

110,064

320,055

$2.6798/$0.134

$294,951/$14,748

30

Jun

5.83

88,838

406,332

$2.5391/$0.127

$225,568/$11,278

31

Jul

5.4

85,028

488,983

$2.493/$0.125

$211,976/$10,599

31

Aug

5.38

84,713

438,422

$2.5433/$0.127

$215,452/$10,773

30

Sep

4.96

75,580

228,279

$2.741/$0.137

$207,167/$10,358

31

Oct

5.38

84,713

141,847

$2.353/$0.118

$199,331/$9967

30

Nov

5.1

77,714

134,140

$3.1088/$0.155

$241,597/$12,080

31

Dec

4.71

74,163

175,254

$2.8485/$0.142

$211,255/$10,563

Total Generation

1,063,851

Saving per year

$2,872,329/$143,616

Figure 7. Photovoltaic generation (PVsyst) [8] vs. consumption.

For the investment cost of the photovoltaic system, 962 Vertex modules, model TSM-DE21 660 W, will be taken into account. The height is 2.50 m at the highest point and 0.3 m at the lowest point, therefore a manufactured aluminum structure is considered. To select the inverters, the installed power is taken into account, in this case 508 kW. Three inverters of 125 - 150 kW Mod. MAX 124 - 150KTL3 and one inverter of 50 - 70 kW Mod. MAC 50 - 70KTL3-X LV/MV; of the Growatt brand were selected. Another important part of the investment is the wiring used, cabinets, trays and/or pipes, accessories, connectors, switches, electrical protections and finally the cost of labor, which accounts for 30% of the total investment cost (Table 11). The lifespan of a high-efficiency photovoltaic system is approximately 25 years.

Table 11. Photovoltaic system investment costs.

Component

Quantity

Unit cost (MXN/USD)

Subtotal (MXN/USD)

Module

962

$4500/$225

$4,329,000/$216,450

Structure

962

$1300/$65

$1,250,600/$625,30

Inversor 150

3

$92,000/$4600

$276,000/$13,800

Inversor 50

1

$55,000/$2750

$55,000/$2750

Accessories

$600,000/$30,000

$600,000/$30,000

Labour

$1,953,180/$97,659

$1,953,180/$97,659

Total Investment

$8,463,780/$406,594

Payback= Investment Annual savings = $8463780 $2872329 =2.95 years

3.3. Water Preheating

The boiler operates at 1200 HP with a feedwater temperature of 22˚C and generates steam at 134˚C, which is supplied directly to a water vat to maintain it at 95˚C and be used in the broccoli precooking process. To determine the heat supplied, the volume of water required during the day must be determined, considering that the boiler is fired for 17 hours, i.e., 1 hour for the vat water to reach the ideal process temperature and 16 hours to maintain the water temperature (Table 12). The fuel consumption log records a consumption of 500 L of LP gas for a daily production of 20 tons of broccoli. Figure 8 shows the heat input of the preheating system compared to the current LP gas input. This calculation methodology was obtained from the book Solar Engineering of Thermal Processes [9] and standard solar thermal design fundamentals [10].

V ˙ LPGas = 500 L 17 h =29.41 L/h

m ˙  Production= 20 t 16 h =1.25 t h

Consumtio n Gas LP = 500 L 20 t =25 L/t

To know the volume of water needed during the day.

m ˙  wate r Boiler = Q ˙ Δh = 1200HP( 898 kW ) 2735 kJ kg −92 kJ kg =0.340 kg s

m ˙  wate r day =0.340 kg s ∗( 3600 s 1 h )∗17 h day =20879.6 kg day

V ˙  wate r day = m ˙  wate r day ρ =[ 20879.6 kg day / 997.8 kg m 3 ]∗ 1000 L 1  m 3 =20925.6 L day

Consumtio n water = 20925.6 L 20 t =1046.28 L/t

Thermal efficiency of the boiler is 85%, calorific value (HV) of LP gas equal to 46,000 kJ/kg and a liquid state density of 500 kg/m3.

m ˙ LPGas =( 29.41 L h )∗( m 3 1000 L )∗( 1 h 3600 s )∗( 500 kg 1  m 3 )=4.08× 10 −3 kg s

Q ˙ fuel= m ˙ LPGas ∗H V LPGas =( 4.08× 10 −3 kg s )∗( 46000 kJ kg )=354.58  kJ/s

46000 kJ kg ∗( 500 kg 1  m 3 )∗( m 3 1000 L )=23000 kJ L

V ˙ LPGas =( 4.08× 10 −3 kg s )∗( 1  m 3 500 kg )∗( 1000 L 1  m 3 )=0.00816 L/s

Qsupplie d LPGas =HV∗L=( 23000 kJ L )∗( 500 L )=11.5× 10 6  kJ

Knowing the volume of water per day, it is possible to size the number of solar collectors to heat the water up to 90°C (Table 12).

Q ˙ sun = m ˙ ∗Cp∗ΔT=( 20879.6 kg day )( 4.186 kJ kg⋅˚C )∗[ ( 90−22 )˚C ]=5943450.2 kJ day

To select the preheating system, the volume of water required for steam generation is taken into account; in this case, the volume is 20,925.6 L/day. A parabolic solar collector system was chosen. This calculation methodology was obtained from the book Solar Engineering of Thermal Processes [9]. The economic savings are shown in Table 12 and Figure 8.

Q ˙ =5943450.2 kJ day ( 1 kWh 3600 kJ )=1651 kWh day

Area= Q ˙ η∗Irradiation = 1651 kWh day 0.7∗5.7 kWh m 2 day =413.78  m 2

No. Solar Collectors= 413.78  m 2 15.3  m 2 =27.04

Q ˙ saved = Q ˙ LPGas − Q ˙ sun

Economic Saving=( Q saved HV [ kJ L ] )∗( $ L )

Table 12. Heat supplied by solar preheating and LP gas.

Month

MJ gas LP

MJ solar collectors

MJ saving LP gas

Saving (MXN/USD)

Nov

172,500

89,152

83,348

$40079.52/$2003.68

Dec

287,500

148,586

138,914

$66799.51/$3339.47

Jan

299,000

154,530

144,470

$69471.23/$3473.04

Feb

276,000

142,643

133,357

$64127.32/$3205.89

Mar

299,000

154,530

144,470

$69471.23/$3473.04

Apr

299,000

154,530

144,470

$69471.23/$3473.04

May

287,500

148,586

138,914

$66799.51/$3339.47

Jun

172,500

89,152

83,348

$40079.52/$2003.68

Total

2,093,000

1,081,708

1,011,291

$486299.06/$24311.31

Savings=( 486299.06/ 1006460 )×100=48.32%

Figure 8. Heat supplied LP Gas vs. solar preheating heat.

Collectors of the brand “Shandong Gaia PT-30” with a useful life of 15 years and a 15,000 liters’ storage tank with thermal insulation coating, were selected since the production day is 16 hours a day and water has to be stored for the hours when there is no solar radiation. With the savings generated by the preheating system and the investment cost (Table 13) the return on investment is estimated.

Table 13. Investment cost.

Component

Unit cost (MXN/USD)

Amount

Subtotal (MXN/USD)

Collector

$40,000/$2,000

27

$1,080,000/$54,000

Installation

$10,000/$500

27

$270,000/$13,500

Accessories

$15,000/$750

1

$15,000/$750

Tariffs

$200,000/$10,000

1

$200,000/$10,000

Shiping

$100,000/$5,000

1

$100,000/$5,000

Water tank

$200,000/$10,000

1

$200,000/$10,000

Total Investment

$1,865,000/$93,250

Payback= Inversment Anual Savings = 1865000 486299.06 =3.84 years

Considering the sum of the two proposals for electricity generation (Table 14), a significant part of the energy consumption can be satisfied, as we can see in Figure 9.

Table 14. Total generation with biogas and photovoltaic panels.

Month

Total consumption

Biogas generation

Ph generation

Generation Ph + Biogas

(kWh)

(kWh)

(kWh)

(kWh)

May

320,055

18,333

110,064

128,397

Jun

406,332

11,000

88,838

99,838

Jul

488,983

0.00

85,028

85,028

Aug

438,422

0.00

84,713

84,713

Sep

228,279

0.00

75,580

75,580

Oct

141,847

0.00

84,713

84,713

Nov

134,140

11,000

77,714

88,714

Dec

175,254

18,333

74,163

92,496

Jan

239,475

19,066

76,525

95,591

Feb

220,923

17,600

85,582

103,182

Mar

312,880

19,066

107,860

126,926

April

389,957

19,066

113,066

132,132

Total

3,496,547

133,464

1,063,846

1,197,310

Figure 9. Consumption vs. total generation.

4. Conclusion

Biogas production from broccoli waste is viable and represents an alternative source of electricity, with the potential to reduce grid electricity consumption. The use of mango waste was ruled out due to its low methane content. The proposed photovoltaic system, with 962 modules, covers a significant portion of the plant’s annual electricity consumption. Its installation represents a high investment, but with a reasonable payback period and a lifespan of up to 25 years. Solar water preheating using parabolic trough collectors reduces LP gas consumption by raising the temperature of the boiler feedwater, thus decreasing thermal costs and improving the overall efficiency of the system. The integration of these technologies makes RÍO NUEVO a more competitive and environmentally responsible company by leveraging local resources and reducing its carbon footprint.

Author Contributions

Julio César Zarate Vega and Iván Vera-Romero: All sections of the article. José Martínez Reyes and Beatriz Martínez Pérez: Sections 2.1, 2.3 and 3.1 and 3.3. Agustina Ortiz Soriano and Ignacio Moreno Nava: Sections 1. and 2. Víctor Manuel Méndez Ábrego: Sections 2.2 and 3.2.

Conflicts of Interest

The authors declare no conflicts of interest regarding the publication of this paper.

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