Program Name or Ancillary Texteere.energy.gov Industrial Assessment Center One-Day Assessment Kelly Kissock Director: University of Dayton Industrial Assessment Center Dayton, Ohio U.S.A. U.S.-Brazil Industrial Energy Efficiency Workshop Rio de Janeiro, Brazil August 8-11, 2011

2 | Industrial Energy Efficiencyeere.energy.gov 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 Industrial Assessment Center Program

3 | Industrial Energy Efficiencyeere.energy.gov Eligibility for IAC Assessment Manufacturing facility SIC: 20 to 39 Annual energy costs: $100,000 - $2,500,000

4 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov Embed Energy Management into IAC Report Develop baseline Identify and quantify saving opportunities Measure savings to sustain efficiency efforts

8 | Industrial Energy Efficiencyeere.energy.gov Baseline Four Components of Plant Baseline 1.Process Description and Plant Layout 2.Utility Analysis 3.Plant Energy Balance 4.Lean Energy Analysis

9 | Industrial Energy Efficiencyeere.energy.gov Process Description and Plant Layout Process Description Plant Layout

10 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov Disaggregate Energy Use

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

14 | Industrial Energy Efficiencyeere.energy.gov Average LEA Scores 39% 58%

15 | Industrial Energy Efficiencyeere.energy.gov 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 Natural Gas Breakdown Electrical Energy Breakdown

16 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov 1. Inside-out Approach Energy flow from outside to inside plant

20 | Industrial Energy Efficiencyeere.energy.gov Inside-out Approach

21 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov 3. Think Counter Flow Q T T x x Q Parallel Flow Counter Flow

23 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov 5. Match Source Energy to End Use

25 | Industrial Energy Efficiencyeere.energy.gov 6. Whole-system Whole-timeframe Design D opt = 200 mm when Tot Cost = NPV(Energy)+Pipe D opt = 250 mm when Cost= NPV(Energy)+Pipe+Pump Energy 250 = Energy 200 / 2

26 | Industrial Energy Efficiencyeere.energy.gov Integrated Systems + Principles Approach

27 | Industrial Energy Efficiencyeere.energy.gov Assessment Day Briefing Plant tour to identify opportuniti es Meet to prioritize Gather data to quantify Debrief

28 | Industrial Energy Efficiencyeere.energy.gov Lighting Maximize day lighting Illumination survey and light inventory Placement Distribution efficiency Control Upgrades

29 | Industrial Energy Efficiencyeere.energy.gov Motor Drive Systems Minimize end-use Reduce transmission losses Optimize repair/replace policy

30 | Industrial Energy Efficiencyeere.energy.gov Fluid Flow Minimize friction losses Efficient flow control –Slow fans –Trim pump impellors –Employ VFDs for variable flow Pump-slow pump- long

31 | Industrial Energy Efficiencyeere.energy.gov Compressed Air Systems Minimize air use Minimize leakage losses Minimize pressure Compress outside air Optimize control mode Optimize multi- compressor operation Reclaim heat

32 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov 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 | Industrial Energy Efficiencyeere.energy.gov Combined Heat and Power Feasibility, sizing, economics –Steam to Power –Power to Thermal –Heat to Power

37 | Industrial Energy Efficiencyeere.energy.gov Prioritize Savings Opportunities Savings by System Type Cumulative Payback and Savings

38 | Industrial Energy Efficiencyeere.energy.gov Measure Energy Savings (Using LEA Baseline Model) Pre-retrofit Post-retrofit Savings

39 | Industrial Energy Efficiencyeere.energy.gov Track Normalized Energy Intensity Normalized Energy Intensity decreased 5.4%.

40 | Industrial Energy Efficiencyeere.energy.gov Share Methods and Software

41 | Industrial Energy Efficiencyeere.energy.gov Thank you!