How to Save Money and Become More Sustainable Through Energy Efficiency

Transcription

1 How to Save Money and Become More Sustainable Through Energy Efficiency Ohio Energy Protection Agency October 31, 2018 Kelly Kissock, Ph.D., P.E. Department of Mechanical and Aerospace Engineering / Renewable and Clean Energy University of Dayton

2 Industrial Assessment Center Program Sponsored by U.S. Department of Energy Began during 1970 s energy crisis 28 centers at universities throughout the U.S. 20 no-cost assessments per year for mid-sized manufacturers Goals Help industry be more resourceefficient and cost-competitive Train new energy engineers Advance practice and science of energy efficiency

3 Helping Industry Be More Energy Efficient UD-IAC conducted 995+ assessments since 1981 Savings opportunities: 12 Simple payback: 2 years Identified savings: 12% Implemented savings: 6%

4 Qualifying For A Free IAC Assessment To qualify for a free assessment, you must: Be a water utility or a manufacturer with SIC code between Have total annual energy costs between $100,000 - $2.5 million

5 UD-IAC Assessments Gather and analyze data before visit One day site visit to work directly with facility personnel to identify energy saving opportunities Write custom report with specific savings suggestions delivered in 4-6 weeks Call back after 9 months to see what was implemented

6 Energy Assessment Approach Develop Baseline Utility Analysis Plant Energy Balance Lean Energy Analysis Identify and Quantify Savings Opportunities Integrated Systems and Principals Approach Integrated Materials and Principals Approach Sustainable Investment Strategies and Measured Results 123-Zero Life-cycle product design Weather and production normalized savings

7 Develop Baseline: Utility Analysis Understand how your plant is billed for electricity and fuel energy. Determines accurate avoided energy costs Identifies utility savings opportunities

8 Develop Baseline: Plant/Building Energy Balance Describes where energy is used in the plant and throughout the production process to help focus efforts on the most important areas.

9 Develop Baseline: Lean Energy Analysis Lean Energy Analysis Defines how energy use changes with weather and production Regress energy versus temperature and production. Identifies wasted energy that doesn t add value to the product or plant environment Provides a baseline for measuring weather and production normalized savings

10 Method For Identifying Savings Opportunities UD-IAC 975+ assessments Multiple processes On-site only one-day With evolving team Energy Supply Conversion Distribution Use Energy Use Must develop method which is: Effective Reproducible Teachable Inside-Out Analysis Approach Significant improvement at minimal cost

11 Twelve Industrial Energy Systems

12 Four Energy Principles

13 Integrated Systems + Principles Approach Electrical Lighting Motors Fluid Flow Comp Air Process Heat Steam Process Cool Ammon Refrig HVAC CHP Renew Energy 1) Think Inside Out 2) Maximize Control Efficiency 3) Maximize Energy Effectiveness 4) Analyze Wholesystems Over Whole-time Frames ISPA: Effective, Reproducible, Teachable

14 Integrated Materials + Principles Approach IMPA: Effective, Reproducible, Teachable

15 Energy Efficiency Principle 1: Think Inside Out

16 Inside: Reduce Blow-off with Solenoid Valves Cost Savings = $8,933 /yr Cost of 3/8-inch solenoid valve = $100

17 Distribution: Add Storage to Enable Full Blowdown Savings from full blowdown Adding storage saves 2.9% and $725 /yr Cost of storage $700

18 Conversion: Sequencer so VSD Always Trims Adding sequencer saves 6% and $1,500 /yr Cost of sequencer $5,000

19 Energy Efficiency Principle 2: Maximize Control Efficiency

20 Inefficient Flow Control By-pass Valve Fan w/ Inlet Vanes By-pass loop (No savings) By-pass damper (No savings) Outlet valve/damper or Inlet Vanes (Small savings) Intermittent Flow (Small savings)

21 Efficient Flow Control Close By-pass Valve dp VFD Trim impellor for constant-volume pumps Slow fan for constant-volume fans VFD for variable-volume pumps or fans

22 For Variable Flow: Install VFD Savings = 66%

23 Then, Reduce Static Set Point Pressure Baseline Pset = 1.5 Mean Damper = 65% Open Post-baseline Pset = 1.0 Mean Damper = 67% Open Savings: 26%

24 Energy Efficiency Principle 3: Maximize Energy Effectiveness 1: Maximize counter flow 2: Minimize mixing

25 Convert from Cross to Counter Flow Cooling Cross Flow e = 0.69 Tw1 = 50 F Counter Flow e = 0.78 Tw1 = 79 F Use cooling tower instead of chiller Save 70% 8 months per year

26 Pre-heat Load Using Counter-flow Current Recommended Savings = Big Enough that Corporate Noticed

27 Energy Efficiency Principle 4: Whole Systems Over Whole Time Frames Whole System

28 UD: 4,026 Solar Panels at 1.26 MW Simple Payback = 18 years NPV whole lifetime = +$300,000 Eliminates 39,000 metric tons of CO 2 emissions

29 State Of The Art Measurement Equipment Power Flow Vibration Combustion Temperature Light Pressure

30 Quantifying Savings Energy savings opportunities are explained in detail All calculations are transparent Quantifies energy, cost, and CO 2 emission reductions Complete economic analysis with implementation cost and available rebates

31 Quantifying Savings: Free Software 14 free software tools available online Compressed air, process heating, process cooling, lighting, HVAC, etc. Methodologies and algorithms published in peer-reviewed literature, and available on line.

32 Manufacturing Energy Efficiency Guidebook Energy Efficiency Guidebook (EEG) Comprehensive industrial energy efficiency toolkit Excel based Customizable Includes best practices, examples, software and calculations Free and on-line

33 Manufacturing Materials Efficiency Guidebook Materials Efficiency Guidebook (MEG) Industrial material efficiency toolkit Excel based Customizable Includes best practices, examples, software and calculations Free and on-line

34 Energy And Carbon Emissions Results Typically identify ~12 specific energy saving opportunities with a combined annual cost savings and carbon emissions reduction of 10-15% Combined simple payback of all recommendations is 2 years

35 Reinvesting Efficiency Savings Enables Net-zero Co 2 At Net-zero Cost PV (without tax credits) Rated Output 2.0 kw Annual Output (Dayton, OH) 2,930 kwh/yr Unit Cost $3 /kw Initial Cost $6,000 Lifetime 20 yrs Lifetime Output 58,600 kwh $/kwh $0.103 /kwh Wind (RECS) $0.001 /kwh to $0.01 /kwh

36 1-2-3-Zero Method For Net-Zero CO 2 At Net-Zero Cost Implement Energy Efficiency Install On-Site Renewable Energy Purchase RECs Achieve Net-Zero Carbon

37 Sustainable Manufacturing Energy savings pays for renewable energy Net CO 2 zero at net zero cost!

38 UD-IAC Students Pursuing masters degree in UD s Renewable and Clean Energy program Win national research, innovation and best paper awards Lead international energy assessments Present work at national conferences Teach energy efficiency seminars

39 What Clients Say About IAC Students I should note that we were impressed with your students. Meeting your students who were well mannered, articulate, hard working and willing to ask tough questions reminds me that there is still hope for the next generation."

40 UD-IAC Graduates Over 80 graduates 97% work in energy efficiency Three founded energy efficiency companies: Go Sustainable Energy, Energize Engineering, Entriq Three D.O.E. Distinguished Alumni Awards: J. Seryak, D. Pohlman, S. Mulqueen One Alliance To Save Energy Rising Star of Energy Efficiency Award: T. Wenning

41 UD-IAC: Improving Energy Efficiency Engineering 70+ publications in peerreviewed literature Teach seminars and conduct assessments in US and across the world Taiwan, Brazil, China, Russia, Singapore, Ireland, Foundation of the UD Renewable and Clean Energy Master s Degree program 50+ students per year from across the world 7 Fulbright Scholars

42 University Of Dayton IAC Awards U.S. D.O.E Energy Center of Excellence Award, 2003, 2015 U.S. D.O.E Energy Excellence in Applied Energy Engineering Research Award, 2012, 2014, 2017 ACEEE Champion of Energy Efficiency in Industry Award, 2011 Ohio Governor s Award for Excellence in Energy, 2006

43 Thank you!

44 University Of Dayton Industrial Assessment Center & Ohio Lean Buildings Program U.S. Department of Energy and State of Ohio Sponsored Programs (937)