1. Alabama Industrial Assessment Center
Keith A. Woodbury
Mechanical Engineering

2. Alabama Technology Network
28 Centers Nationwide
April 21, 2019

3. 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

4. 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

5. 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)

6. 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

7. Typical Recommendations

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

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

10. Compressed Air
Use most efficient controls

11. Compressed Air
Use minimum allowable pressure

12. 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

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

14. 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

15. Contact Information
Keith A. Woodbury (205) AIAC Website: