Kelly Kissock Director: University of Dayton Industrial Assessment Center Dayton, Ohio U.S.A.

1. Kelly Kissock Director: University of Dayton Industrial Assessment Center Dayton, Ohio U.S.A. Industrial Assessment Center One-Day Assessment U.S.-Brazil Industrial Energy Efficiency Workshop Rio de Janeiro, Brazil August 8-11, 2011

2. Industrial Assessment Center Program • Sponsored by U.S. Department of Energy • Program began during 1970s “energy crisis” • 26 centers at universities throughout the U.S. • 25 no-cost assessments per year for mid-sized industries • Goals: • Help industry be more resource-efficient and competitive • Train new engineers in industrial best-practices • Improve practice and science of energy efficiency

3. Eligibility for IAC Assessment • Manufacturing facility SIC: 20 to 39 • Annual energy costs: $100,000 - $2,500,000

4. Structure of IAC Assessment • Gather and analyze data before visit • Team of faculty and students visit plant for one day • Work closely with clients to identify and quantify energy saving opportunities • Write custom, confidential, independent report with specific savings suggestion • Call after 9-months to see what was implemented

5. University of Dayton Industrial Assessment Center • Performed over 825 assessments since 1981 • Check implementation results after one year • Half of recommendations implemented • Energy use reduction ~5%

6. Recruiting the Student Team • 5 undergraduate and graduate engineering students • Senior students mentor junior students • Require specific classes • Energy Efficient Manufacturing • Energy Efficient Buildings • Design of Thermal Systems

7. Embed Energy Management into IAC Report Develop baseline Identify and quantify saving opportunities Measure savings to sustain efficiency efforts

8. Baseline Four Components of Plant Baseline • Process Description and Plant Layout • Utility Analysis • Plant Energy Balance • Lean Energy Analysis

9. Process Description and Plant Layout Process Description Plant Layout

10. Utility Billing Analysis • Analyze rate schedule • Verify billing amounts • Check for saving opportunities: • Primary/secondary • Power factor correction • Meter consolidation • Demand reduction potential • Benchmark costs

11. Lean Energy Analysis • Model energy use as functions of weather and production • Decompose energy into: • Production-dependent • Weather-dependent • Independent • Use models for: • Quantify “Leanness” • Identify savings opportunities • Measuring savings

12. Disaggregate Energy Use

13. Quantify Energy “Leaness” “Independent” is energy not added to product LEA = (1 – Independent) Electricity LEA = 49%

14. Average LEA Scores 58% 39%

15. Calibrated Energy Use Breakdowns • Use plant-supplied lists of: • Major elec equip • Major gas equip • Estimated operating hours • Create energy breakdown by equipment • Calibrate breakdown against: • Lean energy analysis • Plant energy bills Electrical Energy Breakdown Natural Gas Breakdown

16. Approach for Identifying Savings • Each manufacturing process is unique • Can’t become experts in every manufacturing process • Found that manufacturing processes comprised of different sequences of same “building blocks” • Developed: “Integrated Systems + Principles Approach”

17. Energy Systems Lighting Motor drive Fluid flow Compressed air Steam and hot water Process heating Process cooling Heating, ventilating and air conditioning Combined heat and power

18. Principles of Energy Efficiency Inside Out Analysis Understand Control Efficiency Think Counter-flow Avoid Mixing Match Source Energy to End Use Whole-system, Whole-time Frame Analysis

19. 1. Inside-out Approach Energy flow from outside to inside plant

20. Inside-out Approach

21. 2. Understand Control Efficiency All systems sized for peak-load, but operate at part-load Control efficiency quantifies loss from controlling system to operate at part-load

22. 3. Think Counter Flow T Q Parallel Flow x T Q Counter Flow x

23. 4. Avoid Mixing Availability analysis tells us Useful work destroyed with mixing Examples CAV/VAV air handlers Separate hot and cold wells Material reuse/recycling

24. 5. Match Source Energy to End Use

25. 6. Whole-system Whole-timeframe Design Dopt = 200 mm when Tot Cost = NPV(Energy)+Pipe Dopt = 250 mm when Cost= NPV(Energy)+Pipe+Pump Energy250 = Energy200 / 2

26. Integrated Systems + Principles Approach

27. Assessment Day • Briefing • Plant tour to identify opportunities • Meet to prioritize • Gather data to quantify • Debrief

28. Lighting • Maximize day lighting • Illumination survey and light inventory • Placement • Distribution efficiency • Control • Upgrades

29. Motor Drive Systems • Minimize end-use • Reduce transmission losses • Optimize repair/replace policy

30. Fluid Flow • Minimize friction losses • Efficient flow control • Slow fans • Trim pump impellors • Employ VFDs for variable flow • Pump-slow pump-long

31. Compressed Air Systems • Minimize air use • Minimize leakage losses • Minimize pressure • Compress outside air • Optimize control mode • Optimize multi-compressor operation • Reclaim heat

32. Boiler / Steam Systems • Match energy source/use • Insulate hot surfaces, pipes and open tanks • Maintain steam traps • Maximize combustion efficiency • Preheat boiler feed water • Explore combined heat and power

33. Process Heating • Maximize heat delivery efficiency (heat product not air) • Minimize batch heating losses • Minimize air leakage and openings • Insulate hot surfaces • Maximize combustion efficiency • Reclaim heat to preheat combustion air or charge

34. Process Cooling • Heat-exchanger networks to minimize cooling loads • Maximize temperature set points • Maximize use of cooling tower • Replace air-cooled with water-cooled chillers • Stage chillers or employ VFD chillers • Use absorption chillers if waste heat is available • Employ VFDs cooling tower fans

35. Heating, Ventilating, Air Conditioning • Employ temperature setback • Insulate un-insulated envelope • Minimize ventilation loads and balance plant air pressure • Outside air: • If needed, use 100% eff MAU • In unneeded, use 80% eff unit heater • Employ economizers for year-long cooling loads • Improve distribution effectiveness

36. Combined Heat and Power • Feasibility, sizing, economics • Steam to Power • Power to Thermal • Heat to Power

37. Prioritize Savings Opportunities Savings by System Type Cumulative Payback and Savings

38. Measure Energy Savings (Using LEA Baseline Model) Savings Pre-retrofit Post-retrofit

39. Track Normalized Energy Intensity Normalized Energy Intensity decreased 5.4%.

40. Share Methods and Software http://academic.udayton.edu/udiac

41. Thank you!