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Alabama Industrial Assessment Center

Alabama Industrial Assessment Center. Keith A. Woodbury Mechanical Engineering. 28 Centers Nationwide. AIAC Clients. Base activities funded by DOE Advanced Manufacturing Office 13th year of operation About 235 clients served to date

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Alabama Industrial Assessment Center

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  1. Alabama Industrial Assessment Center Keith A. Woodbury Mechanical Engineering

  2. 28 Centers Nationwide

  3. AIAC Clients • Base activities funded by DOE Advanced Manufacturing Office • 13th year of operation • About 235 clients served to date • About $42M in 1,669 energy savings recommendations (typically 5% - 20% of plant use) • About $7.7M in 664 implemented energy savings projects reported

  4. IAC Mission • Assist small-to-medium manufacturers with • Energy Efficiency • Productivity • Waste Management • Train next-generation of engineers in energy practices

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

  6. IAC Assessment Overview Pre-Assessment Analysis & Reporting Assessment Visit Follow Up • Meet with plant management team • Present details of pre-assessment analysis • Tour plant • Collect operating data • Conduct diagnostic testing • Discuss preliminary assessment findings with plant management • Prioritize potential recommendations for further analysis • Duration: One Day • Conduct follow up discussions with plant, 6-9 months following assessment visit • Identify implemented energy savings • Upload implementation data into the IAC database • Conduct engineering and financial analyses of priority recommendations • Develop first order estimates of implementation costs • Document results in “GOLD Standard” format assessment report • Upload report data into IAC database • Deliver report to plant within 60 days from plant visit • 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

  7. Typical Recommendations

  8. Lighting • Replace MH with Fluorescent • Replace Fluorescent with LED 50% reduction 75% reduction 50% reduction

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

  10. Compressed Air • Use most efficient controls

  11. Compressed Air • Use minimum allowable pressure

  12. Compressed Air • Repair Air Leaks • A 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. • Proactive leak detection and repair can reduce leaks to less than 10 percent of compressor output

  13. Boilers • Reduce combustion O2to minimum • Lowers mass flow rate of exhaust • Less energy absorbed by excess air

  14. Boilers • Recover waste heat from stack gas • Preheat combustion air • Preheat boiler feedwater (economizer) • Cool combustion gases only • Condensing economizer also condenses moisture from exhaust and captures latent heat

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

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