Apen Aerogels, Inc.

Aspen Aerogels, Inc. My Summer Internship at Aspen Aerogels

By: Michael FedorenkoProcess Engineer Intern

# 2016 Aspen Aerogels | Confidential & Proprietary ProjectsEnergy Savings ProjectLED Light Fixtures Electric SavingsCooling Towers & Chiller Condensers Electric SavingsSilver Bullet Water Treatment for Cooling TowersTrending Cooling Tower Approach to Wet BulbTrending Chiller Condenser PerformanceCombined Heat & Power ProjectTuning & Optimizing Boilers Power & Natural Gas SavingsOrganizing Paperwork & Updating InformationLabeling Piping & Equipment Updating P&IDs Organizing Engineering FilesUpdating Lighting Panel & Fixture Schedule

# 2016 Aspen Aerogels | Confidential & Proprietary Energy Savings Project - LED Lighting Retrofit Existing HID & Fluorescents to LEDMultiple Locations Throughout East Providence PlantFixtures Installed:229 High Bay Lights w/ wireless control37 Low Bay Lights w/ wireless control42 Totaltube G2 Lights w/ wireless control106 Vapor Tight LightsFinancial Summary: Total Cost Project: $165,725 Utility Electric Incentive: $47,130 Customer Net Cost: $118,595Energy Cost Saving Annually: $53,009 Maintenance Savings Annual: $5000 Simple Payback: 2 YearsAdditional Benefits Better lit areas will help prevent accidents and boost worker moral & productivity

# 2016 Aspen Aerogels | Confidential & ProprietaryEnergy Savings Project - LED Lighting

# 2016 Aspen Aerogels | Confidential & ProprietaryEnergy Savings Project Cooling Towers & Chiller CondensersTrending Cooling Tower approach to wet bulb showed average T from wet bulb went down by 6 degrees Trending Chiller Condenser performance showed an increase in efficiency 1 degree colder water to chiller = 2% Chiller Electric SavingsMechanical cleaning helps to allow a larger volume of air to enter through fill and allows water to flow down the fill in even streams.Maintaining pH above 7 prevents further build up of bio-life in the fill.Silver bullet system oxidizes minerals and contaminants in water, kills bacteria, and breaks down calcium to prevent scaling. Additionally helps decrease amount of biocide and bio-penetrant used.Flow Overflow allows for the foam full of dirt and bio-life to be directly drained from the cooling towersDoes not affect process

Financial Summary1 degree F drop = 25 bucks saved a day6 Degree Drop$150 Saved per Day$54750 Saved per Year

# 2016 Aspen Aerogels | Confidential & ProprietaryEnergy Savings Project Cooling Towers & Chiller Condensers

# 2016 Aspen Aerogels | Confidential & ProprietaryEnergy Savings Project Cooling Towers & Chiller Condensers

# 2016 Aspen Aerogels | Confidential & ProprietaryEnergy Savings Project Cooling Towers & Chiller Condensers

# 2016 Aspen Aerogels | Confidential & ProprietaryCombine Heat & Power Project - BoilersTuning settings & observing temperature trends boilers are now more efficiently heating up water, using less natural gas, and suppling the process with the proper hot water temperature

# 2016 Aspen Aerogels | Confidential & ProprietaryOrganizing Paperwork & Updating InformationLabeled heat exchangers, KO pots, extractors, supply & return linesWent through P&IDs for Phase I & II, Tank Farm, & Utilities. P&IDs not up to date were updated and sent to AZ for redrawing. Added P&ID & Spec Folder to:ENGGROUP Drive (E)Shared-data Drive (S)New Intranet SharePoint under Engineering Documentation.Updated Lighting Panel & Fixture Schedule

Total Number of P&IDs: 212Number of P&IDs Updated/Reviewed: 169Number of P&IDs That Need Redrawing: 70

# 2016 Aspen Aerogels | Confidential & ProprietaryOrganizing Paperwork & Updating InformationUpdated P&IDsPID #PID TitleStatus110Bulk CO2 SystemGave to AZ for Revision111Bulk CO2 SystemGave to AZ for Revision115Nitrogen SystemGave to AZ for Revision116Nitrogen DistributionGave to AZ for Revision117Nitrogen Process DistributionGave to AZ for Revision191ANU Working TankNo Revision Needed192ANU Working TankGave to AZ for Revision193ANU Working TankGave to AZ for Revision195Solvent RecoveryGave to AZ for Revision196ANU SupportGave to AZ for Revision198ANU Thickener/Filter PressGave to AZ for Revision200Sulfuric Acid StationGave to AZ for Revision211Sol PrepGave to AZ for Revision213Sulfuric Acid StationNo Revision Needed221Sol PrepGave to AZ for Revision231MTES Sol Prep ReactorGave to AZ for Revision311Aging Fluid Delivery SystemGave to AZ for Revision312Aging Rinse Delivery SystemGave to AZ for Revision313Aging HeaderNo Revision Needed314 Nitrogen For AgingGave to AZ for Revision317Aging Rinse to ANUGave to AZ for Revision318EP Aging VentGave to AZ for Revision321Aging Fluid Delivery 1.4Gave to AZ for Revision322Aging Rinse IIGave to AZ for Revision323Aging Headers IINo Revision Necessary 324Nitrogen Distribution 1.4No Revision Necessary327Rinse to ANU 1.4Gave to AZ for Revision330-359Aging CansNo Revision Needed360-367Aging Cans 1.4No Revision Needed410 CO2 Working TankGave to AZ for Revision411-415Extractor No Revision Needed416 V/L SeparatorsGave to AZ for Revision417CO2 CompressorGave to AZ for Revision418LPS Liquid CaptureGave to AZ for Revision420CO2 Working TankGave to AZ for Revision421-425ExtractorNo Revision Needed426V/L SeparatorsGave to AZ for Revision431-432Extractor 1.4No Revision Needed550Laboratory Gas SupplyNo Revision Needed901Compressed Air SystemGave to AZ for Revision

Updated P&IDsPID #PID TitleStatus910Chilled Water DistributionGave to AZ for Revision911Chilled Water SystemGave to AZ for Revision912Cooling Tower SystemGave to AZ for Revision920Hot Water DistributionGave to AZ for Revision941CO2 Extractor HeaderNo Revision Needed2117Nitrogen Process DistributionGave to AZ for Revision2190ANU Final FilterGave to AZ for Revision2191ANU Working TankGave to AZ for Revision2192ANU Working TankGave to AZ for Revision2193ANU Working TankGave to AZ for Revision2195Solvent RecoveryGave to AZ for Revision2196ANU SupportGave to AZ for Revision2198ANU Thickener/Filter PressGave to AZ for Revision2199Sulfuric Acid StationNo Revision Needed2210EtOH Day TankGave to AZ for Revision2211Sol PrepGave to AZ for Revision2213Sulfuric Acid StationGave to AZ for Revision2221Sol PrepGave to AZ for Revision2231MTES Sol Prep ReactorGave to AZ for Revision2311Aging Fluid Delivery SystemGave to AZ for Revision2312Aging Rinse Delivery SystemGave to AZ for Revision2313Aging HeaderNo Revision Needed2314Nitrogen For AgingNo Revision Needed2317Aging Rinse to ANUGave to AZ for Revision2318EP Aging VentGave to AZ for Revision2330-2367Aging CansNo Revision Needed2410CO2 Working TankGave to AZ for Revision2411-2416ExtractorGave to AZ for Revision2417V/L SeparatorsGave to AZ for Revision2418LPS Liquid CaptureGave to AZ for Revision2420CO2 Working TankGave to AZ for Revision2421-2426ExtractorGave to AZ for Revision2427V/L SeparatorsGave to AZ for Revision2429CO2 CompressorGave to AZ for Revision2910Chilled Water DistributionGave to AZ for Revision2920Hot Water DistributionGave to AZ for Revision2941CO2 Extractor HeaderNo Revision Needed

# 2016 Aspen Aerogels | Confidential & ProprietaryWhat I Gained From This ExperienceTraining for manufacturing & process engineeringGiving Final PresentationsNetwork connections Real World ExperienceAn understanding of how to apply learned concepts to practiceResume BuilderJumpstart On My Career

# 2016 Aspen Aerogels | Confidential & ProprietaryWhat Aspen Gained From This ExperienceData not available on ABBCleaner & Better Labeled EquipmentOrganized FilesUp to date PIDs & Lighting Panel and Fixture ScheduleLED Lighting Energy & Power Savings

Savings by Hiring Intern$ per hour15Total amount of Time spent on project (hr)hours per week40LED Lighting 150weeks worked 12Cleaning Chillers 100Total Intern Cost$7,200 Updating P&IDs100Tracking Data20Labeling & Organizing30Monthly Electric Saving From Lights$4,416 Tuning Boilers80Monthly Electric Saving From Chillers$4,562 Total480 hrsPayback Period to Hire Intern0.8 Months

# 2016 Aspen Aerogels | Confidential & ProprietaryThank You All For The Great SummerSpecial Thanks to:Harold Klei Jeffrey BallSteve IadarolaQuentin SweeneyMargie Mosher

# 2016 Aspen Aerogels | Confidential & Proprietary