1 Going Green In The Laboratory Laboratory Association of NH September 24, 2009 Greener Chemistry Associates LLC 66 Ridgeview Lane New Boston, NH 03070

1

“Going Green In The Laboratory”

Laboratory Association of NH September 24, 2009

Greener Chemistry Associates LLC

66 Ridgeview Lane

New Boston, NH 03070

Office 603-487-2235

<[email protected]>

Valero Harnesses Wind Energy to Fuel Its Oil-Refining Process

2Wall Street Journal, June 29, 2009

“Embracing new green technology in order to make more money producing old fashioned fossil fuels”

Valero Harnesses Wind Energy to Fuel Its Oil-Refining Process

Key Points Sunray, TX 70 yr old refinery 33 windmills, $115 million Produce gasoline and diesel fuel Payback 10 yrs Produces 50 Megawatts/Hr -> 100% of plant

needs, 40-45% of the time 3 employees

3

Outline

Principles of Green Chemistry Solvent Recycling Energy Conservation & Funds Water Conservation Greener Consumable Materials & Supplies Lab Equipment Laboratories for the 21st Century Additional Resources

4

Principles of Green Chemistry

5

Principles of Green Chemistry Paul Anastas, John Warner

Prevent waste, not clean it up Reduce scale of experiments Reduce excess of chemicals used in an analysis,

when possible Reduce cost/quantity of hazardous waste Preventing a problem is better than trying to solve

the problem

6


Paul Anastas, John Warner

Incorporate all materials into the product Synthesis

7


Paul Anastas, John Warner

Produce substances with little to no toxicity to humans and the environment Synthesis

8


Products should preserve the efficacy of function while reducing toxicity Formulators

9


Reduce the use of auxiliary substances Synthesis

10


Minimize energy requirements for process Heat input for acceleration of reactions Use of catalysts to reduce energy of activation Need for cooling reactions Energy required for separation

11


Use renewable materials when possible Solvents Reagents

12


Avoid unnecessary derivatives Synthesis

13


Catalytic reagents are better than stoichiometric reagents A + B = C is > A + B = C + D

14


Products should degrade to innocuous substances, not persist in the environment, at the end of their function Bioaccumulators that persist in nature

Plastics Pesticides

Degradable products that form more toxic derivatives NPE’s

15


Develop analytical methods for in-process monitoring and control prior to the formation of hazardous substances Synthesis

16


Substances in a chemical process should minimize the potential for chemical accidents, including releases, explosions and fires Toxics Flammables Explosives Chemical recycling

17

Solvent Recycling

18

Solvent Recycling

Most any solvent is capable of being distilled Recycling depends on contaminants (co-solvents;

azeotropes; dangerous mixtures to heating) Commercial units can be from 2.6 gallons on up in

capacity BPts 50-200o C; >200C with vacuum Typical cycle time 4-6 hrs Manual or automatic operation; batch or continuous Explosion proof atmospheres

19

Why Recycle Solvents?

Reduce Cost! (Chemical purchases and waste disposal)

Reduce storage and handling of hazardous waste up to 95%

Reduce shipments of hazardous waste Reduce landfill of hazardous waste Help the environment Be a greener facility

20

Cost Savings With Solvent Recycling?Small Scale Facility-Solvent Information

Solvent Proprietary

Boiling Point 223 C

Vacuum Required? Yes

Solvent Cost/Gallon $10.84

Gallons/Year 1,155

Solvent Purchases/Year $12,520

Hazardous Waste Disposal: Gallons/Year 1,155

Cost/Drum $53

Cost/Year $1,113

Total Solvent Cost/Year $13,633

21

Cost Savings With Solvent Recycling?Small Scale Facility-Recycle Unit

Gallons/Year 1,155

Gallons/Week 23

Gallons/Day 4.6

Shifts Worked/Day 2

Capacity of Recycle Unit Required 2.6 Gallons

Cost of Recycle Unit ~$6,000

Cost of Vacuum ~$4,000

Total Cost ~$10,000

22

Cost Savings With Solvent Recycling?Small Scale Facility-Cash Flow Projection

Solvent Cost/Year (Purchase + Disposal) $13,600

Assumed Recovery Efficiency 90%

Projected Annual Savings $12,240

Total Cost of Recycle Unit + Vacuum $10,000

Payback 10 Months

23

First Year Savings = $2,240

Energy Conservation & Funds

24

Energy ConservationLighting Systems & Components

25


Design of lighting system is critical for work done in the laboratory

Lab lighting is up to 2X greater than office space

Cost of lighting varies from 8% to 25% of total energy consumption

Laboratory lighting codes: 1.3-1.8 W/sf

26


Daylight Integration Electric lighting should supplement daylighting

Fixture Configuration Direct-Indirect (20-40%:60-80%) ambient lighting parallel to benchtop Task lighting (use only when required)

Lamps and Ballasts T5 for new construction “Super” T8 for upgrade from T12 or T8 Electronic ballasts (RF shielded luminaires in instrument labs) Compact Fluorescent (CFL) or Low Wattage Ceramic Metal Halide lamps

instead of incandescent Controls

Bi-level switching Occupancy sensors

27


Light Bulb Lumens/Watt of Heat Gain

Incandescent 5-15

Tungsten-Halogen 20-35

Mercury Vapor 25-50

CFL 15-75

Linear Fluorescent 60-95

Metal Halide 50-100

High Pressure Na 55-110

Daylight/Direct 80-225

Daylight w/o Direct 100-290

28

Energy ConservationHVAC

29

Energy ConservationAudience Poll

How many attendees have hoods in their laboratories?

Is this a major source of energy waste?

30


Energy consumption is typically greater percentage of electricity usage than lighting

31


“RM&M” Regular Monitoring & Maintenance Calibrate, check and adjust thermostats Implement “set-back” strategies Multiple HVAC systems “fighting” each other

(simultaneous heating & cooling) Clean/replace air filters and dampers Inspect ducts and pipe insulation Clean heat transfer coils – chillers, heat pumps,

air conditioners

32

Energy ConservationTypical Causes for Waste

Underutilized or inappropriate fume hoods Fume hoods with large bypass openings Unnecessary reheat of lab space Positive pressure in containment labs Excessive duct static pressure Over ventilated lab spaces Supply air temperature overshoot Lack of load management for equipment Setback of temperature or airflow when

unoccupied33

Energy ConservationFume Hoods

Typical hood uses as much energy in a year as 3 U.S. households

U.S. safety standards require air turnover 6-12 times/hr. Not unusual to measure rates of 15-25 turnovers/hr.

A reduction from 12 to 10 turnovers/hr can reduce amount of fan power by >40%.

Key improvement can be variable air volume by adjust speed of fan

Sash opening34

Energy ConservationFume Hoods

“Sash Police” and Lab Policy Create atmosphere of friendly exchange and

overlook

35

Energy ConservationSustainability

UK Survey of 400 laboratory scientists 95% agreed science & technology are important if

sustainable solutions were to be developed for the future

40% said they always or often considered the effect of their work on the environment

53% of the 40% thought not relevant to their area of science

36

Energy Funds

Regional Greenhouse Gas initiative (State Business Finance Authority)

American Recovery and Reinvestment Act (3X funding for Rural Energy for America Program)

Expanded tax incentives through ARRA Free or reduced cost energy audits Federal grants or tax credits for alternative

energy37

Energy Funds

Utility rebates for more energy efficient lighting, motors and insulation (gas and electric heating) incentives

PSNH training program for energy audits for small and large businesses (Tom Belair)

EPA Portfolio Manager for comparing facility energy efficiency to others in similar business

Federal tax credits of 30% for installing solar, wind and fuel cells with no dollar cap

Federal tax credits of 10% for geothermal systems, microturbines and combined heat and power systems

(secondary heating) with no dollar cap 38

Energy Funds

Tax credits based on facility square-footage to make them more energy efficient

Business Energy Efficiency Program (BEEP) run by NH Dept of Resources and Economic Development provides energy audits free of charge

Loans and grants for energy efficiency- conservation and renewable energy projects

Office of Energy and Planning competitive awards

39

Water Conservation

40

Water Conservation

Laboratory buildings use more water than standard commercial buildings, per SF

More opportunities for cost-effective improvements water usage

Big hitters: cooling towers and special process equipment; water treatment and sterilizing systems

41

Water Conservation

Audience Poll How many attendees have a cooling tower for

their labs or buildings?

42

Water Conservation

Cooling towers offer the greatest potential for improving the efficiency of water usage

43

Water ConservationLaboratory Processing Equipment

Cooling of equipment Single pass (“once through”) 40X more water than a cooling tower at 5 cycles of

concentration to remove the same heat load Equipment:

CAT scanners vacuum pumps Degreasers X-ray equipment Hydraulic equipment Air conditioners Compressors Process chillers Condensers Electron microscopes Gas chromatographsMass Spectrometers

44


Process or cooling loop, at fixed temperature, is best alternative to single pass cooling

Water meter on the loop to determine water volume – separate process water from domestic

Optional uses: Irrigation for farming Initial water rinses followed by clean water Heat recovery and transfer to another process

45


Rinsing equipment Counter flow rinsing operation

Fresh water is last rinse Dirty water is first rinse Number of rinses between determined by process

requirements

46


Flow control Equipment “On” continuously even with

intermittent use 1.5 gpm trickle flow through small cooling unit

becomes 788,400 Gallons of water consumed per year

Control or solenoid valve allows water to run only when equipment is being used

Shut-off valves or timers to automatically turn equipment off after-hours and for maintenance

47


Water-treatment equipment for water free of minerals or organic contaminants

As finer and finer particles are removed, energy use and water waste increases Particle filtration Microfiltration Ultrafiltration Nanofiltration Hyperfiltration

48


Alternative water sources Condensate recovery

Air conditioners Dehumidifiers Refrigeration units

Rainwater harvesting elements Roof or catchment area Downspouts, roof drains Leaf screens, roof washers Cisterns, storage tanks (above or below ground) Conveyance system Treatment system

49

Water ConservationPlumbing

Faucets Automatic on/off Low flow

Urinals Waterless Low flow

Toilets Low flow Variable volume

Plumbing Fixtures Flow restrictors Pressure regulators

50

Greener Consumable Materials & Supplies

51

Greener Consumable Materials & Supplies

Janitorial/Cleaning Environmentally friendly products

Paper Towels Recycled paper content

Bathroom Tissue Recycled paper content

Hand Care Skin compatible soaps and sanitizers

Disposable Wipes Effective and environmentally compatible

52

Lab Equipment

53

Lab EquipmentTypical Laboratory Equipment

Significant energy users Autoclaves Glass washers Refrigerators Computers

Lack of measured equipment load data = “Nameplate” data or assumptions => “Peak equipment loads are frequently overestimated”=> Oversized HVAC systems, increased initial construction costs, increased use of energy due to inefficiencies at low part load operation”

54

Lab EquipmentBest Practice Strategies

Measure equipment loads in a comparable lab

Use a probability-based approach to assess load diversity

Allow for flexibility and growth, especially in the distribution systems

Compare design loads with most-likely maximum loads

55

Lab EquipmentBest Practice Strategies Configure equipment for high part-load efficiency (high

efficiency at low loads) Variable speed drives on chillers, fans and pumps Negotiate risk management between owner and

designer Use energy efficient equipment (EnergyStarTM) Manufacturer’s data for operation at:

Peak mode Nominal mode Dormant (sleep) mode

56

Lab Energy AuditsCheck List

Power Lights Instruments/Equipment

Water Faucets Cooling Water Rinse Water

Air Thermostats Hoods/Sashes

57

Laboratories For The 21st Century(Labs21)

58

Labs21About Labs21 EPA & DOE Professionals exchange information

Partnership Program Training and Education Tool Kit

Growth opportunity for advanced, environmentally preferred, building technologies

Typical Laboratories use far more energy and water per square-foot than office space Ventilation Health and Safety Concerns

Guiding Principle: “Examine the entire facility” Component analysis can miss/eliminate greater opportunities to make other

more significant efficiency improvements

59

Labs21Approach

Sustainable, high performance and low energy laboratories to Minimize overall environmental impacts Protect occupant safety Optimize whole building efficiency on a life-cycle

basis Establish goals, track performance, and share

results for continuous improvement

60

Labs21Partner Commitments

Adopt voluntary goals Assess opportunities using “whole building”

approach Life-cycle cost analysis Include “whole building” approach for new

construction and retrofit projects Measure energy and water consumption Track emission reductions Build with “green” construction materials

61

Labs21Partnership Program Criteria

Identify a central contact Identify and describe a laboratory site Set measurable energy and environmental

performance goals Benchmark existing performance of facility Share results Report project results annually

62

Labs21Benefits of Membership

Cost savings Environmental and health improvements Reduced pollution and greenhouse gas

emissions Expert technical assistance “Tool Kit” and other resources Networking opportunities

63

Labs21Tool Kit Overview

Introduction to low energy design Labs21 video (online)

Core information services Design guide for energy-efficient research labs Best practices guide (20) Case studies Energy benchmarking Laboratory equipment efficiency Wiki

Design process tools Environmental performance criteria Design intent tool Labs21 Design process manual

64

Resources

Anastas and Warner, Introduction to Green Chemistry

Corbyn, Nature, Vol. 445(8) February 2007 U.S.EPA/U.S.DOE Laboratories for the 21st

Century: Best Practices Sanders, New Hampshire Business Review,

August 14-27, 2009

65

Additional ResourcesWebsites outline energy programs

dsireusa.org nh.gov/oep/recovery/sep_programs/index.htm nh.gov/oep/recovery/documents/grant_matrix.pdf energystar.gov/index.cfm?c=tax_credits.tx_index energystar.gov/index.cfm?

c=evaluate_performance.bus_portfoliomanager puc.state.nh.us/Sustainable%20Energy/

SustainableEnergy.htm rurdev.usda.gov/rbs/ Labs21century.gov

66

Documents

1 Going Green In The Laboratory Laboratory Association of NH September 24, 2009 Greener Chemistry Associates LLC 66 Ridgeview Lane New Boston, NH 03070