University of Dayton Industrial Assessment Center

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University of DaytonIndustrial Assessment
Center

• Dr. Kelly Kissock
• Department of Mechanical and Aerospace
  Engineering
• www.engr.udayton.edu/udiac

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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

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Eligibility for No-Cost IAC Assessment

• Manufacturing facility SIC 20 to 39
• Annual energy costs 100,000 - 2,000,000

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Other Assistance to Industry from D.O.E.

• Save Energy Now program
• http//www1.eere.energy.gov/industry/saveenergynow
  /
• D.O.E. Software Tools
• Screening Quick PEP
• Process heating PHAST
• Compressed Air Air Master
• Pumps PSAT
• Steam SSAT
• Motors Motor Master
• General training on D.O.E. software tools
• 1 to 3 day seminars on D.O.E. tools
• Energy Saving Assessments
• 3-day assessment of specific energy system
• Includes training on use of D.O.E. software tool
• gt 300 billion Btu/year (1 kWh 3,412 Btu, 1 mcf
  1,000,000 Btu/yr)

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IAC Assessment

• Gather and analyze data before visit
• Team of faculty and students visit plant for one
  day
• Work closely with clients to
• Reduce energy
• Reduce waste
• Improve productivity
• Write custom, confidential, independent report
  with specific savings suggestions
• Call back to see what was implemented

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UD Industrial Assessment Center

• Performed over 750 assessments since 1981
• Check implementation results after one year
• Half of recommendations implemented lt 2 year
• Average implemented savings gt100,000 per year

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Utility Bill Analysis

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

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Lean Energy Analysis

• Model energy use as functions of weather and
  production
• E a b T c P
• G a b T c P
• Decompose energy into
• Production-dependent
• Weather-dependent
• Independent
• Use models for
• Measuring savings
• Budgeting
• Costing
• LEA Breakdown

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LEA Breakdown
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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  
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UD-IAC Inside-Out Approach
Inside-Out Analysis Sequence for Reducing Energy
Use
Inside-Out Analysis Sequence for Reducing Waste
Result Significant improvement at minimal cost
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State of the Art Equipment

• Power logging
• Ultrasonic flow sensors
• Ultrasonic vibration
• Combustion analysis
• Temperature, light, pressure, air flow, etc.

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Lighting

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

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Compressed Air Systems

• Minimize air use
• Minimize leakage losses
• Minimize pressure
• Compress outside air
• Optimize control mode
• Optimize multi-compressor operation
• Reclaim heat

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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

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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

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Process Cooling

• Heat-exchanger networks to minimize cooling loads
• Maximize temperature set points
• Use in order
• Cooling tower
• Water-cooled chiller
• Air-cooled chiller
• Once-through cooling water
• Stage multiple chillers or employ VFD chillers
• Use absorption chillers if waste heat is
  available
• Employ VFDs cooling tower fans

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Fluid Flow

• Minimize friction losses
• Employ VFDs for
• Variable flow applications
• Injection molding/die casting hydraulic motors
• Pump-slow pump-long

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Space 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

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Motor Drive Systems

• Minimize end-use
• Reduce transmission losses
• Optimize repair/replace policy

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Hazardous Wastes

• Source reduction
• Material substitution
• Bioactive solvents
• Onsite remediation
• Disposal

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Water Conservation

• Process control improvements
• Eliminate once-through cooling
• Counter-flow rinsing
• Sewer exemptions

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Shipping and Packaging Materials

• Reusable containers and pallets
• Match buyers and sellers of waste packaging
• Process optimization to reduce in-process
  containers

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Lean Manufacturing

• One-piece flow
• Quick changeovers
• Inventory reduction
• Lead time reduction
• Energy/productivity

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Institutionalize Knowledge

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Free Energy Analysis Software

• ESim
• HeatSim
• CoolSim
• AirSim
• LightSim
• ETracker

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Student Opportunities

• Training and Meetings
• Compressed Air Challenge Training, Chicago, IL,
  Pittsburgh, PA
• Steam System Training, Columbia, SC
• Lead Student Meeting, Washington, DC
• Conferences
• National Industrial Energy Technology Conference,
  Houston, TX
• World Energy Congress, Atlanta, GE
• National Solar Energy Conference, Austin, TX
• ASHRAE National Meeting, Chicago, IL
• Lost Foam Casting Production Meeting, Chicago, IL

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UD-IAC Alumni

• McDonough-Braungart
• Johnson Controls
• Honeywell
• Energy Resource Solutions
• 2RW Consulting
• Select Energy Services
• Heapy
• Go Sustainable Energy
• And many more

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• U.S. Department of Energy
• 2003 Center of Excellence Award
• To
• University of Dayton
• Industrial Assessment Center

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• State of Ohio
• 2006 Governors Award for
• Excellence in Energy
• To
• University of Dayton
• Industrial Assessment Center

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• U.S. Department of Energy
• 2007 Energy Champion Awards
• To
• UD-IAC Clients
• Empire Die Casting
• Iten Industries

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Interested?

• Dr. Kelly Kissock
• 937-229-2852
• kkissock_at_udayton.edu

www.engr.udayton.edu/udiac