Transcript University of Dayton Industrial Assessment Center Dr. Kelly Kissock Department of Mechanical and Aerospace Engineering.

University of Dayton
Industrial Assessment Center
Dr. Kelly Kissock
Department of Mechanical and Aerospace Engineering
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
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 after one year to see what
was implemented
UD Industrial Assessment Center
 Performed over 700
assessments since 1981
 Check implementation
results after one year
– Half of recommendations
implemented < 2 year
– Average implemented
savings: $220,000 per
year
1,800
16,000
1,600
14,000
Actual Demand (kW)
1,400
12,000
1,200
10,000
1,000
8,000
800
6,000
600
4,000
400
2,000
200
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Actual Demand (kW)
Consumption (kWh/day)
140
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100
80
60
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Consumption (ccf/day)
160
Consumption (kWh/day)
Utility Bill Analysis
 Analyze rate schedule
 Verify billing amounts
 Check for saving
opportunities:
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Primary/secondary
Power factor correction
Meter consolidation
Demand reduction
potential
 Benchmark costs
Lean Energy Analysis
 Model Elec and Gas as
functions of weather and
production
– E=a+bT+cP
– G=a+bT+cP
 Decompose energy into:
– Facility
– Space-conditioning
– Production
 Uses:
– Budgeting
– Costing
– Tracking Improvement
Calibrated Energy Use Breakdowns
Electrical Energy Breakdown
Other
16%
Compressors
10%
CompTech/
Shaffer
21%
Air
Conditioning
1%
Dynos
8%
CompAir
Machining
Equipment
13%
Fans
4%
Lighting
27%
Natural Gas Breakdown
Gas Fired Make-up
Air Unit
10%
Space Heaters
(supplied by
boilers)
59%
Error due to
change in outdoor
temp.
4%
Parts Washer
9%
Powder Washer
9%
Paint Dryer
9%
 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
UD-IAC Inside-Out Approach
Plant Boundary
Ein
Primary
Energy
Conv ersion
Equipment
E
Energy
Distribution
Sy stem
E
Manuf acturing
W
Process and
Equipment
Inside-out analysis sequence
for reducing energy
Inside-Out Analysis
Sequence for
Reducing Energy Use
Waste
Treatment
Sy stem
W
Waste
Disposal
Wout
Inside-out analysis sequence
for reducing w aste streams
Inside-Out Analysis
Sequence for Reducing
Waste
Result: Significant improvement at minimal cost
State of the Art Equipment
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Power logging
Ultrasonic flow sensors
Ultrasonic vibration
Combustion analysis
Temperature, light,
pressure, air flow, etc.
Lighting
 Illumination survey and
light inventory
 Placement
 Distribution efficiency
 Daylighting
 Control
 Upgrades
Compressed Air Systems
Minimize air use
Minimize leakage losses
Minimize pressure
Compress outside air
Optimize control mode
Optimize multicompressor operation
 Reclaim heat
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Process Heating
 Match energy source/use
 Insulate hot surfaces,
pipes and open tanks
 Steam trap maintenance
 Combustion efficiency
 Heat reclaim
 Combined heat and power
Process Cooling
 Heat-exchanger
networks to reduce
cooling load
 Eliminate “once-through”
cooling water
 Use cooling towers
rather than chillers
 Absorption chillers
Fluid Flow
 Reduce pressure loss
and correct flow
 Employ VSDs for:
– Variable-flow
applications
– Injection molding/die
casting hydraulic
motors
 Optimize multi-pump
operation
Space Conditioning
 Minimize ventilation
loads
 Balance plant air
pressure
 Minimize distribution
losses
 Improve control
Motor Drive Systems
 Reduce
transmission losses
 Optimize
repair/replace policy
Cutting Fluids
 Filtration
 Separation
 Scheduling
Hazardous Wastes
 Source reduction
 Material
substitution
 Bioactive solvents
 Onsite remediation
 Disposal
Water Conservation
 Process control
improvements
 Eliminate oncethrough cooling
 Counter-flow rinsing
 Sewer exemptions
Shipping and Packaging Materials
 Reusable containers
and pallets
 Match buyers and
sellers of waste
packaging
 Process optimization
to reduce in-process
containers
Lean Manufacturing
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One-piece flow
Quick changeovers
Material flow
Inventory reduction
Reduced production
time
Share What We’ve Learned…
www.engr.udayton.edu/udiac
Free Energy Analysis Software
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www.engr.udayton.edu/udiac
ESim
HeatSim
CoolSim
AirSim
LightSim
ETracker
UD-IAC Graduates
 Work for top firms:
– Energy Consulting
– Engineering
– Manufacturing
U.S. Department of Energy
2003 Center of Excellence Award
To
University of Dayton
Interested?
Dr. Kelly Kissock
937-229-2852
[email protected]
www.engr.udayton.edu/udiac