Alabama Industrial Assessment Center

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