Completed Projects

OLD KITCHEN REDEVELOPMENT
Since June 2005 we have been enjoying the facilities provided in the new dining room and kitchen. This has given us the opportunity to redevelop what used to be the old kitchen, food store and linen store. We have now added a further 7new small ensuite rooms on the ground and first floor, two of which are 'accessible by all'. In addition 3 further rooms have been refurbished with ensuite facilities.


BIOMASS PROJECT
In 2001 our farm manager, Ray Cousins, started considering how to best utilise the timber collected from our own woodlands, as there was not a viable market for the timber at that time. At the same time we were building the new dining room and accommodation (Jubilee Project), and so the initial technical appraisal for the Biomass Project focussed primarily on the needs of the new building with the possible extension in to other parts of the site. After consultation it was decided to provide heating facilities for the whole campus. Based on the total peak energy requirement of 750kW, the system is based on a Heizomat 500kW wood boiler along with a 300kW oil boiler as back up unit. The boilers are located in a new purpose built boiler house which also incorporates a direct feed wood chip store and headers and pumps to distribute heat around the site.

Surrounding the hall the school owns 72 ha. of estate grounds of which 12 ha. are woodland. Neighbouring the estate are further extensive forestry plantations owned by the Forestry Commission. In addition to the local timber supply the estate operation includes a working farm which provides the labour, material and buildings necessary for the system. The scheme utilises this resource to provide sustainable energy; an important factor which also fits the ethos of the school.

Capernwray has one major advantage over other commercial operators in that it has the space and some of the equipment necessary through their existing farming operation. They also have the labour requirements, again through the farm, but also through the volunteer time provided by students. The system is based around purchased slabwood and timber brought on to site in the round. This is stored within the existing farm working area, in a newly constructed barn. The aim is to bring the round wood timber moisture content down to 35%. Based on a winter felling programme this will require an 18 month drying rotation. Depending on available space the timber will initially be stacked outside under cover for up to twelve months to prevent rewetting. It will then be moved under cover to bring the moisture content below 35%. The lower the moisture content the more energy per ton. Once the rotation has reached the required moisture level it will be chipped on site directly into a trailer and then tipped into the chip storage building alongside the boiler. In order to reduce handling costs chipping will not occur until required. It is anticipated that the estate’s present forestry plantations will be able to provide 34t/pa. of thinnings for the system over the next ten years.

The most recent records indicated an annual usage of 100,000 litres of fuel oil a year. With the new building this would have increased to 120,000 litres. This equates to an annual energy demand of 1,080,000Kwh. When initial plans were formulated (mid 2003), costings were based on an anticipated future average oil price of 23p/litre. The calculated annual oil charge would have been £27,600 (current costs are now in the region of 40p/litre (October 2007). As well as the annual cost savings, the use of sustainable energy, it was also calculated by Mercia Energy that replacing 120,000 litres of oil by burning woodchip would produce a reduction in CO2 emissions of 367 tons.

The project is the largest and first of its kind on this scale in Lancashire. It is only one of a small number in the area. The wider benefit of this system will be felt throughout the county and certain parts of the world, due to the involvement of the national and international student population. The involvement of the community in the mechanics of the timber side on the estate adds a dimension to the project not normally possible with a non-community based property and it is hoped the scheme will also encourage others to consider the possibility of installing a biomass system. It is anticipated that further business opportunities may be created in the area by making the purchased crane and woodchipper available.

The majority of the work was carried out by our own Projects and Maintenance teams, from heating design through boiler construction, installation of pipework and much of the internal control systems. We are also grateful to other individuals and companies who have been involved in this project and for the grants and loans received, without which this would have been impossible.

Contractors: Heizomat GmbH, Mercia Energy Ltd, Nobbs & Jones, Jeff Hall
Grant-making bodies: Aggregates Levy Sustainability Fund, DEFRA Rural Enterprise Scheme, Lancashire Environment Fund, Lancashire Woodlands Project, Leader +, SITA UK, Carbon Trust (interest free loan)