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Research Paper

A methodology for model-based greenhouse design: Part 5,


greenhouse design optimisation for southern-Spanish and
Dutch conditions

Bram H.E. Vanthoor a,b,*, Johannes D. Stigter c, Eldert J. van Henten a,b,*,
Cecilia Stanghellini a, Pieter H.B. de Visser a, Silke Hemming a
a
Wageningen UR Greenhouse Horticulture, P.O. Box 644, NL-6700 AP Wageningen, The Netherlands
b
Farm Technology Group, Wageningen University, P.O. Box 317, 6700 AH Wageningen, The Netherlands
c
Biometris, Wageningen University, P.O. Box 100, NL-6700 AC Wageningen, The Netherlands

article info
An optimisation algorithm, as an essential part of a model-based method to design
Article history: greenhouses for a broad range of climatic and economic conditions, was described. This
Received 25 February 2011 algorithm e a modified controlled random search using parallel computing e maximised the
Received in revised form annual Net Financial Return (NFR) for a tomato grower by selecting the best alternative to fulfil
17 December 2011 eight design elements: type of greenhouse structure, material of the cover, outdoor shade
Accepted 13 January 2012 screen, whitewash properties, thermal screen, heating system, cooling system and CO2
Published online 18 February 2012 enrichment system. As an example, the algorithm was applied to two locations with different
climatic and economic conditions, Almeria and The Netherlands. Due to the warm climate
with high radiation levels in Almeria, a greenhouse with a relatively large specific ventilation
area (20% compared to 14% for Dutch conditions), seasonal whitewash and a low-capacity
direct air heater (50 W m2 compared to 200 W m2 for Dutch conditions) was selected. In
contrast, for the relatively cold climate with low radiation levels of the Netherlands, a 100%
aluminium thermal screen and no whitewash would give the best result. The design method
produced realistic greenhouses and related annual NFR, indicating that the method performs
well. An analysis of the close-to-best greenhouses showed that, for both locations, a structure
with high light transmissivity considerably enhanced the greenhouse performance whereas
an outdoor shade screen, geothermal heating and mechanical cooling would be not
economical. These results demonstrate the feasibility of a model-based design approach that
produces suitable greenhouse designs for given climatic and economic conditions.
ª 2012 Published by Elsevier Ltd on behalf of IAgrE.

1. Introduction “solar greenhouses” with thick energy storage walls as found


in China (Sun, Zhang, Wang, Cao, & Gu, 2006) to the high-tech
An enormous variety of protected cultivation systems can be “closed greenhouses” in Western Europe (Heuvelink, Bakker,
found throughout the world. They range from fully passive Marcelis, & Raaphorst, 2008). This variety is due to prevailing

* Corresponding authors. Wageningen UR Greenhouse Horticulture, P.O. Box 644, 6700 AP Wageningen, Netherlands. Tel.: þ31 317 483328;
fax: þ31 317 423110.
E-mail addresses: bvanthoor@hortimax.com (B.H.E. Vanthoor), eldert.vanhenten@wur.nl (E.J. van Henten).
1537-5110/$ e see front matter ª 2012 Published by Elsevier Ltd on behalf of IAgrE.
doi:10.1016/j.biosystemseng.2012.01.005
b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8 351

Nomenclature Can Canopy


CO2 CO2
State variables Constr Construction element
Q V m2 year1 Cool Cooling
CropYield Economic crop yield
Flux densities
Depreciation Depreciation
H Sensible heat flux density, W m2
Drain Drain water
MC Mass CO2-flux density, mg m2 s1
Elec Electricity
MV Mass vapour flux density, kg m2 s1
Ext External CO2 source
P Electricity consumption, W m2
Fixed Fixed costs
Remaining symbols Flr Floor
CO2Air Carbon dioxide concentration of the air, ppm Fog Fogging system
e Greenhouse design element Fuel Fuel
f Air volume flux, m3 m2 s1 Geo Geothermal heat
I Integer greenhouse design vector Glob Global radiation
IGlob The outside global radiation, W m2 Heat Heating
j Number of different greenhouse design elements Ind Industrial source
J Performance measure, V m2 year1 Invest Investments
j
ne Alternatives to fulfil a design element Maintenance Maintenance
NFR Net financial result, V m2 year1 Max Maximum
q Cost price Min Minimum
RHair Relative humidity of the air, % Mech Mechanical cooling
t0 Beginning of production period, s Net Net flux
tf End of production period, s Pad Pad and fan system
TAir Indoor temperature,  C Pipe Pipe heating system
VPD Vapour pressure difference, kPa Pump Pump
ShScr Shade screen
Subscripts
ThScr Thermal screen
Air Greenhouse air
Vent Ventilation
Blow Direct air heater
Var Variable costs
Boil Boiler
Water Water

local conditions, such as climate, economy, social aspects, Alankus‚, 2004), electronics (Abido, 2002) and cold store
availability of resources and legislation. When the current design (Lukasse, Broeze, & Van der Sluis, 2009). However, to
state of greenhouse design is considered, most studies have the best of our knowledge, a methodology to design protected
focused on optimising the design for a specific location, or cultivation systems for the wide variety of conditions that
they considered only a single design parameter. Specifically, exist around the world is not yet available.
Engel (1984) optimised step by step the roof geometry, insu- Therefore, we developed a model-based method that is
lation level and the size of the heat storage of an energy able to design greenhouses for a broad range of climatic and
passive greenhouse for use in the Southern California area, economic conditions (Fig. 1). The key components of the
Amir and Hasegawa (1989) optimised the structural design of method are a greenhouse climate model (Vanthoor,
a greenhouse with respect to mechanical properties and Stanghellini, Van Henten, & De Visser, 2011a), a tomato yield
Kacira, Sase, and Okushima (2004) optimised the vent model (Vanthoor, De Visser, Stanghellini, & Van Henten,
configuration. 2011b), an economic model (Vanthoor et al., 2012) and an
However, for strategic decision making of greenhouse optimisation algorithm which is the topic of this paper. The
configuration for world-wide climate conditions, a systematic optimisation aims to maximise the annual net financial result
approach that integrates physical, biological and economical by modifying the greenhouse design. The design method
models is the most promising way, as suggested by Baille focuses on selecting the best alternative to fulfil the following
(1999). Greenhouse design should then be addressed as eight design elements: (i) the type of greenhouse structure, (ii)
a multi-factorial optimisation problem that relies on a quan- the material of the cover, (iii) the presence and type of outdoor
titative trade-off between the economic return of the crop and shading screen, (iv) the presence of a whitewash and its
the costs associated with construction, maintenance and properties, (v) the presence and type of thermal screen, (vi) the
operation of the greenhouse facility (Van Henten et al., 2006). type of heating system and its capacity, (vii) the type of cooling
The feasibility of optimisation to solve complex design prob- system and its capacity and (viii) the type of CO2 enrichment
lems has already been demonstrated in other application system and its capacity.
domains e.g. aerospace engineering (Anthony & Keane, 2003; The aim of this study is to integrate an optimisation algo-
Begg & Liu, 2000), automobile design (Yildiz, Kaya, Öztürk, & rithm into the model-based design method to select the best
352 b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8

Fig. 1 e An overview of the model-based greenhouse design method. The method focuses on the optimisation of the
following eight design elements: the type of greenhouse structure, the cover type, the outdoor shade screen, the whitewash,
the thermal screen, the heating system, the cooling system and the CO2 enrichment system. The key components of the
method are a greenhouse climate model (Vanthoor., 2011a), a tomato yield model (Vanthoor., 2011b), an economic model
(Vanthoor et al., 2012) and an optimisation algorithm. The optimisation algorithm is described in this study.

set of greenhouse design elements from a large number of 2.1.2. The integer greenhouse design vector
alternatives. To demonstrate the feasibility of this approach, This optimisation focuses on the following eight design
the greenhouse design is optimised for two different loca- elements: (i) the type of greenhouse structure, (ii) the material
tions: Almeria, Spain and De Bilt, The Netherlands. The paper of the cover, (iii) the presence and type of outdoor shading
is organised as follows. First, a description of the optimisation screen, (iv) the presence of whitewash and its properties, (v)
problem is presented. Second, an optimisation algorithm is the presence and type of thermal screen, (vi) the type of
selected and briefly discussed. Third, the assumptions for the heating system and its capacity, (vii) the type of cooling
Spanish and Dutch optimisation studies are presented. system and its capacity and (viii) the type of CO2 enrichment
Fourth, the optimisation results are presented and discussed system and its capacity (Fig. 2). To optimise this set of design
with respect to literature results. elements, an integer greenhouse design vector, as shown in
Fig. 3a, was defined, which consists of eight design elements:

I ¼ fe1 ; e2 ; .; e8 g with 1  ej  nje and j ¼ 1; 2..8 ½   (2)

where each design element is denoted by an integer design


2. Materials and methods j
variable ej that can be fulfilled by ne alternatives as described
in Table 1. For example, the particular realisation of the
2.1. Description of the optimisation problem
integer greenhouse design vector as presented in Fig. 3b is
thus represented as:
2.1.1. Model overview
An overview of the design method is shown in Fig. 1. The I ¼ f2; 1; 1; 2; 5; 3; 4; 1g ½ (3)
greenhouse climate model is described by Vanthoor et al. From Fig. 3 and Table 1 it can be inferred that this integer
(2011a), the crop yield model is described by Vanthoor et al. vector presents a multi-tunnel structure type 2 covered with
(2011b), and the economic model is described by Vanthoor a PE film and equipped with: no outdoor shade screen,
et al. (2012). Therefore only a concise description of these seasonal whitewash with a transmission of 75%, 100%
models is presented here. aluminium thermal screen, a direct air heater with a capacity
The various models consist of a set of differential of 1.0 MW (equivalent to 100 W m2), a fogging system with
equations: a capacity of 600 g m2 h1 and no CO2 enrichment.

X_ ¼ f ðX; U; D; P; tÞ ½ (1)


2.1.3. Performance measure
where X is the state vector containing the indoor climate The performance measure to be maximised is the expected
variables, the crop variables and the resource consumption annual net financial result (NFR) of the grower, described by:
variables, X_ denotes the derivative of the state vector with
respect to time, U is the climate control vector containing the Zt¼tf
   
climate control valve settings, D is the outdoor climate vector, max J tf ¼ QFixed þ Q_ CropYield  Q_ Var dt V m2 year1 (4)
I
P is the model parameter vector and t (s) is time. t¼t0
b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8 353

Structure Outdoor shade screen


Cover Light Whitewash
Indoor thermal screen

CO2Air Vspeed
Direct air heaterr Natural Electricity
ssil fuell
Fossil Tout,
ventilation
VPout
Electricity
Fossil
ssil fuel TAir VPAir TAir
Water
Tout
Boiler VPout
Pad and fan cooling
Geothermal
Electricity
ectricity
Electricity
Mechanical cooling
Electricity
Fogging
Water

Pure CO2
Pad and fan cooling
Fogging Heat supply
Heat removal
CO2-supply
Vapour supply
Industrial CO2 Natural ventilation Vapour removal
Mechanical cooling

Fig. 2 e Functions (coloured boxes) and design elements (text blocks and pictures below the accompanying functions) used
to manage the greenhouse climate (transparent boxes inside the greenhouse). The coloured arrows represent the various
energy and mass fluxes (legend at the bottom right). The selection of alternatives to fulfil the following eight design
elements: the type of greenhouse structure, the cover type, the outdoor shade screen, the whitewash, the thermal screen,
the heating system, the cooling system and the CO2 enrichment system is optimised in this study.

1: No
1: PE film 1: No 2 - 5: Direct air heater 1: No
2: Double PE film 2: 75% transmission 6 - 9: Boiler heating 2 - 5: Pure CO2 supply
a 3: Glass 3: 50% transmission 10: Geothermal heat 6 - 8: Industrial CO2

nej = 8 3 3 3 Indoor 5 10 12 8
Outdoor Heating Cooling CO2 supply
Structure Cover Whitewash thermal
shade screen systems systems systems
screen

1 - 4: Multi-tunnel 1: No 1: No 1: No
5 - 8: Light structure 2: 46% transmission 2: 100% PE 2 - 4: Fogging
3: 25% transmission 3: 50% PE, 50% Alu 5 - 8: Pad and fan
4: 25% PE, 75% Alu 9-12: Mechanical cooling
5: 100% Alu

b
nej = 8 3 3 3 5 10 12 8
2 1 1 2 5 3 4 1

Fig. 3 e An overview of the integer greenhouse design vector (a) with an example (b). Fig. 3a an overview of the integer
greenhouse design vector. Each coloured box represents a design element that could be executed by several alternatives as
presented in the light-blue boxes. The number of alternatives to fulfil a design element nje, is presented in the upper right
corner of the coloured boxes. Fig. 3b an example of an integer greenhouse vector which can be interpreted using Table 1 and
represents: a multi-tunnel structure type 2 covered with a PE film and equipped with: no outdoor shade screen, a seasonable
whitewash with a transmission of 75%, a 100% aluminium thermal screen, a direct air heater with a capacity of 1.0 MW,
a fogging system with a capacity of 600 g mL2 hL1 and no CO2 enrichment. Detailed information about the specific
properties and/or capacities of the design elements is presented in Table 1.
354 b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8

Table 1 e The economic parameters needed to determine the annual costs of the maintenance and depreciation for all
design elements as described by Vanthoor et al. (2012): the investments qInvest,i, the depreciation hDepreciation,i, and the
maintenance hMaintenance,i.
Design element ej qInvest,i qInvest,i hDepreciation,i hMaintenance,i QConstr,i
V m2 kV % year1 % year1 V m2 year1

Structure (j ¼ 1)
Multi-tunnel 1 ha, 0% Vent 1 15.00 7.0 2 1.35
Multi-tunnel 1 ha, 29% Vent 2 18.00 7.0 2 1.62
Multi-tunnel 1 ha, 45% Vent 3 21.30 7.0 2 1.92
Multi-tunnel 1 ha, 77% Vent 4 30.14 7.0 2 2.71
Venlo 1 ha, 0% Vent 5 29.00 7.0 0.5 2.18
Venlo 1 ha, 14% Vent 6 32.00 7.0 0.5 2.40
Venlo 1 ha, 20% Vent 7 33.25 7.0 0.5 2.49
Venlo 1 ha, 38% Vent 8 47.50 7.0 0.5 3.56

Covers (j ¼ 2)

PE film, Spain 1 1.38 33.3 5 0.53


PE film, Netherlands 1 4.00 12.5 5 0.70
Double PE film, Spain 2 2.38 33.3 5 0.91
Double PE film, Netherlands 2 5.00 12.5 5 0.88
Glass 3 5.00 7.0 0.5 0.38

Outdoor shade screen (j ¼ 3)

No 1 0.00 0.0 0 0.00


OLS 50 Abri, 46% transmission 2 3.81 20.0 5 0.95
OLS 70 Abri, 25% transmission 3 3.97 20.0 5 0.99
Structure shade screen 13.30 10.0 5 2.00

Whitewash (j ¼ 4)

No 1 0.00 0.0 0 0.00


Whitewash 75% transmission Spain 2 0.07 100.0 0 0.07
Whitewash 75% transmission Neth 2 0.80 100.0 0 0.80
Whitewash 50% transmission Spain 3 0.09 100.0 0 0.09
Whitewash 50% transmission Neth 3 0.82 100.0 0 0.82

Indoor thermal screen (j ¼ 5)

No 1 0.00 0.0 0 0.00


100% PE 2 1.50 20.0 5 0.38
50% Aluminium/50% PE 3 4.06 20.0 5 1.02
75% Aluminium/25% PE 4 4.24 20.0 5 1.06
100% Aluminium 5 5.58 20.0 5 1.40
Structure thermal screen 2.97 10.0 5 0.45

Heating systems (j ¼ 6)

No 1 0 0.0 0 0.00
Direct air heater: 0.5 MW 2 16.73 15.0 2.5 0.29
Direct air heater: 1 MW 3 29.23 15.0 2.5 0.51
Direct air heater: 1.5 MW 4 44.85 15.0 2.5 0.78
Direct air heater: 2 MW 5 57.35 15.0 2.5 1.00
Boiler: 1.16 MW 6 60.00 7.0 1 0.48
Boiler: 1.74 MW 7 66.00 7.0 1 0.53
Boiler: 2.32 MW 8 80.40 7.0 1 0.64
Boiler: 3.48 MW 9 92.40 7.0 1 0.74
Geothermal 7 MW 10 6000 4.0 5 54.00
Heating pipes, 1 pipe per m 5.45 7.0 0.5 0.41

Cooling systems (j ¼ 7)

No 1 0.00
Fogging: 200 g h1 m2 2 5.50 10.0 5 0.83
Fogging: 400 g h1 m2 3 7.00 10.0 5 1.05
Fogging: 600 g h1 m2 4 10.00 10.0 5 1.50
Pad and fan: 50 m3 h1 m2 5 3.54 10.0 5 0.53
Pad and fan: 100 m3 h1 m2 6 5.07 10.0 5 0.76
Pad and fan: 150 m3 h1 m2 7 6.60 10.0 5 0.99
Pad and fan: 200 m3 h1 m2 8 8.14 10.0 5 1.22
Mechanical cool: 0.5 MWe unit1 9 240 7.0 2 2.16
b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8 355

Table 1 e (continued )
Design element ej qInvest,i qInvest,i hDepreciation,i hMaintenance,i QConstr,i
V m2 kV % year1 % year1 V m2 year1

Mechanical cool: 1 MWe unit1 10 480 7.0 2 4.32


Mechanical cool: 1.5 MWe unit1 11 720 7.0 2 6.48
Mechanical cool: 2 MWe unit1 12 960 7.0 2 8.64

CO2 supply (j ¼ 8)

No 1 0 0.0 0 0.00
Pure supply: 50 kg ha1 h1 2 3.12 10.0 0 0.03
Pure supply: 100 kg ha1 h1 3 3.12 10.0 0 0.03
Pure supply: 150 kg ha1 h1 4 4.32 10.0 0 0.04
Pure supply: 200 kg ha1 h1 5 4.32 10.0 0 0.04
Industrial CO2: 100 kg ha1 h1 6 20 6.7 2 0.17
Industrial CO2: 150 kg ha1 h1 7 21 6.7 2 0.18
Industrial CO2: 200 kg ha1 h1 8 22 6.7 2 0.19
CO2 distribution system 0.34 10.0 5 0.05

Remaining costs for irrigation, crop protection, internal transport, sorting and packaging etc.

Spain 11.13 10.0 5 1.67


The Netherlands 38.73 10.0 5 5.81

where J (V m2 year1) is the annual net financial result of the greenhouse air, qElec is the electricity price (V kWh1), PPad, PFog,
grower, t0 (s) and tf (s) are the beginning and the end of the PGeo and PMech, are the electricity consumption of the pad and
production period respectively, QFixed (V m2 year1) are the fan system, the fogging system, the pump of the geothermal
fixed costs related to the tangible assets, QCropYield source and the mechanical cooling system respectively.
(V m2 year1) is the economic value of crop yield, QVar Calculation of electricity consumption rates is presented in
(V m2 year1) are the costs related to the crop (i.e. plant Appendix A.
material, fertilisers, crop protection and other crop assets),
resource use (in this study defined as water, CO2, fossil fuel 2.1.4. Impact of extreme humidity levels on tomato quality
and electricity) and labour. A more detailed description of the parameters
individual cost elements can be found in Vanthoor et al. As presented by Vanthoor et al. (2012), the economic crop yield
(2012). Labour costs consisted of fixed cost related to crop is described as a function of crop yield mass and two quality
maintenance plus a fraction that was linearly related to crop parameters i.e. the fraction of first class tomatoes and the
yield. The cost of the use of individual resources was calcu- marketable fraction. A description of the impact of indoor
lated with: climate on these quality parameters was not integrated in the
 h   design method. Therefore, as a first approach, two quality
Q_ Water ¼ 103 qWater 1 þ Drain MVCanAir þ MVFogAir þ MVPadAirNet filters were developed to describe the impact of humidity on
  100
V m2 s1 (5) the marketable fraction and fraction of first class tomatoes.
These quality filters were based on real climate data and
    quality parameters as described in Appendix B.
Q_ CO2 ¼ 106 qCO2 Ext MCExtAir þ qCO2 Ind MCIndAir V m2 s1 (6)

qFuel     2.2. The controlled random search optimisation


Q_ Fuel ¼ HBoilPipe þ HBlowAir V m2 s1 (7)
hFuel algorithm

qElec    
Q_ Elec ¼ PPad þ PFog þ PGeo þ PMech V m2 s1 (8) 2.2.1. Description and implementation of the algorithm
3:6$106
The controlled random search (CRS) method of Price (1977)
where qWater (V m3) is the water price, hDrain (%) is a fraction of was used to solve the optimisation problem. Such a deriva-
crop transpiration needed to ensure sufficient irrigation, tive-free global optimisation method was required because
MVCanAir (kg m2 s1) is the transpiration rate of the crop, the performance measure will have many local maxima and
MVFogAir (kg m2 s1) is the fogging rate, MVPadAirNet (kg m2 s1) its gradient is not continuous. In addition, the CRS allows
is the water added to the inlet air of the pad and fan system, efficient parallel computing, it is easy to implement, it is
qCO2_Ext (V kg1) is the price of pure CO2, MCExtAir (mg m2 s1) is a robust optimisation method and there is no need to fine-
the CO2 enrichment rate of pure CO2, qCO2_Ind (V kg1) is the tune many algorithm parameters. Because of the time
price of industrial CO2, MCIndAir (mg m2 s1) is the CO2 needed to solve the optimisation problem (Table 2), a solution
enrichment rate of industrial CO2, qFuel (V m3) is the fuel based on parallel computing is needed to achieve manageable
price, hFuel (J m3) is the energy efficiency of the fuel, HBoilPipe CPU times. Furthermore, due to its population-based nature,
(W m2) is the heat supply to the heating pipes, HBlowAir the output of the CRS method produces valuable information
(W m2) is the heat supply from the indirect air heater to the about the close-to-best designs.
356 b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8

Steps 5 to 8 determine the performance measure value for


Table 2 e The number of design alternatives, time needed
to evaluate all design alternatives and the time needed each individual in the population A.
for design optimisation using parallel optimisation.
5. Update the variable counter: Counter ¼ Counter þ 1
Location Number Years needed Days needed
of design to evaluate all for parallel 6. If Counter  N, proceed with step 7. If Counter > N, go to
alternatives design optimisationb step 8.
alternatives 7. Obtain the design vector I, located at row number Counter of
by one computera matrix A. Determine JI, the value of the performance measure
Spain 5.40  105 26 2 of I and store JI in the common matrix A at row number
Netherlands 8.64  105 41 3 Counter and column number n þ 1. Proceed with step 5.

a a single simulation time of 25 min was assumed.


These steps are performed to improve the population A.
b parallel optimisation with 50 computers and an optimisation
algorithm that evaluates at most 1% of all design alternatives to
come up with a solution. For the Spanish case fewer designs were 8. Choose randomly n þ 1 distinct sets of the design vectors
evaluated because the CO2 supply from industry was not optimised. R1, R2,. Rnþ1 from the population A. Determine the
centroid G of the points R1,.,Rn. Then determine the next
design vector I such that I ¼ 2G  Rnþ1 . Where I; G; Rnþ1
The original CRS method of Price (1977) iteratively
represent the position vectors in the n-space.
improves a candidate population A of best guesses for
9. Round I to the nearest allowed integer values so that the
a number of continuous design parameters. This population
quantified Iq is obtained. Keep the original I in the floating-
consists of N continuous design vectors constituting each of n
point parameter domain.
continuous design variables and the accompanying perfor-
10. Is Iq consistent with the constraints? If not go to step 8; if
mance measure values. After each iteration, a new design
so, proceed with step 11.
vector I, is created based on A and the performance measure JI
11. Update the variable counter: Counter ¼ Counter þ 1
is evaluated. If JI is higher than the lowest performance
12. Does Iq exist in the quantified population matrix Aq or in
measure value in A, the design vector associated to the lowest
the memory stack B? If not, proceed with step 13; if so,
performance measure is replaced by I and the lowest perfor-
obtain JIq from A or B and go to step 14.
mance measure value is replaced by JI.
13. Evaluate the performance measure to determine JIq , the
The original CRS was developed for continuous optimisa-
value of the performance measure at Iq.
tion problems whereas the greenhouse design optimisation is
14. Determine from A the design vector, L, which has the
approached as an integer-based problem. However, according
lowest performance measure value JL.
to Lampinen and Zelinka (1999), population-based methods
15. If JIq  JL , proceed with step 16. If JIq > JL , go to step 17.
developed for continuous problems could solve discrete opti-
16. Store Iq and JIq in the B matrix. Is Counter  CounterMax? If so,
misation problems provided that the discrete parameters are
maximum number of iterations reached and exit optimi-
represented as floating-point values even when the problem is
sation algorithm. If not, go to step 8.
inherently discrete. The performance measure is thus evalu-
17. Replace in A, the design vector L by I and the performance
ated once the floating-point parameter values are rounded to,
measure JL by JIq . Thus I and not Iq is stored in A as rec-
but not overwritten by, their nearest allowable discrete values
ommended by Lampinen and Zelinka (1999) and Price
(Price, Lampinen, & Storn, 2005). The original CRS algorithm
et al. (2005). Store the quantified design vector Lq and its
was thus modified to ensure that the integer design problem
performance measure JL in B.
was efficiently solved. In addition, to speed up the optimisa-
18. Is Counter  CounterMax? If so, maximum number of itera-
tion process, a new design vector could only be evaluated once
tions reached. If not, go to step 8.
by the model. Specifically, only design vectors which are not
stored in population A, nor in the memory stack B will be
This modified CRS algorithm was implemented in a parallel
evaluated. A detailed description of the modified CRS algo-
processing program that used 50 personal computers (each
rithm is presented as software steps below:
equipped with a 3000 MHz Intel core 2 DUO processor with 2 GB
Steps 1 to 4 are performed to initialise the optimisation internal memory). These computers could simultaneously:
parameters. read N and CounterMax; read and write the matrices A, B and the
Counter variable. Each computer evaluated a particular
1. Define N, the number of design vectors. Price (1983) performance measure by solving the differential equations of
proposed N as a function of the total number of n ¼ 8 the model with a variable time step ODE solver as included in
design variables: N ¼ 25n. Matlab 7.1. After each evaluation, the common variables and
2. Choose randomly N sets of n design variables over the matrices were modified, a new greenhouse design was deter-
search domain V and store the design vectors in the first n mined as described by the modified CRS algorithm and this
columns of the N  (n þ 1) population matrix A. design was evaluated. All greenhouse design evaluations in
3. Initialise Counter ¼ 0 and the memory stack B as an empty the parallel computation process were synchronised in time so
1  (n þ 1) vector. The memory stack B is used to store the as to guarantee an objective search. The number of integer
evaluated design vectors and accompanying performance design vectors in the population matrix A was set to N ¼ 250
measures. which was larger than Price’s (1983) proposition of
4. Initialise the maximum number of iterations CounterMax. N ¼ 25  8 ¼ 200 so as to increase the probability that a global
b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8 357

maximum was found. Based on the consistent convergence of crop conditions, outdoor climate, climate management and
the performance measure during optimisation, the maximum economic parameters.
number of iterations CounterMax was set to 7500.
2.3.1. Greenhouse design description
2.2.2. Analysis of the results of an optimisation run A long tomato growing period was used for both locations: in
As the CRS method is a population-based optimisation method, Almeria from August 1st to July 1st and in De Bilt from
the exit-population offers interesting additional insights. The December 15th to December 1st. For both locations the stan-
population of greenhouse designs can be evaluated using dard climate year was used as described in Section 2.3.2 and
distribution curves and sensitivity analysis techniques. the crop conditions are described in Table 3. Both greenhouses
The distribution curves show, for the set of close-to-best were assumed to have a rectangular shape of 200  50 m
greenhouse designs, the frequency of all alternatives to fulfil resulting in a floor area of 1ha.
each design element. In this study, the set of close-to-best An overview of the set of eight greenhouse design elements
greenhouse designs consisted of greenhouses for which the to be optimised and their accompanying economic parame-
NFR differed less than X V m2 year1 compared to the NFR ters are presented in Table 1. For both locations, the same
of the best greenhouse (in this paper denoted with possible design alternatives were considered with the excep-
ΔNFR < X V m2 year1). The frequency of each alternative was tion that CO2 enrichment from an industrial source was not
expressed as a % of the resulting population size. In this study considered possible in Spain.
the distribution curves of the design elements were deter- The two possible greenhouse structures were an arch sha-
mined for two sets of best greenhouses, i.e. ΔNFR ped multi-tunnel and a Venlo-type structure. As we did not
< 0.25 V m2 year1 and ΔNFR < 1.50 V m2 year1. have information on the transmissivity of the structure alone,
The sensitivity analysis shows the impact of all alternatives we derived it from existing data of overall transmissivity: 72%
to fulfil each design element. The sensitivity was defined as for a Venlo-type glasshouse fitted with a thermal screen (De
follows. For each alternative, a sub-population was created that Zwart, personal communication) and 52% for a multi-tunnel
existed of only designs equipped with this specific alternative. covered with PE film, and fitted with both an external
Subsequently, the mean of the NFR of this sub-population shadow screen and an indoor thermal screen (Magán, López,
was determined and shown in the sensitivity analysis. When Pérez-Parra, & López, 2008). Knowing the specific trans-
evaluating the impact of one alternative, the other alternatives missivity of the cover materials (82% glass and 81% PE); the
to fulfil the remaining seven design elements were thus allowed light absorption of a thermal screen and overhead fittings (7%
to vary. This single-variate analysis was used to reduce in a Venlo house and 5% in a multi-tunnel) and outdoor shade
complexity when analysing the optimisation results. screen (5%) we calculated the transmissivity of the structure as
the unknown. Somewhat surprisingly, the result was 71% light
transmissivity for a multi-tunnel geometry and 95% for a Venlo
2.3. Two cases: Almeria, Spain and De Bilt, the structure. The latter figure is confirmed by calculations by
Netherlands Janssen, Oversloot, Van der Wiel, and Zonneveldt (2006), who
demonstrated the higher light transmissivity of the Venlo
To demonstrate how the optimised design depends on local geometry, although our figure for the multi-tunnel is lower
climate and economic conditions, two locations were than they expected. It is possible that there was a significant
selected: Almeria, Spain and De Bilt, the Netherlands. In this amount of dust on the multi-tunnels whose data we have
section, the assumptions underlying the optimisation study used. However, it is a fact that Dutch Venlo-houses are cleaned
are presented. This includes the greenhouse design elements, much more frequently than Spanish multi-tunnels, thanks to
the existence of dedicated cleaning machines. Both structures
could be coupled to four possible specific ventilation areas. The
multi-tunnel had side ventilation in the 2 long sides and
Table 3 e Overview of the crop conditions and the applied continuous roof ventilation in one side of each span. The
whitewash strategy used for the greenhouse design
Venlo-type structure had only roof ventilation.
optimisation.
The possible greenhouse cover materials were: a single PE
Crop conditions Almeria, Spain De Bilt, the
film, a double PE film and a single glass cover, the latter was not
Netherlands
an option for the multi-tunnel, obviously. For the movable
LAI_start 0.3 0.3 outdoor shade screen and for the whitewash, several alterna-
LAI_max 2.5 2.5 tives with different light transmission could be selected. For
Start growing August 1st December 15th
the movable indoor thermal screen there were several alter-
period, t0
natives with different ratios of aluminium and PE (influencing
End growing July 1th December 1st
period, tf the far infrared radiation fluxes). For the heating system,
Whitewash August 1st e June 1st e a number of capacities, including zero, of a direct air heater,
September 15th August 15th a boiler and geothermal heat could be selected. A direct air
(full whitewash) (50% whitewash) heater supplies heat, CO2 and the water vapour directly to the
March 1st e April 15th greenhouse air, whereas a boiler and a geothermal source both
(50% whitewash)
supply heat to the heating pipes, which, in turn, heat up the
April 16th e June 30th
(full whitewash)
greenhouse air by convective and radiative heat exchange. The
boiler system had lower investment costs and higher variable
358 b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8

costs compared to the geothermal source. The CO2 produced by economic conditions. However, the period for which
the boiler is also supplied to the greenhouse air. The source to a seasonal whitewash could be applied was longer in Spain
supply CO2 to the greenhouse could be selected between pure than in the Netherlands as presented in Table 3. The strategy
CO2 from a tank and industrial waste CO2, all with a number of for controlling the air temperature is presented in Fig. 5. The
capacities, although waste CO2 was not an option in Spain. At set point for CO2 enrichment, CO2Air_ExtOn, increased with
equal capacity, pure CO2 supply had lower investment costs increasing outside global radiation and decreased with
and higher variable costs than industrial CO2. The possible increasing ventilation rate, which was based on Magán et al.
cooling systems were: high-pressure fogging, pad and fan, and (2008) as described in Appendix D. The outdoor shade screen
mechanical cooling, all possible with a number of capacities. was used when the outdoor global radiation was higher than
A commonly encountered growing system was selected for Iglob_ShScr_on which was 650 W m2.
each location. In Almeria, plants were assumed to grow in soil
whereas, in the Netherlands, plants were grown in substrate 2.3.4. Economic conditions
above a white foil. Therefore, the reflection coefficient for The performance measure was calculated using the equations
visible light of the floor layer was higher in The Netherlands presented in Section 2.1.3 and described by Vanthoor et al.
than in Spain. A closed irrigation system with disinfection (2012). The economic parameters needed to determine the
unit was used in the Netherlands which resulted in a lower annual fixed costs related to the tangible assets are presented
fraction, compared to Spain, of crop transpiration needed to in Table 1. Similar costs for the tangible assets were used for
ensure sufficient irrigation. the two locations, except for the films and the whitewash, for
which the investment costs were higher in The Netherlands
2.3.2. Local climate than in Spain. Since different growing systems were used,
Variations between different outdoor climate years have each location had different remaining costs. The economic
a significant impact on the NFR as demonstrated by Vanthoor parameters to determine the variable costs are presented in
et al. (2012). Therefore, a standard climate year representing Table 4. For Almeria, the weekly tomato price of the first and
long term climate data was created using the algorithm based second class long life tomatoes (Cajamar, 2009) were averaged
on Breuer and Van de Braak (1989) as presented in Appendix C. over four successive production periods between 2006 and
This algorithm selects from the long term series climate data, 2010. For Dutch conditions, the 4 week period price of the first
each single month with the closest match to the mean and second class truss tomatoes of (Vermeulen, 2010) were
monthly values of temperature and global radiation sums. averaged over four successive years i.e. 2006e2009.
Spanish climate data of the period 2004e2009 and Dutch
climate data of the period 1989e2009 were used to determine
such standard climate years. Fig. 4 presents the monthly
3. Results and discussion
mean values of the daily global radiation as a function of the
monthly mean outdoor temperature for Almeria and for De
For each location, the evolution of the two design populations
Bilt.
A are presented in Section 3.1. Then, in Section 3.2 the best
designs are discussed and relevant economic aspects are
2.3.3. Greenhouse climate management
described. The close-to-best designs are analysed in Section
The climate control valve settings are determined as a func-
3.3 using distribution curves and sensitivity analysis. In
tion of the climate control strategy and the applied climate
Section 3.4 the performance of the model-based design
set-points. For both locations the same greenhouse climate
method is discussed.
set-points were used to ensure that differences between
optimisation results were only caused by climatic and
3.1. Evaluation of the performance measure during
optimisation
Daily global radiation (MJ m day )
-1

30
For both locations, the CRS algorithm was able to solve the
-2

25
multi-factorial greenhouse design optimisation problem.
20 Specifically, with increasing iteration number, the perfor-
mance (NFR) of the design population A increased (Fig. 6). Two
15
different start design populations yielded the same maximum
10 NFR with similar end design populations and each time the
mean NFR of the design population converged to the same
5 maximum NFR. Therefore we can claim with some confidence
that a global maximum NFR was found.
0 The highest NFR was reached after 3000 iterations for the
0 10 20 30
Temperature (°C) Spanish case, whereas the Dutch one required some 5000
since there were more design alternatives, as presented in
Fig. 4 e The monthly mean values of the daily global Table 2. These numbers indicate that the evaluation of less
radiation as a function of the monthly mean outdoor than 1% of all design alternatives was sufficient to come up
temperature for Almeria (solid line with circles) and for De with the greenhouse with the highest performance in both
Bilt (dashed line with triangles). cases. The optimisation was stopped after 7500 iterations
b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8 359

Fig. 5 e The greenhouse temperature control strategy based upon climate set-points. Values of the climate set-points were
similar for both locations namely: Tout_ThScr_on [ 14 C, Tair_heat_on [ 17 C at night and 19  C at day time, RHair_vent_off [ 85%,
Tair_vent_on [ 24  C, Tair_cool_on [ 26  C and CO2air_vent_off [ 200 ppm.

because it was expected that, due to the flat trajectory of the The technology level selected for the best greenhouse for
NFR, the design could not be improved much further. Almeria resembles in some aspects the technology level of
current greenhouses in Almeria. Whitewash and no other
means for cooling was selected. This is indeed current local
3.2. Evaluation of the best greenhouse design for both practice and agrees with an economic analysis by Gázquez
conditions et al. (2008) who demonstrated that whitewash in combina-
tion with sufficient ventilation area was the most cost-
3.2.1. The best design as a function of local conditions efficient cooling treatment for sweet peppers under
Table 5 shows that the best greenhouses were adapted to southern-Spanish conditions. Similarly, an outdoor shade
Spanish and Dutch climate conditions as presented in Fig. 4. screen, an indoor screen and CO2 supply (all rarely applied in
For the relatively warm climate with high radiation levels in horticultural practice in Spain) were not selected. However,
Almeria, a greenhouse with a relatively large ventilation area differences from current Spanish practice were also found.
(20% compared to 14% for Dutch conditions), with seasonal Our results suggest that the performance of Spanish protected
whitewash to reduce the indoor temperature and fitted with cultivation systems might be improved by; (i) increasing the
direct air heating of small capacity (0.5 MW compared to overall light transmissivity of the greenhouse, (ii) increasing
2.0 MW for Dutch conditions) was selected. In contrast, the mean ventilation area from 13% to 20%; and (iii) by
whitewash was not selected in view of the low radiation levels installing a low-investment heating system with a limited
in the Netherlands, and a thermal screen was selected to capacity. The use of a higher light transmission (Soriano et al.,
increase the heating efficiency for the relatively cold climate. 2004) and higher specific ventilation area (Pérez-Parra, Baeza,
For both conditions, a structure of high light transmissivity Montero, & Bailey, 2004) to increase crop yield has already
was selected to benefit as much as possible from outdoor been demonstrated. Therefore, the Venlo-type structure was
radiation. CO2 application was worthwhile only for Dutch selected since it increased the overall light transmissivity
conditions, thanks to the lower ventilation requirement (and significantly compared to the arch shaped multi-tunnel.
thus a higher CO2 supply set-point, Appendix D) and the larger Admittedly, possible accumulation of dust has been ascribed
difference between the average tomato price and the variable to the arch shaped structure. However, glass (rather than the
CO2 price in the Netherlands. Specifically, this difference was much more widely applied single PE film) was selected as
in the Netherlands 0.73e0.06 ¼ 0.67 V kg1 and in Spain cover material, more for its lower annual costs
0.56e0.20 ¼ 0.36 V kg1. (0.38 V m2 year1 compared to 0.53 V m2 year1) than the
For Spanish conditions the annual NFR was slightly higher light transmission (81% PE film and 82% of
0.11 V m2 year1 and for Dutch conditions the annual NFR a glass cover).
was 9.41 V m2 year1. The latter agreed reasonably well This result indicates that a greenhouse with more
with Vermeulen (2008) who determined an annual NFR of advanced technology might be feasible provided that enough
11.06 V m2 year1 for a similar greenhouse. These negative funds are available for the required additional investment.
values indicate that growers, under the economic conditions Specifically, the investment cost of the selected design is
considered, could not make a living at either location. For 52.44 V m2 which is much higher than the 21.54 V m2
Spain, some assumptions related to the depreciation, main- required for a common parral greenhouse. This large differ-
tenance and the short-term borrowing costs might have ence in investment cost was probably caused by our choice
resulted in negative NFR values. For the Netherlands, it is not to constrain the investment potential.
known that only growers with a co-generator to sell electricity For Dutch conditions the optimised greenhouse design was
(not considered in this study) have earned money because of quite similar to the common greenhouses, with exception of
the relatively low tomato prices of recent years. However, the heating system. The design method suggests that a direct
these negative values will not have affected the optimisation air heater would give a higher NFR, whereas a boiler with pipe
outcome, since in this study the annual NFR was maximised. heating system is used in practice. Simulations revealed that
360 b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8

Table 4 e An overview of the costs-related variables used in this study.


Parameter explanation Parameter Unit Almeria Source De Bilt Source
1 6 6
The average conversion factor from hDMFM kg mg 15.95 10 Based on 18.18 10 Based on practice
tomato dry matter to fresh matter Magán et al. (2008)
A fraction of crop transpiration needs hDrain % 30 Based on practice 0 Closed system
to assure sufficient irrigation
Marketable fraction of harvest hFMsold e e Depends on e Depends on
indoor climate indoor climate
Energy content of gas hFuel J m3 31.65 106 Known 31.65 106 Known
Interest rate hInterest % 3.5 Cajamar 5 Vermeulen (2008)
The cost of short-term borrowing hInterest_Short % 1 Cajamar 1 Vermeulen (2008)
The labour cost coefficient that hLabour_kg h kg1 FM 0.010 Based on Peréz, 0.0043 Vermeulen (2008)
describes impact of the production de Pablo Valenciano,
level on labour cost and Escudero (2003)
The labour cost coefficient that hLabour_m2 h m2 0.270 Based on 0.825 Vermeulen (2008)
describes the impact of plant- Peréz et al. (2003)
related labour (no harvest) on
variable labour cost
The annual maintenance cost hMaintenance,i % year1 e See Table 1 e See Table 1
coefficient of design element i
The annual depreciation coefficient hDepreciation % year1 e See Table 1 e See Table 1
of design element i
The material costs for packaging hPackage V kg1 0 Included in 0.009 Vermeulen (2008)
sales cost
The unaccounted fraction of hRem % 2.5 Assumed 2.5 Vermeulen (2008)
greenhouse construction costs
The sales cost coefficient for sorting hSales % 9 Cajamar 2.75 Vermeulen (2008)
and selling the tomatoes
The fraction of first class tomatoes in hTom1 % e Depends on e Depends on
marketable yield indoor climate indoor climate
The transport cost per kg tomatoes hTransport V kg1 0.02 Cajamar 0 Included in
sales costs
Greenhouse floor area AFlr m2 10000 Assumed 10000 Assumed
Pure CO2 costs qCO2_Ext V kg1 0.20 Cajamar 0.10 Vermeulen (2008)
Industrial CO2 costs qCO2_Ind V kg1 Not available Not available 0.06 OCAP
Electricity costs qElec V kWh1 0.13 Cajamar 0.07 Vermeulen (2008)
Gas costs qFuel V m3 0.38 Cajamar 0.25 Vermeulen (2008)
Initial investment of design element i qInvest,i V e See Table 1 e See Table 1
The labour costs qLabour V h1 5.4 Cajamar 16.0 Vermeulen (2008)
The price of first class tomatoes qTom1 V kg1 e Cajamar e Vermeulen (2008)
which is time dependent
The price of second class tomatoes qTom2 V kg1 e Cajamar e Vermeulen (2008)
which is time dependent
Water costs qWater V m3 0.25 Cajamar 0 Rain water is used
Plant material V plant1 0.45 Cajamar 0.65 Vermeulen (2008)
Plant density m2 2.5 Based on practice 2.5 Based on practice
Fertiliser V m2 0.6 Cajamar 0.9 Vermeulen (2008)
Crop protection V m2 0.35 Cajamar 1 Vermeulen (2008)
Waste treatment V m2 0.36 Cajamar 0.75 Vermeulen (2008)
Remaining materials V m2 0.3 Cajamar 1.15 Vermeulen (2008)
Substrate V m2 0 Not used 1.3 Vermeulen (2008)

a direct air heater had higher heat efficiency than a boiler-pipe boiler capacity and higher CO2 efficiency of exhaust gasses. In
heating system. The lower heat efficiency of the boiler-pipe addition, the direct air heater might exhaust flue gasses and
heating system was caused by higher heat losses from the increase spatial climate differences which both might nega-
cover to outside (due to the far infrared radiation (FIR) from tively affect crop growth. Since these processes were not
pipes to cover) and because of the higher ventilation demand described by the model, the results of the design optimisation
due to higher humidity levels caused by a higher transpiration are not surprising.
rate (due to the FIR from pipes to canopy resulting in a higher
canopy temperature). 3.2.2. Relevant cost aspects that determine the NFR
However, in reality, the boiler-pipe heating system has Both locations had the same four main cost aspects i.e. fixed
several advantages: the pipes can be used as internal trans- costs, and labour, energy and plant-related costs (Table 6). The
portation system; the heat can be buffered enabling a smaller contribution of water, electricity and CO2 to the total costs was
b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8 361

a b
Net Financial Result (€ m )

Net Financial Result (€ m )


0 -10
-2

-2
-2 -12

-4 -14

-6 -16

-8 -18

-10 -20
0 2000 4000 6000 8000 0 2000 4000 6000 8000
Iteration number Iteration number

Fig. 6 e The evolution of the net financial result of the design population ‘A’ in Almeria (a) and in the Netherlands (b). For
both figures, the solid line represents the maximum NFR of the first optimisation run, the dotted line represents the
maximum NFR of the second optimisation run, the dashed line represents the mean NFR of the first optimisation run and
the dashed-dotted line represents the mean NFR of the second optimisation run.

small. Although the greenhouse climate model and tomato particular: the crop yield (56.5 kg m2 and 57.5 kg m2,
yield model were both successful (Vanthoor et al., 2011a; measured and simulated, respectively), labour (16.74 V m2
Vanthoor et al., 2011b), to ensure reliable NFR values, the year1 and 17.73 V m2 year1) and energy use (43.4 m3,
crop yield value, labour costs and energy were compared with 37.9 m3 gas). Consequently, as described before, the negative
values described in literature. simulated NFR agreed reasonably well with the NFR presented
In Spain, the calculated marketable tomato yield of by Vermeulen (2008).
40.3 kg m2 was considerably higher than the marketable The higher economic crop yield in the Netherlands was
tomato yield of 23.8 kg m2 measured in a high-tech green- caused by the higher average tomato price of 0.73 V kg1
house by Magán, López, Escudero and Pérez-Parra. (2007). The compared to 0.56 V kg1 in Spain, and by the higher marketable
higher simulated crop yield was caused by a 50 days longer yield of 57.5 kg m2 year1 compared to 40.3 kg m2 year1 in
simulated production period (using a simulated production Spain. The lower crop yield in Spain was caused by the lower
period similar to the measured one would have resulted in light transmission of the greenhouse due to the application of
a simulated crop tomato yield of 32.1 kg m2) and by the seasonal whitewash and by not applying CO2 enrichment.
higher light transmission of the optimised greenhouse since it
had less light absorbing design elements i.e. no shading 3.3. Evaluation of the close-to-best greenhouses
screen and no thermal screen. To check the order of magni-
tude, simulation results were compared with values obtained For this analysis we combined the population of greenhouse
for a sweet pepper crop by Magán, López et al. (2008). They designs obtained during the two optimisations runs for each
found similar amounts for labour costs (2.3 V m2 year1 case.
versus the simulated labour of 3.63 V m2 year1) and energy
costs (4.56 V m2 year1 versus the simulated gas consump- 3.3.1. Southern Spanish conditions
tion of 6.54 V m2 year1). The simulated labour costs were For Spanish conditions, the distribution of the design element
higher because of the higher production and simulated gas alternatives of the greenhouses for which the NFR differed
costs were higher because no thermal screen was used. These less than V 0.25 m2 year1 from the NFR of the best green-
results indicate that for Spanish conditions the method house (ΔNFR < 0.25 V m2 year1) is presented in Fig. 7. This
produced realistic model output. figure shows that there were only minimal differences among
In the Netherlands, the simulated costs agreed with fair the close-to-best greenhouses which indicates that the opti-
accuracy with the national greenhouse statistics of misation converged to an optimum.
Vermeulen (2008) indicating that for Dutch conditions the Allowing for larger differences (ΔNFR < 1.50 V m2 year1)
method produced realistic model outputs as well. In resulted obviously in a broader spectrum of design elements

Table 5 e The optimised greenhouse design in Almeria and the Netherlands. The * indicates the specific ventilation area of
the greenhouse.
Location Structure Cover Outdoor White Indoor Heating Cooling CO2 NFR
screen wash screen (MW) supply (V m2 year1)
(kg ha1 h1)

Almeria Light, 20%* Glass No 50% trans No Dirair: 0.5 No No 0.11


Netherlands Light, 14%* Glass No No 100% Al Dirair: 2.0 No Ind 200 9.41
362 b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8

(Fig. 8). Specifically, compared to ΔNFR < 0.25 V m2 year1,


Table 6 e The simulated net financial result (NFR) of the
optimised greenhouses in Spain and in the Netherlands. a light structure with a specific ventilation area of 14%, a single
PE film, no appliance of whitewash and a direct air heater with
Location Spain Netherland
a capacity of 1.0 MW were also feasible design solutions. In
(V m2 year1) (V m2 year1)
addition, the broad spectrum of the alternatives related to the
Crop yield 22.50 41.73 indoor screen and the CO2 supply indicated that the effect of
Fixed costs 6.43 14.57
these factors were marginal.
Variable costs The sensitivity analysis presented in Fig. 9 shows the
Labour 3.63 17.73 impact of all alternatives to fulfil each design element on the
Energy 6.54 9.48 NFR. Alternatives for which the accompanying mean NFR was
Water 0.21 0.00
high indicate that these individual alternatives enhanced the
Electricity 0.00 0.21
CO2 0.00 0.34
overall performance of a greenhouse significantly. Since the
Plant related costs 5.80 8.81 design element alternatives with a high NFR were present as
Net financial result 0.11 9.41 well in the set of close-to-best greenhouse designs (Figs. 7
and 8), it is expected that a global maximum was found.

Structure Cover Outdoor screen Whitewash


100 100 100 100
Frequency (%)

50 50 50 50

0 0 0 0
1 2 3 4 5 6 7 8 1 2 3 1 2 3 1 2 3
-1 -1
Indoor screen Heating (MW) Cooling CO2 supply (kg ha hour )
60 100 100 100
Frequency (%)

40
50 50 50
20

0 0 0 0
1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9101112 1 2 3 4 5

Fig. 7 e The frequency of the design element alternatives expressed in % of the best 12 designs for which the ΔNFR
<0.25 V mL2 yearL1 (i.e. all greenhouses for which the net financial result differed less than V 0.25 mL2 with respect to the
best greenhouse) for Spanish conditions. The indices on the x-axis correspond with the design element alternatives
presented in Table 1.

Structure Cove r Outdoor screen Whitewash


60 60 100 60
Frequency (%)

40 40 40
50
20 20 20

0 0 0 0
1 2 3 4 5 6 7 8 1 2 3 1 2 3 1 2 3
-1 -1
Indoor screen Heating (MW) Cooling CO2 supply (kg ha hour )
30 60 20 30
Frequency (%)

20 40 20
10
10 20 10

0 0 0 0
1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5

Fig. 8 e The frequency of the design element alternatives expressed in % of the best 781 designs for which the ΔNFR
< 1.50 V mL2 yearL1 for Spanish conditions. The indices on the x-axis correspond with the design element alternatives
presented in Table 1.
b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8 363

Structure Cover Outdoor screen Whitewash


-5 -5 -5 -5
-10 -10 -10 -10
NFR (€ m )
-2

-15 -15 -15 -15


-20 -20 -20 -20
-25 -25 -25 -25
-30 -30 -30 -30
1 2 3 4 5 6 7 8 1 2 3 1 2 3 1 2 3
Indoor screen Heating (MW) Cooling CO2 supply (kg/HA/hour)
-5 -5 -5 -5
-10 -10 -10 -10
NFR (€ m )
-2

-15 -15 -15 -15


-20 -20 -20 -20
-25 -25 -25 -25
-30 -30 -30 -30
1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5

Fig. 9 e For all 8 design elements and associated alternatives individually, the mean average of the NFR belonging to the
greenhouse designs that were equipped with a particular alternative for Spanish conditions. All designs evaluated by the
CRS algorithm were used for this analysis.

It follows from the observation above that NFR was not summer conditions to increase the NFR. This result indicates
sensitive to the selection of an alternative to fulfil the indoor that the impact of the cover transmission on NFR varies
screen and CO2 supply, as demonstrated by the relatively flat with seasons, which was already pointed out by Vanthoor,
response of the NFR to these alternatives. Therefore, focussing Van Henten, Stanghellini, and De Visser (2011c).
first on the optimisation of the design elements for which the
NFR is sensitive to changes in the selected alternatives would 3.3.2. Dutch conditions
in this case mean focussing on the greenhouse structure, For Dutch conditions, the design element distribution of ΔNFR
cover, whitewash and a heating system. Given the applied < 0.25 V m2 year1 revealed that a thermal screen consti-
assumptions on greenhouse floor area and economics, tech- tuting of 75% aluminium and 25% PE, a direct air heater of
niques with an extreme low NFR, i.e. geothermal heating and capacity 1.5 MW and several capacities of CO2 supply from the
mechanical cooling should be discarded from the alternatives tank or industry were feasible alternatives as well (Fig. 10).
to be optimised under the given conditions. The design element distribution of ΔNFR < 1.50 V m2 year1
Additionally, a high light transmissivity structure rather demonstrated that cooling and CO2 supply could be fulfilled by
than a low light transmissivity structure was preferable several feasible alternatives (Fig. 11). Although these cooling
(Fig. 9). The large positive impact of a higher light trans- techniques did not have a significant impact on simulated
mission on yield and resulting NFR was already demon- crop yield and variable costs, their selection resulted from
strated by the sensitivity analysis of a Spanish greenhouse their low annual fixed cost (Table 1).
performed by Vanthoor et al. (2012). However, as indicated Since the impact of design element alternatives on NFR
by the selection of a whitewash with a transmission of 50%, differed considerably between Spanish (Fig. 9) and Dutch
a higher greenhouse transmission was not favourable in conditions (Fig. 12), the need to adjust greenhouses to local

Structure Cove r Outdoor screen Whitewash


100 100 100 100
Frequency (%)

50 50 50 50

0 0 0 0
1 2 3 4 5 6 7 8 1 2 3 1 2 3 1 2 3
-1 -1
Indoor screen Heating (MW) Cooling CO2 supply (kg ha hour )
100 60 100 30
Frequency (%)

40 20
50 50
20 10

0 0 0 0
1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8

Fig. 10 e The frequency of the design element alternatives expressed in % of the best 14 designs for which the ΔNFR
< 0.25 V mL2 yearL1 for Dutch conditions. The indices on the x-axis correspond with the design element alternatives
presented in Table 1.
364 b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8

Structure Cover Outdoor screen Whitewash


100 100 100 100
Frequency (%)

50 50 50 50

0 0 0 0
1 2 3 4 5 6 7 8 1 2 3 1 2 3 1 2 3
-1 -1
Indoor screen Heating (MW) Cooling CO2 supply (kgha hour )
60 60 30 20
Frequency (%)

40 40 20
10
20 20 10

0 0 0 0
1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 910 1112 1 2 3 4 5 6 7 8

Fig. 11 e The frequency of the design element alternatives expressed in % of the best 245 designs for which the ΔNFR
< 1.50 V mL2 yearL1 for Dutch conditions. The indices on the x-axis correspond with the design element alternatives
presented in Table 1.

conditions is demonstrated once again. Specifically, the using a model-based greenhouse design method. For Spanish
different trajectories of the mean NFR for the indoor screen and Dutch conditions, this method adjusted the greenhouse
and heating system indicates that, in the relatively cold designs to the local climate and economic conditions in order
Netherlands, an indoor thermal screen and a large heating to obtain a maximum NFR. Additionally, the distribution
capacity are more relevant than in Spain. As presented before, curves and sensitivity analysis revealed the impact of design
for both locations a high light transmissivity structure was elements on greenhouse design and related NFR.
obviously the best. However, the NFR difference between Although, the design method was able to optimise green-
a high light and a low light structure is much larger in the house designs for different climatic and economic conditions,
Netherlands than in Spain which in turn indicates that light in several issues need to be addressed to improve the perfor-
the Netherlands is a much more limiting growth factor, as mance and generality of the model-based design method. The
expected. modified CRS algorithm was able to solve efficiently the multi-
factorial greenhouse design optimisation problem as demon-
3.4. Discussion of the model-based design method strated in Fig. 6. Although the CRS was developed for contin-
uous design variables, the modified CRS could solve the
In contrast to other greenhouse design studies (Amir & integer greenhouse design problem because the discrete
Hasegawa, 1989; Engel, 1984; Kacira et al., 2004; Vanthoor optimisation parameters were represented as floating-point
et al., 2012) a broad set of design elements were optimised values as proposed by Lampinen and Zelinka (1999). It might

Structure Cover Outdoor screen Whitewash


-15 -15 -15 -15
-20 -20 -20 -20
NFR (€ m )
-2

-25 -25 -25 -25


-30 -30 -30 -30
-35 -35 -35 -35
-40 -40 -40 -40
1 2 3 4 5 6 7 8 1 2 3 1 2 3 1 2 3
-1 -1
Indoor screen Heating (MW) Cooling CO2 supply (kg ha hour )
-15 -15 -15 -15
-20 -20 -20 -20
NFR (€ m )
-2

-25 -25 -25 -25


-30 -30 -30 -30
-35 -35 -35 -35
-40 -40 -40 -40
1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8

Fig. 12 e For all 8 design elements and associated alternatives individually, the mean average of the NFR belonging to the
greenhouse designs that were equipped with a particular alternative for Dutch conditions. All designs evaluated by the CRS
algorithm were used for this analysis.
b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8 365

be expected that other population-based optimisation condition. Because of the modular structure of the design
methods like simulated annealing and a genetic algorithm method, the performance measure and boundary conditions
could be used as well (Dréo, Pétrowski, Siarry, & Taillard, can be adjusted easily to the demands of the designer.
2006). Provided that these more elegant optimisation algo- As demonstrated by Vanthoor et al. (2011c) and Vanthoor
rithms also may benefit from parallel computing, these et al. (2012) the greenhouse climate set-points, economic
methods might decrease optimisation time compared to the input parameters and outdoor climate have a significant
modified CRS algorithm. Even though two optimisation runs impact on NFR. In addition, Vanthoor, Stanghellini, Van
with different start sets found the same optimised green- Henten, and De Visser (2008) have shown that the choice of
house, like all other optimisation methods, the CRS could not climate set-points even affected some optimal design
guarantee a global maximum. parameters. These results indicate that changes of economic
The performance of an optimisation depends mainly on input parameters, outdoor climate data and climate set-point
three factors. First, the optimisation takes into account only parameter might influence the optimised design. The design
processes which are included in the models. In our project, the optimisation horizon was one year whereas the optimised
focus was to optimise a limited set of design elements. greenhouse will have a lifespan of approximately 15 years.
Therefore, optimisation of the structural design, climate Therefore, these input parameters should be determined in
control, heat buffers, fertigation systems, labour and logistics such a way that they represent, with the currently known
was not carried out. Consequently, for example the positive information, the future input parameters at best.
effects of a boiler-pipe heating system on heat storage, labour
and logistics were not incorporated and therefore these
advantages of this heating system could not be optimised by 4. Conclusion
the design method. As demonstrated by Vanthoor et al.
(2011c), the cover properties have a large impact on green- The aim of this study was to integrate an optimisation algo-
house performance and therefore it will be interesting to rithm into the model-based design method to select the
incorporate more cover alternatives such as a double glass, greenhouse design that would yield the largest annual Net
diffuse covers, glass with an anti-reflecting coating and NIR- Financial Return for a tomato greenhouse for different
reflecting covers. The generic nature of the design method climatic and economic conditions. This aim was fulfilled. A
allows design elements, key components and model aspects modified CRS optimisation algorithm using parallel
to be adjusted or added easily. Second, the accuracy of the computing was able to select the best set of alternatives to
models determines the confidence limits of the NFR and fulfil the design elements for Almeria and Dutch conditions.
consequently the performance of the optimisation. In spite of Specifically, due to the relatively warm climate with high
the validation, the greenhouse climate model and tomato radiation levels in Almeria, a greenhouse with a relatively
yield model might be improved as discussed in Vanthoor et al. large ventilation area (20% compared to 14% for Dutch
(2011a) and Vanthoor et al. (2011b) respectively, which might conditions), seasonal whitewash and a relatively low capacity
also influence the optimised design. Furthermore, since of the direct air heating (0.5 MW compared to 2.0 MW for
tomato quality aspects are not only affected by humidity Dutch conditions) was selected. In contrast, for the relatively
levels but also by other climatic variables (Adams, Cockshull, cold climate with low radiation levels in the Netherlands,
& Cave, 2001), model performance might be improved by whitewash was not selected and a 100% aluminium thermal
replacing the tomato quality filter described in appendix B by screen was applied. CO2 enrichment was applied only for
a more detailed description of the quality aspects. As knowl- Dutch conditions. The design method produced realistic
edge on crop modelling under suboptimal conditions designs and related annual NFR which indicates that a robust
develops, more complete functions to assess tomato yield and and reliable design method had been developed.
quality could be easily incorporated (or substituted) in the A population-based optimisation method offers the
design method. opportunity to analyse the close-to-best greenhouses. The
Third, the selection of the performance measure and distribution curves of the close-to-best greenhouse designs
boundary conditions has an impact on the optimised design. and a sensitivity analysis of the mean NFR to the design
In this study, greenhouses were optimised by maximising the element alternatives revealed: a) the relevant design elements
annual NFR per square metre (V year1 m2) under the and associated alternatives for optimisation and b) whether
boundary condition of a fixed greenhouse area (1 ha). The there are many different greenhouses with a very similar NFR.
investment potential was not constrained, because in this For both locations, the selection of a high-light transmissivity
way we were able to find out the best performing greenhouses structure with sufficient ventilation area was important and
in given market and climate conditions. In this way, for an outdoor shade screen, geothermal heating and mechanic
instance, local authorities could find out whether productivity cooling were not feasible for the given conditions. Addition-
in a region could be improved through subsidies or other ally, for Spanish conditions, one should also focus on the
financial stimuli. Results demonstrated that the investment optimisation of the cover material, whitewash and heating
cost of the best greenhouse in Spain was higher than for the system to increase the NFR whereas for Dutch conditions, the
local commercial parral greenhouses which indicates that indoor screen and heating system have a large impact on
these financial stimuli might be beneficial under these performance.
conditions. It might be interesting as well to optimise both the With these results, all four key components of the model-
surface and greenhouse design by maximising the annual NFR based design method i.e. the greenhouse climate model, the
(V year1) with a limited investment potential as boundary tomato yield model, the economic model and an optimisation
366 b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8

algorithm were successfully integrated. This design method is UMechCool (-) is the control valve of the mechanical cooling
able to describe the economic performance of a greenhouse as mechanism, hMechCool (-) is a fraction to account for pump
a function of outdoor climate, climate management and costs of the mechanical cooling system, PMechCool (W) is the
greenhouse design. The modified CRS algorithm adapts the electric power of the mechanical cooling system, AFlr (m2) is
greenhouse to given conditions so that the maximum net the greenhouse floor area, cPad (W s2 m4) is the characteristic
financial result will be obtained. To the best of our knowledge, of the fans in terms of electricity consumption, fPad
it is the first time that this multi-factorial optimisation (m3 m2 s1) is the ventilation flux due to the pad and fan
problem is addressed and a partial solution of the more system, PPadMax (W m2) is the maximum electrical
complex problem is obtained. These results demonstrate the consumption of the fans expressed per square metre
feasibility of a model-based approach towards greenhouse greenhouse, fPadMax (m3 m2 s1) is the maximum air flow of
design for a wide variety of climatic and economic conditions. the fans, nVents () is the total number of fans, PVentMax
(W m2) is the maximum electric power of one fan, and
fVentMax (m3 s1 fan1) is the maximum air flux of one fan.

Acknowledgement

We would like to thank Gerard Folkerts, Andre Aalten and


Appendix B. Determination of the fraction of first
Reggie Naumann from Wageningen University to make the
class tomatoes and marketable fraction as
parallel computing possible. The economic parameters were
a function of humidity
kindly provided by Ana Cabrera from the Economic Studies
Institute of the Cajamar Foundation and the staff from the
Körner and Challa (2003) indicated that the growth and
Agrifood Business Division of Cajamar (Agricultural Credit
development of a chrysanthemum crop is affected by the 24 h
Cooperative) and by Marc Ruijs from the Agricultural
running mean value of the vapour pressure difference (VPD24)
Economics Institute, Wageningen UR. In addition we would
and that incidence of botrytis is affected by the 48 h running
like to thank Bas Speetjens from Ecofys, Gerard van Wil-
mean value of the relative humidity of the greenhouse air
ligenburg, Bert van ‘t Ooster from Wageningen University and
(RH48). We adopted here the same approach and assumed that
Feije de Zwart and Gert-Jan Swinkels from Wageningen UR
the fraction of first class tomatoes can be described as
Greenhouse Horticulture for their useful comments. This
study was part of the strategic research programmes
"Sustainable spatial development of ecosystems, landscapes,
100
seas and regions" and "Sustainable Agriculture", both funded a
First class tomatoes (%)

by the former Dutch Ministry of Agriculture, Nature Conser-


80
vation and Food Quality.
60
Appendix A. Calculation of electrical
consumption of climate modification techniques 40

20

pFog $MVFogAir  
PFog ¼ Wm2 (A.1) 0
1000$hFogPump 0 0.5 1 1.5 2
24 hour integrated VPD (kPa)
 
PGeo ¼ hGeo HGeoPipe Wm2 (A.2)

  100
PMech ¼ UMechCool ð1 þ hMechCool ÞPMechCool =AFlr Wm2 (A.3) b
Marketable fraction (%)

80
 
PPad ¼ cPad fPad
2
Wm2 (A.4)
60
where
40
PPadMax  
cPad ¼ 2 Ws2 m4 (A.5)
fPadMax 20

nVents PVentMax   0
PPadMax ¼ Wm2 (A.6) 0 20 40 60 80 100
AFlr
48 hour integrated RHair (%)
nVents fVentMax  3 2 1 
fPadMax ¼ m m s (A.7) Fig. B1 e a. The fraction of first class tomatoes (hTom1) as
AFlr
a function of the 24 h running mean value of the vapour
where pFog (Pa) is the static pressure of the fogging system, pressure difference (VPD24). Fig. B1 - b. The marketable
hFogPump (-) is the efficiency of the fogging pump, hGeo (J J1) is fraction (hFMsold) as a function of the 48 h running mean
the electrical energy needed to pump the geothermal heat, value of the relative humidity (RH48).
b i o s y s t e m s e n g i n e e r i n g 1 1 1 ( 2 0 1 2 ) 3 5 0 e3 6 8 367

Table B1 e The estimated fraction of first class tomatoes Appendix D. The calculation of the CO2 set-point
and the estimated marketable fraction of harvest agreed
for CO2 enrichment
reasonably well with the measured quality parameters
(between brackets) of a low-tech greenhouse and a high-
tech greenhouse in South Spain. A description of the The CO2 set-point increases linearly with global radiation,
tomato production and indoor climate of these two IGlob, until a defined maximum CO2 set-point, CO2Air ExtMax , is
greenhouses is given by Vanthoor et al. (2011b). reached and, simultaneously, the CO2 set-point decreases
Low-tech High-tech linearly with the total ventilation rate of the greenhouse,
greenhouse greenhouse fVentTot:

First class tomatoes, hTom1 (%) 69.9 (65) 92.5 (95)


   
CO2Air ExtOn ¼ f ðIGlob Þ$g fVentTot $ CO2Air ExtMax  CO2Air ExtMin
Marketable fraction hFMsold (%) 90.1 (90) 95.2 (95)
þ CO2Air ExtMin ½ppm (D.1)

8
IGlob
< ; IGlob < IGlob Max
a function of VPD24 and that the marketable fraction can be f ðIGlob Þ ¼ IGlob Max ½ (D.2)
:
described as a function of RH48. These two functions are each 1; IGlob  IGlob Max
8
fVentTot
described by a trapezoid function as presented in Fig. B1.   <1  ; fVentTot < fVentExtCO2 Max
g fVentTot ¼ fVentExtCO2 Max ½
The boundary conditions at which the quality parameters :
0; fVentTot  fVentExtCO2 Max
were still maximal were derived from local common practice
about humidity management in tomato crops and were: (D.3)
VPDmin ¼ 0.3 kPa;VPDmax ¼ 1.5 kPa; RHairmin ¼ 35% and 2
where IGlob (W m ) is the outdoor global radiation, fVentTot
RHairmax ¼ 85%. The slopes of these functions were estimated (m3 m2 s1) is the total ventilation rate, CO2Air_ExtMax
by fitting the estimated quality parameters on the measured (1000 ppm) is the maximum CO2 concentration set-point,
values as a function of the measured indoor climate in a low- CO2Air_ExtMin is the minimum CO2 concentration set-point
tech and high-tech greenhouse. It was assumed that, for the (390 ppm), IGlob_Max (500 W m2) is the outdoor global radia-
current approach, these quality filters estimated the fraction tion at which the maximum CO2 concentration set-point
of first class tomatoes and marketable fraction sufficiently could be reached and fVentExtCO2_Max (6.95 103 m3 m2 s1) is
accurately. Specifically, Table B1 shows that the predicted the total ventilation rate at which the CO2 concentration set-
quality parameters agreed reasonably well with the quality point equals the minimum CO2 concentration set-point (ppm).
parameters observed in a low-tech and high-tech greenhouse
in South Spain. A description of the tomato production and
indoor climate of these two greenhouses is presented in references
Vanthoor et al., 2011b.

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