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Energy Recovery System
Hadi FattahChris KorkuchScott LaceyRyan NearyColin O’Neill
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Overview1. Project Scope2. Benchmarking3. Concept Choice4. Concept Description5. Detailed Design6. Manufacturing and Assembly7. Prototype Components8. Operation and Testing9. Results10. Analysis11. Cost of Prototype12. Cost Savings for Sponsor13. Conclusion
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Project Scope
• ASHRAE prohibits the recirculation of air in chemistry labs
• Large amounts of energy are lost• Large amounts of money is spent on
HVAC• Any amount of energy recovered
would provide substantial savings• Our objective is to find a way to
recover energy within ASHRAE standards
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Benchmarking
• Heat pipe– Heat transfer via evaporation,
condensation of fluid that moves by negative pressure, gravity and capillary action
– No contamination occurs between flows, and the system tends to be
45% - 65% effectiveness.
• Run-around coil– Indirect heat exchanger of sensible
energy between two fluid streams
– Effectiveness: 55 to 65%
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Benchmarking
• Enthalpy Wheel– This system consists of a
rotary heat exchanger involving the transfer of sensible and latent heat
– Small amount of contamination may occur into inlet air stream, but fulfills ASHRAE requirements.
– 75% effectiveness (highest among its competitors).
http://www.ice-us.com/CustomSeries-Product.htm
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Why Enthalpy Wheels?
• Enthalpy Wheels offer the most efficiency through the simultaneous transfer of latent and sensible energy
• Heat Pipes and Run around coils do not transfer latent heat
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How an Enthalpy Wheel WorksCooling Mode (Summer)
http://labs21.lbl.gov/DPM/Assets/a3_fischer.pdf
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How an Enthalpy Wheel WorksHeating Mode (Winter)
http://labs21.lbl.gov/DPM/Assets/a3_fischer.pdf
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Our concept
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Detailed design
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Manufacturing and assembly
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• 8kW of power• Temperature range
30-75 degrees @ 850 cfm
• Powered by three phase 208V, 30A rated socket
Heater
• 0-10V controller for 10 levels of heating (0=off, 10=max)• Pitot tube ensures minimum flow rate to prevent burn-up
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• Steam outlet faces against airflow to maximize effectiveness.
Humidifier• 8lb/hour steam
humidification• Shares three phase
208V, 20A rated socket with fan
• Linked with control panel for automatic humidity regulation.
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• Provides low cross-contamination between flows (<0.04%)
• Coated with silica gel for performance
• Rotates using small electric motor running of regular 120V socket
Enthalpy Wheel• AirXchange Inc. Model
ERC-25 Enthalpy Wheel
• Provides latent and sensible energy recovery
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• Capable of 2200 cfm flow rate
• Controlled by 0 to 60Hz VFD
• Shares three phase 208V, 20A rated socket with humidifier
Fan
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• 0-10V output for temperature and humidity scaled for 0%-100% RH and 0 – 100 degrees temperature scale
• Linked to control panel for active readings
• Installed on inlet and exhaust of enthalpy wheel for both streams
Temperature/Humidity Sensors
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• Mounted (2) sensors in 14” section of metal duct before fan
• Average flow rate between two sensors outputs to control panel
• Volume dampers in both streams also installed to even flows by reducing flow area (if needed).
Flow Rate Meter
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• Powered by regular 120V socket
• Reads temperature, humidity, and flow rates
• Linked to dehumidifier for automatic humidity control
Control Panel
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Operation & Testing
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Results
Temperature vs. Efficiency
0102030405060708090
100
25 35 45 55 65 75 85 95
Outdoor Temperature (F)
Eff
icie
ncy
(%
)
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Analysis
OALA
OAIAwheel hh
hh
IAEAOALA hhhh
)()( // outinsteamwatersteamwaterLAIAair TTcpmhhm
OALA
OAIA
hh
hh
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Cost of prototype
• Equipment:$13032• Labor: $434• Subcontractors:$4955• Miscellaneous: $115
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AstraZeneca Cost Savings
• Winter (3 months)– Boiler creates steam to heat air– Boiler runs off Natural Gas at $5.40/MMBtu– 1 month of operation saves: $111,856
• Summer (3 months)– Chiller cools water to cool air– Chiller runs off electricity at $41.40/MWh
• Estimated yearly savings: $1,125,681
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Payback Period by Region
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Conclusion
• Through benchmarking and research, the best concept involved use of an Enthalpy wheel
• After designing the system in collaboration with MDavis & Energy Transfer Solutions, the prototype was built
• Experimentation supports expected results of efficiency
• Cost savings are significant, and the payback period is well within industry standards at 0-2 years.
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Acknowledgements
• Special thanks to John Sorantino and Joe from MDavis & Sons, Mike Haggarty and Dave from Energy Transfer Solutions – without them prototype fabrication would not be possible
• Thanks to Professor Hartman for all the help and guidance
• Finally, and most importantly, Thank You to George Sestak and AstraZeneca – for their generous support and for this opportunity.
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Questions?