Industrial Assessment Centers: Growing the Energy Workforce of Tomorrow
From the Fall 2008 issue of Energy Matters
IAC students get hands-on training by helping companies identify energy savings opportunities.
DOE's university-based Industrial Assessment Center program recently marked the completion of its 14,000 energy assessment, demonstrating sustained, widespread impact in identifying energy savings opportunities for industry today and molding energy engineers for our nation's future.
The Industrial Assessment Center (IAC) program was launched in 1976 during the energy crisis to help identify energy-saving opportunities in the industrial sector. Thirty-two years later, the role of the IACs in meeting U.S. energy and environmental demands is even more critical. This dedicated program continues to meet these challenges by conducting industrial energy assessments, training the energy workforce, and creating technical resources that inform companies about energy efficiency.
DOE's Industrial Technologies Program (ITP) sponsors the IAC program as part of its efforts to transfer energy-efficient and environmentally sound practices and technologies to U.S. industry and increase industrial competitiveness. The fledgling IAC program that originated in four engineering schools in 1976 has grown into a successful program operating in 26 universities throughout the United States, a testament to its positive and long-term impact.
14,000 and Still Counting
Recently, the program celebrated an important milestone: the completion of its 14,000 energy assessment. Over the life of the program, this translates into energy savings of more than 400 trillion Btu in natural gas for U.S industry, equivalent to powering 3.1 million U.S. homes. In addition, CO2 emissions were reduced by 22 million metric tons, or equal to removing 4 million cars from the road.
The landmark 14,000 assessment was conducted at Mid-South Metallurgical, a quintessential small U.S. company of 15 employees which provides precision and specialty heat-treating services to industry in the manufacturing-rich Middle Tennessee area. The major energy-consuming equipment in the plant includes eleven furnaces and two barium chloride salt baths. During the assessment, the Tennessee Technological University IAC team identified seven potential areas for energy savings which could save the company 2,989 MMBtu per year (875,941 kWh), or $74,685 in energy costs—an annual savings of 18%.
The IAC team is providing technical assistance to implement the energy efficiency recommendations and will follow up in 6 months to quantify actual energy savings.
Mid-South Metallurgical was very pleased with the energy assessment. "The team did an excellent job of providing a summary of recommendations, and then followed up with a detailed written report. These recommendations are on the top of our priority list for implementation." said Clif Coleman, owner of Mid-South Metallurgical. "This program is a great opportunity for students to gain exposure to industry and apply their skills in a practical way."
Immediate and Long-Term Benefits
Universities Operating IACs
- University of Alabama, Engineering
Satellite: Tuskegee University - Bradley University
- Colorado State University
- Georgia Institute of Technology
- Iowa State University
- Lehigh University
- Mississippi State University
- North Carolina State University
Satellite: NC AT&T - Oklahoma State University
Satellites: University of Arkansas, Fayetteville; Wichita State University - Oregon State University
- San Diego State University
Satellite: Loyola Marymount University - San Francisco State University
- Syracuse University
- Tennessee Tech University
Satellite: University of Memphis - Texas A&M University at College Station
- University of Dayton
- University of Delaware
- University of Florida
- University of Illinois at Chicago
- University of Louisiana at Lafayette
- University of Massachusetts
- University of Miami
- University of Michigan
- University of Missouri
- University of Washington
- West Virginia University
The IAC program has proven to be a "win-win" for industry, engineering students, faculty, and employers by providing benefits such as:
- No-cost energy assessments for local small- and medium-sized manufacturers
- Hands-on training that molds students into energy-savvy engineers who can "hit the ground running" in their professional careers
- A public database resource of more than 14,000 assessment results
- Implementation of new energy-saving technologies into manufacturing processes
- Strong relationships between universities and local industrial manufacturers.
The IAC program assists small- and medium-sized manufacturers who sometimes lack in-house expertise or resources to make energy efficiency improvements. This assistance can often make the difference between a company's ability to remain competitive in the market, or close its doors.
Energy Assessments That Save Energy Now
The IACs work with personnel at eligible small- to medium-sized manufacturing plants to perform no-cost energy assessments that identify ways to improve energy use, waste, and productivity. The IAC team, which includes faculty and students, typically conducts the assessment during a one-day site visit. During this assessment, the team analyzes the plant's energy-consuming systems, focusing on areas of special concern to the company. After the assessment, the team provides recommendations to the plant manager, and follows up in 6 to 9 months to obtain implementation results. Learn more about the assessment process.
The average energy cost savings from recommended measures is $135,000 per year. Identified waste and productivity recommendations add an additional $85,000 to each average savings potential, bringing the total cost savings for an average IAC assessment to more than $220,000 per year. This can often mean 5%-10% in energy cost savings—significant to a company's bottom line.
When the Oklahoma State University IAC evaluated the Southwest United Industries metal coating manufacturing plant in Tulsa, Oklahoma, they identified nine energy-saving opportunities. These implemented improvements are now saving the company more than $60,000 annually in energy costs. "OSU's team of industrial engineers was very thorough in assessing potential energy savings in our plant. I would highly recommend that every company take advantage of these services provided through the DOE," said Jon Barrows of Southwest United Industries. Read the case studies about other major energy and cost savings the IACs have identified.
Building the Future Energy Workforce
Perhaps the greatest long-term benefit of the IAC program comes from transforming students into a trained workforce of outstanding engineers who can continue to address the nation's energy challenges throughout their careers. To date, more than 2,600 engineering students have participated in the IAC program, with an estimated 60% pursuing careers in energy-related fields across industrial, commercial, institutional, and residential sectors. IAC alumni can be found across the spectrum of professional engineering roles, including R&D, product development, project engineering, project management, and construction management. Currently, about 250 students are trained each year through the IAC program. This network of IAC students and alumni stays connected through a dedicated Web site and newsletter, annual meeting, and Internet-based professional group.
Again and again, IAC alumni express their appreciation for the knowledge and experience gained through the program. This experience not only enriches their education, but gives students an edge with prospective employers.
Sieglinde Kinne, a Colorado State University (CSU) IAC alumni, and now with Siemens Building Technology's Energy and Environmental Solutions, recounts, "My years working with Industrial Assessment Center faculty and students at CSU was pivotal to my career development," she says. "I imagined that my mechanical engineering degree would push forward my career in renewable energy. When I found out about the IAC, I instantly knew that I wanted to work in the field of energy efficiency. I believe that energy efficiency IS one form of renewable energy, and is typically the most cost-effective way to reduce fossil fuel consumption. The benefits we provided to the industrial clients was very rewarding; reducing energy costs at these plants may very well help to retain American jobs by making companies more competitive.
According to Satyen Moray, his experience through the IAC program was critical in preparing him for his position at Energy and Resource Solutions, Inc. (ERS), a leading energy engineering firm based in Boston. "The two years I spent at my IAC taught me to interact with customers, understand systems, develop new tools, and write and present clear reports. The IAC also gave me the necessary motivation to hit the ground running at ERS from day one."
Marcus Wilcox is an Oregon State University alumnus who credits his IAC experience with helping him to launch his own consulting firm, Cascade Energy Engineering. "As the first student in the Oregon State University program, I had no idea how valuable the training and experience would be," he says. "Participating in site visits, monitoring and assessing energy-using systems, and preparing reports for customers provided a broad education that has supported my career. We founded Cascade Energy Engineering 15 years ago, and now have 19 engineers providing industrial energy efficiency consulting. I can honestly say that our company and engineers would not be in existence without the original opportunity provided by the IAC program."
Technical Resources and Outreach
And the benefits don't stop there. Results from the assessments are compiled into the IAC database for use as a free resource available to the public. The IAC database is recognized as one of the most comprehensive industrial databases in the world. Users can search by assessment (size, industry, energy usage), and recommendations (type, energy, and cost savings) to find energy, waste and productivity improvements that may apply in their plant. Currently, the IAC database houses information on 14,000 assessments and 104,000 recommendations.
In 2007, IACs and the National Institute for Science and Technology's Manufacturing Extension Partnership (MEP) joined forces to leverage the MEP's vast network of small and medium-sized manufacturing plants and the IAC's energy expertise. Through this relationship, MEP customers receive information about ITP tools and resources, and are referred to IACs for assessments. The IACs have also conducted 90 joint assessments with MEPs nationwide, and sponsored 13 student internships at local MEPs to increase awareness of energy efficiency.
The IAC Adopt-a-Technology program introduces individual centers to commercially available technologies developed by the Industrial Technologies Program. Centers select a technology to research based on applicability in their region, and become the expert resource for that technology and its application. The students also research vendors, distributors, and installations of the technology to examine adoption levels and effectiveness.
Resources for Energy and Economy
In this time of economic and energy uncertainty, DOE's Industrial Assessment Centers provide a positive and useful resource for U.S. industry. As energy use and environmental concerns escalate, the IACs continue to boost U.S. industrial energy efficiency by conducting energy assessments, growing an energy workforce, and creating technical resources that increase public awareness about energy efficiency. The completion of its 14,000 assessment signifies a major achievement for this unique and dedicated program, and highlights one avenue to a brighter national energy future.
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