Alabama Industrial Assessment Center Keith A Woodbury Mechanical

Alabama Industrial Assessment Center Keith A. Woodbury Mechanical Engineering

28 Centers Nationwide

AIAC Clients • Base activities funded by DOE Advanced Manufacturing Office ü 13 th year of operation üAbout 235 clients served to date üAbout $42 M in 1, 669 energy savings recommendations (typically 5% - 20% of plant use) üAbout $7. 7 M in 664 implemented energy savings projects reported

IAC Mission 1. Assist small-to-medium manufacturers with üEnergy Efficiency üProductivity üWaste Management 2. Train next-generation of engineers in energy practices

Assessment Activities • Pre-visit analysis and preparation • One-day on-site assessment • Reporting (60 days) and Implementation Follow-up (12 mos)

IAC Assessment Overview Pre-Assessment • Gather plant data including product type, annual sales levels, production levels, operating hours • Study processes and plant layout • Analyze utility billing data • Identify key energy systems • Develop assessment day strategy • To be completed before assessment visit Assessment Visit • Meet with plant management team • Present details of preassessment analysis • Tour plant • Collect operating data • Conduct diagnostic testing Analysis & Reporting • Conduct engineering and financial analyses of priority recommendations • Conduct follow up discussions with plant, 6 -9 months following assessment visit • Develop first order estimates of implementation costs • Identify implemented energy savings • Discuss preliminary assessment findings with plant management • Document results in “GOLD Standard” format assessment report • Prioritize potential recommendations for further analysis • Upload report data into IAC database • Duration: One Day Follow Up • Deliver report to plant within 60 days from plant visit • Upload implementation data into the IAC database

Typical Recommendations

Lighting • Replace MH with Fluorescent 50% reduction 75 %r • Replace Fluorescent withed. LED uct io n 50% reduction

Lighting • Use photocells to advantage natural light • Install motion sensors to avoid unnecessary illumination

Compressed Air • Use most efficient controls

Compressed Air • Use minimum allowable pressure work input decrease for 2 psi change 1. 6% 1. 4% 1. 2% 1. 0% 0. 8% 0. 6% pct_v 0. 4% avg 90 -110 psi 0. 2% 0. 0% 60 80 100 120 Discharge pressure, psig 140 160

Compressed Air • Repair Air Leaks üA typical plant that has not been well maintained will have a leak rate equal to, or greater than, 20 percent of total compressed air production capacity. üProactive leak detection and repair can reduce leaks to less than 10 percent of compressor output

Boilers • Reduce combustion O 2 to minimum üLowers mass flow rate of exhaust ØLess energy absorbed by excess air

Boilers • Recover waste heat from stack gas üPreheat combustion air üPreheat boiler feedwater (economizer) ØCool combustion gases only ØCondensing economizer also condenses moisture from exhaust and captures latent heat

$Contact Information Keith A. Woodbury keith. woodbury@ua. edu (205)348 -1647 AIAC Website: https: \iac.$