2007 the solar dodecahedron scaling up the solar decathlon to industrial size paul westbrook, texas...
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2007The Solar Dodecahedron
Scaling up the Solar Decathlon to Industrial SizePaul Westbrook, Texas Instruments
2007
Outline
• Solar Decathlon; Efficiency; Sustainability
• Buildings
– Start small - house
– Scaling up - Texas Instruments RFAB• Semiconductor - the other silicon industry
• What is a fab and what are the opportunities
• Project features
• Supplying silicon for solar and sustainability
• Biomemetics – nature as a mentor
2007
Efficiency FirstWhich one requires more power to operate?
sprawling right sized
2007
Social SustainabilityCultural IdentityEmpowerment
Accessibility Stability
Equity
Sustainable DevelopmentThe Balance of People, Profit, and the Planet
Environment
SocietyEconomy
Human Well Being
Environmental SustainabilityEcosystem IntegrityCarrying CapacityBiodiversity
EconomicSustainabilityGrowthDevelopmentProductivity
2007
Why Buildings Matter• Buildings consume:• 12% of the potable water• 40% of the raw materials• 39% of all primary energy
used in the US• 70% of all U.S. electricity
And buildings are responsible for 48% of all U.S. carbon emissions
Source: 2006 DOE Buildings Energy Data Book and USGBC
2007
Start Small - The House
• Westbrook House - built in 1996• Design Goals:
– Energy Efficiency– Low Maintenance – Low Environmental Impact (Sustainable)
• REDUCE - Reduce the need for power, water, and materials.
• REUSE - Make use of “waste” for other purposes. • RECYCLE - Use recycled products where possible to
help close the loop.
– Affordable / Cost-Effective
2007
Design Methodology
• Site Selection/House Placement & Orientation
• Structure Size/Shape/Material• Window & Door Selection / Location• Heating, Ventilation, and Air-Conditioning
(HVAC)• Water Heating / Water Efficiency• Roof Material• All the Little Things
2007
Site Selection/House Placement & Orientation
• Good southern exposure / evergreen trees to the north and west• Preferably an east-west street (front / back of the house N / S)• Long axis of the house running east-west
– maximizes southern solar exposure– minimizes east and west solar exposure
N
2007
Shape Matters
Square Rectangle C-Shape
• The shape and orientation of the house can affect energy use by up to 30%
2007
• A 2-story rectangle is a space efficient and practical plan• Structural Insulated Panels (SIPs) for the walls and roof offer
several advantages– Very little air infiltration– Good, consistent insulation value
• Thermal bridging is underestimated in stick built construction• 6” SIP wall=R26; 8” SIP roof=R33
– Very cost effective
Pre-fabricated in large sections off site, minimizing on-site erection time, waste, and construction crew size
Structural Size/Shape/Material
2007
SIP Thermal PerformanceThese are infrared pictured of a SIP house and a standard construction house
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40.0
60.0
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Westbrook House - South Wall Westbrook House - North Wall
Standard Construction House Standard Construction House
Outside Temp = 43 deg F
2007
Window & Door Selection/Location/Placement
• Use double-pane, argon-filled, low-E units.
• I selected vinyl for the low-maintenance and thermal performance.
• The majority of the windows should be on the south (60%+), the next most on the north, with as few as possible on the E&W.
• Placement and overhang size are critical. High Summer Sun
does not enter window
Low Winter Sunenters window
2007
Window Placement & Overhang Sizing
Summer Shade Winter Sun
Passive Solar - taking advantage of the earth’s tilt
2007
Window Science
• Double pane provides an insulating air space
• Argon is denser than air (38% more), and does not conduct heat as readily (19% reduction)
• Low-E coatings block infrared (long wave) radiation and contribute to the comfort level of the home
• Radiation can account for a large percentage of the unwanted losses or gains by a window
OutsideInside
Sunlight passes through
Arg
on fi
lled
sp
ace
Long wave (infrared)radiation isblocked
Metal filmlow-E coating
2007
HVAC - Load Calculation• Oversizing an HVAC system
increases the initial cost and decreases the comfort. A short cycling unit does not fully dehumidify.
• Two-speed units meet the variable loads more efficiently.
• Zoned duct is helpful in a two story home.
• Good design choices can greatly minimize the HVAC system size. The Westbrook House only needs 2 1/2 tons of cooling (2713 SF) in the hot climate near Dallas, TX.
HeatRejection
HeatAbsorption
2007
Ground Source Heat Pump (GSHP)
• The GSHP uses the relatively constant temperature of the earth as a heat sink or source.
• A GSHP can also be used as an efficient method of water heating.
• An “efficient” unit has an SEER of 12. The Westbrook House GSHP has an SEER of 22.
• There is no noisy outdoor fan unit and we don’t reject heat to the already overheated air.
2007
Efficient Lighting
• Passive solar design usually results in good natural lighting, decreasing the need for daytime artificial lighting
• Clerestory windows can bring in daylight without the heat gain, and can be operable for ventilation
• Use of compact fluorescent lighting reduces electrical usage by 75% vs. incandescent bulbs.
• Incandescent bulbs and halogen lights convert almost all of the electric energy to heat, which increases your A/C load.
• Compact fluorescent lights last significantly longer than incandescent bulbs - each CF has a higher initial price, but the energy savings and long life makes each bulb a net $50 (or more) savings.
2007
Water Heating• Water heating can account for up to
30% of the electric use in a home.
• Solar Flat Plate water heating is very cost effective in the Dallas area.
• A side benefit of ground source heat pumps is the hot water recovery option which provides free hot water during the summer.
• R-25 polybutylene water heater / storage tank provides for long storage and long tank life.
2007
Outdoor Water Efficiency• Rain water collection from the
roof can be used to:
– provide water for outdoor use.
– reduce urban runoff.
– significantly lower your water bill.
• The first approach should be a native, low-maintenance lawn to reduce need.
• Rain water can also be used for human consumption.
• Our aerobic septic system uses our “waste” water to water the lawn.
1600 gallon rain water storage tank
2007
Roof
• In hot climates, exterior colors should be light for reflectivity.
• The roof material is a major heat absorber and should be light colored. Look for a roof material with high reflectance and high emissivity.
• A Galvalume metal roof reflects heat, provides a clean surface for rain collection, and reduces homeowners insurance rates (hail resistance). It also has a 50+ year life.
• A metal roof with a light colored coating is even better because the coating improves the emittance.
2007
All the Little Things• Insulated hot water lines in the walls.• Consolidated all plumbing to one area - low line loss.• Earth bermed the west wall of the attached garage and insulated it - lowest
garage winter temperature = 51 degrees F.• Installed enthalpy wheel air to air heat exchanger for fresh air and humidity
control.• Used 100% recycled polypropylene carpet from Image.• Installed motorized operators on clerestory windows for ventilation.• Used efficient indoor appliances (refrigerator, etc.) for reduce load.• Installed glass doors and outside air intake for fireplace combustion.• Installed horizontal axis washing machine for efficient water use.• Insulated the concrete slab foundation perimeter.• Installed ceiling fans in almost every room.• Compact fluorescent bulbs in almost every light fixture.• “Wall wart” transformers on plug strips so they can be turned off when not in
use.
2007
Utility Usage Comparison
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1000
2000
3000
4000
5000
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7000
8000
An
nu
al
Us
ag
e (
KW
h)
A/C Total
HeatMisc.
Refrig/Freeze Total
Water Heater Total
Light Total
Dryer Total
Cooking Total
Washer Total
Dishwasher Total
Electric Usage - Average Home vs. The Westbrook HouseAvg Home Westbrook
2007
Annual Utility CostsWestbrook House Annual Utility Data 2,713 sf, 3 people
Year kWh sumkWh utility
kWh wind Cost/Yr
Average Cost/Mo
Elec Rate ($/kWh)
kBtu/ sf
kWh/ sf/yr
kWh/ Degree
Day
Water Use/Yr (gallons)
1997 8,952 8,952 0 $ 739 $ 61.55 $ 0.083 11.3 3.3 1.8 34,700
1998 10,195 10,195 0 $ 781 $ 65.09 $ 0.077 12.8 3.8 1.9 27,900
1999 9,309 9,309 0 $ 644 $ 53.63 $ 0.069 11.7 3.4 2.0 45,500
2000 9,966 9,966 0 $ 684 $ 56.99 $ 0.069 12.5 3.7 2.0 38,400
2001 9,875 9,875 0 $ 753 $ 62.79 $ 0.076 12.4 3.6 2.1 36,000
2002 10,404 10,404 0 $ 893 $ 74.45 $ 0.086 13.1 3.8 2.1 28,000
2003 10,257 10,257 0 $ 934 $ 77.87 $ 0.091 12.9 3.8 2.1 38,000
2004 10,624 10,624 0 $ 988 $ 82.37 $ 0.093 13.4 3.9 2.4 25,000
2005 11,205 11,205 0 $1,177 $ 98.08 $ 0.105 14.1 4.1 2.3 37,000
2006 10,633 10,555 78 $1,443 $ 120.28 $ 0.137 13.4 3.9 2.2 35,000
Sums and Averages kWh sum kWh util
kWh wind Cost/Yr Cost/Mo
Elec Rate ($/kWh)
kBtu/ sf
kWh/ sf/yr
kWh/ Degree
DayWater Use (gallons)
Total> 101,420 101,342 78 $9,037 310,500
Annual> 10,142 10,134 $ 904 $ 0.083 12.8 3.7 2.1 34,500
Monthly> 845 845 $75.31 2,875
2007
Efficiency Can Be Beautiful
2007
Efficiency First . . . Then Generation
• Since I have driven the consumption down I recently installed a wind turbine to generate electricity
• My Skystream 3.7 from Southwest Windpower went on line on September 6th, 2006.
2007
2007
Silicon Based IndustriesTwo silicon based industries:
Semiconductor Manufacturing and Photovoltaics (PV)
2007
What is a Wafer Fab A very large, clean facility . . .
300 mm diameter1500-5000 chips ea30,000 wafers/mo1 billion chips/yr
2 mm
2 mm
. . . that fabricates very small chips on large silicon wafers
86nm
39nm
Hair = 80,000 nm dia
Total space:1,100,000 gsf (102,000 m2)
Clean room space:220,000 sf (20,400 m2)
Atom = 0.1 nm diaDNA = 2 nm dia
Gate = 39 nm dia
2007
The Opportunity• Very tight temperature and humidity requirements . . .
– 70F+/-2 (21C+/-1) and 45% RH +/- 3%• Combined with a large amount of exhaust and subsequent
make up air . . .– 650,000 cfm (307 m3/sec) = 41 Macy’s Snoopy balloons
a minute• Combined with the need to recirculate a large volume of air
through the filters for cleanliness . . .– 4,400,000 cfm (2077 m3/sec) = 22 Goodyear blimps a
minute • Combined with hundreds of process tools with vacuum
pumps, RF generators, and support equipment . . .• Combined with extensive use of deionized (DI) water to
rinse the wafers during processing . . .
Could lead to annual power consumption of 170,000 mWh (10,000+ homes worth)
and water consumption of 3 million gallons/day (6,000 homes worth)
Annual utility bills could total $20M - $25M
2007
TI Path to Sustainability • Strategy Team - Fabscape
– 4 strategy teams were formed in advance of project– Request made to add a 5th team - sustainability– Generated early white papers on a number of ideas
• Tour (Westbrook House – www.enerjazz.com/house)
– Invited 3 VP’s to tour active/passive solar home– Low utility bills for “normal” house spurred interest
• Design Charrette– Teamed up with Rocky Mountain Institute (RMI)– Held 3-day design charrette to brainstorm ideas– Generated 15 “Big Honkin’ Ideas” to carry forward along with a
large list of other good ideas– Made a first pass at LEED score sheet
2007
What is LEED?Leadership in Energy and Environmental Design
• The LEED Green Building Rating System™ is a voluntary, consensus-based national standard for developing high-performance, sustainable buildings. There are 5 broad categories that force an emphasis on a holistic approach to design:– Sustainable Sites– Water Efficiency– Energy & Atmosphere– Materials & Resources– Indoor Environmental Quality
2007
CUP
Fab
Support
Admin
TI RFAB
92 acre site Site Layout
2007
Sustainable Sites
Compost tubes
Pond collects runoff from most of the 92 acres. 2.7 million gallon base + 2 million gallon buffer. The pond meters runoff and settles sediment. Pond water is used for all site irrigation.
Windmill drives an air compressor to aerate the pond.
< Areas were restored to native prairie grass to minimize irrigation and provide biodiversity.
2007
Sustainable Sites
Typical silt fence
Reflective roof saves energy and reduces the urban heat island effect. Concrete, instead of asphalt, also reduces heat buildup.
Covered parking for bicycled and showers / lockers encourage alternate transportation. >
< Solar bollards guide the way and full cutoff downlights preserve dark skies
2007
Water Efficiency
A small water turbine recharges the batteries for the automatic sensors on the sinks
Each water free urinal saves about 40,000 gallons / year
2007
Cooling load
Energy and Atmosphere
2007
Energy and AtmosphereSematech (14 fabs) and TI Fab Data
Newer 300mm fabs are moving closer to a 50% / 50% ratio.
Facilities Systems 59%
Process Tools 41%
Electric Power Use
Facilities Breakout
Process Breakout
CoolingLoadBreakout
2007
Energy Savings – Shell and Admin – Passive solar orientation with exterior shading– Energy and Daylight modeling– Optimized glazing (high VLT, low SHGC, low U value)– Reflective roof (high reflectivity, high emissivity)– Natural daylighting with light shelves– High efficiency lighting (motion + daylight sensors)
– Demand controlled ventilation (control on CO2)
– Attention to detail on insulation and infiltration– Solar water heating
2007
Chiller Plant
40F CHWS
54F CHWR
54F CHWS
70F (21C)CHWR
4560 tons – 40F (4.4C)
8000 tons – 54F (12.2C) with
heat recovery
1520T
1600T
1600T
1600T
1600T
1600T
1520T
1520T
• Make-up air pre-cool • Cleanroom recirc. air • PC Water• Plant Vacuum• Cooling for DIW • Misc. AHU
MUA dehumidification
2007
Energy Savings – Hot Water
100F(38C) HRWS
65F (18C) HRWR
54F heat recovery bundles
HR
HR
HR
HR
HR
• MUA pre-heat/re-heat• Raw water heating for DIW
500 HP
500 HP
Boiler back-up
CDA
25 HP
25 HP HDIW heating
140F HWR
180F HWS
HDIW boilers
Cooling Towers
1
2
3
2007
Materials and Resources
• Recycled 89.3% of all construction waste
• Reached 50% for recycled content of purchased materials– Fly ash in concrete and steel are
two large contributors• 75% of the materials were
manufactured within 500 miles
2007
Indoor Environmental Quality
• CO2 sensor controlled ventilation
• Low emission materials
– Paints
– Carpet
– Adhesives and sealants
• Thermal comfort
• Daylight and views
2007
Parallels• Solar Decathlon:
– Architecture– Engineering– Market Viability– Communications– Comfort Zone– Appliances– Hot Water– Lighting– Energy Balance– Getting Around
• TI RFAB– Architecture– Engineering– Competitive Advantage– Communications– Clean Room/People Comfort– Manufacturing Equipment– Hot Water– Lighting– Energy Balance– Employee Transportation
2007
Parallels
• Maybe RFAB should be renamed SOLAR Fab– Sustainable– Optimized– Large– Architectural– Research
2007
Cost / Benefit• We invested <1% of the project cost (<$1.5M) in LEED related
items – predominately efficiency improvements that we would consider regardless of LEED
• The overall project cost 30% LESS than our previous 300mm fab.• The first full year we should recover $1M in operating savings• At full build out we will save >$4.0M per year in operating costs
– 20% energy reduction– 35% water use reduction– 50% emissions reduction
www.ti.com/rfab
2007
Silicon for Solar and Sustainability
• TI supplies thousands of scrap and pilot wafers per year to solar PV manufacturers
• Since 2000 those wafers have been used to produce:
– 1.4 million square feet of PV
(equivalent to 107,500 160W panels or over 17.2MW of power)
2007
Silicon for Solar and Sustainability
• Semiconductor products
– DLP TV – lowest power use per square inch of picture (CNET test)
2007
• Power management products can stack energy phases to create power trains that provide stable energy for plugged in products with minimum power waste.
• Power factor correction technology adapts power supply according to how much power a device needs, minimizing waste and reducing energy consumption.
• Green mode controller technology senses if a device is plugged into a wall adaptor and adjusts the power supply accordingly to save over 58 billion kilowatt-hours of wasted energy per year – equal to the output of 10 large power plants!
• Boost Technology elevates or reduces voltage based on specific requirements. For example, it elevates the peak voltage of a solar or fuel cell to a usable voltage level needed to power a portable application.
• Battery Gas Gauge operates within 1% accuracy so consumers use almost all energy stored in the battery of a notebook PC or other portable handheld device.
Power Management is Key
2007
• Electronic meters that reduce wasted energy by up to 30 percent • Motion and video sensors that control lights and HVAC based on movement within a
room or building • Battery-powered, portable devices that run off a single battery for over ten years
• HDTVs and other electronics that achieve up to 90% energy efficiency
• Hybrid and plug-in electric cars and motorcycles with motor/battery management to improve mileage and battery life
• Industrial applications and home appliances that improve efficiency by up to 88 and 30 percent, respectively, due to more efficient motor control and power management
Motors make a difference – 2/3 of the world’s industrial electricity runs electric motors. Only 5% of these use variable speed drives, which consume 1/8 of the energy as a constant speed drive. The 5% of efficient motors save the energy produced by 10 power plants and annually prevent
the emission of 68 million tons of greenhouse gases
Efficient Use of Power
2007
Silicon for Inverters
• Solar and Wind output in DC (direct current)
• Inverters are used to turn DC power into AC (alternating current) power and synchronize with the electric grid
• Digital Signal Processing enables the transformation and synchronization
2007
BiomimicryBiomimicry
Opportunity
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500-Series Shinkansen