Presented by Mary C. Emplaincourt, M.S.

2004 Presentation at a MMA Energy Meeting

Presentation Outline

• What is the IAC?

• What has the IAC done for MS industries?

• What can the IAC do for MS industries?

• Who qualifies for an IAC assessment?

• How do MS companies get an IAC assessment?

• How do IAC Assessments work? • DOE requirements for the IAC

What is the IAC?

• Provides energy, waste, and productivity assessments to small and mid-sized manufacturers.

• Funded by the U.S. Department of Energy.

• Established at Mississippi State University in 1993.

• Assistance provided by upper-level engineering students.

IAC Mission

• Foster Industry/University Relationships • Provide No-Cost Engineering Services to Local Companies • Energy Conservation, Waste Minimization, and Productivity Enhancement • Undergraduate and Graduate Student Involvement

Students Working for the IAC Conducting an Assessment Locating Information about a Motor Finding Motor Speed with a Stroboscope Obtaining Temperature with an Infrared Thermometer Checking Combustion Efficiency with a Combustion Analyzer

IAC’s Areas of Focus

• ENERGY (such as heat recovery, energy efficient lighting retrofit, HVAC controls, power quality, combustion efficiency, etc.) – WASTE (such as recycling, solvent recovery, and minimization, etc.) – PRODUCTIVITY (such as process flow improvement, materials handling improvement, etc.)

What has the IAC done for MS industries?

• Over 2000+ Recommendations Made in 263 Assessments • 250+ Different Recommendation Types • $8 Million in Recommended Energy Savings • $3.25+ Million in Recommended Waste Savings • $9+ Million in Recommended Productivity Savings

Summary of IAC Activities

Productivity Cost Savings $9,000,000 Energy Cost Savings $8,000,000 Waste Cost Savings $3,250,000

As of 2004 263 Site Visits since 1993 throughout Mississippi and Surrounding States.

A Well Used Resource to Locate Clients

Examples of Facilities Visited

• Furniture Factories • Automotive Equipment Manufacturers • Metal Working/Casting Facilities • Clothing Manufacturers • Food/Drink Processors • Valve Manufacturers • Plastic Injection Molding Manufacturers

SIC Distribution

Transportation 2% Instrumentation 1% Misc. Man.

1% Food 8% Electronics 9% Machinery 11% Textile 2% Apparel 4% Lumber & Wood 2% Furniture & Fixtures 17% Fabricated Metal 7% Primary Metal 5% Stone, Clay, Glass & Concrete 3% Rubber 15% Printing Chemical 4% 2% Paper 2%

Examples of Recommendation Types

• Heat Recovery • Power Factor Correction • Energy Management Systems • Energy-Efficient Lighting • Compressed Air Analysis • Process Automation • Process Flow Realignment

What can the IAC do for MS industries?

• We can help companies save MONEY!

• On average, recommended actions from an assessment result in annual cost savings of about $89,000 prior to 2003.

Year 2003 Implemented Savings $900,000+

Who qualifies for an IAC Assessment?

• Standard Industrial Classification (SIC) Codes of 20-39.

• Within 150 miles of MSU. (Optional) • Gross annual sales below $100 million.

• Fewer than 500 employees at the facility.

• Annual utility bills more than $100,000 and less than $2 million.

– Must have at least one full year of utility bills • No in-house staff to perform these analyses.

How do companies get an IAC Assessment?

• Fill out an “Application for Industrial Assessment” form.

• Complete a “Utilities Release Authorization” form.

• Complete “Preliminary Questionnaire”.

• Provide Preferred Site Visit Days.

How do IAC Assessments work?

• Assessment team consists of: – 4 to 6 undergraduate students including a Lead Student – Staff Engineer – Faculty member • Fill out preliminary questionnaire with facility personnel.

• Conduct a plant walk through.

• Break into smaller groups and begin counting equipment.

How do IAC Assessments work?

• List recommendation ideas.

• Collect data and measurements for recommendations.

• Conduct exit interview with facility personnel.

• Average sized facility: 1-day visit • Larger sized facility: 2 or more days

DOE requirements for the IAC

• Mailing of the assessment report within 60 days of the assessment visit.

• Follow-up phone call 6 to 9 months after report mailing.

• Collect data on recommendation implementation rates and costs.

Additional Benefits DOE Special Projects The MSU IAC received funds to develop a Best Practices Guide the wood furniture industry.

for

Additional Benefits DOE Special Projects The MSU IAC,the State Energy Office,ORNL, and DOE are investigating the feasibility of implementing a hydrogen fuel cell in a chemical facility in Mississippi.

Additional Benefits FEMP Special Projects— Assessing Federal Buildings’ Energy Usages The MSU IAC is currently modeling the IRS Computing Center in Memphis, Tennessee

Questions?

B.K. Hodge, Ph.D. P.E.

Richard Forbes, Ph.D. P.E.

Mary C. Emplaincourt, M.S.I.E

Jeremy Childers, B.S.M.E. E.I.T

IAC Tel: (662) 325-8268 IAC Fax (662) 325-0102 www.me.msstate.edu/iac/iac.html

www.oipea.rutgers.edu

Office of Industrial Productivity and Energy Assessment