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Gas Air Conditioning Technologies and Opportunities
6/5/12
Presenter:Eric BurgisDirector Commercial and Residential MarketsEnergy Solutions Center
© 2012 Energy Solutions Center Inc. All Rights Reserved
Air Conditioning IntroductionTechnologiesEconomicsEnvironmental BenefitsMarket Strategies and Opportunities
2
Topics for Today’s Webinar
© 2012 Energy Solutions Center Inc. All Rights Reserved
In a typical office building, lighting, heating, and cooling represent about 65 percent of total use Energy represents about 19 percent of total expenditures for the typical office building
3
Cooling Technology Introduction
Source: E Source Companies LLC.
© 2012 Energy Solutions Center Inc. All Rights Reserved
HVAC – Heating Ventilating and Air Conditioning (System)Ton of Refrigeration – Approximately equal to the cooling effect of 2000 pounds of ice melting in a 24‐hour period
The value is defined as 12,000 BTU per hour, or 3517 wattsEfficiency for Gas Systems:
Coefficient of Performance (COP). COP is defined as the ratio of heat removal (Cooling) or delivered (Heating) to the energy input.
Efficiency for Electric SystemsSEER = BTU/hr ÷ Watts for Unitary systemskW/Ton for Chillers
4
Some Terminology
WARNINGThe next
several slides are a bit technical
© 2012 Energy Solutions Center Inc. All Rights Reserved
Chemistry provides us that the Modern Gas LawPV=nRT or re‐written T= PV/nR.Temperature = (Pressure X Volume) / nRR is a gas constant and n is related to the refrigerant
In short, if the pressure and volume rise, the temperature increases and vice versa.
5
Cooling Science
© 2012 Energy Solutions Center Inc. All Rights Reserved 6
...simpler explanation
The pressure and volume inside the can goes down when it is sprayed, therefore the temperature also drops and the can feels cold.
The can gets hot if we were to pressurize it.
© 2012 Energy Solutions Center Inc. All Rights Reserved
Vapor Compression – uses a compressor to provide coolingAbsorption – uses heat to provide coolingAdsorption – uses the interaction of gases and solids to provide cooling Heat Pumps – uses either a compressor or a heat source to provide heating and cooling
7
Primary Cooling Technologies
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Step 1: Refrigerant enters the compressor in a low pressure, low temperature, gaseous formStep 2: The refrigerant is compressed to a high pressure and temperature gaseous state
8
Vapor Compression Cycle
Compressor
EvaporatorEvaporator
Hot Refrigerant Vapor
Drive
EngineMotorTurbine
Cold Refrigerant Vapor
CoolingTower
Rejected Heat
Load Heat
1
2
3
4Simplified
Fill aerosol Can
Can heats up
Warm Refrigerant Liquid
Cold Refrigerant Liquid
Condenser
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Step 3: The high pressure and temperature gas enters the condenser where it changes phase from the high pressure and temperature gas to a high temperature liquid by transferring heat to a lower temperature medium, usually ambient air
9
Vapor Compression Cycle
Simplified
Cool can
Gas inside changes phases
from vapor to liquid
9
Compressor
EvaporatorEvaporator
Hot Refrigerant Vapor
Drive
EngineMotorTurbine
Cold Refrigerant Vapor
CoolingTower
Rejected Heat
Load Heat
4Warm Refrigerant Liquid
Cold Refrigerant Liquid
Condenser
1
2
3
© 2012 Energy Solutions Center Inc. All Rights Reserved
Step 4: The high temperature liquid then enters the expansion device allowing a portion of the refrigerant to enter the evaporator
Vapor Compression Cycle
Simplified
Spray can for cooling effect
1010
Compressor
EvaporatorEvaporator
Hot Refrigerant Vapor
Drive
EngineMotorTurbine
Cold Refrigerant Vapor
CoolingTower
Rejected Heat
Load Heat
Warm Refrigerant Liquid
Cold Refrigerant Liquid
Condenser
1
2
3
4
© 2012 Energy Solutions Center Inc. All Rights Reserved
Controls the amount of refrigerant flow into the evaporator – a metering device
Thermal expansion valve
Electronic expansion valve
11
Expansion Devices (Valves)
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Vapor Compression (Mechanical Systems)Reciprocating compressorScrew compressorCentrifugal compressorScroll compressor
Absorption (Chemical process)Single effectDouble effect
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Cooling System Types
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Compressor Size Ranges
Scroll <2 RT – 10 RT
Reciprocating 20‐200 RT
Rotary Screw 60‐350 RT
Centrifugal 200 RT +
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Electric motorConstant speedVariable Speed Drive (VSD)
Natural Gas EngineSteam Turbine
14
Vapor Compression Drive Options
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Technologies
15
Engine DrivenTurbine DrivenAbsorption/AdsorptionHeat PumpsHybrid Systems
16© 2011 Energy Solutions Center Inc. All Rights Reserved 16
Engine Drives
Engine replaces electric motor in an Engine Driven systemRequires very little electricity for operation, ~5KW ancillary electricOffer variable speed capability (just like your automobile)
Can run at 20% capacity without loosing efficiency
© 2012 Energy Solutions Center Inc. All Rights Reserved 17
Engine Driven Chiller with Heat Recovery Options
Cooling
Condenser
Evaporator
Expansion Valve CoolingTower
Exhaust Gas /Heat Recovery
Compressor
From LoadTo Load
© 2012 Energy Solutions Center Inc. All Rights Reserved 18
Engine Fuel Use and Heat Recovery
Radiation (3%)
Shaft Power to Drive Chiller Compressor
33%
Exhaust Unrecoverable (16%)
Recoverable Energy (81%)
Fuel InputEnergy(100%)
Jacket Coolant 33%
Exhaust (15%)
© 2012 Energy Solutions Center Inc. All Rights Reserved 19
Engine Chiller Manufacturers
Alturdyne Energy Systems Tecogen
Trane York
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25 – 300 Tons (Chillers/DX units)Single or duel enginesReciprocating compressor
20
Alturdyne
© 2012 Energy Solutions Center Inc. All Rights Reserved 21
Tecochill Packages
TECOCHILL Water‐Cooled Chillers150 – 400 Ton packaged unitsR‐134a refrigerant800,000 Btu/hr@ 230oF hot water is available per engine
TECOCHILL Air‐Cooled Chillers25 – 50 Ton packaged unitsEnvironmentally‐friendly HFC‐404a refrigerantUp to 175,000 Btu/hr@ 160oF hot water available
© 2012 Energy Solutions Center Inc. All Rights Reserved 22
Trane Package
Trane CentraVac centrifugal chiller package coupled to a Waukeshau Enginatorgenerator package.Each can be individually operated to control energy costs165‐3,950 tonsLean burn engine technology provides low emissions
© 2012 Energy Solutions Center Inc. All Rights Reserved 23
York Package
Millennium® Gas Engine Drive (GED) offers a COP from 1.9 at design conditions and part‐load performance as high as 2.4GED chiller line available in 350‐2,100 RTIncorporates single‐stage centrifugal compressors on HFC‐134a refrigerantUtilizes Caterpillar natural gas engines
24© 2011 Energy Solutions Center Inc. All Rights Reserved 24
Turbine Driven Chillers
Utilizes steam to drive refrigeration compressorExcellent use for heating boilers in the summer monthsSizes 700 to 2800 Tons1.8 Coefficient of Performance (COP) York International is the only manufacturerVariable speed capability
© 2012 Energy Solutions Center Inc. All Rights Reserved
The thermodynamic cycle of an absorption chiller is driven by a heat source – a chemical process rather than a mechanical process.steam, hot water, or combustion as heat source
Compared to electrically powered chillers, an absorption chiller has very low electrical power requirements 15 kW combined consumption for both the solution and the refrigerant pumps
25
Absorption Cooling
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COP is often 0.6 (single‐effect) to 1.2 (double‐effect)Requires a larger cooling tower than a vapor‐compression chiller (~ 30%‐50% larger)Absorption units excel where low cost, high grade heat or waste heat is readily availableExcellent for Co‐Generation
26
Absorption Cooling …cont
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Consists of four major elementsGeneratorCondenserEvaporatorAbsorber
27
Absorption System Components
Single Stage Absorber Components
Simplified
Chemical process in a vacuum that creates high pressure refrigerant and cools without using a
mechanical compressor
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Adsorption works with the interaction of gases and solidsThese systems are less common than Absorption.The Adsorption process is used in Liquid Desiccant systems.
28
Adsorption Chillers
© 2012 Energy Solutions Center Inc. All Rights Reserved 29
Absorption Chiller ManufacturersManufacturer Sizes Special Features
Broad USA 5‐2600 Can be waste heat fired from exhaust.
Carrier Corporation 100‐680 Used in Capstone “Pure Comfort” unit
Cention Corporation 40‐650 Can be waste heat fired from exhaust.
Energy Concepts 15‐150 Available as a heat pump.
Fulton Boiler 4‐25 Incorporates Robur heat pump unit
Power Partners, Inc. 30‐250 Adsorption chiller
Robur Corporation 5‐25 Link into 25 ton units. Heat pump.
Thermax (Trane) 10‐2000 Steam, Hot Water, Thermal Fluid, or gas fired
Trane 112‐1650 Steam, Hot Water or Direct Fired
Yazaki 10‐100 Direct fired and Indirect fired units
York 120‐1350 Steam, Hot Water or Direct Fired
© 2012 Energy Solutions Center Inc. All Rights Reserved
Gas Heat Pumps
Absorption based systemsHydronic based systemCan produce hot waterAvailable for geothermal applications5 – 25 ton systems
Engine‐driven heat pumps Variable speed loading/unloadingScroll compressors for high efficiency8 to 20 Ton units
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What is a Gas Absorption Heat Pump?
31
Small gas fired boiler (traditional combustion)
95,500 BTU/HR input
Produces HOT (up to 149oF) or COLDwater (down to 37oF)Additional process to use energy from a renewable source (exothermic reaction with a refrigerant)Hydronic product
Piped into hydronic loop just like a hydronic boiler
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Achieving >100% Thermal EfficiencyHow is this possible?
10%Heat flue loss
Up to 149%Heat
Energy available
100%Inlet primary Energy for the combustion
50%Energy fromnatural source
(ground, water, air)
32
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Ground or Water Source
Well field reduction up to 40% compared to electric ground source systems!
34
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Efficiency ComparisonHeating Product
CategoryMaximum Thermal
EfficiencyNon‐Condensing Boilers 88%
Condensing Boilers 99%
Gas Absorption Heat Pumps 149%
35
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Capital Investment & PaybackLIST prices of the Invictus heat pumps range from $8,800 ‐ $9,900 per unit.Can achieve reasonable initial capital investment by designing hybrid systems with boilers, chillers or other technologies.
36
Fulton Heating Solutions, Inc.
© 2012 Energy Solutions Center Inc. All Rights Reserved
GAHP SystemsAir‐source water‐ammonia absorption heat pumpsUp to 140oF hot water availableSingle phase power requirementsCan be linked using single or multiple controllers
Re‐Packaged by Fulton Boiler, known as Invictus
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Robur CorporationAbsorption Heat Pump
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15‐300 Tons Absorption Heat PumpUsed for Cooling or refrigeration160oF hot water at 1.5 COPCustom designed for application
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Energy ConceptsAbsortption Heat Pump
39© 2011 Energy Solutions Center Inc. All Rights Reserved
Similar to electric heat pumps.
Electric motor replaced with a natural gas driven engine.
Excellent part load efficiencies
Multiple zone capable
Heating efficiency COP = 1.6
Engine Driven Heat pumps
39
© 2012 Energy Solutions Center Inc. All Rights Reserved
Multi‐Zone GHP OverviewFeatures Application Benefit
8‐ton & 15‐ton
R‐410A
Multi‐zones (up to 33 zones)
Ground or roof mounted
Designed to operate in extreme high and low temperatures
Space saver on existing or future mechanical rooms
Quiet as a whisper, 58 dB
Lower operating cost than two or four pipe systems
Commercial buildings
Custom & semi‐custom residential
New or retrofit construction
Ducted, ductless, or combination of both
Outdoor unit can be set back as far as 400 feet from the building
Up to a total of 1,706 relative feet
Best applications are large 100, 200, 300+ tonnage, multiple zones
Highly efficient in both heating and cooling modes
All‐in‐one heating and cooling unit
Multi‐zone feature provides higher comfort level
Potential for innovative building design with ductless capabilities
Fully optimizing part loads (IPL)
Freeing up electricity for redistribution within the facilities
40
© 2012 Energy Solutions Center Inc. All Rights Reserved
Packaged GHP OverviewFeatures Application Benefits
11‐ton
R‐410A
Rooftop package
Built in the U.S.
Made for harsh temperatures of the desert Southwest
Commercial
Retrofit
New construction
Mounted on rooftop curb, similar to electric rooftop units
Avoid high demand and time‐of‐use electric charges
Highly efficient in both heating and cooling modes
Captures and utilizes waste heat from the engine in heat mode
Future option to capture waste heat from the engine for water heating
Saves water compared to electric units
41
© 2012 Energy Solutions Center Inc. All Rights Reserved
8, 10 & 15 Ton units availableZoning capabilities17 zone capability on 8 RT unit
Ducted or ductless air handlers availableAir‐cooled condensing in packaged unitCOP 1.4 for Cooling and 1.6 for heating
42
IntelliChoice EnergyEngine Driven Heat Pump
43© 2011 Energy Solutions Center Inc. All Rights Reserved
Committed to smart, sustainable technology.
43
Coming soon
© 2012 Energy Solutions Center Inc. All Rights Reserved
Incorporate electric & gas chillers into a combined chiller plantInstall both unit types into system50% electric/50% gas capacities
Base load chiller based on utility costs or time of dayIdeal for facilities that have minimal electrical service
44
Hybrid Chiller Applications
45© 2011 Energy Solutions Center Inc. All Rights Reserved
Utilize a Life Cycle Cost AnalysisA detailed Cost Analysis is essentialfor evaluating any Cooling project at a facility.Using the real energy costs associated with the cooling technology is critical.
45
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Provide comparison of technologies
46
Sample Payback Analysis Tools
Natural Gas vs. Electric Air Conditioning
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Size: 500 Tons, Equivalent Full Load Hours: 1,500
Life Cycle Cost of Ownership
Energy Maintenance Capital
Life Cycle Costs consider the full costs of ownership over the life of the equipment including fuel, inflation costs, maintenance costs, and capital costs
$1M
$2M
GasAbsorber
GasEngine
Electric Chiller
$1.3M without heat recovery &
$1.2M with recovery
$1.9M
$1.7M
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Environmental Benefits
49
•No CFC’s or HCFC’s in Absorption Cooling•Potential for Reduced Carbon Footprint with Gas Cooling
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Emissions for various cooling technologies need to be consideredCO2 emissions need to be evaluated on a site vs. source basisIn General….
Emissions are lower for Engine Driven chillers and Steam Turbine Chillers than electric ChillersEmissions may or may not be lower for absorption than electric cooling
50
Emissions
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www.gasairconditioning.com
51
Emissions Calculator for Engine Driven and Steam Turbine Chillers
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Gas Engine Chiller CO2 Reduction Benefits
Peak Demand (kW)
272272
220220
33
Conventional Electric ChillerCoal Central StationGas Central Station (advanced GT)
High Efficiency Electric ChillerCoal Central StationGas Central Station
Gas EngineWithout Heat RecoveryWith Heat Recovery (Boiler Credit)
CO2 (tons/yr)
770320
614255
300100-150
Annual CO2 Outputs - 400 Ton Chiller Alternatives
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Market Strategies & Opportunities
53
•Electric Grid Issues•Case Studies
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Typical Gas & Electric Demand Profile
Gas cooling reduces peak electric demand which reduces billed demand
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T & D Constraints continue to increase
Gas Air Conditioning can reduce demand
9,000 MW > 7,000 MW < 8,000 MW
Generation: (Growing)
Transmission
& Distribution:
(?????)
Load: (Growing)
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Average Gas vs. Electric Pricing
$‐
$5.00
$10.00
$15.00
$20.00
$25.00
$30.00
$35.00
$40.00
$45.00
Year 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
$/MMBT
UAverage Commercial Retail Energy Rates
Electric
Natural Gas
*EIA data as of September 2011, uses 1032 BTU/CF Natural Gas and 3412 BTU/KWH Electric.
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Why is Owning an Electric Chiller Like an Iceberg?
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Total Cost of Electric Chiller Ownership
First Costs
Hidden Costs(Future Costs)
Price
Energy CostsBurden on Electrical System
59© 2011 Energy Solutions Center Inc. All Rights Reserved 59
Applications
Residential
Commercial
Industrial
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Engine driven heat pump
Fire Station # 13, May 2011 (LEED Silver), Plano, TX
Plan to compare to “sister” Fire Station # 12 (electric VRV heat pump)
Firehouse, TX
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Healthcare – Cedars Sinai, CA
•Two 1,500‐ton double‐effect, steam‐fired absorption chillers
• One 1,500‐ton electric chiller
•Three gas‐fired steam boilers
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University Medical Center, IL
•Two absorption chillers, 4,600 tons absorption cooling
•Part of Co‐gen plant
•Supplies electric power and steam to 32‐building campus
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Office Building – One Parkway, PA
•Two 400‐ton natural gas engine‐driven chillers
•Hybrid cooling system for peak Shaving
•Free heating for domestic hot water
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Hybrid Installation, MA
•350 Tone Engine Driven Chiller
•United States Military Building
•Military Entrance Processing Station
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Air Cooled Engine Driven Units, NY
•5 x 50 Ton Engine Driven Chillers
•Air‐Cooled Roof Top Chillers
•Jamaica, NY Hospital
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Industrial – Ghirardelli, CA
145 Tons Absorption
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Industrial – Poultry Processor
100 tons chilling and 3.2 MBH heat pumped hot water from 2 MBH steam.Saves 30% of water heating and 80% of chilling energy.40ºF chill water and 136ºF hot water.
Custom built Heat Pump
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Break down & Field Reassembly
Apartment Building
West Hartford, CT
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Office Building – Heat Pump, NV
•113 Tons of Engine driven heat pumps
•7, 15 Ton units
•1, 8 Ton unit
•42 Indoor air handlers
71© 2011 Energy Solutions Center Inc. All Rights Reserved
AdditionalResources
71
www.gasairconditioning.org