integrated systems + principles approach. source: california energy commission (2000) manufacturing...
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![Page 1: Integrated Systems + Principles Approach. Source: California Energy Commission (2000) Manufacturing Energy End-Use Breakdown](https://reader035.vdocuments.us/reader035/viewer/2022081516/56649d3e5503460f94a17352/html5/thumbnails/1.jpg)
Integrated Systems + Principles Approach
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Source: California Energy Commission (2000)
Manufacturing Energy End-Use Breakdown
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Energy Systems– Lighting– Motor drive– Fluid flow– Compressed air– Steam and hot water– Process heating– Process cooling– Heating, ventilating and air conditioning– Cogeneration
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Principles of Energy Efficiency
Inside Out Analysis Understand Control Efficiency Think Counter-flow Avoid Mixing Match Source Energy to End Use Whole-system, Whole-time Frame Analysis
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Integrated Systems + Principles Approach
Integrated systems + principles approach (ISPA) = Systems approach + Principles of energy efficiency
Electrical Lighting Motors Fluid FlowCompress
Air SteamProcess Heating
Process Cooling HVAC CHP
Lean Energy Analysis BaselineInside Out AnalysisMinimum Theoretical EnergyConversion and Control EfficiencyMatch Source Energy to End UseMaximize Counter-flowAvoid MixingWhole-system, Whole-time Frame Analysis
ISPA is both effective and thorough.
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1. Inside-out Approach
Conversion Distribution UseEnergySupply
Energy Use
Inside-Out Analysis Approach
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Inside-out Approach
Conversion Distribution Use
EnergySupplySavings
Energy End–Use Savings
Inside-Out Analysis Approach
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Inside-out: Amplifies Savings
Reduce pipe friction: Savings = 1.00 kWhPump 70% eff: Savings = 1.43 kWhDrive 95% eff: Savings = 1.50 kWhMotor 90% eff: Savings = 1.67 kWhT&D 91% eff: Savings = 1.83 kWhPowerplant 33% eff: Savings = 5.55 kWh
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Inside-out: Reduces Costs
Original design: 95 hp in 14 pumps Re-design:
– Bigger pipes: Dp = c / d5
• (doubling d reduces Dp by 97%)– Layout pipes then equipment
• shorter runs, fewer turns, valves, etc…– 7 hp in 2 pumps
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Avoid Outside-in Thinking
EinPrimaryEnergy
Conv ers ion Equipment
EnergyDis tribution
Sy s tem
Manufac turing
Plant Boundary
Proc es s andEquipment
E EWas te
TreatmentSy s tem
Was teDis pos al
W W Wout
Inside-out analysis sequence
for reducing energy
Inside-out analysis sequence
for reducing waste streams
Traditional Analysis Sequence
for Reducing Energy Use
Traditional Analysis Sequence for
Reducing Waste
Result: Incremental improvement at high cost
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Think from Inside Out!
EinPrimaryEnergy
Conv ers ion Equipment
EnergyDis tribution
Sy s tem
Manufac turing
Plant Boundary
Proc es s andEquipment
E EWas te
TreatmentSy s tem
Was teDis pos al
W W Wout
Inside-out analysis sequence
for reducing energy
Inside-out analysis sequence
for reducing waste streams
Inside-Out Analysis Sequence for
Reducing Energy Use
Inside-Out Analysis Sequence for
Reducing Waste
Result: Significant improvement at minimal cost
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2. Understand Control Efficiency
Systems design for peak load, but operate at part-load
System efficiency generally changes at part load Recognize and modify systems with poor part-
load (control) efficiency
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Control Efficiency
Energy
Production
Poor
Excellent
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Air Compressor Control
FP = FP0 + FC (1 – FP0)
0.00
0.25
0.50
0.75
1.00
0.00 0.25 0.50 0.75 1.00
Fraction Capacity (FC)
Fra
ctio
n P
ow
er (
FP
)
Blow Off
Modulation
Load/Unload
Variable Speed
On/Off
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Power and Flow Control
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%0%
20%
40%
60%
80%
100%
By-pass Outlet Damper
Variable Inlet Vane Variable Frequency Drive
Volume Flow Rate (%)
Po
wer
(%
)
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Chiller Control
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Boiler Control
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Data Scatter Indicates Poor Control
2001 Gas Usage vs. Lime Production
0
5,000
10,000
15,000
20,000
25,000
30,000
0 500 1,000 1,500 2,000 2,500 3,000
Lime Production (tons)
Gas
Co
nsu
mp
tio
n (
mcf
)
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3. Think Counter Flow
Heat transfer Fluid flow
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Counter-flow Improves Heat Exchange
Q
T
T
x
x
Q
Parallel Flow
Counter Flow
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Stack Furnace Pre-heats Charge
Reverb Furnace Stack Furnace
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Molten Glass Transport:Each Exhaust Port Is A Zone
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Counter-flow Within Zones
Increases convection heat transfer by 83%
Contact length = 2 x (5 + 4 + 3 + 2 + 1) = 30 feet
Contact length = (10 + 9 + 8 + 7 + 6 + 5 + 4 + 3 + 2 + 1) = 55 feet
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Tile Kiln (Counter flow?)
TileExit Tile
Entrance
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Counter Flow Cooling Enables Cooling Tower
Cross-flow cooling of extruded plastic uses 50 F water from chiller
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4. Avoid Mixing
Availability analysis…Useful work destroyed with mixing
Examples– CAV/VAV air handlers– Separate hot and cold wells– Material reuse/recycling
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HVAC Applications
Cooling Energy Use Heating Energy Use
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Cooling Applications
Separate hot and cold water tanks
ProcessLoad 1
ProcessLoad 2
Chilled Water Tank
Cooling Tower
BypassValve
Tp2
Tc2 Process Pump
Tp1
Cooling Tower Pump
Tc1
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5. Match Source Energy to End Use
0
50
100
150
200
250
300
Compressed air Open loopcooling
Chillers Cooling towers
$/m
mB
tu c
oo
lin
g
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Match Source Energy to End Use
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Utilize Current Daylighting
Wright Brothers Factory, Dayton Ohio
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Replace Colored / Fiberglass Windows with Corrugated Polycarbonate
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Employ Skylighting
Skylights:– Highest quality light– Reduce lighting energy costs– Increase heating/cooling costs
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6. Whole System Whole Time Frame Design
Design heuristic derived from natural evolution Nothing evolves in a vacuum, only as part of a system No optimum tree, fan, … Evolutionary perspective: ‘optimum’ synonymous with
‘perfectly integrated’ Optimize whole system, not components Design for whole time frame, next generation
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Whole System “Lean” Manufacturing
400 ft/min 200 ft/min
200 ft/min
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Whole System Energy EngineeringOptimum Pipe Diameter
Dopt = 200 mm when Tot Cost = NPV(Energy)+Pipe Dopt = 250 mm when Cost= NPV(Energy)+Pipe+Pump Energy250 = Energy200 / 2
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Whole System Accounting
Budgeting and capital processes separate from operational processes
Organizational structures within companies constrains optimum thinking
Enlarge system boundary to include entire company
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Whole-Time Frame Accounting“Efficiency Gap”
“Numerous studies conclude 20% to 40% energy savings could be implemented cost effectively, but aren’t…..”
Discrepancy between economic and actual savings potential called “efficiency gap”.
Puzzled economists for decades: “I can’t believe they leave that much change lying on the table.”
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Don’t Eat Your Seed Corn
SP = 2 years is ROR = 50%
SP = 10 years is ROR = 10%