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Using IAC Database for Longitudinal Study of Small to Medium Sized Automotive Industry Suppliers' Energy Intensity Changes

SAE International Journal of Materials and Manufacturing

S. Chaudhari
Southeast Missouri State Univ.-Deepak Gupta
  • Journal Article
  • 2013-01-0833
Published 2013-04-08 by SAE International in United States
Industries related to automotive manufacturing and its supply chain play a key role in leaving a carbon footprint during an automobile's life cycle. Per the report from Lawrence Berkeley National Laboratory (LBNL) in March, 2008 [1], “motor vehicle industry in the U.S. spends about $3.6 billion on energy annually.” The proposed research will focus on energy savings opportunities in automotive manufacturing and its supplier network. The US Department of Energy (DOE) funds 24 Industrial Assessment Centers (IAC) throughout the U.S. that conduct energy assessments at many of these facilities. The results of these assessments are summarized in a database maintained by Rutgers University which acts as the central management body for all the IACs. This research will present key concepts summarized from this database. These concepts include: (1)top 10 energy saving recommendations,(2)top 10 energy savings implemented measures,(3)comparison of energy efficiency investment in small-and mid-sized automotive industry supply chain in pre and post economic slump,(4)impact of major federal incentives on energy efficiency investments and its correlation with the implementation of recommended measures from database, and(5)energy savings…
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Analysis of Compressed Air and Process Heating Systems - A Case Study from Automotive Parts Manufacturer in Mexico

AAM-Afif Bitar
Southeast Missouri State Univ.-Deepak Gupta
Published 2012-04-16 by SAE International in United States
Automotive industries in the US and around the world have enormous impact on the economy of each country. Not just the major vehicle manufacturer, but all the other companies in the supply chain are equally important. This was evident with the earthquake and Tsunami that happened in March 2011. Because of the massive destruction at suppliers' facilities, the automakers in the US and other countries struggled to get the necessary parts and supplies. This created a ripple effect throughout the world and led to the closure of several automakers' facilities for a long time. Thus, the automotive supply chains are as important as the main automotive manufacturing facilities. Since these suppliers produce a lot of parts and supplies, the corresponding energy usage is also significant. The current research is focused on compressed air and process heating system analysis at one of the automotive parts manufacturer in Mexico. The Best Practices software tools (AIRMaster+ and PHAST) developed by the US Department of Energy (DOE) were used to create a baseline of the two systems and estimate…
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Investigation of Relationship between System Efficiency Curve & Measurement and Verification (M&V) of Energy Savings

SAE International Journal of Materials and Manufacturing

Southeast Missouri State University-Deepak Gupta
West Virginia Univ.-Subodh Chaudhari, Bhaskaran Gopalakrishnan
  • Journal Article
  • 2011-01-0324
Published 2011-04-12 by SAE International in United States
This research attempts to investigate the effect of change in system curve on the energy intensity method of measurement and verification of energy savings. With recent push from US government on energy efficiency through EPACT 2007 and upturn in performance contracted energy efficiency project implementations the effective and accurate evaluation of energy savings as compared to the baseline is of paramount importance. The authors have studied different methods of Measurement and Verification (M&V) of energy savings from literature to compare and contrast and clearly bring out merits and de-merits of each. Finally, the role of production level variable plays in establishing the baseline energy usage is discussed. Though modern models proposed in the literature of determining baseline energy usage consider production level, this variable is compounded from two variables viz., time of usage of a system and fraction of total capacity usage. This study aims to find if a model considering these variables yields significantly different baseline energy usage than the traditional model.
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Compressed Air Energy Saving Assessments (ESA) for the Automotive Supply Chain

Southeast Missouri State University-Deepak Gupta
West Virginia University-Bhaskaran Gopalakrishnan
Published 2009-04-20 by SAE International in United States
This research is based on the energy saving opportunities in compressed air systems in seven manufacturing facilities in the automotive supply chain, located in the United States. These plants received compressed air Energy Saving Assessments (ESA) from the US Department of Energy (US DOE)/Industrial Technologies Program (ITP) as a part of the Save Energy Now (SEN) initiative. Data logging equipment were used to monitor the compressed air system. US DOE ITP BestPractices software tools AIRMaster+ and LogTool [Web: Best Practices Software Tools] and other spreadsheet tools were used to develop energy efficiency measures. The most prominent energy efficiency measures were found with respect to installation of automatic sequencers, reducing compressed air leaks, improving end use efficiency, and reducing the compressed air system pressure. Few other interesting energy efficiency measures are also discussed. The paper describes the pre-assessment, assessment, and post assessment activities and the methods that were used to make the assessment effective and beneficial to the plant personnel. The paper discusses the recommended and implemented compressed air energy efficiency measures at the manufacturing facilities.…
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Energy Conservation through Productivity Enhancement in Manufacturing Facilities

SAE International Journal of Materials and Manufacturing

Hydro Aluminum-Hima Bindu Godavarthy
Southeast Missouri State University-Deepak Gupta
  • Journal Article
  • 2008-01-1164
Published 2008-04-14 by SAE International in United States
The goal of this research work is to explore the energy savings that may result from productivity improvement recommendations. The productivity improvement recommendations on setup time reduction and finished goods inventory reduction were taken from Industrial Assessment Center (IAC-WVU) and Industries of the Future (IOF-WVU) databases at West Virginia University (WVU) and analyzed to evaluate the corresponding energy savings. A simulation analysis was performed to compare the peak energy demands (kW) in the present and proposed scenarios for the setup time reduction recommendation. It was found that productivity improvement recommendations can result in significant energy savings (2% to 4%).
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Speciation of Heavy Duty Diesel Exhaust Emissions under Steady State Operating Conditions

West Virginia Univ.-Mridul Gautam, Deepak Gupta, Laila EI-Gazzar, Donald W. Lyons, Sriram Popuri
Published 1996-10-01 by SAE International in United States
This paper presents results from a study on speciation of the emission profiles and on the ozone forming potential of heavy-duty diesel exhaust under steady state engine operation. Very limited attempts have been made at determining the ozone forming potential of heavy duty diesel exhaust emissions. In this study a proportional sample of the dilute exhaust was drawn from a CFV-CVS system using a temperature controlled sampling line. The particulate matter was collected on a 70 mm Teflon coated glass fiber filter (TX40HI20WW), the semi-volatiles on XAD-2 copolymer resin and volatiles in Tedlar bags. The samples were analyzed by gas chromatography after conditioning and chemical extractions.The initial phase of the study was directed towards developing techniques and establishing protocols to determine the ozone forming potential of heavy-duty diesel exhaust. A pre-chamber naturally aspirated engine was tested on steady-state modes 1, 3, 5, 7 and 8 of the ISO 8 mode cycle. Mass emission rates and grams of ozone (potential) are presented for the volatiles, semi-volatiles and the particulate bound organics and also for the total…
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Sampling Strategies for Characterization of the Reactive Components of Heavy Duty Diesel Exhaust Emissions

West Virginia Univ.-Mridul Gautam, Brian Kelly, Deepak Gupta, Nigel Clark, Richard Atkinson, Laila El-Gazzar, Donald W. Lyons
Published 1994-11-01 by SAE International in United States
Techniques have been developed to sample and speciate dilute heavy duty diesel exhaust to determine the specific reactivities and the ozone forming potential. While the Auto/Oil Air Quality Improvement Research Program (AQIRP) has conducted a comprehensive investigation to develop data on potential improvements in vehicle emissions and air quality from reformulated gasoline and various other alternative fuels. However, the development of sampling protocols and speciation of heavy duty diesel exhaust is still in its infancy [1, 2, 3, 4, 5 and 6]. This paper focuses on the first phase of the heavy duty diesel speciation program, that involves the development of a unique set of sampling protocols for the gas phase, semi-volatile and particulate matter from the exhaust of engines operating on different types of diesel fuel. Effects of sampling trains, sampling temperatures, semi-volatile adsorbents and driving cycles are being investigated.Dilute exhaust is sampled from a total exhaust double dilution tunnel system via two separate streams, viz. a “cold” stream with a filter face temperature of less than 52°C (125°F) and a “hot” stream at…
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