University of Dayton
Industrial Assessment Center
Kelly Kissock, Ph.D., P.E.
Professor and Chair,
Mechanical and Aerospace Engineering / Renewable and Clean Energy
Director: University of Dayton Industrial Assessment Center
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.
– 20 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
Eligibility for No-Cost IAC Assessment
 Manufacturing facility
SIC: 20 to 39
 Annual energy costs:
$100,000 - $2,500,000
Other Assistance to Industry from D.O.E.
 Save Energy Now program
– http://www1.eere.energy.gov/industry/saveenergynow/
 D.O.E. Software Tools
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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
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
UD Industrial Assessment Center
 Performed over 800
assessments since 1981
 Check implementation
results after one year
– Half of recommendations
implemented < 2 year
– Average implemented
savings: >$100,000 per
year
UD-IAC Energy Assessment Approach
 Develop Baseline
– Billing analysis: how energy is priced
– Energy balance: where energy is used
– Lean energy analysis: why energy use changes
 Identify and Quantify Savings Opportunities
– Integrated Systems and Principals Approach to Identifying Savings
•
•
Consider relevant energy systems (elect, lights, motors, fluid flow, compressed air, steam, process heating and cooling, HVAC)
Apply principals of energy efficiency (inside out, control efficiency, counter flow, etc.)
– Use engineering fundamentals and fundamental-based software to quantify savings
 Measure and Benchmark
– Measurement: extend LEA with sliding NAC and EI to measure energy efficiency
improvement
– Benchmarking: compare NAC and EI for inter-facility benchmarking
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
1/
24
/0
2
2/
25
/0
2
3/
25
/0
2
4/
25
/0
2
5/
24
/0
2
6/
25
/0
2
7/
25
/0
2
8/
26
/0
2
9/
25
/0
2
10
/2
4/
02
11
/2
2/
02
12
/2
3/
02
1/
24
/0
3
2/
24
/0
3
3/
25
/0
3
4/
24
/0
3
5/
23
/0
3
6/
24
/0
3
7/
25
/0
3
8/
26
/0
3
0
Actual Demand (kW)
Consumption (kWh/day)
140
120
100
80
60
40
20
0
3/
6/
02
4/
6/
02
5/
6/
02
6/
6/
02
7/
6/
02
8/
6/
02
9/
6/
0
10 2
/6
/0
11 2
/6
/0
12 2
/6
/0
2
1/
6/
03
2/
6/
03
3/
6/
03
4/
6/
03
5/
6/
03
6/
6/
03
7/
6/
03
8/
6/
03
Consumption (ccf/day)
160
Consumption (kWh/day)
Baseline: 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
Baseline: Calibrated Energy Use Breakdowns
Estimated Electrical Use Breakdown
Vacuum Pumps
Process Blowers/Fans
Lighting
Dust Collectors
Sanders
Other Process Motors
Air Compressors
Process Heating
Other
0%
20%
18%
17%
12%
12%
8%
6%
5%
2%
12%
24%
36%
48%
60%
Baseline: Lean Energy Analysis
 Model energy use as
functions of weather and
production
– E=a+bT+cP
– G=a+bT+cP
 Use models for:
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Measuring savings
Budgeting
LEA Breakdown
Benchmarking
Identifying Savings Opportunities
LEA: High Independent
Identifies Operating Opportunities
LEA: High Scatter
Identifies Control Opportunities
Heating Energy Varies by 3X at Same Temp!
LEA: Departure From Expected Shape
Identifies Malfunctioning Economizers
 Air conditioning electricity use should flatten below 50 F
 Audit found malfunctioning economizers
Energy Systems
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Electrical
Lighting
Motor drive
Fluid flow
Compressed air
Steam and hot water
Process heating
Process cooling
Heating, ventilating and air conditioning
Cogeneration
Renewable Energy
Principles of Energy Efficiency
•
•
•
•
•
•
Inside Out Analysis
Understand Control Efficiency
Think Counter-flow
Avoid Mixing
Match Source Energy to End Use
Whole-system, Whole-time Frame Analysis
P-1: Think ‘Inside-out’
Energy
Supply
Conversion
Distribution
Use
Energy
Use
Inside-Out Analysis Approach
Result: Significant improvement at minimal cost
P-2: Understand Control Efficiency
Poor
Energy
Excellent
Production
(Systems sized for peak but operate at part-load)
P-3: Think Counter Flow
T
Q
Parallel Flow
T
x
Q
Counter Flow
x
P-4: Avoid Mixing
• Availability analysis…
Useful work destroyed with mixing
• Examples
– CAV/VAV air handlers
– Separate hot and cold wells
– Material reuse/recycling
P-5: Match Source Energy to End Use
P-6: Whole System/Timeframe Design
• Dopt = 200 mm when Tot Cost = NPV(Energy)+Pipe
• Dopt = 250 mm when Cost= NPV(Energy)+Pipe+Pump
• Energy250 = Energy200 / 2
Integrated Systems + Principles Approach
Compress
Process Process
Electrical Lighting Motors Fluid Flow Air Steam Heating Cooling
Lean Energy Analysis Baseline
Inside Out Analysis
Minimum Theoretical Energy
Conversion and Control Efficiency
Match Source Energy to End Use
Maximize Counter-flow
Avoid Mixing
Whole-system, Whole-time Frame Analysis
 Effective and Thorough
HVAC
CHP
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
 End Use
– Turn off blocked light
– Occupancy sensors
– Maximize day-lighting
 Distribution
– Add reflectors
– Task Lighting
– White ceilings / walls
 Conversion
– Upgrade fixtures
Motor Drive Systems
 End Use
– Turn off when not in use
 Distribution
– Smooth to notched V-Belts
 Conversion
– Replace rather than rewind
– Right-size motors
Compressed Air Systems
 End Use
– Eliminate inappropriate
uses
– Air saver nozzles
 Distribution
– Fix leaks
– Timed to demand control
drains
 Conversion
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Reduce Pressure
Efficient control
Compress outdoor air
Properly stage
Adequate storage
Reclaim heat to space
Fluid Flow
 End Use
– Decrease head
– Pump slower/longer
 Distribution
– Reduce friction
 Conversion
– Trim impellor / slow fan
– VFDs for variable flow
Process Heating
 End Use
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Insulate hot surfaces
Block radiation
Minimize infiltration
Reduce cooling losses
Reduce conveyor losses
Reduce batch losses
 Distribution
– Counter flow heat exchange
 Conversion
– Reduce excess combustion air
– Pre-heat combustion air or load
– Cascade waste heat
Boiler / Steam Systems
 End Use
– Insulate hot surfaces
– Cover open tanks
 Distribution
– Repair failed steam traps
 Conversion
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Reduce excess combustion air
Pre-heat combustion air or feed-water
Minimize steam pressure
Reduce blow-down
Modulation control
Add O2 trim control
Process Cooling
 End Use
– Insulate cold surfaces
– Increase HX effectiveness
– Pinch analysis
 Distribution
– Avoid mixing
 Conversion
– Utilized most efficient cooling
process
– Properly stage chillers
– VFDs on CT fans
Heating Ventilating and Air Conditioning
 End Use
– Reduce set-points
– Reduce infiltration/ventilation
– Insulate un-insulated envelope
 Distribution
– Reduce temp stratification
– Radiant heaters
 Conversion
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Reclaim heat from process
100% efficient MAU for ventilation
Differential pressure control for MAUs
Outdoor air economizers
Measurement and Benchmarking
 Measurement
– Extend LEA with sliding NAC and EI to measure energy
efficiency improvement
 Benchmarking
– Compare NAC and EI for inter-facility benchmarking
Measure: Extend LEA by Calculating Sliding
Normalized Annual Consumption (NAC)
•
AC up
by 10%
•
NAC
down by
12%
Benchmark: Compare NACs of Multiple Facilities
Biggest Energy Increase
DNAC
Smallest Energy Users
Biggest Energy Users
Biggest Energy Decrease
NAC
Institutionalize Knowledge
Free Energy Analysis Software
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ESim
HeatSim
CoolSim
AirSim
LightSim
ETracker
UD-IAC Alumni
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McDonough-Braungart
Johnson Controls
Honeywell
Energy Resource Solutions
2RW Consulting
Select Energy Services
Heapy
Go Sustainable Energy
And many more…
Awards
 U.S. DOE 2003 Center of Excellence
 State of Ohio 2006 Governor’s Award for Excellence in
Energy
 U.S. DOE Energy Champion Awards to UD-IAC Clients
Interested?
Dr. Kelly Kissock
937-229-2852
kkissock@udayton.edu
Franc Sever
937-229-3343
severfrj@notes.udayton.edu
http://academic.udayton.edu/kissock/http/IAC