Protoplex: Advanced Manufacturing Innovation Facility

The Missouri Protoplex is an innovative facility serving as the headquarters for a statewide manufacturing ecosystem. It is the first building of the Innovation Campus at Missouri University of Science and Technology (MS&T). Spanning approximately 116,000 sq. ft., the Protoplex aims to unite industry and academia to research, prototype, test manufacturing processes, develop workforce skills, and address challenges in cyber-physical manufacturing systems.

The Protoplex fosters innovation, addresses manufacturing challenges, and boosts entrepreneurship and economic development in the state. It focuses on Materials, Manufacturing & Methods; Pre-Production Testing & Development; The Forge–Steel and Advanced Metallurgy; and Cyber-Physical Systems Security, Testing & Development, encouraging interdisciplinary collaboration. The 116,000 sq. ft. facility includes flexible high bay spaces, laboratories, workspaces, and meeting rooms. The shared spaces enhance communication among different fields, while extensive glazing highlights its purpose and processes.

Energy Efficiency

The MS&T Protoplex Project stands as a testament to innovative energy efficiency techniques. At the heart of this project is a hybrid geothermal plant that combines heat recovery chillers, conventional chillers, hydronic boilers, and cooling towers, alongside 204 geothermal wells piped from 17 circuits and hydronic air handlers and a process chilled water loop. This intricate system is designed to maximize energy efficiency, showcasing the project’s commitment to sustainability.

This geothermal plant operates as a standalone entity although it was designed with future expansion in mind, allowing it to potentially tie into a campus-wide system, thereby extending its energy-saving benefits beyond the Protoplex.

Indoor Air Quality

Key to the project’s energy efficiency is the air-side energy management. For most spaces within the Protoplex, energy recovery wheels are employed to reclaim exhaust energy, a method that significantly reduces waste. In lab spaces, a glycol runaround coil system is utilized to recover energy, further enhancing the building’s energy efficiency. Additionally, the air monitoring system plays a crucial role by determining the necessity of air recirculation, ensuring optimal energy use without compromising air quality.

Operation and Maintenance

A noteworthy feature of the geothermal system is that it is equipped with just eight compressors, a stark contrast to the 30 or 40 typically required for a similar facility. This choice not only simplified the maintenance process but also reduced the number of potential failure points, ensuring smoother long-term operation.

Collaboration with the maintenance staff at MS&T was crucial, as their familiarity with the equipment played a significant role in the project’s sustainability. The equipment selection process prioritized long-lasting, low-maintenance options, aligning with McClure Engineering’s commitment to reliability and efficiency.

Cost Effectiveness

The hybrid geothermal system offered a cost-effective solution, outperforming the traditional 100% geothermal setups. This hybrid approach struck a balance between operational efficiency and financial viability.

Environmental Impact

In terms of environmental impact, the system promised substantial reductions in water usage and carbon emissions. The use of environmentally friendly refrigerants and the system’s potential to significantly lower carbon footprints underscored its eco-friendly credentials.