Building catches some rays

Minnesota's largest solar energy project is expected to be completed this month in the north-metro suburb of Vadnais Heights.

By JEAN HOPFENSPERGER, Star Tribune

Last update: August 22, 2008 - 10:50 PM

A Minnesota first is unfolding this month on the rooftop of a Vadnais Heights social service agency, where 525 solar panels are being installed to take energy conservation to new heights.

When completed this month, the largest solar electric project in the state will sit atop an agency best known for helping adults with disabilities. State officials say it will increase Minnesota's solar capacity by 10 percent.

What's even more unusual is that the rooftop rays will fuel a geothermal energy system hidden below the concrete parking lot of the building, home to Merrick Inc., a nonprofit that is making its energy production -- and its own products -- a Minnesota model of green.

Large-scale solar experiments

"We've married two emerging technologies, geothermal and solar, in a commercial setting,'' said John Wayne Barker, executive director of Merrick Inc. "We've taken an ugly duckling -- this building -- and turned it into a swan. Hopefully we'll inspire others to do the same.''

The 100-kilowatt project reflects the rise of large-scale solar experiments in Minnesota, said Stacy Miller, solar administrator at the Minnesota Office of Energy Security. Of the 250 or so solar installations, the average-sized project is just four kilowatts, she said.

But Quality Bicycle Products in Bloomington installed a 40-kilowatt system, she said, and Great River Energy in Maple Grove has a 72-kilowatt system. And there's a proposal to build a 600-kilowatt system atop the Minneapolis Convention Center.

"These projects are getting bigger and bigger,'' Miller said.

Merrick's project was funded largely by a $735,000 grant from Excel Energy's Renewable Development Fund. Merrick contributed $52,000, which is likely to be saved in energy costs in about four years, said Mike Greenbaum, Merrick's finance director. He hopes Merrick can be a model for Minnesota's large nonprofit network and businesses searching for ways to curb soaring energy costs.

Breaking a state solar record was not on the agenda when Merrick bought a one-story commercial building in 2001. Like many nonprofits and small businesses, it just wanted to save money on fuel costs and help the environment.

Workers gutted the 52,000-square-foot building in this north metro suburb -- tearing out everything from water pipes to wiring -- and then proceeded to convert it into a "thermal envelope'' with energy-efficient insulation and windows throughout the building. They next installed a geothermal energy system.

"Over there, underneath our parking lot, we have 108 wells that are 200 feet deep,'' explained Greenbaum, pointing out the large window next to his desk. "The fluid that runs through them is used to heat and cool this building.''

There are other signs of energy conservation. Clients use skylights above the work spaces to save on electricity. A project to install smart lights, which turn off and on automatically is in the works. And the solar panels sit on a white roof, chosen because it helps cool the building on hot days.

"Don't go up there unless you wear sunglasses,'' Greenbaum said, pulling his shades out of his pocket. "It's blinding."

In one work area, disabled workers recycle more than 1 million pounds of plastic bags each year that are then turned into plastic decking material. The bags are collected at grocery stores around the Twin Cities.

Nearby, several workers pull foam pieces out of the blue caps of Culligan water jugs. Each year Merrick recycles about 1 million caps that are shredded and used for plastic products.

The entire Merrick package impressed Craig Tarr, an engineer and owner of Energy Concepts, a Wisconsin-based firm that installed the panels.

"They took a warehouse and spent their money on energy efficiency instead of doing things that just made it look pretty,'' Tarr said. "Now they have a [solar] system that will produce 130,000 kilowatts a year.''

Jean Hopfensperger • 651-298-1553