University of Dayton Industrial Assessment Center Dr. Kelly Kissock Department of Mechanical and Aerospace Engineering.
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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
0
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Actual Demand (kW)
Consumption (kWh/day)
140
120
100
80
60
40
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Consumption (ccf/day)
160
Consumption (kWh/day)
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
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
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
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
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
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