Alabama Industrial Assessment Center Keith A. Woodbury Mechanical Engineering

Alabama Technology Network 28 Centers Nationwide April 21, 2019

Alabama Technology Network AIAC Clients April 21, 2019 Base activities funded by DOE Advanced Manufacturing Office 13th year of operation About 235 clients served to date About $42M in 1,669 energy savings recommendations (typically 5% - 20% of plant use) About $7.7M in 664 implemented energy savings projects reported

Alabama Technology Network IAC Mission April 21, 2019 Assist small-to-medium manufacturers with Energy Efficiency Productivity Waste Management Train next-generation of engineers in energy practices

Assessment Activities Alabama Technology Network Assessment Activities April 21, 2019 Pre-visit analysis and preparation One-day on-site assessment Reporting (60 days) and Implementation Follow-up (12 mos)

Alabama Technology Network April 21, 2019 IAC Assessment Overview Pre-Assessment Assessment Visit Analysis & Reporting Follow Up Gather plant data including product type, annual sales levels, production levels, operating hours Study processes and plant layout Analyze utility billing data Identify key energy systems Develop assessment day strategy To be completed before assessment visit Meet with plant management team Present details of pre-assessment analysis Tour plant Collect operating data Conduct diagnostic testing Discuss preliminary assessment findings with plant management Prioritize potential recommendations for further analysis Duration: One Day Conduct engineering and financial analyses of priority recommendations Develop first order estimates of implementation costs Document results in “GOLD Standard” format assessment report Upload report data into IAC database Deliver report to plant within 60 days from plant visit Conduct follow up discussions with plant, 6-9 months following assessment visit Identify implemented energy savings Upload implementation data into the IAC database

Typical Recommendations

Lighting Replace MH with Fluorescent Replace Fluorescent with LED 50% reduction 75% reduction 50% reduction

Lighting Use photocells to advantage natural light Install motion sensors to avoid unnecessary illumination

Compressed Air Use most efficient controls

Compressed Air Use minimum allowable pressure

Compressed Air Repair Air Leaks A typical plant that has not been well maintained will have a leak rate equal to, or greater than, 20 percent of total compressed air production capacity. Proactive leak detection and repair can reduce leaks to less than 10 percent of compressor output

Boilers Reduce combustion O2 to minimum Lowers mass flow rate of exhaust Less energy absorbed by excess air

Boilers Recover waste heat from stack gas Preheat combustion air Preheat boiler feedwater (economizer) Cool combustion gases only Condensing economizer also condenses moisture from exhaust and captures latent heat

Contact Information Keith A. Woodbury keith.woodbury@ua.edu (205)348-1647 AIAC Website: https:\\iac.ua.edu