Purdue School of Engineering and Technology

Purdue School of Engineering and Technology

Energy Assessment of Industrial Processes

ME 50101 / 3 Cr. (3 Class)

The Course describes a systematic approach for improving energy efficiency in the manufacturing sector. The manufacturing equipment and processes will be analyzed in terms of energy consumption improvement. It provides the technical foundation for students on assessing industrial processes to identify energy efficiency opportunities in industrial, electrical, motor drive, compressed air, process heating, process cooling, lighting, space conditioning, combined heat and power systems.

The course consists of three parts: (1) fundamentals of energy assessment, (2) understanding of industrial processes in terms of energy consumption and energy efficiency, and (3) the energy assessment of industrial processes.

The presentation will be live with video streaming  

Course prerequisites: Senior or graduate standing

This course designed for students who are interested in energy efficiency improvement of manufacturing processes and equipment.

Text Book:  Class note materials. Reference Books: 1.      Energy Efficiency Manual, 1st Edition, Donald R. Wulfinghoff, ISBN: 0-9657926-7-6, Energy Institute press. 2.      Simple Solution to Energy Calculations, 4th Edition, Richard R. Vaillencourt , ISBN: 0-88173-356-3,The Fairmont Press, Inc.   3.      Managing Energy from the top to down: Connecting Industrial Energy Efficiency to Business Performance, 1st Edition, Christopher Russell, ISBN: 0-88173-625-2, The Fairmont Press, Inc.


Upon the completion of this course, students will be able to:

  1. Master the common industrial processes and evaluate them in terms of energy consumption.
  2. Apply engineering principles on various energy sources and their industrial applications.
  3. Design the energy assessment process for various energy systems 
  4. Determine the key measurable parameters for each system analysis and provide adequate measurements using basic metrology equipment.
  5. Analyze the energy system, identify alternatives, and optimize the energy consumptions
  6. Make recommendations for energy consumption improvement.
  7. Quantify energy saving based of the improvement recommendation.
  8.  Produce professional technical reports and presentations.
  1. Energy conservation and irreversibility concepts for energy systems analysis. These principles are used to analyze energy consumption of closed and open systems.
  2. Process analysis of heating, cooling and power generation.  This analysis will apply irreversibility concepts to identify the process efficiency and quantify the energy efficiency improvement.
  3. Reynolds’s Transport Theorem, conservation of mass, momentum & energy for fluid flow analysis of manufacturing processes, e.g. compressors, pumps and energy loss in fluid flow transport.
  4. Heat and mass transfer modes for ovens, boilers and insulation for equipment and industrial facility.
  5. Manufacturing process analysis for energy consumption and energy efficiency improvement through the application of economic, heat transfer, fluid mechanics, and thermodynamic principles. The thermodynamic, fluid mechanics principles and heat and mass transfer methods will be applied to industrial application such as chiller, process heating and cooling system for energy efficiency improvement. These principles are also used to analyze energy consumption of common industrial equipment such as compressors, pumps, turbines and thermal units.
  6. Energy performance and energy efficiency savings for manufacturing processes. For each system, fundamental equations of energy consumption to identify energy saving opportunities and quantify expected savings will be developed.
  7. Analysis of manufacturing component in terms of energy consumption and identify the areas of efficiency improvement. Pumping system, Compressors, Motor drives, Boilers, Steam Distribution Systems, Heating and cooling process, Waste-Heat-Recovery and Maintenance will be covered.
  8. Lighting and Building envelop principle.