Advanced Energy Efficiency, Lecture 2: Industry - Rocky Mountain ...

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Lots of luscious low-hanging fruit: two Asian fab retrofit examples by RMI Senior Fellow LEE Eng Lock, Singapore ◊ Big Asian back-end fab: 1997 retrofit, mainly HVAC • Cut energy use 56% (69%/chip) in 11 months with 14-month average payback; further projects then saved even more ◊ STMicroelectronics’s world-class Singapore fab • ’94–97 retrofits saved US$2.2M/y with 0.95-y av. payback • ’91–97 improvements saved $30M; kWh/150mm std. wafer fell 60%—providing 80% of energy capacity for a 3.5× expansion; 80% paid back within 18 months • All retrofits were performed during continuous operation via cryogenic freeze-plugs and hot-taps (>20 each)! ◊ This low-hanging fruit already fell down and is mushing up around the ankles—and the tree keeps pelting our heads with more fruit ◊ If these fabs had been properly designed, none of this would be possible—but they used infectious repetitis
Or consider LEE Eng Lock’s 92% retrofit reduction in electric power used for fluid movement: cold-room water pumps, air-handling-unit fans, and rooftop toilet stack exhaust fans (Hyatt Hotel, Singapore) From 27 to 1 Exhaust Fans (25 kW → 1.60 kW) From 7 to 4 AHU fans with low face velocity (45 kW → 2.56 kW) Walk-In Refrigeration CRWP – Eliminate valves – Bigger pipes – No elbows – Much simpler pipe layout (22 kW → 3.1 kW) 24th Floor 1st Floor Exhaust AHU Fans kW Original 25 kW Retrofit 1.6 45 2.6 CRWP 22 3.1 Total 92 7.3 92→7.3 kW, a 92% saving % Δ - 94% - 94% - 86% - 92% 9
Page 2 and 3: MAP/Ming Visiting Professorship, En
Page 4 and 5: First Industrial Revolution: People
Page 6 and 7: The resource cycle: a massflow pers
Page 10 and 11: Typical areas for big industrial sa
Page 12 and 13: Information is cheap, powerful, but
Page 14 and 15: Benefits of monitoring with good gr
Page 16 and 17: It’s not mainly about the hardwar
Page 18 and 19: 2. Basic hydraulic innovations www.
Page 20 and 21: Designing for breakthrough industri
Page 22 and 23: Examples from RMI’s industrial pr
Page 24 and 25: High efficiency doesn’t always ra
Page 26 and 27: New design mentality: expanding ret
Page 28 and 29: New design mentality • Redesignin
Page 30 and 31: No new technologies, just two desig
Page 32 and 33: This case is archetypical ◊ Most
Page 34 and 35: Why focus on pumping examples? ◊
Page 36 and 37: So how do we do this magic? “Like
Page 38 and 39: First seek to eliminate part or all
Page 40 and 41: Next, let’s minimize the piping s
Page 42 and 43: High-efficiency pumping / piping re
Page 44 and 45: Minimizing piping friction ◊ Surf
Page 46 and 47: Choice of valves ◊ Wide-open full
Page 48 and 49: Next, let’s optimize the pump The
Page 50 and 51: Optimize for the operating conditio
Page 52 and 53: Chiller system efficiency (not just
Page 54 and 55: Most induction-motor retrofits…
Page 56 and 57: = An oil major’s 1/99 min. (EP, w
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Prompt retrofits of induction motor
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Premium-efficiency motors aren’t
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Premium-efficiency motors also...
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Capture system synergies ◊ For ex
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Motor procurement, installation, ma
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Putting it all together: the patter
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Eating the Atlantic lobster ◊ Big
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Case-study of a huge LNG plant The
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The tasty morsels ◊ Systematicall
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Optimized fin fan schematic V ~ 6 m
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Heretical questions ◊ Is the plan
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AND A NONPROPRIETARY NEW-INSTALLATI
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Capability growth is outpacing effi
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Intel’s nominal data-center power
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IBM PS-2E ~5×-efficiency desktop P
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1U Wintel Rack Mounted Server, ~200
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Wu-chun Feng’s Green Destiny blad
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Some ways to cool a data center 1 r
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Simple heat management ◊ ◊ ◊
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IT-equipment-to-total-kW multiplier
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Front claws: heat transfer and remo
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The whole lobster: a fantasy ◊ Op
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What is all this but good simple en
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