Energy recovery presentation

1 www.1-ACT.com/HVAC

Innovations in Action

Advanced Cooling Technologies, Inc. Energy Recovery Systems

Overview Mark Stevens, New Business Development

[email protected], 717-344-0061 Pete Dussinger, VP Engineering, ER Products

[email protected]

mailto:[email protected]







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


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.



Primary Markets Energy Recovery

Military & Industrial Cooling

Satellite Thermal Control

Temperature Calibration and Control

Contract R&D and Technical Services

ISO 9001:2008 Certified for Terrestrial Product Design and Manufacturing

AS/EN/JISQ9100:2009 Certified for Aerospace Products Design and Manufacturing

Quality System



ACT Team Overview

73 Full Time Employees

33 Engineers

34 Technicians / Production

5 SG&A

Engineering Backgrounds

11 Ph.D’s

12 Masters

11 Bachelors

M.E. , E.E., Chem. E, Nuclear,

Physics & Manufacturing

Cumulative Professional

Team Experience:

Publications : > 400+

200 Years

Patents Granted : > 70


ACT Capabilities and Equipment

Capabilities – Thermal Design and Analysis

– Thermal Testing Characterization, and Validation

– Prototype Assembly

– Heat Pipe Manufacturing

– Assembly Manufacturing

– Certified Welding

– Brazing

– Soldering

Equipment – 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


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

http://www.1-act.com/resources/heat-pipe-fundamentals/heat-pipe-article-1968/

http://www.1-act.com/resources/heat-pipe-fundamentals/heat-pipe-article-1968/


Heat Pipes Are Super Conductors

Vapor Space

Liquid Film


Heat Pipes Are Super Conductors 200 Times Better Thermal Conductor Than Copper

Isothermal


Examples of Heat Pipe Applications

Satellite Heat Pipes: TACSAT 4

Military Satellite


Examples of Heat Pipe Assemblies

High-Power Heat Pipes up to 500 Watts/cm2

Heat Sinks Optimized with Heat Pipes

Heat Pipes for Electronics

High Temperature Heat Pipes


Embedded Heat Pipe Application Shipboard Radar Application Reduced Hot Spots by 30°C

13” x 20”

Pumped liquid cool rail on plate edge

WITHOUT HEAT PIPES

WITH HEAT PIPES


Heat Pipes in Energy Recovery


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


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


ACT Energy Recovery Technology Types

Wrap-Around Systems Enhanced Dehumidification

Air-to-Air Systems

PASSIVE-SPLIT THERMOSYPHON LOOP


ACT Energy Recovery Technology Types

SUMMER/WINTER PUMP LOOP SYSTEM

PASSIVE SUMMER/ PUMP WINTER


Comparison of Energy Recovery Systems

Energy Recovery Technology Comparisons

Energy Recovery Type

Sensible Heat Transfer

Latent Heat Transfer

PRESSURE DROP

TYPICAL

TYPICAL EFFECTIVENESS

CROSS CONTIMINATION

MOVING PARTS

MAINTENANCE REQUIED OTHER THAN CLEANING

DUCT WORK REQUIED SIDE-

BY-SIDE

INSTALLATION DIMENSIONAL

ISSUES

Electrical Power

Required

Heat Pipe Wrap-Around YES Enhanced

Dehumidification UNDER 0.5 10-50%(*) NO NO NO NO NO NO

Heat Pipe Air-to-Air 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 cost > 0.75 < 1.2 50-80% NO NO NO YES Very Large as

CFM Increase NO

Energy Recovery Wheels YES YES > 0.75 < 1.2 50-80% YES upto 12% YES YES YES NO YES

* Effectiveness is calculated for each application to meet the desired re-heat temperature.


Wrap-Around Heat Pipe Heat Exchangers for

100% Dedicated Outdoor Air Energy Recovery


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


ACT-HP-WAHX Wrap-Around System Typical Air Handler Application

92ºF / 78.0FWB

80.0ºF / 74.9 FWB

52.0ºF / 51.9 FWB 64.2ºF / 56.9 FWB

Pre-Cool Coil

Cooling Coil

Re-Heat Coil

Outside Hot & Humid Air

Comfortable Air


ACT-HP-WAHX Wrap-Around System Typical Air Handler Application

12°F 12°F


ACT-HP-WAHX Wrap-Around System Installation Configurations


AHU Added Performance With ACT ‘s Wrap-Around Heat Pipes

• Typical cooling systems provide sensible and latent cooling.

• Adding WAHX pre-cooling enhances AHU’s ability to 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%

Sensible Cooling,

75%


Wrap - Around Heat Pipe System Profile

Saved BTUs

Saved BTUs


What Effect Does Adding More Rows Have on Installed Performance?

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

1000cfm; 480fpm face velocity, ½” Heat Pipes @ 12fpi


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”


ACT-WAHX Performance Calculation Increasing Tonnage Performance

25 Tons AHU No WAHX 2R WAHX = 21 Ton AHU 6R WAHX = 18 Ton AHU


ACT-WAHX Performance Calculation Increasing Dehumidification Performance

25 Tons AHU No WAHX 2R/25 Tons AHU +23%

99.4%

6R/25 Tons AHU +41%


WAHX Calculation with Engineering Schedule


WAHX Rows Estimate


WAHX Pressure Drop = 0.20 inches of water


WAHX Performance Result


Typical Quote Response Sheet for a Wrap -Around Dehumidification System

• 1 Day for a budgetary number • 2-3 Days for firm hardcopy quote


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.


How to Specify an WRAP – AROUND System

Specification Sheet Front Specification Sheet Back


CARRIER WRAP-AROUND HEAT PIPE RETROFIT

Added WAHX Coils Modified Drip Pans Modified Filter Racks Modified Side Panel

(bumped out)


TRANE WRAP-AROUND HEAT PIPE RETROFIT

Added WAHX Coils Modified Drip Pans Modified Filter Racks Slight Modifications to

Side Panels


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…


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.”

http://ijlct.oxfordjournals.org/content/current


ACT-HP-ERS/A-A Air - to - Air (Heat Pipe)

Heat Exchangers

Air-to-Air Heat Exchangers Are Very GREEN


ACT - ERS/A-A Air - to - Air (Heat Pipe) Heat Exchangers Captures Building’s Energy for Pre-

Cooling 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.


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)

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.



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.



ACT - ERS/A-A Installation Air - to - Air (Heat Pipe) Heat Exchangers


Heat Pipe AAHX Selection Example:


Control Heat Pipe AAHX Function by Tilting Center Tilting the HP-AAHX will transfer operation from summer to winter


HP-AAHX Vertical Installation

• Effectiveness: 80% • Btu/hr.: 315,000 • 10 Rows Vertical , 540 Heat Pipes: • Pressure Drop: 1.0


Typical Quoted Response Sheet for Heat Pipe Heat Exchanger System


ASHRAE 90.1 Standard Climate Zones

Percentage of Outside Air

Choose Your Zone

Example: Zone 5-A • ≥50% - <60% Outside Air • ≥ 3,500 cfm systems

gain improvements with energy recovery systems


IECC 2004, ASHRAE 90.1 Commercial State Energy Code Compliance

http://energycodesocean.org/code-status-commercial


Other Heat Pipe Based Heat Exchangers for

Energy Recovery


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…


PASSIVE-SPLIT THERMOSYPHON LOOP

HP-AAHX Passive-Split System


HP-AAHX Passive-Split Air Handling System

VAPOR LINE LIQUID LINE

CONTROL VALVE

ENERGY TRANSFER SUMMER 160,000 Btu/hr 12,000 Btu/hr = 1 Ton 13+ tons saved Design points: 95°F & 75°F

ENERGY TRANSFER WINTER 600,000 Btu/hr Design points: 0°F & 70°F


SUMMER/WINTER PUMP LOOP SYSTEM

• Summer/Winter Energy Recovery (Pump operates 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)

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.

EVAPORATOR

EVAPORATOR CONDENSOR

CONDENSOR


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


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.


Industry Application Drivers


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

http://dsireusa.org


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.



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.



ASHRAE 90.1 2010 Energy Standard for Buildings Except Low-Rise Residential Buildings


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 Number of Buildings

Airports/Air Transport operations 11,445

Food Stores 171,057

Public Elementary/Secondary Schools 89,508

Private Elementary/Secondary Schools 27,402

Universities, Colleges, Professional Schools 4,064

Hospitals 8,841

Skilled Nursing facilities 15,032

Mental Health Care facilities 3,742

Warehousing operations 580,000

State/Federal Correctional facilities 1,500

Theaters 8,298 Statistics from the Fredonia Group


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Wrap up…

Innovations in Action

Mark Stevens, New Business Development Energy Recovery Products [email protected], 717-344-0061 www.1-ACT.com/HVAC

Pete Dussinger, VP, Energy Recovery Products [email protected], 717-295-6052

Contact info:


http://www.1-act.com/HVAC/index.php


Energy recovery presentation

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