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Energy recovery presentation


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Energy recovery presentation

  1. 1. Innovations in Action Advanced Cooling Technologies, Inc. Energy Recovery Systems Overview Mark Stevens, New Business Development, 717-344-0061 Pete Dussinger, VP Engineering, ER Products 1
  2. 2. Presentation Overview • • • • • • • • • Company History ACT Capability & Product Scope Heat Pipe Basics Energy Recovery System Types & Comparison Overview Heat Pipe Wrap-Around Heat Exchangers Calculated Performance & Savings Examples for WAHX Air-to-Air Heat Pipe Heat Exchanger Overview Other Energy Recovery Systems Industry Drivers 2
  3. 3. Advanced Cooling Technologies, Inc.  Founded in 2003  Located in Lancaster, PA  40,000 sq.ft.+ Office, Laboratory & Manufacturing Space   2011 Tibbett's Award Winner Made annually to small firms, projects, organizations and individuals judged to exemplify the very best in Small Business Innovative Research (SBIR) achievement. 3
  4. 4. Advanced Cooling Technologies, Inc.  Primary Markets  Energy Recovery  Military & Industrial Cooling  Satellite Thermal Control  Temperature Calibration and Control  Contract R&D and Technical Services  Quality System ISO 9001:2008 Certified for Terrestrial Product Design and Manufacturing AS/EN/JISQ9100:2009 Certified for Aerospace Products Design and Manufacturing 4
  5. 5. Advanced Cooling Technologies, Inc.  ACT Team Overview  73 Full Time Employees  Cumulative Professional Team Experience:  33 Engineers  Publications : > 400+  34 Technicians / Production  200 Years  5 SG&A  Patents Granted : > 70  Engineering Backgrounds  11 Ph.D’s  12 Masters  11 Bachelors  M.E. , E.E., Chem. E, Nuclear, Physics & Manufacturing 5
  6. 6. ACT Capabilities and Equipment  Capabilities – – – – –  Equipment Thermal Design and Analysis – Thermal Testing Characterization, and Validation Prototype Assembly Heat Pipe Manufacturing – Assembly Manufacturing – – Certified Welding – – Brazing – – Soldering – – – – – High Temperature Furnaces – Reducing Atmosphere – Vacuum HVAC HPHX Testing Thermal Chambers Data Acquisition Flow Bench Vacuum Chamber Process Oven Swager Heat Pipe Production Line Helium Mass Spectrometer 6
  7. 7. Heat Pipe Beginnings • The original heat pipe operating principle was developed by Richard S. Gaugler of the General Motors Corporation in 1942. • Modern heat pipe technology was originated from the Los Alamos Scientific Laboratory by George Grover in 1963. • Advanced Cooling Technologies’ Yale Eastman (currently a Director of ACT), a few years later describes the theory and history of the heat pipe technology in an article published in Scientific American, May 1968 7
  8. 8. Heat Pipes Are Super Conductors Vapor Space Liquid Film 8
  9. 9. Heat Pipes Are Super Conductors 200 Times Better Thermal Conductor Than Copper Isothermal 9
  10. 10. Examples of Heat Pipe Applications Satellite Heat Pipes: TACSAT 4 Military Satellite 10
  11. 11. Examples of Heat Pipe Assemblies High Temperature Heat Pipes Heat Sinks Optimized with Heat Pipes Heat Pipes for Electronics High-Power Heat Pipes up to 500 Watts/cm2 11
  12. 12. Embedded Heat Pipe Application Shipboard Radar Application Reduced Hot Spots by 30°C WITH HEAT PIPES WITHOUT HEAT PIPES 13” x 20” Pumped liquid cool rail on plate edge 12
  13. 13. Heat Pipes in Energy Recovery 13
  14. 14. ACT Energy Recovery Performance Testing Testing of Heat Pipe Power (Watts) for HVAC Applications Test Measurement Criteria Include: 1. Size (diameter) of heat pipe 2. Performance based on amount of charge (ccs) 3. Performance based on internal heat pipe design (smooth or grooved) 4. Refrigeration Type performance (R-134a, R-410A) 5. Response to temperature 6. Testing angle Energy Recovery Test Setup: Multiple temperature measurements are profiled along each energy recovery heat pipe under test 14
  15. 15. ACT Climate Test Chamber Testing Psychrometric Performance of Wrap-Around Dehumidification Heat Pipe Systems Test Chamber Capabilities: • • • • 0 – 700 fpm Face Velocity Up to 100% Relative Humidity Temperature Range: Ambient to >120º F Multiple Data Point Acquisition AHRI 930P Committee Performance Rating of Heat Exchangers in Series with Dehumidification Cooling Apparatus 15
  16. 16. ACT Energy Recovery Technology Types PASSIVE-SPLIT THERMOSYPHON LOOP Wrap-Around Systems Enhanced Dehumidification Air-to-Air Systems 16
  18. 18. Comparison of Energy Recovery Systems Energy Recovery Technology Comparisons Energy Recovery Sensible Heat Type Transfer Latent Heat Transfer PRESSURE MAINTENANCE DUCT WORK INSTALLATION Electrical TYPICAL CROSS MOVING DROP REQUIED OTHER REQUIED SIDE- DIMENSIONAL Power EFFECTIVENESS CONTIMINATION PARTS TYPICAL THAN CLEANING ISSUES BY-SIDE Required Heat Pipe WrapAround YES Enhanced Dehumidification UNDER 0.5 10-50%(*) NO NO NO NO NO NO Heat Pipe Air-toAir YES NO UNDER 0.5 45-65% NO NO NO YES Fit's in place of sensible wheel NO Heat Pipe Split Passive YES NO UNDER 0.5 40-60% NO NO NO NO FullFlexibility NO Run Around Loops YES NO UNDER 0.5 40-60% NO YES YES NO NO YES Plate Exchangers YES YES with increased > 0.75 < 1.2 cost 50-80% NO NO NO YES Very Large as CFM Increase NO Energy Recovery Wheels YES 50-80% YES upto 12% YES YES YES NO YES YES > 0.75 < 1.2 * Effectiveness is calculated for each application to meet the desired re-heat temperature. 18
  19. 19. Wrap-Around Heat Pipe Heat Exchangers for 100% Dedicated Outdoor Air Energy Recovery 19
  20. 20. ACT –HP-WAHX Wrap-Around Dehumidification Features:  Provides pre-cooling of incoming air stream to increase the AHU’s ability to remove moisture (latent energy)  Accomplishes system re-heat passively saving gas or resistive reheat cost  Sizes up to 100,000 CFM  Generally easy to retrofit without major duct work.  Low Maintenance (no moving parts) No plugging – No Belts – No Bearings  45% - 65% effectiveness  Small drop in static pressure, typically 0.15 to 0.45 inches of water 2-6 Row WAHX 20
  21. 21. ACT-HP-WAHX Wrap-Around System Typical Air Handler Application 52.0ºF / 51.9 FWB 92ºF / 78.0FWB Pre-Cool Coil 64.2ºF / 56.9 FWB Re-Heat Coil Comfortable Air Outside Hot & Humid Air Cooling Coil 80.0ºF / 74.9 FWB 21
  22. 22. ACT-HP-WAHX Wrap-Around System Typical Air Handler Application 12°F 12°F 22
  23. 23. ACT-HP-WAHX Wrap-Around System Installation Configurations 23
  24. 24. ACT-HP-WAHX Wrap-Around System Installation Configurations 24
  25. 25. AHU Added Performance With ACT ‘s Wrap-Around Heat Pipes • Typical cooling systems provide sensible and latent cooling. Sensible • Adding WAHX pre-cooling Cooling, enhances AHU’s ability to 75% reach dewpoint with less energy • A smaller AHU may be considered. • Typical systems over cool to drop out moisture and consume higher energy for reheat. WAHX passively re-heat. • Reduced humidity levels minimize chances for mold, mildew and slip hazards at: healthcare facilities, supermarkets, eateries, libraries, government buildings target. All target 50% humidity. Latent Cooling, 25% 25
  26. 26. Wrap - Around Heat Pipe System Profile Saved BTUs Saved BTUs 26
  27. 27. What Effect Does Adding More Rows Have on Installed Performance? 1000cfm; 480fpm face velocity, ½” Heat Pipes @ 12fpi Rows EAT Pre-Cool (F) LAT Pre-Cool (F) EAT Re-Heat (F) LAT Re-Heat (F) Delta T (F) Power (BTUH) Delta P (In H2O) 2 Rows 85.0º 75.0º 50.0º 60.0º 10.0º 10,900 0.14 4 Rows 85.0º 69.5º 50.0º 65.5º 15.5º 16,895 0.27 6 Rows 85.0º 66.0º 50.0º 69.0º 19.0º 20,710 0.41 27
  28. 28. Typical Wrap –Around or Air-to-Air Energy Recovery Coil Width Dimensions • Two Row Wrap-Around Heat Pipes need approximately 3” of installation width before and after the coiling coil. • Four Row Wrap-Around Heat Pipes need approximately 5” of installation width before and after the cooling coil. • Six Row Wrap-Around Heat Pipes need approximately 7” of installation width before and after the coiling coil. TWO ROW 3” FOUR ROW 5” SIX ROW 7” 28
  29. 29. ACT-WAHX Performance Calculation Increasing Tonnage Performance 25 Tons AHU No WAHX 2R WAHX = 21 Ton AHU 6R WAHX = 18 Ton AHU 29
  30. 30. ACT-WAHX Performance Calculation Increasing Dehumidification Performance 99.4% 25 Tons AHU No WAHX 2R/25 Tons AHU +23% 6R/25 Tons AHU +41% 30
  31. 31. WAHX Calculation with Engineering Schedule 31
  32. 32. WAHX Rows Estimate 32
  33. 33. WAHX Pressure Drop = 0.20 inches of water 33
  34. 34. WAHX Performance Result 34
  35. 35. Typical Quote Response Sheet for a Wrap -Around Dehumidification System • 1 Day for a budgetary number • 2-3 Days for firm hardcopy quote 35
  36. 36. Web Based Wrap-Around Heat Pipe Selection Tool • Easy Web-Based Selection Tool (no down-loading required) • Fully selectable data fields for: - Fins per inch - Pressure drop - Outside Air Parameters - Delivered Air Parameters - City/State • Screen Print Option • Send Data to Factory Option for Review. 36
  37. 37. How to Specify an WRAP – AROUND System Specification Sheet Front Specification Sheet Back 37
  38. 38. CARRIER WRAP-AROUND HEAT PIPE RETROFIT     Added WAHX Coils Modified Drip Pans Modified Filter Racks Modified Side Panel (bumped out) 38
  39. 39. TRANE WRAP-AROUND HEAT PIPE RETROFIT     Added WAHX Coils Modified Drip Pans Modified Filter Racks Slight Modifications to Side Panels 39
  40. 40. Department of Energy Support s ACT Wrap - Around Technology The US Department of Energy has sighted heat pipes as “Underutilized” and a viable energy saving technology. They have listed the following review of for heat pipe technology performance in general… 40
  41. 41. Oxford Journals Support of Passive Heat Pipe Technology Oxford Journals Report Quote: “The results of the economic analysis are stark and demonstrate that the initial additional cost of the heat pipe is marginal when taking into account the reduced size of other equipment while energy and corresponding cost savings are considerable. An alternative return on investment calculation may be used to demonstrate the savings that would be accrued over a number of years; this would generate figures equally as attractive as those demonstrated in the simple payback analysis.” 41
  42. 42. ACT-HP-ERS/A-A Air - to - Air (Heat Pipe) Heat Exchangers Air-to-Air Heat Exchangers Are Very GREEN 42
  43. 43. ACT - ERS/A-A Air - to - Air (Heat Pipe) Heat Exchangers  Captures Building’s Energy for PreCooling or Pre-Heating in a Counter Flow Design  Sizes can match all existing coils  Typical installations where duct work is side-by-side  No cross contamination of airstreams  ASHRAE Standard 62-2010 ventilation for acceptable indoor air quality. 43
  44. 44. ACT - ERS/A-A Air - to - Air (Heat Pipe) Heat Exchangers  Reduces the size of air conditioning or heating plant  Low Maintenance (no moving parts) No plugging – No Belts – No Bearings  Payback periods between 1-2 years  50% - 80%+ effectiveness  Limited drop in static pressure, under 0.15 to 0.45 inches of water (2-6 Row AAHX) 44
  45. 45. ACT - ERS/A-A Air - to - Air (Heat Pipe) Heat Exchangers Geometry of the ACT-ERS/A-A can match all existing duct profiles. Energy Recovery does not need to be square. 45
  46. 46. ACT - ERS/A-A Air - to - Air (Heat Pipe) Heat Exchangers Every ACT Air-to -Air Heat Pipe Heat Exchange is designed to yield the optimal effectiveness in Btu/hr. savings. Passive energy recovery transfer is custom engineered to each project to yield the best performance versus cost ratio. 46
  47. 47. ACT - ERS/A-A Installation Air - to - Air (Heat Pipe) Heat Exchangers 47
  48. 48. Heat Pipe AAHX Selection Example: 48
  49. 49. Heat Pipe AAHX Selection Example: 49
  50. 50. Control Heat Pipe AAHX Function by Tilting Center Tilting the HP-AAHX will transfer operation from summer to winter 50
  51. 51. HP-AAHX Vertical Installation • • • • Effectiveness: 80% Btu/hr.: 315,000 10 Rows Vertical , 540 Heat Pipes: Pressure Drop: 1.0 51
  52. 52. Typical Quoted Response Sheet for Heat Pipe Heat Exchanger System 52
  53. 53. Example: Zone 5-A • ≥50% - <60% Outside Air • ≥ 3,500 cfm systems gain improvements with energy recovery systems ASHRAE 90.1 Standard Climate Zones Percentage of Outside Air Choose Your Zone 53
  54. 54. IECC 2004, ASHRAE 90.1 Commercial State Energy Code Compliance 54
  55. 55. Other Heat Pipe Based Heat Exchangers for Energy Recovery 55
  56. 56. HP-AAHX Passive-Split Air Handling System Energy Recovery can take place summer or winter. A modulating ball valve can trim the amount of cooling or heating from HP coils. No pumps… 56
  58. 58. HP-AAHX Passive-Split Air Handling System ENERGY TRANSFER SUMMER 160,000 Btu/hr ENERGY TRANSFER WINTER 600,000 Btu/hr Design points: 0°F & 70°F VAPOR LINE CONTROL VALVE 12,000 Btu/hr = 1 Ton 13+ tons saved Design points: 95°F & 75°F LIQUID LINE 58
  59. 59. SUMMER/WINTER PUMP LOOP SYSTEM • Summer/Winter Energy Recovery (Pump operates CONDENSOR EVAPORATOR both seasons) • System can be split between ducts up to 30’+ • Low Pressure System Drop • Sizes up to 25,000 CFM+ • Positive Recovery Efficiency Ratio (RER) CONDENSOR EVAPORATOR Recovery Efficiency Ratio (RER): RER = Net conditioning energy recovered Total electric power consumed …where the net space conditioning energy can be either heating, cooling, or a combination thereof and the total electric power consumed includes the power required to move air through both sides of the AAHX. 59
  60. 60. Energy Recovery Passive Summer/ Pump Winter System • Summer/Winter Energy Recovery • Passive in Summer • Pump in Winter • Ducts are side-by-side • Low Pressure System Drop • Sizes up to 25,000 CFM+ • Positive Recovery Efficiency Ratio (RER) PASSIVE SUMMER/ PUMP WINTER CONDENSOR EVAPORATOR 60
  61. 61. ACT Process Cooling Applications • • • • Large Cooling Radiator for CertainTeed Building Products. Continuous operation, 460V ,10HP motor, VFD for fan speed control 600,000 BTU/hr. of cooling. Cools process water to programmed temperature. 61
  62. 62. Industry Application Drivers 62
  63. 63. DSIRE: Database of State Incentives for Renewables & Efficiency DSIRE is the most comprehensive source of information on incentives and policies that support renewables and energy efficiency in the United States 63
  64. 64. Standards Driving and Promoting the Use of Energy Recovery Systems  ASHRAE Building EQ Standard The EQ building energy labeling program provides the general public, building owners and tenants, potential owners and tenants, and building operations and maintenance staff with information on the potential and actual energy use of buildings.  ASHRAE 189.1 Green Building Standard Standard for the Design of High-Performance Green Buildings The energy efficiency goal of Standard 189.1 is to provide significant energy reduction in addition to those introduced under ANSI/ASHRAE/IESNA Standard 90.1-2007. It offers a broader scope than Standard 90.1 and is intended to provide minimum requirements for the siting, design and construction of high performance, green buildings. 64
  65. 65. Standards Driving and Promoting the Use of Energy Recovery Systems  LEED Points possible for; Energy and Atmosphere, Indoor Environmental Air Quality, Innovation in Design.  Energy Policy Act of 2005, EPACT2005, Went in to effect on January 1, 2010. The Act contains 1,700 pages of incentives for traditional energy production efficiencies and incentivizes new technologies for energy conservation in the commercial, residential and industrial markets. EPACT2005 Incentives: Agencies may retain utility cost savings and invest them in future energy projects. Additionally, commercial buildings designed to consume 50% less energy than ASHRAE 90.1 receive a $1.80/square foot tax deduction (for federal facilities, the deduction is allocated to the architect(s) and/or engineer(s) responsible for the building’s design).  EPA Sponsored Energy Star Portfolio Manager. 65
  66. 66. Standards Driving and Promoting the Use of Energy Recovery Systems  ASHRAE 90.1 2010 Energy Standard for Buildings Except Low-Rise Residential Buildings 66
  67. 67. Opportunity: Dedicated Outside Air Systems 4.5 million existing commercial buildings Types of DOAS facilities that would utilize , or directed by new building codes to install Energy Recovery Systems Facility or Institution Airports/Air Transport operations Food Stores Public Elementary/Secondary Schools Private Elementary/Secondary Schools Universities, Colleges, Professional Schools Hospitals Skilled Nursing facilities Mental Health Care facilities Warehousing operations State/Federal Correctional facilities Theaters Number of Buildings 11,445 171,057 89,508 27,402 4,064 8,841 15,032 3,742 580,000 1,500 8,298 Statistics from the Fredonia Group 67
  68. 68. Innovations in Action `` Wrap up… Contact info: Mark Stevens, New Business Development Energy Recovery Products, 717-344-0061 Pete Dussinger, VP, Energy Recovery Products, 717-295-6052 70