The Frito-Lay plant in Killingly, Conn., has installed a combined heat and power (CHP) system designed to help remove it from the Northeast power grid. Located in a region with severe electrical transmission constraints, Frito-Lay, a business unit of PepsiCo, saw CHP as a potential opportunity for achieving near-term energy efficiency improvements, reducing the site’s carbon emissions, and supporting PepsiCo’s and Frito-Lay’s overall sustainability strategy.

Funding from the state of Connecticut helped support the installation of the CHP system. In addition, a grant from the U.S. Department of Energy’s (DOE’s) Industrial Technology Program was awarded to demonstrate the applicability of CHP in the food processing industry.

The Killingly plant’s combustion turbine CHP system is comprised of:

• A Solar Turbines 4.6 MW Centaur 50 natural gas combustion turbine generator, which includes combustion air inlet chilling to increase power generation during warm weather operations.

• A Rentech heat recovery steam generator designed to provide steam supply.

• A selective catalytic emission reduction system to help the plant meet local and state emission requirements.

The 275,000-square-foot Killingly plant processes more than 500,000 lbs. per day of corn and potatoes for snack foods. The CHP system is designed to meet 100 percent of the plant’s power needs and can provide more than 80 percent of the plant’s current maximum steam needs. To maximize the system, the Killingly plant will utilize the generated waste heat to produce steam to help in the manufacturing process.

Waste-heat recovery could also be used for space heating, cooling, or dehumidification.

Leslie Starr Keating, senior vice president, operations, Frito-Lay North America, said, “Working with the state of Connecticut and the Department of Energy, we are able to invest in sustainable business practices that benefit this community and the country by providing relief to the Northeast power grid and using technologies with a lower environmental impact.”

Gov. M. Jodi Rell stated, “Frito-Lay North America has proven to be more than just one of Connecticut’s most important employers - it has also been a great partner with the state as we work to reduce our dependence on imported energy and increase the use of alternative power. From cutting its use of fuel in production by more than 30 percent to using solar power at distribution centers and production plants, the company has not only made a commitment to these goals - it has lived it.”

Publication date: 10/05/2009