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The Solar Dodecahedron

The Solar Dodecahedron. Scaling up the Solar Decathlon to Industrial Size. Paul Westbrook, Texas Instruments. Outline. Solar Decathlon; Efficiency; Sustainability Buildings Start small - house Scaling up - Texas Instruments RFAB Semiconductor - the other silicon industry

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The Solar Dodecahedron

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  1. The Solar Dodecahedron Scaling up the Solar Decathlon to Industrial Size Paul Westbrook, Texas Instruments

  2. 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

  3. Efficiency First Which one requires more power to operate? right sized sprawling

  4. Sustainable Development The Balance of People, Profit, and the Planet Environmental Sustainability Ecosystem Integrity Carrying Capacity Biodiversity Environment Social Sustainability Cultural Identity Empowerment Accessibility Stability Equity Economy Society Economic Sustainability Growth Development Productivity Human Well Being

  5. 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

  6. 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

  7. 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

  8. 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

  9. Shape Matters • The shape and orientation of the house can affect energy use by up to 30% Square Rectangle C-Shape

  10. Structural Size/Shape/Material • 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

  11. SIP Thermal Performance These are infrared pictured of a SIP house and a standard construction house Westbrook House - South Wall Westbrook House - North Wall Outside Temp = 43 deg F Standard Construction House Standard Construction House

  12. 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. Low Winter Sun enters window High Summer Sun does not enter window

  13. Window Placement & Overhang Sizing Winter Sun Summer Shade Passive Solar - taking advantage of the earth’s tilt

  14. 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 Sunlight passes through Metal film low-E coating Long wave (infrared) radiation is blocked Argon filled space Outside Inside

  15. HVAC - Load Calculation Heat Rejection • 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. Heat Absorption

  16. 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.

  17. 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.

  18. 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.

  19. Outdoor Water Efficiency 1600 gallon rain water storage tank • 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.

  20. 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.

  21. 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.

  22. Utility Usage Comparison

  23. Annual Utility Costs

  24. Efficiency Can Be Beautiful

  25. 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.

  26. Silicon Based Industries Two silicon based industries: Semiconductor Manufacturing and Photovoltaics (PV)

  27. 39nm 86nm What is a Wafer Fab A very large, clean facility . . . Total space: 1,100,000 gsf (102,000 m2) Clean room space: 220,000 sf (20,400 m2) . . . that fabricates very small chips on large silicon wafers Hair = 80,000 nm dia 2 mm 2 mm 300 mm diameter 1500-5000 chips ea 30,000 wafers/mo 1 billion chips/yr Gate = 39 nm dia DNA = 2 nm dia Atom = 0.1 nm dia

  28. 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

  29. 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

  30. 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

  31. TI RFAB 92 acre site Site Layout CUP Fab Support Admin

  32. Sustainable Sites < Areas were restored to native prairie grass to minimize irrigation and provide biodiversity. 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.

  33. Sustainable Sites Typical silt fence Reflective roof saves energy and reduces the urban heat island effect. Concrete, instead of asphalt, also reduces heat buildup. < Solar bollards guide the way and full cutoff downlights preserve dark skies Covered parking for bicycled and showers / lockers encourage alternate transportation. >

  34. Water Efficiency Each water free urinal saves about 40,000 gallons / year A small water turbine recharges the batteries for the automatic sensors on the sinks

  35. Energy and Atmosphere Cooling load

  36. Energy and Atmosphere Sematech (14 fabs) and TI Fab Data Newer 300mm fabs are moving closer to a 50% / 50% ratio. Process Tools 41% Process Breakout Facilities Systems 59% Electric Power Use Facilities Breakout Cooling Load Breakout

  37. 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

  38. 1520T 1520T 1520T 1600T 1600T 1600T 1600T 1600T Chiller Plant 70F (21C)CHWR • Make-up air pre-cool • Cleanroom recirc. air • PC Water • Plant Vacuum • Cooling for DIW • Misc. AHU 8000 tons – 54F (12.2C) with heat recovery 54F CHWS 40F CHWS 4560 tons – 40F (4.4C) • MUA dehumidification 54F CHWR

  39. 500 HP Energy Savings – Hot Water 65F (18C) HRWR • MUA pre-heat/re-heat • Raw water heating for DIW HR 54F heat recoverybundles HR 2 HR HDIW boilers 140F HWR HR 100F (38C) HRWS 25 HP HDIW heating HR 180F HWS 25 HP CDA 1 Boiler back-up 500 HP 3 Cooling Towers

  40. 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

  41. Indoor Environmental Quality • CO2 sensor controlled ventilation • Low emission materials • Paints • Carpet • Adhesives and sealants • Thermal comfort • Daylight and views VOC

  42. Parallels • TI RFAB • Architecture • Engineering • Competitive Advantage • Communications • Clean Room/People Comfort • Manufacturing Equipment • Hot Water • Lighting • Energy Balance • Employee Transportation • Solar Decathlon: • Architecture • Engineering • Market Viability • Communications • Comfort Zone • Appliances • Hot Water • Lighting • Energy Balance • Getting Around

  43. Parallels • Maybe RFAB should be renamed SOLAR Fab • Sustainable • Optimized • Large • Architectural • Research

  44. 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

  45. 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)

  46. Silicon for Solar and Sustainability • Semiconductor products • DLP TV – lowest power use per square inch of picture (CNET test)

  47. Power Management is Key • 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.

  48. Efficient Use of Power • 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 carsand 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

  49. 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

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