CSIRO Energy Centre Newcastle, New South Wales, Australia

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1 CSIRO Energy Centre Newcastle, New South Wales, Australia Trevor Moody BE, BEc Commonwealth Scientific and Industrial Research Organisation (CSIRO), Australia. PO Box 227 Dickson ACT 2602 Australia. Telephone: Fax: trevor.moody@csiro.au 1. INTRODUCTION CSIRO is Australia s premier, largest and most diverse scientific research institution with a staff of approximately 6,500 working at some 65 laboratories and field station sites throughout Australia conducting research in 22 sectors of the Australian Economy, ranging from Pasture Crops to Mining Technology to Manufactured Products. The CSIRO Energy Centre will provide state of the art research accommodation for staff of CSIRO s Division of Energy Technology on a 5-hectare site on an Eco-Industrial Park called Steel River at Newcastle, New South Wales, Australia. Now under construction, the research complex will demonstrate unique, leading edge, commercially practical examples of building energy demand reduction and environmentally conscious realistic energy supply options. The Centre will provide a focal point in Australia for energy research excellence, particularly in the fields of: Sustainable energy, including energy storage and renewable energy; Environmental impacts of energy, particularly those associated with greenhouse gas emissions; and Cost competitive and environmentally acceptable fossil fuel research and development. Key criteria in the design of the Centre included: Provision of energy efficient buildings with flexibility and adaptability for changing scientific research needs over the life of the buildings; Generation of energy on site from renewable and other sources; and Ability to match as closely as possible, the base buildings energy demand and the site generated energy. A prime objective of the project is to accommodate CSIRO s energy research programs in a landmark facility that showcases what is possible in a contemporary Ecologically Sustainable Design (ESD) building and present CSIRO as a leader in this field. CSIRO s intent is for the facility to be the most energy efficient research complex of its type in Australia.

2 2. BUILDING DESCRIPTION Stage 1 of the Centre will comprise buildings of approximately 9,800 square metres total floor area, consisting of three principal functional areas: Laboratories, Bay and Support Facilities, and Office/Support Facilities. These main functional spaces have been arranged as three separate wings, plugged onto a central circulation spine element, which will form the main circulation link for the complex. The spine will house main plant areas for the Centre, together with renewable energy plant and equipment such as photo voltaics, wind turbines and other future energy research elements such as fuel cells and battery systems. The integration of renewable energy systems will be a central feature of the Complex. The laboratories and offices will each be housed in a separate wing on the east of the spine on a hillside which characterises 40% of the site. The process bays and associated facilities will be housed off the western side of the spine on the flat part of the site. A site Masterplan provides for future expansion of the Centre by the addition of further process bays, office and laboratory wings. The Masterplan was developed from detailed analysis of various options for development of the site. In each option consideration was given to building image, views to and from the site, quality of internal working environment, relationship between office/laboratory elements and process bays, staff interaction, circulation, functionality, site access and egress, and suitability for incorporation of energy conservation and energy generation initiatives. Figure 1 CSIRO Energy Centre - Stage 1 3. ENERGY RELATED INITIATIVES 3.1 Energy Optimisation The unique Energy Centre development will incorporate and demonstrate leading edge, commercially practical examples of energy initiatives appropriate for modern buildings, particularly laboratory/scientific research facilities.

3 The initiatives being employed can be categorised in the areas of: Building energy demand reduction; Energy conservation; Energy generation; Energy management; and Ecologically sustainable development. Objectives of the building energy optimisation process included: Establishment of a baseline energy model; Reduction of laboratory process loads; Reduction of building envelope impacts; Maximisation of natural climate opportunities; Reduction of internal equipment loads; and Optimisation of the building services design. 3.2 Building Energy Demand Reduction Energy demand patterns were identified early in the design process for each type of space (laboratories, offices, process bays, etc) in the Centre. Base case designs were then determined for the building and process loads so that they could be compared with proposed designs, which included varying energy conservation initiatives. Various studies were undertaken for possible energy demand reduction initiatives that included consideration of: The most effective building positioning in relation to site topography; Building siting to maximise use of natural light, including use of light shelves; Computer simulations of varying light conditions for daily and seasonal conditions, as part of the lighting and lighting controls design process; Individual staff comfort condition perceptions and requirements. The data resulting from a detail staff survey was used to develop a sophisticated, tailored system of internal climate conditions; Flexible use of base building services by individual users to achieve desired conditions (openable windows, low velocity air via an underfloor plenum); and Passive solar heating of thermal mass elements, especially in industrial function areas. 3.3 Energy Conservation The options evaluation process for energy conservation initiatives comprised a series of simulations and modelling techniques in conjunction with the design of systems. Extensive building user consultation in the form of a questionnaire and workshops was also employed to ensure that strategies were developed that provided the most appropriate balance of user needs and energy use. While a key project goal was to achieve the most energy efficient building of its type in Australia, it was essential that it be balanced with appropriate functionality. Conservation initiatives incorporated in the project include a wide range of both passive and active measures.

4 Passive measures, which are considered in the context of initiatives to reduce the impact of the building envelope include: Building orientation - maximum north/south exposure to maximise opportunity for solar control in summer and passive solar energy in winter; Elongated building envelope; Optimum building layout - maximisation of daylighting and minimisation of artificial lighting; Sunscreening to northern façade to control summer sun penetration and solar heat gains; Use of light shelves on north walls to promote effective natural daylighting; Openable windows - to create opportunity for natural ventilation to office areas; Insulation of building fabric to reduce heating and cooling loads; Window fenestration (Low E glass); Louvered windows to Process Bays; Minimal east and west facing windows; Thermal mass for heat retention and cold reduction; and Minimisation of infiltration. Active measures include: Underfloor air conditioning system - features a low velocity plenum and consequent energy reduction (plus ability to accommodate services); Variable speed pumps and fans to match system load fluctuations closely and minimise power requirements; Separate air handling plant for laboratory modules provides for independent control and out-of-hours operation; Provision of economy cycles on all air handling plant Outside air economy cycle - to make full use of free cooling of outside air when appropriate; Variable volume air handling technology to allow reduction in supply of air to designated areas where appropriate; Choice of energy efficient chiller design, e.g. multiple step controls to match building load profiles, i.e. as load decreases, compressors are switched off to save energy; Low velocity air conditioning and mechanical ventilation duct systems in laboratories saving fan power and minimizing energy consumption; Dedicated automatic lighting control system time clock control, passive infra-red detectors, photo-electric controls; High performance fluorescent light tubing with low loss electronic ballasts; Power factor correction to transformer supplies to improve building power factor and reduce energy usage and cost; Water saving devices on hydraulic fittings and fixtures to minimise water consumption; and Building Management System to operate, control and monitor energy consumption for automatic control of mechanical services to provide efficient systems operation, alarm monitoring and implementation of energy management programs.

5 Figure 2 CSIRO Energy Centre Cross Sectional View Energy conservation measures also include the provision of building space heating energy from heat recovery from the renewable energy generation suite. It is expected that heat energy supplied in this manner will match the maximum possible heat load and consumption. Domestic hot water will be supplied from heat recovered from the energy generation suite. 3.4 Energy Generation The Energy Centre will incorporate an energy generation suite developed for both efficiency and the showcasing of available technologies. An Energy Task Force was instituted early in the design process to develop, analyse, evaluate, cost and recommend energy sourcing alternatives. While output and efficiency of the systems, initial capital costs and payback periods were factors in the analysis of options, development of the energy generation suite was primarily based on an evaluation process and other criteria determined by the Energy Task Force through a value management workshop process. The key evaluation criteria (not necessarily in priority order) were: Ability to minimise carbon emissions; Buildability - ability to integrate the technology into the buildings and the site; Deliverability - the degree of risk associated with availability of support; Commercialisation opportunity - ability to obtain support from the energy industry; Ability to accept future new technologies; and Image of CSIRO positive public perception of the initiative. The options evaluation process considered a number of main combined source options, all capable of delivering a power capacity of up to 500kW, estimated to be the average base building demand, excluding process loads. Several other options were initially eliminated from consideration for the following reasons: All single source options one system does not reflect the agreed energy strategy; Two identified two-source options - insufficient spread of technology and risk; Options with a high dependence on photovoltaics - payback periods would be long term; and Options with a high dependence on wind energy - the wind energy resource at the site is sub-optimal (based on 5 years monitoring in adjacent area). The selected energy generation suite comprises: Wind turbines - of both medium size with outputs ranging from 20kW to 100kW; Building integrated photovoltaic cell arrays - output approximately 90kW;

6 Gas fired micro-turbines -capable of generating up to 150kW of electricity; and Future Fuel cells - fired by natural gas and water conversion to hydrogen, providing 100kW total output The fuel cells and micro-turbines will be located within the central plant area and space has been allowed for the future addition of similar and/or more advanced technologies. A CSIRO developed battery energy storage system capable of storing a maximum power level of 500 kw of site generated electricity, will be incorporated in the future to provide load levelling capability and an uninterruptible power supply backup. PHOTOVOLTAIC CELL ARRAYS SMALL FUEL CELL 25 kw proton exchange membrane fuel cell fired with hydrogen from natural gas and water Building-integrated cell arrays in vertical position on Process Bay north wall Building-integrated cell arrays on office roof at 20 degree tilt facing north-north west SMALL WIND TURBINE Australian made prototype of 20 kw wind turbine - twin blade option Figure 3 Energy Generation Initiatives

7 The recovery of waste heat from energy generation will be used in the provision of domestic hot water and winter heating of office and laboratory spaces. This facility will eliminate the need to provide a boiler for these requirements. 3.5 Energy Management Energy management at the Energy Centre will be structured at two levels and utilise two separate control mechanisms. The management of energy generation will be provided by a dedicated System Control and Data Acquisition (SCADA) facility, which will report on energy quality and quantity and its distribution. The system will comprise monitoring and control points for plant elements or group of plant elements in one area of the site communicating to a single control centre. (For example; it will be possible for generation output from individual elements, such as one wind turbine, to be displayed on a continuous basis and/or as required. Energy audits will be available from the facility to monitor actual performance for comparison with design target). The buildings will be grid-connected such that in periods of high demand, electricity will be imported from the grid to supplement site-generated energy but in periods of low demand site-generated energy will be exported to the grid Management of energy efficiency/conservation initiatives will be provided by the Building Management System, which will monitor and/or control all building engineering services throughout the complex. The system will cover plant and equipment, air flows, filter performance, fume and other exhaust systems, heating and chilled water, steam, vacuum and gases reticulation, constant temperature rooms and artificial lighting. The system will also be programmable with graphics interfaces for full zone control, will incorporate facilities for external monitoring and will be capable of expansion. Energy audits will also be available from this system to monitor the energy performance of the Centre. 3.6 Ecologically Sustainable Design Initiatives From the purely buildings design perspective, ecologically sustainable design is the overriding consideration in the development of the Energy Centre. It incorporates all of the elements outlined and requires that all such elements form an integral part of the design and not appear to be add-ons. The ESD initiatives can be summarised as follows: Building Energy Demand Reduction A responsible and well-structured approach to the consideration of energy demand reduction in the Centre s development process, has demonstrated that significant results can be achieved Building Energy Supply While the Energy Centre s energy needs could be supplied by connection to the statewide electricity and gas grids, emerging energy efficient and renewable technologies have been incorporated into the building s design to the maximum reasonable extent. This approach

8 reflects a corporate recognition and acceptance by CSIRO that the long-term view must be taken as part of both a national and international responsibility. Accordingly, the CSIRO Energy Centre will be both a demonstration of these technologies to a wider audience as well as an ongoing platform for further development as part of the energy research programs of the Division Building Energy Storage Provision has been made for the future storage of between 500 kwh and 1000kWh of power (equivalent to 100% of the Centre s estimated bas buildings requirements). This will provide for the most cost-effective controlled use of power that is generated in off-peak times and/or in excess of demand. This facility will enable the demonstration of the interaction between energy supply and energy storage systems Environmental initiatives The environmental initiatives planned for incorporation in the Centre cover all aspects of the energy design, buildings design and systems development process. They include for example, passive design considerations, active building service elements and comfort conditions awareness. These considerations translate into building inclusions such as: Rainwater collection and retention tank storage with a pumping system to provide water for irrigation; Air quality monitoring particularly for carbon dioxide. The provision of sensors in return air ducts in the offices will be used to monitor indoor air quality; Photovoltaic cell arrays will be located to avoid overshadowing from buildings; The site energy generation system will be controlled by a System Control and Data Acquisition (SCADA) facility and accordingly all elements of the plant will be linked to a central computer system which will enable selective public display of energy generation from wind turbines and photovoltaics; Heat recovery form site energy generation to provide for heating and some domestic water requirements; Waste treatment systems; Water saving devices on hydraulic fittings and fixtures; and Sustainable use of site indigenous native vegetation. 4. ENERGY SAVING OUTCOMES The result of building energy demand reduction initiatives will be a base building energy demand load estimated from Energy Simulation studies to be less than 60% of the energy demand for a comparable modern, conventional building to serve a similar function.

9 Benchmarking - Office Wing Figure 4 Energy Simulation Studies Outcomes It is predicted that the greenhouse gas emissions savings from the Project will be up to 2000 tonnes of carbon dioxide per year compared with a modern similar research facility. Benchmarking - Laboratory Wing 5. CONCLUSION The achievement of the expected energy saving outcomes in practice will establish the Energy Centre as a tangible and unique expression of commercially practical examples of building energy demand reduction and environmentally conscious, realistic energy supply options. The expected level of performance of the Centre will be a valuable national example of the possibilities that sensible and responsible building design can produce. It will be clear and unarguable through the development of the Centre that buildings and energy systems design can contribute to national greenhouse and ESD commitments and obligations.