Hudson Technologies, Inc. · NASDAQ:HDSN
Hudson Technologies — Technical Presentation (June 2009)
24 slides from Hudson Technologies's technical presentation, Jun 9, 2009
Slide 1: Energy Optimization of a Large Central Plant Chilled Water System
Energy Optimization of a Large Central Plant Chilled Water System Riyaz Papar, PE, CEM Hudson Technologies Company Harold Myart, PE, CEM Mark Krawczyk, PE, CEM Freescale Semiconductor, Inc. Texas Chemical Council Seminar June 09, 2009
Slide 2: Agenda
Agenda Objectives System Description Data Collection & Models System Optimization Opportunities System Optimization Results Conclusions
Slide 3: Objectives
Objectives Conduct a chilled water system Energy Savings Assessment (ESA) using a Systems Approach at the Oak Hill Plant site Identify (and quantify) chilled water plant energy savings opportunities Assist plant personnel to gain familiarity with certain bestpractices and to continue to identify ene
Slide 4: System Description
System Description Chilled Water loop (42°F supply temperature) Chiller #1: Trane CVHF 1280 Centrifugal – 1,250 RT Chiller #2: Trane CVHF 1280 Centrifugal – 1,250 RT Chiller #3: Trane CVHF Centrifugal – 1,470 RT (New) Chiller #4: York YSNNNNS7 Screw – 1,180 RT Chiller #5: York YSNNNNS7 Screw – 1,180
Slide 5: System PFD
System PFD Air Coils 1 2 3 4 5 6 Water Chillers (42°F) Glycol Chillers (32°F) 1 2 3 Air Coils
Slide 6: Identified Chiller Plant Best Practices
Identified Chiller Plant BestPractices Site-level integrated chilled water and glycol loops High efficiency two-stage centrifugal chillers for base load and screw machines to provide for swing capacity Use of variable speed drives on the secondary pumping loop Use of variable speed drives on the con
Slide 7: Data Collection
Data Collection Hourly average data for one year (10/01/07 – 09/30/08) for each chiller Ambient conditions Temperature Humidity Chilled water flow Condenser water flow Power consumption Chilled water supply and return temperatures Condenser water supply and return temperatures Bypass flow
Slide 8: Load Profile
Load Profile 10,000 6 8,000 5 Number of Operating Chillers 42F Chiller Plant Load (RT) 6,000 4 4,000 3 2,000 2 - 1 9/5/07 10/25/07 12/14/07 2/2/08 3/23/08 5/12/08 7/1/08 8/20/08 10/9/08
Slide 9: Chilled Water Plant Efficiency
Chilled Water Plant Efficiency 0.800 0.750 Overall Plant Efficiency (kW/RT) 0.700 0.650 0.600 0.550 0.500 0.450 0.400 9/5/07 10/25/07 12/14/07 2/2/08 3/23/08 5/12/08 7/1/08 8/20/08 10/9/08
Slide 10: Chilled Water Plant Efficiency
Chilled Water Plant Efficiency Overall Chiller # 1 2 3 4 5 6 Plant Operating hours 7,469 7,458 2,633 6,877 6,336 2,591 8,750 Load (RT) 924 944 868 887 863 846 3,428 Power (kW) 553 511 610 599 561 591 2,144 Efficiency (kW/RT) 0.597 0.541 0.705 0.677 0.650 0.704 0.623
Slide 11: Chiller Efficiency
Chiller Efficiency 0.90 0.85 0.80 Chiller Efficiency (kW/RT) 0.75 0.70 0.65 0.60 0.55 0.50 68 70 72 74 76 78 80 82 Condenser Water Temperature (°F)
Slide 12: Chiller Efficiency
Chiller Efficiency 0.80 0.75 0.70 Chiller Efficiency (kW/RT) 0.65 0.60 0.55 0.50 0.45 0.40 39.0 40.0 41.0 42.0 43.0 44.0 45.0 46.0 47.0 Chilled Water Supply Temperature (°F)
Slide 13: Savings Opportunity: Reduce Condenser Water Temperature
Energy Savings Opportunity Reduce condenser water temperature Condenser water maintained currently at 75°F Controlled by two-speed fans Typically, 10% energy used by fans, 20% by pumps and 70% by compressor Compressor kW/RT increases with higher condenser water temperature Float condenser pressure f
Slide 14: Savings Opportunity: Constraints / Precautions
Energy Savings Opportunity Constraints / Precautions - Reduce condenser water temperature Check manufacturers’ recommendations – 65°F minimum condenser water temperature Refrigerant Stacking issues Concerns about leaks in low pressure (R123) chillers
Slide 15: Savings Opportunity: Reduce Number of Operating Chillers
Energy Savings Opportunity Reduce number of operating chillers 8,000 A ctu al P lan t L oa d 7,000 O pe ra tin g Ca p a city Ex ce ss C a pa city 6,000 Chiller Tons (RT) 5,000 4,000 \ 3,000 2,000 1,000 - 09/05/07 10/25/07 12/14/07 02/02/08 03/23/08 05/12/08 07/01/08 08/20/08 10/09/08
Slide 16: Savings Opportunity: Reduce Number of Operating Chillers
Energy Savings Opportunity Reduce number of operating chillers Typically, one more chiller than needed – capacity in excess of 1,200 RT on average and sometimes as high as 2,000 RT Bypass flowmeter readings (average ~2,500 gpm) Benefits of shutting down one chiller Reduction of overall chillers kW/R
Slide 17: Savings Opportunity: Increase Primary Chilled Water Flow
Energy Savings Opportunity Increase primary chilled water flow through chillers Design rating is based on 42°F chilled water, 85°F condenser water and 100% load (Tons) But this happens for 1-3% of the operating hours Chiller has a lot more capacity at off-design conditions Implement – Variable Prima
Slide 18: Savings Opportunity: Transfer Glycol Loop Load
Energy Savings Opportunity Transfer load from 32°F glycol loop to 42°F chilled water loop Full load operating efficiency 32°F glycol chiller – 0.727 kW/RT 42°F water chiller – 0.60 kW/RT It is possible to transfer 50% of the glycol loop load Potential energy savings – 3-5% Constraints / Precautions
Slide 19: Savings Opportunity: SMART Algorithm Reset
Energy Savings Opportunity Implement SMART algorithm to reset chilled water supply temperature 1°F increase in chilled water supply temperature leads to a reduction of 0.015 kW/RT DAS has information on chilled water flow control valve positions of almost all the air-handling units Automatically inc
Slide 20: Best Practices
BestPractices Implement real-time calculation of chiller efficiencies and trending Will provide information for further optimization All the data is already available Implement a Chiller Chemistry™ program Fluids – Refrigerant, Oil and Water should be tested every six months An engineering analysis
Slide 21: Energy Savings Opportunities
Energy Savings Opportunities Energy Savings Cost Project Opportunity PB Savings ($) Cost ($) kWh Therms Reduce condenser water temperature 815,000 0 53,000 40,000 N Reduce number of operating chillers 1,400,000 0 91,000 25,000 N Increase primary chilled water flow through the 930,000 0 60,000 10,000
Slide 22: Conclusions
Conclusions Instrumentation & monitoring of “critical” parameters was key for optimization of the chilled water plant A Systems Approach is needed for optimizing any energy system Typically, chilled water and refrigeration systems are neglected in plants but they offer significant energy savings pot
Slide 23: Acknowledgments
Acknowledgments Kathey Ferland TX Industries of the Future Paul Lloyd & Dean Blackman Freescale Semiconductor, Inc.
Slide 24: Discussion & Questions
Discussion & ONeenenenee TECHNOLOGIES
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