NASR E.

ALKADI, PhD, CEM, CDSM

Knoxville, TN 37931 Cell: (636) 734-4143 nasr.alkadi@gmail.com

Senior Energy Sustainability Engineer

Portfolio
Energy Savings Project Implementation (E$PI), Measurement and Verification (M&V) using IPMVP Water and Waste Analysis, ISO 50001, Combustion systems analysis/HVAC systems/Energy conservation in industry, buildings, and petroleum refineries/Product design for energy consumption/Green Design & Manufacturing/Sustainable Design/Demand Response (DR)/Demand side management (DSM)/Life Cycle Cost Analysis/In depth Analysis of cutting edge energy efficiency technologies/ Additive Manufacturing

Profile
Six years of energy sustainability working experience in manufacturing plants environment. Five years of experience with governmental energy efficiency programs. Strong understanding of the theoretical aspects of energy conversion, cogeneration, HVAC systems, combustion systems and thermodynamics. Life Cycle Analysis of Advanced Manufacturing methods compared to Conventional Manufacturing methods Design, development and deployment of energy efficiency and energy management strategies for manufacturing industries and buildings. Developed several energy simulation and energy tracking and diagnostic tools for industry and buildings. Highly competent with the evaluation of energy savings and economic analysis of energy management projects. Accomplished at developing new business and managing engagements, including recruiting and developing teams to consistently complete projects on time and within budget. Editor in Chief of the International Journal of Energy Technology and Policy (IJETP). Published author/presenter.

Professional Experience
2009 - 2013 Oak Ridge National Laboratory (ORNL) Oak Ridge, Tennessee
Senior Energy Development Engineer

Provided technical support for the DOEs National Energy Programs. This includes Energy Technology R&D and Energy Technology Deployment in the US industrial and building sectors. Objective is to help the following Corporations achieve 25% savings in energy intensity in 10 years: ALCOA, Nissan, 3M, Toyota, VOLVO, Huntsman chemicals, Goodyear, Bridgestone-Firestone, Kenworth. Technical support includes: - Energy GAP Analysis studies to prioritize energy efficiency focus areas (process and energy systems). - Energy Baselining studies and M&V to validate energy efficiency results (statistical modeling). - Plants Energy Profiling studies to pinpoint energy intensive processes (DOE ePEP tool). - Technology needs assessment. Developed the DOEs In-Plant Training (INPLT) Model through collaborations with DOE and industry experts. Objective is to promote and replicate energy efficiency implementation in the US Industrial Sector. This program resulted in more than $6 Million per year of identified energy projects in 20 manufacturing plants and over 380 trainees from industries, utilities, state energy offices, and private sector vendors. Team member in Nationwide Demand Response and Storage Integration Study. Objective is to investigate and deploy demand response technologies in the US industrial sector. This program identified tens of GW potential for DR in industrial sector and helping DOE to shape the policies for smart grid technologies and regulations. The DR study included: - Development of an estimate of the amount of regulation that could be expected from industrial loads based on statistical modeling and data analysis of DOEs EIA, MECS, IAC, and relevant databases. - Analyze the potential impact of regulation on the manufacturing processes - Experimental Work including Measurements in Selected Manufacturing Plants Supported the development of Additive Manufacturing Energy Efficiency Impacts Calculator - Life-cycle phases - The calculation of embodied energy embodied energy of materials, processes, and transportation modes - Identifying and setting boundaries for life-cycle phases

Supported the Measurement and Verification component of ISO 50001 Energy Management Standard including: - Development the method for treatment of Biomass fuel in the ISO 50001 Energy Standard - Validated energy savings due to implementing ISO 50001 and DOEs Superior Energy in VOLVO Assembly Plant in Norfolk, VA. Developed IGATE-E CHP analysis tool (Patent Pending) to evaluate CHP capabilities of manufacturing plants at the Zip code level. Supported ORNLs initial exploration of low grade heat applications in industrial sector.

Energy Modeling
a.

Developed an energy model to analyze and compare the energy use in the reheat furnace in steel industry under cold and warm charging conditions (Alkadi, N.M., 2011). Baseline cold charging conditions was taken as 50oF whereas eight warm charging conditions ranging from 100 oF to 800oF were considered. During the trials, the average slab discharged temperature and heating time were kept constant at 2250oF and 152 minutes respectively. The study was based on an average production rate of 205 tons/hr for a carbon steel slab of 9 x 48 x 394. This production rate is the hourly average furnace rate during the years 1999 and 2000. All calculations were based on the gross heating value of mixed gas of 720 Btu/ft3 and at 5% excess air. Savings calculations were estimated using an average gas price of $4.00 per MMBtu. Furnace yearly operating hours was taken as 7,000 hrs./yr. Five material and energy balances (MEB) were performed on the reheat furnace as part of the developed mathematical model. The iterative solution of the five equations representing the MEB allowed for the estimation of inlet air and fuel flow rates besides to the prediction of different furnace temperature setting within each zone. The furnace was divided into three main zones, the unfired or the recuperative zone (RZ), the preheating zone (PZ), and the heating and soaking zones (HZ). Participated in the development of an energy consumption modeling and benchmarking in continuous galvanizing lines (Gopalakrishnan, B., Ratnakar, R, Gupta, D, Alkadi, N.M., 2009). The simulation model was developed to assist in decision making with respect to investment in new pot hardware that will extend campaign periods. The model provided the engineers a good comparison between product types with respect to energy and cost consumption and energy intensity. Changes made to the line in terms of motors, furnace equipment and pot characteristics can be evaluated in terms of energy, cost and productivity. It can simulate a scenario to identify energy, cost, and productivity benefits obtained from energy savings measures and can evaluate the economic desirability of investment in new and improved pot hardware.

b.

Energy Analysis Tool Suite Developed:

a. EBEAT - Energy Based Evaluation and Analysis Tool using Visual Basic. Objective was to analyze the product, process, and system design parameters from energy point of view and will evolutionary provide timely advice on possible ways to reduce product manufacturing energy consumption at each stage (Level) of product design process in a concurrent engineering framework. (Alkadi, N.M., WVU PhD Research, 2007) PEITS - Plant Energy Intensity Tracking Scorecard using Excel. Objective was to help US Industry to baseline and track their energy intensity performance against defined targets in a simple and effective manner. The tool performs Baselining and tracking of energy intensity on a corporate level as well as a plant level. The Corporate Level part of the Tool is called Corporates Energy Intensity Tracking Scorecard - CEITS Tool and the plant level part is called Plants Energy Intensity Tracking Scorecard - PEITS Tool. The Baselining tool adjusts energy intensity for weather and production related variations. The computational module of the tool uses linear regression models (Backcast and Forecast regression methods) to perform the Baselining and the energy intensity analysis. The tool has a graphical interface with an auto color coded charts and tables to provide plant and corporate management with a simple, yet decisive visual aid to track their plants and Corporates performance towards defined Goal. (Alkadi, N.M., etl., ORNL, 2010) GAP Analysis tool - to help US Industry to manage their energy efficiency program by identifying the GAP that needs to be bridged to achieve defined program goals. This GAP consists of the energy savings in one or more of the following energy systems (steam, process heating, compressed air, fans, pumps, process cooling, and others). The data is entered to the tool using EPEP and the actual energy saving projects identified by plant team or by outside consultants. The results obtained from the EPEP tool is further tweaked during the in plant analysis phase. The GAP is represented by steps and each step represents the percent of energy saving towards defined energy reduction goal. The tool features a simple follow up on implementation of each identified energy saving project with an auto color coding that turns into green once project is implemented. The tool is simple, interactive with links in Excel Format. (Alkadi, N.M., etl., ORNL, 2010) IGATE-E DR and IGATE-E CHP Industrial Geospatial Analysis Tool for Energy Evaluation (Matlab) Invention Disclosure Completed Patent is in Progress STEPS - Sustainability through Energy-Based Process Simulation (STEPS): Framework Development and Prototyping (Any Logic).

b.

c.

Other Energy Models:

a. b.

2003-2009

DTE Energy assigned to General Motors Corporation (GMC)

Wentzville, MO

Energy and Sustainability Manager Energy Partnership and Services (EP&S)

DTE Energy Co. is a diversified energy company involved in the development and management of energy related businesses and services nationwide. For almost 6 years, I have been working in multiple energy assignments within DTE Energy as well as EP&S scheme. DTE Energy Primary assignment is supporting DTE Energys customers to reduce their operational and structural costs by implementing energy efficiency, sustainable, and renewable energy technologies and methodologies. Analyze and resolve issues with unusual challenging projects to solve customers issues related to energy efficiency. Developed, instructed and mentored an energy manager training workshop to 25 energy & account managers. Continuously engaged in ideas and actions to contribute to the department business improvement process.
DTE Energy EP&S with GMC Auto Assembly Plant

Assigned to General Motors Corporation, Wentzville Assembly Center in Missouri with the objective of driving the customers to meet their operational and structural Costs. Energy Savings Project Implementation Corporate Performance Contracts as follows: o Managed, designed, and implemented Energy Conservation Projects of Multi Million Dollars Capital Investment and ROI < 1.5 Years. Projects took place in Paint Department, Body Shop, General Assembly, Stamping, and Powerhouse. Projects range from converting T12s to T8s to installing Magnets instead of Vacuum Cups to Implementation of Energy Management System to automatically turn off giant exhaust fans (27 x 200 hp) and Paint Process Air Supply Houses during non-production hours, hence saving steam and electricity. Projects also included HVAC systems performance optimization through upgraded controls. Supported plant ISO 14001 Environmental Management System documentation, such as procedures and work instructions. Energy and Sustainability Business Plan development and deployment resulted in Real Energy Savings (Electricity, Coal, Natural Gas, and Water & Sewer) in excess of $1.8 Million Jan-Dec06 compared to Jan-Dec05. Lead GM Plant Energy Conservation Campaign as part of the Plant ISO 14001 including behavioral change strategies to save energy through numerous plant wide small wins. Energy Business Plan Deployment through 5 Levels of the Organization Plant Manager Level, Departments Level, Superintendent Level, Supervisor Level, and Operator Level. This includes identifying scope of work for each level to achieve end of year reduction goal. Setting Energy & Water Vision for the Organization including Budget & Reduction Strategies. Setting Target Reductions for Energy & Water Year over Year. Energy efficiency, Renewable energy, and water reduction projects identification & evaluation to achieve the end of Year Goals including writing technical specifications for required equipment, BOM, Implementation, Supervision, Measurement and Verification (M&V) using IPMVP. Plant energy forecasting, energy usage, and budgeting. Development of plant benchmark studies and alignment with best practices program ideas through other GM plants. Detailed data analysis via analytics or visual intelligence to identify energy, operational, or comfort anomalies Using Energy Management System (EMS) to analyze building operations and implement improvement strategies; set up and monitor historical trend data logs. Utilize spreadsheet or automated data analysis tools to provide building energy use/demand modeling Work closely with Utilities and State Energy offices to establish rebate and incentive programs. Responsible for delivering energy efficiency, demand response and energy management solutions. Perform onsite energy audits, developing energy analyses including recommendations for operational efficiencies, identification and implementation of energy saving projects. Sustainment plans for the compressed air leak program.

1999-2003 DOE Industrial Assessment Center (IAC) at West Virginia University Morgantown, WV
Team Leader Energy, Water, Waste, and Productivity The Industrial Assessment Center program (IAC) is funded out of the US Department of Energy (DOE) since 1976. As a component of the National Energy Strategy, the IAC program is a major energy conservation initiative of the U.S. DOE as well as supporting waste reduction and improvements in productivity in the US industrial sector. Within the IAC, the following energy research projects were undertaken:
1. Energy, Waste, and Productivity Improvements for Manufacturing Facilities, DOE funding, 1992-2011, $ 2,340,000.

The project entails performing energy, waste, and productivity research for small and medium sized manufacturing facilities (from SIC 20-39). Research includes generation of energy conservation, waste minimization, and productivity improvement opportunities that can be implemented . Dr. Alkadi has participated as a team leader in over 250 energy research studies between 1999 and 2003. He has developed many energy efficiency measures after intensive research and has documented the details through well-developed recommendation details.

Dr. Alkadi has participated in training activities that were research based for graduate students in terms of enhancing overall research productivity.
2. Energy Assessments for West Virginia Industries of the Future (IOF), West Virginia Development Office (WVDO) funding, 20022007, $ 375,000.

The project entails performing energy analysis for small and medium sized manufacturing facilities that do not qualify for an IAC assessment. Research includes generation of energy conservation opportunities that can be implemented. Dr. Alkadi has worked closely with teams from the university and industry to research the energy reduction options for the identified industries.
3. Industries of the Future-West Virginia (IOF-WV) Special Projects Submission, USDOE/WVDO funding, 2002-2007, $ 300,000.

The project research aims to develop technical project proposals in enhancing the energy savings in the aluminum, steel, glass, chemicals, metal casting, and wood industry in WV. Dr. Alkadi has worked extensively for the benefit of the IOF WV program in terms of energy efficiency research. He has played a major role in assisting with the development of research proposals to the US DOE and other agencies and has actively participated in research activities on-site in terms of energy analysis and diagnostics data collection and analysis.
4. Industries of the Future Plant Wide Energy Efficiency Opportunity Assessment at the Bayer Corporation Plant, New Martinsville, WV, USDOE funding, 2001-2003, $ 85,960. The project focuses on on-site energy assessment research for the Bayer Corporation

located in New Martinsville, WV. The assessment dealt with compressed air systems, steam systems, electrical motor driven systems, and refrigeration systems. Results from the assessment are being subject to research and analysis at this time. Dr. Alkadi was instrumental through his research efforts for enabling success in this very important research project funded by private industry. His research experience and knowledge in energy systems has been pivotal in obtaining significant energy savings that have been implemented by the manufacturing facility.
5. Wood Industry Assistance Program Energy Assessments for Wood Processing Facilities, USDOE/WVDO funding, 2000-2008, $ 325,000. This project is for performing industrial assessment and research in wood processing industries. The analysis of the data obtained from the onsite

assessments generate results that is of benefit to the industrial sector . Dr. Alkadis expertise in research that encompassed electrical data logging methods and protocols has been an important ingredient for this WV project. His research activities for this project have enabled accurate energy profiling and determination of energy intensity, a factor most important to manufacturing facilities.

Awards/ Certifications/Membership
Award of highest scholastic standing from the College of Engineering and Mineral Resources, West Virginia University 2002, and 2003. Nomination Crew Award for the World Facilities Group of General Motors Corporation for contribution in General Assembly Ventilation Optimization Project in GMC, Wentzville Assembly Plant in Missouri, 2007. Certified Energy Manager (CEM) and Certified Demand Side Management Professional (CDSM) of the Association of Energy Engineers (AEE). Demonstrates a high level of experience, competence, proficiency, and ethical fitness in the energy efficiency arena. Sigma Xi, The Scientific Research Society, June 2010 Present Member of American Society of Heating, Refrigerating and Air-Conditioning, ASHRAE, since spring 2001. Member of American Association of Energy Engineers, AEE, since fall 2001. Editor in Chief International Journal for Energy Technology and Policy (IJETP) http://www.inderscience.com/browse/index.php?journalCODE=ijetp
IJETP is a vehicle to provide a refereed and authoritative source of information in the field of energy technology and policy. It aims to establish channels of communication between relevant academics and research experts, policy-makers and executives in industry, commerce and investment institutions.

Leadership Services to Scientific Community

Editorial board member and reviewer for the International Journal of Renewable Energy Research and

Development, the Gyan Ganga Institute of Technology and Sciences (GGITS), Jabalpur(MP)India. 2012. Serving as a reviewer for the International Journal of the Society of Automotive Engineers (SAE), 2011 Serving as a reviewer for the Energy Policy Journal, International Journal of the Political, Economic, Planning, Environmental and Social Aspects of Energy, 2012 Alkadi, N., Nimbalkar, S, Defontaine, A, and Schoeneborn, F, The DOEs In-Plant Training (INPLT) Model to Promote Energy Efficiency in the Industrial Sector, ACEEE 2013. Alkadi, N., An Overview of Sustainable Practices at the US Automotive Manufacturing Industry, SAE 2013 World Congress, Detroit, Michigan, April 2013 (Oral Presentation Only) Alkadi, N., M. Starke, O. Ma, K. Dowling, B. Johnson, S. Khan, S. Nimbalkar, D. Cox, IGATE-E (Industrial Geospatial Analysis Tool for Energy Evaluation), 35th Industrial Energy Technology Conference, May 2013 O. Ma, Alkadi, N., P. Cappers, P. Denholm, J. Dudley, S. Goli. M. Hummon, S. Kilicotte, J. MacDonald, N. Matson, D. Olsen, C. Rose, M. Sohn, M. Starke, B. Kirby, M. OMalley, Demand Response for Ancillary Services, IEEE Transactions on Real Time Demand response, July 2013 Alkadi, N., Gopalakrishnan, B., Chaudhari, S., Product Design for Energy Reduction in Concurrent Engineering: An Inverted Pyramid Approach, International Journal of Industrial and Systems Engineering, 2012.

Referred Publications (Samples)

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S. U. Nimbalkar, Mahabir Bhandari, Nasr Alkadi, DOEs Save Energy Now Assessments at the Automotive & Supportive Industries in the Supply Chain Lessons Learned and Results from Over 100 Assessments Conducted in 2006 2011, SAE 2012 World Congress, Detroit, Michigan, April 2012 (Oral Presentation Only) Alkadi, N., Product Design for Energy Reduction in Concurrent Engineering: A Case Study on Reheat Furnace in Steel Industry, 34th World Energy Engineering Congress (WEEC), October 12-14, 2011 - Navy Pier, Chicago, IL Alkadi, N., Kissock, J.K., Improving Compressed Air Energy Efficiency in Automotive Plants - Practical Examples and Implementation SAE International, April 2011. http://papers.sae.org/2011-01-0325 Peter L. Fuhr, Timothy McIntyre, David Fugate, Kenneth Woodworth, Nasr Alkadi Wireless Sensors and Energy Efficiency at Alcoa, Future of Instrumentation Workshop, Oak Ridge National Laboratory, November, 2011. Gopala, B, Chavan, R.C., Gupta, D, Alkadi, N., Energy consumption modeling and benchmarking in continuous galvanizing lines, Int. J. Energy Technology and Policy, Vol. 7, No. 3, 2010 Alkadi, N., Gopala, B., Plummer, R., Johnston, W., McKendall, A, Product Design for Energy Reduction in Concurrent Engineering, An Inverted Pyramid Approach , Ph.D. Dissertation, West Virginia University, 2007 . Alkadi, N., Energy and Productivity, two sides of a coin in US Auto Industry , SAE, Detroit, USA, April 2006 B. Gopalakrishnan, R.W. Plummer, Alkadi, N., Analysis of Energy Conservation Opportunities in Glass Manufacturing Facilities, Journal of the Association of Energy Engineering, Vol. 98, No. 6, pp. 27-49, 2001. B. Gopalakrishnan, R.W. Plummer, Alkadi, N., Comparison of Glass Manufacturing Facilities Based On Energy Consumption And Plant Characteristics, The Journal of Energy and development, Volume number (27), 2002. B. Gopalakrishnan, Alkadi, N., Product Design for Energy: An Inverted Pyramid Approach, Twenty-fourth Industrial Energy Technology Conference, April 17 and 18, 2002, Houston, Texas. Alkadi, N., Fattah, A.R., Nosier, M.A. and Shahien, M.A, "The Characteristics Of Cylindrical Water-Cooled Furnaces When Burning Liquid, Gaseous, Or Dual Liquid-Gas Fuels", Joint International Combustion Symposium, Kauai, Hawaii, September 2001. Alkadi, N., Gelil, I.A., El-Touny, S.A, El-Haggar, S.A., and Elias, M.N., "Energy-Environmental Auditing Program In SMEs In Alexandria", International Conference On Demand Side Management, (DSM), Cairo, December, 1997. Alkadi, N., El-Touny, S.A., "Energy Conservation in Egyptian Industrial Sector ", Sixth International Energy Conference, Beijing, China, June, 1996. Alkadi, N., Alnakeeb, H.A., "How The Combustion Community Can Help in Petroleum Industry", International Conference on Energy Challenges For Sustainable Development in The Developing World, Cairo, Egypt, October, 1995.

Professional Presentations
1. Instructor, Near Zero Zone Technical Training Event, January 8-9, 2013, Istanbul, Turkey 2. Alkadi, N., and Michael R. Starke. "Scoping Study on Industrial Regulation.", Lawrence Berkley National Laboratory, 2012. 3. Alkadi, N., "In Plant Training (INPLT) Module for DOEs Technical Account Managers , DOE Webinar, November, 2011. 4. Alkadi, N., "In Plant Training (INPLT) Models for Better Plants Participating in National Better Buildings, Better Plants Program, DOE Webinar, November, 2011. 5. Alkadi, N., "In Plant Training (INPLT) Industry Testimony - Better Plants Participating in National Better Buildings, Better Plants Program, DOE Webinar, December, 2011. 6. Alkadi, N., "In Plant Training (INPLT) Models for DOEs Energy Experts TRAINING MODULE -, DOE Webinar, May, 2012. 7. Alkadi, N., "What the Worlds GREATEST Energy Managers Do Differently?.", DOE Tuesday Webinars for Industry, http://www1.eere.energy.gov/manufacturing/pdfs/ ju, July 10, 2012. 8. Starke, Michael and Nasr E. Alkadi. "Industrial DR Assessment.", DOE, Washington, 2012. 9. Alkadi, N., "Energy Management Tool Box, ALCOA Corporation, March, 2010. 10. Alkadi, N., "Energy Management Tool Box, 3M Corporation, January, 2010

EDUCATION West Virginia University

Ph.D. Industrial & Manufacturing Engineering (Energy Research) GPA 3.93/4.0 Dissertation: Product Design for Energy Reduction in Concurrent Engineering: An Inverted Pyramid Approach (IPA). In this research, the objective was to develop a methodology to evaluate the product design from the energy consumption standpoint during the early stages of the product life cycle.

Helwan University (Cairo)

BS and MS Mechanical Engineering (Combustion Research)

Thesis: An investigation of Flame Structure in Dual Fuel Combustors. Designed, developed and tested a new dual fuel burner system which has the ability of simultaneous burning of gaseous and liquid fuel simultaneously. The performance of the burner was tested in a water cooled cylindrical furnace.