Kooyong and Port Phillip Estate Winery, Mornington Peninsula, Victoria

Kooyong and Port Phillip Estate, nestled in the heart of the Mornington Peninsula wine region, stands as a captivating destination 80 km south of Melbourne, Victoria, Australia. Situated on the land of the Boon Wurrung/Bunurong people of the Kulin Nation, the estate specialises in crafting exceptional chardonnay, pinot gris, and pinot noir, drawing from the region's renowned cool-climate maritime influences.

An architectural landmark, Port Phillip Estate is distinguished by its monumental limestone rammed earth walls, winding gracefully from the ground, and creating anticipation for the treasures within. In addition to its renowned wines, Port Phillip Estate offers exclusive luxury accommodation on the Mornington Peninsula. Notably, the estate is committed to sustainability, evident in its recent initiative to replace the existing gas system for domestic hot water, extending this commitment to both the winery bar and kitchen, as well as the accommodation.

Project background and requirements

Kooyong and Port Philip Estate winery stand as a trailblazer in sustainable winemaking, boldly embarking on a mission to eradicate gas usage across their facilities, including the bottling plant. This initiative marks a pivotal moment in its sustainability journey, focusing on the strategic optimisation of existing infrastructure to achieve unparalleled energy efficiency and waste reduction.

At the heart of its eco-friendly transformation lies the impressive 99.8 kW solar photovoltaic (PV) system, a powerhouse generating abundant electricity for on-site operations. The team realised that during peak solar periods surplus power was flowing back to the grid, with untapped potential waiting to be harnessed. This opportunity was seized with the development and implementation of demand response strategies to channel excess energy into thermal storage systems.

Building on this success, the integration of the winery's solar thermal system with cutting-edge heat pump technology emerged as a game-changer. By eliminating the need for electric resistance elements reliance on the main AC supply dwindled, a greener, more efficient energy landscape through PV load-shifting technology was possible. This innovative fusion not only maximised the usage of renewable solar resources but also slashed operational costs and carbon footprints with each sustainable cycle.

The project culminated with the deployment of high-performance commercial heat pumps which had the capacity to deliver temperatures to 80 °C with minimal energy consumption. Complemented by the advanced ENERMAX thermal storage units, engineered with high-levels of insulation and negligible heat loss (1.4 kWh/24 hours @ 60 °C hot water, ambient 10 °C), the solution guarantees optimal heating efficiency and performance across the winery's sprawling facilities.

Existing system:

The existing system is a solar pre-heated domestic hot water (DHW) system. This system provides DHW for wash-down, cellar, restaurant and accommodation:

• 5 kW solar thermal with 60 evacuated-tubes collector with propylene-glycol combined with 1 x 400 L unit and 1 x 650 L unit of electric-boosted thermal storage tank.

• 2 x 165 kW condensing gas boiler with 4 x 1000 L electric backup thermal storage tank.

Heat pump and thermal storage solution

Thermal Energy Solutions designed and constructed the ENERMAX Hybrid System, providing a modular plug-and-play solution that integrates the on-site solar thermal evacuated tube system with a modular heat pump and thermal storage system. The incorporation of smart power manager technology enables efficient management and utilisation of surplus PV and solar thermal storage system.

The primary project goal is to transition from gas to a more sustainable solution for domestic hot water supply at the cellar door, accommodation facilities and winery processing plan usage. The system was retrofitted to the existing DHW connection on the roof, minimising impact and enhancing environmental sustainability.

Design and implementation:

• 2 x 500 L ENERMAX SMARTcube (unpressurised) thermal energy storage/thermal batteries.

• 2 x 19 kW commercial high-temperature ENERMAX Air-to-Water Heat Pump, generating a 75 °C output temperature.

• Integration of the existing 5 kW solar thermal evacuated tube system with ENERMAX solutions.

• Integration of the existing 99.8 kW solar photovoltaic (PV) system with ENERMAX solutions to utilise excess PV generation prior to exporting to grid.

The system is designed to maximise excess PV through ACTHOR9s (3-phase) PWM Power Diverter, combined with a 9 kW element for each thermal storage unit to enable effective load-shifting for demand and response.

Project performance and system benefits:

Energy reduction The winery achieved an exceptional 86.1% reduction in daily energy input, now standing at 30.8 kWh/day compared to the previous 202.6 kWh/day. This translates to a decrease from 81.33 MWh/year 11.23 MWh/year.

CO2 emissions reduction

Annual CO2 emissions have been slashed by 46%, from 19.91 tonnes to 10.78 tonnes. This significant reduction reflects the winery's commitment to environmental sustainability.

Demand management: The implementation of the ENERMAX power management system optimised the use of the 5 kW solar thermal unit, heat pumps, and 99 kW PV system. Excess PV load was efficiently shifted to thermal storage, enabling effective load management.

Financial and environmental benefits:

• Gas consumption decreased nearly 50%, from 26,000 L to less than 14,000 L annually, resulting in substantial cost savings.

• Major financial benefits with maintenance costs reduced 72.9%, from $1,990 to $550/year, and energy costs reduced by 76.6%, from $10,085 to $2,358/year.

• The calculated 4.8-year ROI underscores the project's financial viability

  
  

Innovation in sustainable design:

The project showcased a blend of innovative technologies, including the ENERMAX Heat Pump, power management system and ENERMAX SMARTcube thermal battery. These cutting-edge solutions revolutionised energy storage capacity and efficiency, ensuring a reliable energy supply for critical operations.

The electrification of the hot water system, replacing a 165 kW gas boiler with two 19 kW heat pumps, significantly improved efficiency and enhanced hot water supply throughout the winery. This dedication to innovation sets a precedent for the industry, proving that sustainability and technological advancement go hand in hand.

Conclusion

The transformative project at Kooyong and Port Philip Estate Winery stands as a testament to the power of sustainable technologies and innovation in the wine industry. By integrating cutting-edge solutions, optimizing existing infrastructure, and showcasing exceptional environmental stewardship, the winery has achieved remarkable results in energy efficiency, cost savings, and CO2 emissions reduction.

Client/owner: Kooyong and Port Phillip Estate

Engineering, design and construction: Thermal Energy Solutions (TES)

Supplier: ENERMAX by Energy Smart Water

Grants utilised: Energy Efficient Communities Program Grants from the Australian Government

Award recognition: Energy Efficiency Council - EEC Awards 2024

Kooyong and Port Philip Estate Winery was honored with the prestigious EEC (Energy Efficient Council) Award 2024 for leading energy management project: commercial. The collaborative efforts of Thermal Energy Solutions and Energy Smart Water in decarbonising and electrifying the winery's facilities exemplify excellence in energy efficiency and environmental stewardship.