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Campus Conversion to GeothermalBall State University’s Conversion to a Campus Geothermal System
Jim LoweAssociate Vice President for
Facilities Planning and ManagementBall State University
Mike Luster, PE, LEED APPrincipal | Sr. Mechanical Designer
MEP Associates, LLC
Ball State University’s Conversion to a Campus Geothermal System
Learning Objectives
- Campus Geothermal Systems Fundamentals- History of the Ball State Project- Applying Geothermal to Ball State- Benefits of the Ball State Project- Lessons Learned- Industry Impact
Ball State University’s Conversion to a Campus Geothermal System
Heat Removed from the Earth in Winter
Ball State University’s Conversion to a Campus Geothermal System
Air Temperature vs. Ground Temp
Ball State University’s Conversion to a Campus Geothermal System
Performance Measurement
Evaporator Condenser
Compressor
Motor
Input work
Chiller:Useful Work Heat Pump:
Useful work
COP (Coefficient of Performance) = Useful work Input work
Ball State University’s Conversion to a Campus Geothermal System
Heat Exchanger Options
• Vertical Heat Exchanger • Open Pit Horizontal
• Directional Bore Horizontal • Closed Loop Pond/Lake
• Open Loop Pond/Lake
Ball State University’s Conversion to a Campus Geothermal System
• Appling Geothermal Systems in a New Way
• Take Advantage of Campus Simultaneous Heating and Cooling Loads
• Potential to Eliminate Coal and Gas Fired Boilers
• Reduce Energy Footprint, Carbon Emissions and Utility Costs
• Reduce Water Usage
Geothermal for Campus Systems
Ball State University’s Conversion to a Campus Geothermal System
History of Ball State University
• Founded in 1918• 7.1 Million SF• 47 Major Buildings• 731 acres• 22,113 students• Beneficence is a 6 ft. bronze
statue that has graced the BSU campus since 1937. Her name, means the quality of performing acts of kindness and charity.
Ball State University’s Conversion to a Campus Geothermal System
Steam and Chilled Water Plant Operations
Rejected heat$$$$$$$$$
Boiler (Steam) PlantChilled
Water Plant
Stopped burning coal March, 2014
• Steam Plant:• 4 Coal Fired Boilers• 3 Natural Gas Fired Boilers• 320,000 Lbs./Hr. nameplate• 240,000 Lbs./Hr. current• 700,000,000 Lbs./Year
• Chilled Water Plant:• 5 Electrical Centrifugal Chillers• 9,300 ton capacity• 25,000,000 Ton Hours/Year
Ball State University’s Conversion to a Campus Geothermal System
Pollutants / Waste Produced from Burning 36,000 tons of Coal
• Carbon Dioxide 85,000 tons (Global Warming)• Sulfur Dioxide 1,400 tons (Acid Rain)• Nitrogen Oxide 240 tons (Smog)• Particulate Matter 200 tons (Breathing)• Carbon Monoxide 80 tons (Headache)
• Multiple Hazardous Air Pollutants now regulated by EPA’s Boiler MACT rules: Mercury
• 3,600 tons of coal ash
Ball State University’s Conversion to a Campus Geothermal System
Alternatives Evaluated
Fossil Fuel Boiler (CFB) All Natural Gas Boiler Ground Source Geothermal Heat PumpHigh capital cost Low capital cost Highest capital costNo CO2 reduction CO2 half that of coal Campus CO2 reduced 50% High maintenance costs Low maintenance cost Low maintenance costEmission control equipment No emission control No emission controlAlternative fuel capable High fuel costs Electric power dependent
Note: BSU needed to make changes due to:• Age/condition of equipment• EPA regulations • Growth in campus• reduction in equipment capacity
Ball State University’s Conversion to a Campus Geothermal System
Geothermal Research
• Internet Research:• International Ground Source Heat Pump Association (IGSHPA) • GeoExchange: case studies about dozens of projects• National Ground Water Association (NGWA)--drilling• Found some huge-–Ft. Polk (4003 units in 1290 buildings)• Galt House --Louisville (1.5 M square feet)• Stockton College (NJ) (400 wells under parking lots)
• AUL/One America• 1 M square feet in 36 story tower• Second most efficient building in US (1983-87)
Ball State University’s Conversion to a Campus Geothermal System
Geothermal Research
• Senator Lugar arranged a NREL conference call (12/8/2008)• List of key heat pump designers and researchers
• Dr. Steve Kavanaugh and Kevin Rafferty• Jointly “wrote the book” on heat pumps• Disfavor district system; focus is on unitary systems
• New Oak Ridge study (Dec 2008) • Patrick Hughes• Latest DOE efficiency info re: geothermal• Barriers to implementation- first costs; public understanding
Ball State University’s Conversion to a Campus Geothermal System
Different Ways to Apply Geothermal to a Campus
• Key pieces of information to evaluate to decide what is best for the campus- Identify the Campus Thermal Profile- Existing Infrastructure- Phasing and Funding- Potential Bore Location- Geology- Well Field Model- Building Conversions and Hot Water Temp- Equipment Selection
Ball State University’s Conversion to a Campus Geothermal System
Heating & Cooling Loads for the Campus
Ball State University’s Conversion to a Campus Geothermal System
Campus Heating & Cooling Loads
MBT
U/
Hr
Campus Heating Load
Campus Cooling Load
Ball State University’s Conversion to a Campus Geothermal System
Campus Heating & Cooling Loads
MBT
U/
Hr
Campus Heating Load
Campus Cooling Load
Simultaneous Load
Ball State University’s Conversion to a Campus Geothermal System
Central Energy Plan
Cooling Mode COP = 5.93 / EER 20.23 (Avg.)
Chiller
Heating
Cooling
Building 4
C
Building 2
C
Building 3
C
Building 1
C
Well Field
Ball State University’s Conversion to a Campus Geothermal System
Heating ModeCOP = 3.4
Chiller
Heating
Cooling
Building 4
H
Building 2
H
Building 3
H
Building 1
H
Central Energy Plan
Well Field
Ball State University’s Conversion to a Campus Geothermal System
Simultaneous Heating/CoolingCOP > 7
Well Field
Chiller
Heating
Cooling
Building 4
H
Building 2
C
Building 3
H
Building 1
C
Central Energy Plan
Ball State University’s Conversion to a Campus Geothermal System
Drill Test Well
• Outcomes of Test Well- Geological Conditions- Conductivity- Diffusivity- Earth Temperature
Ball State University’s Conversion to a Campus Geothermal System
Ground Temperature Model
Thermal Energy Added During the Summer
Ground Temperature 55 Degree F
Thermal Energy Removed During the Winter
Ball State University’s Conversion to a Campus Geothermal System
Effects Of Different Hot Water Temps
Ball State University’s Conversion to a Campus Geothermal System
150° Hot Water Temperature
Ball State University’s Conversion to a Campus Geothermal System
Heat Pump Chillers
• Centrifugal Chillers- 600 - 2500 Tons- Up to 155 F HW temp for 600 - 2,500 Tons- Up to 170 F HW temp for 2,500 - 4,000 Tons
• Screw Chillers- 50 to 430 Tons- Up to 140 F HW temp
• Scroll Chillers - Up to 150 Tons- Up to 120 F HW temp
Ball State University’s Conversion to a Campus Geothermal System
• 5,600,000 GSF Heating Conversion• 47 Building Heating Conversion• Includes 300,000 GSF of Expansion• 1,800 - 400 ft. Bore Holes• 1,583 - 500 ft. Bore Holes• 2 Well Fields• 152,000,000 BTU/HR Heating• 150°F HWS • 20°F HW Delta T• 10,000 Tons Cooling• 2 Major Phases
Conversion Facts
Ball State University’s Conversion to a Campus Geothermal System
North + South Bore Hole Site
• 3,383 Total Bore Holes
• North Bores completed in 2010
• South Bores completed in 2014
• Over 1,000 miles of pipe installed
Ball State University’s Conversion to a Campus Geothermal System
Bore Hole Construction
Drilling 400/500 Feet
One borehole per day per rig
Installing the Pipe
Ball State University’s Conversion to a Campus Geothermal System
Bore Hole Design
• 15 feet apart• 225 SF per borehole• 400/500 feet deep• Double and Single Loop• 1-1/4 inch diameter pipe• High Density Polyethylene
3,383 boreholes (1,000 miles of pipe)
Boreholes spaced 15 feet apart
Header pipeburied 60 inches
Drilled the final borehole onOctober 17, 2014
Ball State University’s Conversion to a Campus Geothermal System
District Energy Station - North
Completed June 30, 2011
Ball State University’s Conversion to a Campus Geothermal System
• 12,000 SF• (2) 2,500 Ton Compound Centrifugal
Compressor Heat Pump Chillers• 38,000,000 BTU/HR
• Accessory Components• 1,000 Ton Fluid Cooler • Heating - 150° Hot Water • Cooling - 42°Chilled Water • LEED Gold Certified
District Energy Station - North
Ball State University’s Conversion to a Campus Geothermal System
District Energy Station - South
District EnergyStation SouthJanuary 2015
Natural Gas FiredSteam Boilers
Stacks to be removed2017/18
Ball State University’s Conversion to a Campus Geothermal System
• 16,480 SF• (2) 2,500 Ton Compound Centrifugal
Compressor Heat Pump Chillers• Accessory components • (4) 1,000 Ton Cooling Towers• Reuse (2) existing Water-Cooled Chillers• Anticipated LEED Silver
District Energy Station - South
Ball State University’s Conversion to a Campus Geothermal System
Distribution Utilities
• 8 Utility Packages• 10 Miles of Hot & Chilled Water
piping installed
Ball State University’s Conversion to a Campus Geothermal System
Building Interface Connections
Ball State University’s Conversion to a Campus Geothermal System
Building AHU Conversions
Ball State University’s Conversion to a Campus Geothermal System
BSU Geothermal Benefits
Reduction in Emissions• Carbon Dioxide 75,000 tons • Sulfur Dioxide 1,400 tons• Nitrogen Oxide 240 tons• Particulate Matter 200 tons• Carbon Monoxide 80 tons• Coal ash 3,600 tons
Other BenefitsBTUs per year reduction: 500,000,000,000BTUs/SF/Year reduction: 175,000 to 105,000 ( FY 15/16: 109,088)Water reduction: 45,000,000 gallonsDollars Saved: $2,200,000
Ball State University’s Conversion to a Campus Geothermal System
Geothermal Conversion Costs($ Millions)
Bore Holes $27Distribution Pipe $18Building HVAC Modifications $8District Energy Buildings $18.4Heat Pump Chillers $7.5High Voltage Improvements $4Total Construction Cost $82.9*
* US Department of Energy $5* State of Indiana $77.9
Carbon Emissions
100,000
110,000
120,000
130,000
140,000
150,000
160,000
170,000
2008 2009 2010 2011 2012 2013 2014 2015 2016
Car
bon
Emis
sion
s, M
etric
Ton
s
Year
Carbon Emissions
DESN STARTS OPERATION
Electrical Consumption
95,000,000
100,000,000
105,000,000
110,000,000
115,000,000
120,000,000
125,000,000
130,000,000
135,000,000
2008 2009 2010 2011 2012 2013 2014 2015 2016
KW
Hr
Year
Electrical Consumption
Energy Use Intensity
80
90
100
110
120
130
140
150
160
170
180
2008 2009 2010 2011 2012 2013 2014 2015 2016
Ener
gy U
se In
tens
ity (K
Btu
/SFY
r)
Year
Energy Use Intensity
80
90
100
110
120
130
140
150
160
170
180
2008 2009 2010 2011 2012 2013 2014 2015 2016
Ener
gy U
se In
tens
ity (K
Btu
/SFY
r)
Year
Energy Use Intensity
Ball State University’s Conversion to a Campus Geothermal System
Lessons Learned
• Keep the System Clean!• Know your true heating and cooling loads for good
balance• Equipment Turn Down & Phasing of Construction• Obtaining Hot Water Delta T at the Buildings
Ball State University’s Conversion to a Campus Geothermal System
Purging Equipment
Ball State University’s Conversion to a Campus Geothermal System
Debris Moved from Well Field
Ball State University’s Conversion to a Campus Geothermal System
Geothermal Project Visits and Inquiries
• Dartmouth College• Stanford University• University of Notre Dame• Ohio State University• University of Iowa• Northern Kentucky University• Colorado College• Slippery Rock University• Hampton University• Pratt Institute• Oakland University• Purdue University• Miami University, Ohio• Cornell University• Toledo University• Bowling Green State/Bowling Green• Wright State/Dayton
• University of Michigan• The Evergreen State College• Northwestern University• University of Illinois• Ohio University• Lake Land College• Indiana University-Purdue
University Indianapolis• DePauw University• University of Washington• Montana State University-Bozeman• Penn State University• University of Kentucky• Indiana State University• Northampton Community College• Colorado State University• Berea College
Ball State University’s Conversion to a Campus Geothermal System
Geothermal Project Visits and Inquiries
• U.S. Department of Energy• Indiana Department of Natural Resources• Indiana Office of Energy Development• Representatives of Isparta, Turkey• National Wildlife Federation• Union of Concerned Scientists• Building Indiana Magazine• WFYI Indiana Expeditions• The Chronicle for Higher Education• Delta Sky Magazine• Second Nature (2010 Climate Leadership
Award)• Japan News Crew
• Geo Outlook Magazine• Allison Transmission• Waterwell Journal• International District Energy Association• Biz World• The Christian Science Monitor• National Public Radio • Argonne National Laboratory• National Ground Water Association• Hoosier Environmental Council (2010 Technology
Innovator of the Year Award)• Waste Management• General Service Administration• Korea: Engineering Firm
Ball State University’s Conversion to a Campus Geothermal System
• Western Campus Infrastructure Phase 1 & 2
• Central Energy Plant• North Chiller Plant & East Quad
Infrastructure
Miami University – Oxford, OH
Ball State University’s Conversion to a Campus Geothermal System
Conversion Facts • 2,000 Tons Cooling• 40,272,000 BTU/HR Heating• 2,170,000 SF / 15 Bldgs.• 645 Vertical Bores• 558,600 lineal feet of 1¼ “ u-bend pipe
Missouri University of S&T – Rolla, MO
Missouri S&T geothermal system exceeds first-year goals.
Ball State University’s Conversion to a Campus Geothermal System
Utility Master Plan (Currently in Phase 1)
Goal: Eliminate current steam system and boilers, and replace with Low Temp Heating Hot Water System
Utilities Addressed • High pressure steam• Chilled water• Natural gas• Electrical distribution• Domestic water
Production Systems • Natural gas boilers• CHP• Chillers• Dry coolers• Ground Source Heat Pumps• Solar thermal• Hybrid systems
Carleton College – Northfield, MN
The new system will reduce central plant carbon emissions by over 70%
PH1 Building Conversions
Ball State University’s Conversion to a Campus Geothermal System
FORD MOTOR COMPANYLocation: Dearborn, MIType: Low Entropy Campus DesignStatus: Phase 1 - 2019Engineering Services: Development of low entropy campus with highly efficient Central energy plant
FIVE POINTSLocation: San Francisco, CAType: Eco-District Campus DesignStatus: Schematic DesignEngineering Services: Sustainable mechanical infrastructure development & system design
Eco-District SystemsThe next generation…
Ford Campus Utilities Plan
Ball State University’s Conversion to a Campus Geothermal System
Jim LoweAssociate Vice President for
Facilities Planning and ManagementBall State University
Mike Luster, PE, LEED APPrincipal | Sr. Mechanical Designer
MEP Associates, LLC
Questions?