Industrial Technologies ProgramEnergy Outlook, Initiatives, & Resources
Forum on EnergyMay 15, 2006
Appleton, Wisconsin
Paul ScheihingIndustrial Technologies Program
Office of Energy Efficiency and Renewable Energy
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Challenges for Energy-Intensive Industries• Volatile energy prices• Industry concern about natural
gas costs and availability• Influence of the emerging
economies on energy andcommodity prices
• Difficulty for process industries to make needed investments in R&D and commercialization
• Potential for “game-changing”scientific advances (e.g. nanotechnology) to transform industries
Dollars per Million Btu
Natural Gas Prices, Henry Hub, LA
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• 37% of U.S.natural gasdemand
• 29% of U.S.electric demand
• 30% of U.S. greenhouse gas emissions
• Uses more energy than any one of the other G8 nations
Industry33%Transportation
28%
Commercial18%
Residential 21%
2004 Energy Use*100.3 Quads
*Includes electricity losses
Source: DOE/EIA Monthly Energy Review 2004 (preliminary) and estimates extrapolated from MECS
Industry is the largest energy using sector
(Quadrillion Btu)
Chemicals
Forest Products
Petroleum Refining
Iron & SteelFood ProcessingNon-Metallic Minerals
Non-Mfg
Other Mfg.
Aluminum
Fabricated Metals
Plastic & Rubber
3.8
4.1
1.61.9
3.3
7.3
7.8
1.4
0.9
0.7
0.7
Japan Total Energy C
onsumption: 22.4 Q
uads
Industry: Key to National Energy Picture
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Collaborative R&D
Technology Delivery
Partnerships
• Energy-intensiveProcess Technologies
• Crosscutting Technologies
• Assessments• Training & Tools
Delivering Technology Solutions
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Response to Energy Supply & Cost Issues
“America’s businesses, factories, and manufacturing facilities use massive amounts of energy. To help them during this period of tightening supply and rising costs, our Department is sending teams of qualified efficiency experts to 200 of the nation’s most energy-intensive factories. Our Energy Saving Teams will work with on-site managers on ways to conserve energy and use it more efficiently.”
Secretary of Energy BodmanNational Press Club
October 3, 2005
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112,398
4,014
200,710
84,298
0
50,000
100,000
150,000
200,000
250,000
Relatively Few Plants Use the Most Energy
U.S. Manufacturing Plants: By Size
Small Plants
<25 BBtuAnnual EnergyConsumption
Mid-Size Plants
26-500 BBtu
Large Plants
>500 BBtu
Num
ber o
f U.S
. Pla
nts
2002 EIA MECS
All Plants
Percent of Total Industrial Energy
Small &Medium
42%Large58%
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Energy Use - Large Plants by SectorTop 1,000 Manufacturing Facilities*
Site Energy Use (Trillion Btu)
Transportation EquipmentComputer, Electronics, & Other
Fabricated MetalsPrimary Metals
Nonmetallic MineralsPlastics and Rubber
ChemicalsPetroleum & Coal
PaperWoodFood
* Not including Mining 0 1000 2000 3000
942 TBtu
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Secretarial Initiative: “Save Energy Now”
Status to Date• 200 plants selected in 39 States
(14% of manufacturing gas use; equivalent to 13 million typical US homes that use natural gas)
• Initial results from 33 assessments:– Potential savings over 11 trillion Btu natural gas
(equivalent to more than 150,000 US homes)– $92 million/year energy cost savings
• 52 assessments completed as of April 14th, 2006
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Energy Savings Teams• Teams Composed of DOE Qualified Energy Experts and Plant Personnel• Teams focus on either steam generation or process heating• Plant personnel and affiliates are trained on DOE efficient tools
Completed and Scheduled Assessments As of April 11, 2006
Completed Assessments
Scheduled Assessments
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Savings Potential
Natural gas savings identified from 200 plants could:• Exceed 75 trillion Btu per year by Winter 2008
(>0.3% of total US demand, 1% of industrial non-feedstock natural gas)
• Surpass $500 million per year at current natural gas prices• Potentially save an amount of natural gas equivalent to that
used by 1 million US houses that use natural gas
Additional energy savings will accrue as results are replicated across plants assessed and at other company manufacturing sites
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• 30 Forest Products mills selected in 19 states
• Total energy consumption:367 TBtu
• Total natural gas consumption: 91 TBtu
Assessments for Forest Products Industry
Energy Savings AssessmentsCompleted and Planned, 2006
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ESAs in Forest Products IndustryCompleted and Planned, 2006
Energy Savings Assessment
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ESA Results in Forest Products Industry
Six assessments completed at Forest Products facilities have averaged total energy savings of 6.3%.
– Total Energy Cost Savings:$23.5 million
Mills selected to receive ESAs:• Alabama River Newsprint• Alsip Paper Condominium
Assoc.• Boise Cascade• Boise Paper Solutions• Boise Packaging &
Newsprint• Bowater• CraftMaster Manufacturing,
Inc.• Domtar Industries Inc• Georgia Pacific• International Paper• J.R Simplot Co.• Kimberly-Clark Corp.• MeadWestvaco
• The Newark Group• NewPage• Packaging Corporation
ofAmerica
• Potlatch Corp.• Sappi Fine Paper• Smurfit-Stone
ContainerCorp.
• Sonoco• SCA Tissue North
America• Stora Enso Kimberly
Mill• Wausau Paper• West Linn Paper Co.
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Qualification Criteria• Annual sales under $100 million
• 500 or less employees at plant
• No designated energy manager
• Energy bill less than $2 M/yr and greater than $100K/yr
• Plant located 150 miles or less from IAC school
Industrial Assessment Centers
• Located at accredited engineering schools
• Assessment teams include facultyand students
• Assessments usually entail aone-day site visit
• Integrated approach considersenergy, waste, and productivity
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Industrial Assessment Centers
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IAC Assessments in Forest Products Mills
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IAC Recommendations in Paper Mills• Modifications to compressed air systems• Recover waste heat• Employment of energy-efficient motors and belts• Insulate bare pipes and equipment• Install adjustable-speed drives• Optimize plant power factor• Tune-up boilers
Implemented Energy Projects Saved these Companies 2.7 Trillion Btu
$14.6M Energy Savings$27.1M Total Savings
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Eliminating compressed air leaks is one of thetop recommendations for the Paper industry.• Recommended 280 times• Average identified savings of 823 MMBtu and $4,544 • 83.6% of the recommendations were fully
implemented
Recovering waste heat from flue gases and otherequipment is one of the highest-payingrecommendations.• Recommended over 100 times• Average identified savings of 5,000 MMbtu and
$23,500• 25% of these recommendations were implemented
IAC Recommendations in Paper Mills
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All Industrial Plants Receive Assistance
• Applicant plants that do not meet the criteria for an Energy Savings Assessment are offered other assistance, such as– Industrial Assessment Center assessment – Personalized phone consultation to address energy
efficiency in their plant– Self assessment tools– Information products, DOE software tools, and training
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To provide a mill or plant a quick method for answering these questions:
• Where is my energy is going? • What is my potential for improvement? • What resources are available to help me?
Plant Energy Profiler (PEP) Tool• What is the purpose of
this software tool?
• How long does it take?
• What information do I need to get started?
Within 30 minutes you will have :• An overall picture of plant energy use • A summary of energy cost distribution • Estimated energy cost savings potential
As a minimum you will need :• A monthly bill for each purchased energy
stream (electricity, fuel & steam) • Plant production data for the same month
(optional)
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• Energy analysis software tools
• Case studies/tip sheets/manuals
• Energy efficiency trainingfor plant staff
• Qualified software specialists
• DOE-supported energy assessments
• Plant information package & CD
Websites: 877-337-3463www.eere.energy.gov/industrywww.eere.energy.gov/industry/saveenergynow
Resources for Plants to Save Energy
Info Center:
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Save Energy Now Website
Visit:www.eere.energy.gov/industry/saveenergynow
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More Good News
• Save Energy Now impacting ITP BestPractices energy saving metrics; $8 million FY2006 budget will yield substantially greater benefits than previous years
• More savings to be achieved in other ITP areas
– Industrial Assessment Center outreach
– ITP technology commercialization
• Energy savings assessments are also identifying R&D needs
– Waste heat recovery
– Enhanced sensors and controls
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Emerging ITP Technologies
Steam Cycle Washer
Directed Green Liquor Utilization Pulping
Oxalic Acid Pretreatment
Fibrous Paper Fillers
Advanced Gas-FiredPaper Dryer
Laser-Ultrasonic Web Stiffness Sensor
ElectrohydraulicContaminant Removal
Low Temperature Plasma Technology for Controlling VOC Emissions
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Commercialized ITP Technologies
Methane de-NOx ReburnProcess
Pressurized Ozone/Ultra-filtration Membrane System for TDS Removal
PyrOptix Detection and Control of Deposition on Pendant Tubes
ThermodyneTM Evaporator: Molded Pulp Products Dryer
XTREME Cleaner for Removal of Sticky Light Contaminants
Borate Autocausticizing
EnviroSensitiveTM
Screenable, Pressure-Sensitive Adhesives
MultiWaveTM Automated Sorting System for Efficient Recycling
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Websites: 877-337-3463www.eere.energy.gov/industry
Resources for Plants and Companies
Call:
Learn more about ITP’sR&D projects, BestPracticesactivities, and wide range of other resources of potential interest to your mill.
