Kelly Kissock Director: University of Dayton Industrial Assessment Center Dayton, Ohio U.S.A.
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Transcript of Kelly Kissock Director: University of Dayton Industrial Assessment Center Dayton, Ohio U.S.A.
Program Name or Ancillary Text eere.energy.gov
Industrial Assessment Center One-Day Assessment
Kelly KissockDirector: University of DaytonIndustrial Assessment CenterDayton, Ohio U.S.A.
U.S.-Brazil Industrial Energy Efficiency WorkshopRio de Janeiro, Brazil August 8-11, 2011
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• 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
– Improve practice and science of energy efficiency
Industrial Assessment Center Program
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Eligibility for IAC Assessment
• Manufacturing facility SIC: 20 to 39
• Annual energy costs: $100,000 - $2,500,000
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Structure of IAC Assessment
• Gather and analyze data before visit
• Team of faculty and students visit plant for one day
• Work closely with clients to identify and quantify energy saving opportunities
• Write custom, confidential, independent report with specific savings suggestion
• Call after 9-months to see what was implemented
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University of Dayton Industrial Assessment Center
• Performed over 825 assessments since 1981
• Check implementation results after one year – Half of recommendations
implemented– Energy use reduction
~5%
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Recruiting the Student Team
• 5 undergraduate and graduate engineering students
• Senior students mentor junior students
• Require specific classes– Energy Efficient
Manufacturing– Energy Efficient Buildings– Design of Thermal
Systems
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Embed Energy Management into IAC Report
• Develop baseline
• Identify and quantify saving opportunities
• Measure savings to sustain efficiency efforts
Table of Contents I. Executive Summary ............................................................................................................ 6
Corporate Data .................................................................................................................................................. 9 Utility Summary ................................................................................................................................................. 9 Summary of Assessment Recommendations (ARs) ........................................................................................... 10 Summary of Selected Exemplary Practices (EPs) ............................................................................................... 16
II. Baseline ........................................................................................................................... 17
Current Electric Rate Structure – Main Plant ............................................................................................... 18 Electricity Use – Total .................................................................................................................................. 19 Natural Gas Use - Total ............................................................................................................................... 20 Water and Sewer Use .................................................................................................................................. 21 Marginal Costs ............................................................................................................................................ 22
Lean Energy Analysis ........................................................................................................................................ 23 Lean Energy Analysis of Electricity Use ........................................................................................................ 24 Lean Energy Analysis of Natural Gas Use .................................................................................................... 30
Plant Energy Balance........................................................................................................................................ 36 Electricity Use by Equipment ....................................................................................................................... 36 Natural Gas Use by Equipment.................................................................................................................... 38
Plant Description .............................................................................................................................................. 40 Plant Layout ................................................................................................................................................ 40 Process Description ..................................................................................................................................... 40
III. Assessment Recommendations (ARs) .............................................................................. 41
AR 1: Consolidate Electricity Meters and Switch to Primary Rate Structure ................................................. 42 AR 2: Install Capacitors to Improve Power Factor ........................................................................................ 44 Comment 1: Consider Consolidating Electricity Meters ............................................................................... 47
Energy Efficient Lighting ................................................................................................................................... 49 Current Plant Lighting ................................................................................................................................. 51 AR 3: Replace 400-W Metal Halide Fixtures in Manufacturing Areas with 4-lamp T5 High Bay Fluorescent Fixtures .................................................................................................................................... 53 AR 4: Replace 400-W Metal Halide Fixtures in Distribution Center with 4-lamp T5 High Bay Fluorescent Fixtures with Occupancy Sensors .............................................................................................. 57 AR 5: Replace 4-lamp 40-W T12 Fluorescent Fixtures in Offices, Fabrication and Paint Areas with 4-lamp 32-W T8 Fluorescent Fixtures ............................................................................................................. 61
Energy Efficient Motor Systems ........................................................................................................................ 64 AR 6: Turn off Stamping Presses When Not in Use ...................................................................................... 65
Energy Efficient Compressed Air Systems ......................................................................................................... 69 Current Compressed Air System .................................................................................................................. 72 AR 7: Establish Preventative Maintenance Program to Identify and Fix Compressed Air Leaks ................... 73 AR 8: Install Air-Saver Nozzles on Machine Continuous Blowoff .................................................................. 75 AR 9: Reduce Pressure Loss through Custom Compressed Air Dryer ........................................................... 77 AR 10: Replace Compressed Air Grinders with Electric Grinders .................................................................. 79
Energy-Efficient Fluid Flow ............................................................................................................................... 82 AR 11: Install VFDs on Pumps and Open Throttling Valves on Pretreatment Line ........................................ 83
IV. Measuring Savings .......................................................................................................... 87
V. Appendix ......................................................................................................................... 88
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Baseline
Four Components of Plant Baseline
1. Process Description and Plant Layout2. Utility Analysis3. Plant Energy Balance4. Lean Energy Analysis
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Process Description and Plant Layout
Process Description Plant Layout
Wax Tree Preparation
Refractory Dip
Flash Fire Furnace
Inspection
Baking
Liquid Wax
Liquidized Sand, Binders
Wax
Refractory Tree
1,600 F
Foam Padding
Foundation Making
Foam Pad Removing
Pouring
Baking
Wood Pattern, Foam
Refractory
Zircon Slurry Foam
1,400 F
Pattern Making
Settling
Flask, Wood Pattern, Binders Sand
Pre-heating Ladle, Gas
Burners
Weighing Alloy Steels
Cleaning Melting
Pouring
Knocking
Cleaning
Shot Blasting
Sand
Cope
Raw Material
Drag
Molds
Sand Recycling
Annealing Finishing
Heat Treating
Inspection Packaging Shipping
Steel Shots Steel Shots
Metal Scrap
Quenching Nitrogen Vacuum
1,500 F ~ 2,240 F
1,600 F
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Utility Billing Analysis
• Analyze rate schedule• Verify billing amounts• Check for saving
opportunities:– Primary/secondary– Power factor correction– Meter consolidation– Demand reduction
potential• Benchmark costs
0
200
400
600
800
1,000
1,200
1,400
1,600
1,800
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
10/24
/02
11/22
/02
12/23
/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
Actu
al D
eman
d (k
W)
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
Cons
umpt
ion
(kW
h/da
y)
Actual Demand (kW) Consumption (kWh/day)
0
20
40
60
80
100
120
140
160
3/6/02
4/6/02
5/6/02
6/6/02
7/6/02
8/6/02
9/6/02
10/6/
02
11/6/
02
12/6/
021/6
/032/6
/033/6
/034/6
/035/6
/036/6
/037/6
/038/6
/03
Cons
umpt
ion
(ccf
/day
)
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Lean Energy Analysis
• Model energy use as functions of weather and production
• Decompose energy into:– Production-dependent– Weather-dependent– Independent
• Use models for:– Quantify “Leanness”– Identify savings
opportunities– Measuring savings
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Disaggregate Energy Use
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Quantify Energy “Leaness”
Production39%
Independent51%
Weather10%
“Independent” is energy not added to productLEA = (1 – Independent)
Electricity LEA = 49%
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Average LEA Scores
39%
58%
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Calibrated Energy Use Breakdowns
• 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
Natural Gas Breakdown
Electrical Energy Breakdown
CompTech/Shaffer
21%
CompAir Machining Equipment
13%
Dynos8%
Compressors10%
Lighting27%Fans
4%
Air Conditioning
1%
Other16%
Gas Fired Make-up Air Unit
10%
Error due to change in outdoor
temp.4%
Parts Washer9%
Paint Dryer9%
Space Heaters (supplied by
boilers)59%
Powder Washer9%
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Approach for Identifying Savings
• Each manufacturing process is unique• Can’t become experts in every manufacturing
process• Found that manufacturing processes comprised
of different sequences of same “building blocks”• Developed:
“Integrated Systems + Principles Approach”
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Energy Systems
– Lighting– Motor drive– Fluid flow– Compressed air– Steam and hot water– Process heating– Process cooling– Heating, ventilating and air
conditioning– Combined heat and power
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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
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1. Inside-out Approach
Conversion Distribution UseEnergySupply
Energy Use
Inside-Out Analysis ApproachEnergy flow from outside to inside plant
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Inside-out Approach
Conversion Distribution Use
EnergySupplySavings
Energy End–Use Savings
Inside-Out Analysis Approach
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2. Understand Control Efficiency
• All systems sized for peak-load, but operate at part-load
• Control efficiency quantifies loss from controlling system to operate at part-load
Energy
Production
Poor
Excellent
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3. Think Counter Flow
Q
T
T
x
x
Q
Parallel Flow
Counter Flow
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4. Avoid Mixing
• Availability analysis tells us– Useful work destroyed with mixing
• Examples– CAV/VAV air handlers– Separate hot and cold wells– Material reuse/recycling
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5. Match Source Energy to End Use
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6. Whole-system Whole-timeframe Design
• Dopt = 200 mm when Tot Cost = NPV(Energy)+Pipe • Dopt = 250 mm when Cost= NPV(Energy)+Pipe+Pump• Energy250 = Energy200 / 2
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Integrated Systems + Principles Approach
Electrical Lighting Motors Fluid FlowCompress
Air SteamProcess Heating
Process Cooling HVAC CHP
Lean Energy Analysis BaselineInside Out AnalysisMinimum Theoretical EnergyConversion and Control EfficiencyMatch Source Energy to End UseMaximize Counter-flowAvoid MixingWhole-system, Whole-time Frame Analysis
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Assessment Day
• Briefing • Plant tour
to identify opportunities
• Meet to prioritize
• Gather data to quantify
• Debrief
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Lighting
• Maximize day lighting
• Illumination survey and light inventory
• Placement• Distribution
efficiency• Control• Upgrades
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Motor Drive Systems
• Minimize end-use• Reduce
transmission losses
• Optimize repair/replace policy
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Fluid Flow
• Minimize friction losses
• Efficient flow control– Slow fans– Trim pump
impellors– Employ VFDs for
variable flow• Pump-slow pump-
long
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Compressed Air Systems
• Minimize air use• Minimize leakage
losses• Minimize pressure• Compress outside air• Optimize control mode• Optimize multi-
compressor operation• Reclaim heat
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Boiler / Steam Systems
• Match energy source/use
• Insulate hot surfaces, pipes and open tanks
• Maintain steam traps• Maximize combustion
efficiency• Preheat boiler feed
water• Explore combined
heat and power
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Process Heating
• Maximize heat delivery efficiency (heat product not air)
• Minimize batch heating losses
• Minimize air leakage and openings
• Insulate hot surfaces• Maximize combustion
efficiency• Reclaim heat to preheat
combustion air or charge
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Process Cooling
• Heat-exchanger networks to minimize cooling loads
• Maximize temperature set points
• Maximize use of cooling tower
• Replace air-cooled with water-cooled chillers
• Stage chillers or employ VFD chillers
• Use absorption chillers if waste heat is available
• Employ VFDs cooling tower fans
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Heating, Ventilating, Air Conditioning
• Employ temperature setback
• Insulate un-insulated envelope
• Minimize ventilation loads and balance plant air pressure
• Outside air:– If needed, use 100% eff MAU– In unneeded, use 80% eff
unit heater• Employ economizers for
year-long cooling loads• Improve distribution
effectiveness
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Combined Heat and Power
• Feasibility, sizing, economics– Steam to Power– Power to Thermal– Heat to Power
Boiler
Turbine
Shaft work out
Qcoal
Pump
Electrical Generator
Electricity
Qcondensor
~ 50 - 150 psig steam to plant
Condensor Low-pressure steam
Make-up water
Combustor
Compressor Turbine
Shaft work to compressor
Shaft work out
Qnatural gas
Ambient air Boiler
Electrical Generator
Electricity
Exhaust at ~375 F
Steam Turbine exhaust at
650 – 1,000 F
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Prioritize Savings Opportunities
Savings by System Type Cumulative Payback and Savings
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Measure Energy Savings (Using LEA Baseline Model)
Pre-retrofit
Post-retrofit
Savings
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Track Normalized Energy Intensity
Normalized Energy Intensity
decreased 5.4%.
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Share Methods and Software
http://academic.udayton.edu/udiac
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Thank you!