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Rod MacGregor is a serial entrepreneur and company founder who has brought a number of companies to market before selling them and moving on to the next area. Now Rod has the globalgypsum wallboard industry in his sights - or at least those factories which are currently wastingmoney on burning gas when there is a perfectly good energy source beating down on the factory- the sun. Rod MacGregor is serious about this - and you should be too!
New solar power solutions for the global
New solar power solutions for the global
gypsum wallboard industry
gypsum wallboard industry
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Below:
Rod MacGregor
S
o Rod, what has changed since you gave a presentationat the Global Gypsum Conference in Rio de Janiero? 
Rod MacGregor:
“A lot o progress has been madesince the Rio conerence in May. First and oremost,we’ve changed our business model rom a manuacturero solar-made gypsum wallboard to a supplier o solarthermal equipment. o refect this transition, we’vechanged our company name rom CleanBoard to Glass-Point Solar, Inc, and have been very busy building outour customer pipeline in the drywall space. We have alsobeen very ortunate to have solar thermal veteran JohnO’Donnell join GlassPoint as Vice President o BusinessDevelopment. John was the co-ounder o Ausra, oneo the early leaders in the eld o solar thermal powergeneration, and he brings valuable industry knowledgeand experience in launching innovative technolo-gies to the team.
Global Gypsum Magazine:“ 
Why did you de-cide to change the name o your company romCleanBoard to GlassPoint?”
Rod MacGregor:
“Originally we planned touse our solar thermal technology to manuac-ture gypsum wallboard and market the productunder the CleanBoard brand. However, as wordspread o CleanBoard’s technology and minimalcarbon ootprint, several drywall manuacturersapproached CleanBoard to learn more about theuse o solar industrial process heat (SIPH) intheir own acilities.It was clear that CleanBoard could grow more quickly by partnering with existing players rom the outsetrather than building our own acility and manuacturingsolar-made wallboard entirely on our own resources. Inlight o this strong industry demand, we switched gears- rebranding the company as GlassPoint Solar and o-cusing our eorts towards converting existing drywallplants to solar power.Given our growth trajectory, we can convert morethan one billion square eet o existing production ca-pacity to solar power in the same time that it would havetaken us to organically build-up just a ew hundred mil-lion square eet o new production capacity.In the end, our transition to GlassPoint means thatthe industry is able to reduce its carbon emissions aster,that our customers are able to integrate solar into theirmanuacturing process while reducing production costsand that more end consumers have the option to pur-chase environmentally riendly building products withlow-embedded energy.”
Global Gypsum Magazine:“ 
Where did the idea orsolar-made drywall come rom?
Rod MacGregor:
“During a recent tour o a drywallplant in China, I noticed that their ovens were beingheated indirectly by burning coal to heat thermal oil andthen running the oil through a series o pipes inside theoven. While this was very ine cient and emitted largeamounts o pollution, it was cheap.On the fight back to Caliornia I was reading about
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solar thermal power plants thatwere being developed in Spain.Tese power plants use sunlightto heat thermal oil to 40C,which is then used to makesteam to power a turbine thatgenerates electricity.And then the light bulbmoment - combine the two sys-tems: use the hot oil rom a solararray and pump it through anindirectly-heated drywall ovento manuacture drywall with thesun’s abundant resources insteado dirty ossil uels. At rst wehoped to purchase equipmentreadily available on the marketbut soon discovered this was not cost-eective. Processheat derived rom current solar thermal systems wouldbe about our or ve times more expensive than heatproduced by burning natural gas.Solar ‘uel’ is ree - there is no charge or sunlight - sowe asked ourselves, why were these systems so expensiveto own and operate? Aer a detailed analysis o existingsystems, our engineering team created a new low costsolar collector design that could deliver industrial proc-ess heat or less than the price o burning natural gas.Tis technology became the core o the CleanBoard -now GlassPoint - system. For the rst time, a solar BUwas cheaper than a natural gas BU.”
Global Gypsum Magazine:“ 
How does GlassPoint’ssystem integrate with the manuacturing line?”
Rod MacGregor:
“Te GlassPoint solar collector eldproduces thermal oil at around 4°C. Tis oil can be ap-plied in a number o ways to power an existing drywalloven. ypically a customer would install an oil-to-airheat exchanger to produce hot air that is then passedthrough existing gas burners and into the appropriateoven zone. Te gas burners are running continuously,but they are throttled back with the bulk o the heatcoming rom the solar array. I the supply o solar heat isinterrupted or any reason (e.g. a cloud passed by or thesun sets), the gas burner’s control system increases thefow o natural gas to maintain a constant process tem-perature. In this way, the oven can seamlessly transitionrom solar power to natural gas power and back againwithout operator intervention.Tere are several variations to this design. For exam-ple, the oil-to-air heat exchangers can be placed insidethe oven’s upper ductwork, or even as in the old-styleoven designs, inside the oven itsel. Te method selecteddepends on the design o the existing oven and whatpercentage o the oven’s energy is to be supplied romsolar instead o natural gas.Te GlassPoint system is a gas-solar hybrid, custom-ised to meet individual customer specications. Solarenergy is used during the day and gas is burned at night.Systems like this can displace about 3% o the gas usedin the oven. Since a GlassPoint BU costs less than a gasBU, wallboard producers will see a signicant reduc-tion in plant operating costs.I heat storage is added to the system, the GlassPointsolar array can continue to provide process heat oncloudy days and throughout the night. Tese systemscan displace over 85% o the gas used by the drywalloven.”
Global Gypsum Magazine:“ 
How much additionalland is needed? What are other implications to con-sider?”
Rod MacGregor:
“Te amount o heatproduced by an acre o land varies depending on its lo-
Above:
Direct NormalIrradiation (DNI).
Left:
Connectionbetween solar felds, anyheat storage tank and thedrywall actory.
 
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cation. An acre o land in the Mojave Desert in Caliorniawill generate more heat than an acre o land in Glasgowin the UK. However, a rough rule o thumb is that one-acre o GlassPoint’s solar array will produce about 1,MMBtu per annum.”Te land used or the GlassPoint solar array needsto be reasonably fat with no more than a 3% grade, andwhile it’s most e cient to have the array adjacent to theplant, it can be up to a mile or so away.”
Global Gypsum Magazine:“ 
In which geographicalareas is solar industrial process heat (SIPH) most cost-eective? Can a system like this work in cloudier areaslike the UK?”
Rod MacGregor:
“Solar thermal systems like Glass-Point’s rely on direct sunshine and are thus unable tocollect energy when clouds conceal the sun. Tereore,the most practical locations are those with bright sun-light or much o the year (
see map, above
).Some o these areas include theSouthwestern United States, SouthernEurope, North Arica, Northern India,Australia and much o the Middle East.Te map (on the ollowing page) showsthe locations o the drywall plants in theSouthwestern US that have enough solarresources to produce heat or less thanthe cost o natural gas.”
Global Gypsum Magazine: 
“How doproject costs and ongoing costs stack up,compared to ‘normal’ production?”
Rod MacGregor:
“We have two mod-els or providing solar industrial processheat to our customers. Te rst optionis to enter into a Power Purchase Agree-ment (or PPA) with the drywall plantto supply heat at a specic price andschedule. Instead o paying the local util-ity or BUs o natural gas, the drywallplant pays GlassPoint or BUs o solarenergy. In good solar locations the price paid will bemuch lower than the price paid or natural gas. Further-more, the price paid to GlassPoint will be a xed ratethroughout the duration o the PPA, decoupling thedrywall industry rom volatile natural gas prices. In thisscenario, GlassPoint owns, operates, and maintains thesolar eld.Some customers preer to own and operate theirown equipment. Tis model provides the lowest costper solar MMBtu while oering the most operatingfexibility. Te drywall plant can choose to operate andmaintain the equipment internally or enlist GlassPoint via an operations and maintenance contract. Operationsand Maintenance (O&M) makes up a small raction o the cost per solar MMBtu. Te graph below comparesthe price o natural gas paid by industrial users to that o a GlassPoint solar-thermal system located in the South-western US. Tis gure depicts a system with a cost o $2.57 per MMBtu, o which O&M costs accountor just $.35 per MMBtu and the remaining$2.22 goes toward the cost o capital.”
Global Gypsum Magazine:“ 
Reducing greenhouse gasses is an international issue with many countries discussing legislation limiting carbonemissions. How does this aect the drywallindustry? How does GlassPoint address this con-cern?”
Rod MacGregor:
“Every BU o solar energy that is used in a drywall plant avoids burning aBU o natural gas and the subsequent emissionsit would have produced. In this way, the adoptiono solar power reduces the carbon ootprint o theentire drywall operation. Legislation pending inthe United States may enorce a limit on carbonemissions rom industrial users, implementing acap and trade system with nancial implicationsto those that emit large amounts o greenhousegases. Manuacturers that take preventive steps to
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Below:
Graph comparingnatural gas prices paid byindustrial users (Jan 2001to Aug 2009) to GlassPointsolar thermal system(modeled ater drywallplant in SouthwesternUS). The natural gas datais rom the US DOE EIA.The chart models the costo a GlassPoint systemwith and without USederal tax incentives.
Above:
Solar resourcemap o the contiguousUS, showing the locationo wallboard plants withviable solar resources.
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