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

20.0

40.0

60.0

20.0

40.0

60.0

20.0

40.0

60.0

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20.0

40.0

60.0

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

0

1000

2000

3000

4000

5000

6000

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

2007

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500-Series Shinkansen