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Industrial Technologies Program - tappi. · PDF fileIndustrial Technologies Program ......

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  • 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-changingscientific advances (e.g. nanotechnology) to transform industries

    Dollars per Million Btu

    Natural Gas Prices, Henry Hub, LA

  • 3

    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




    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)


    Forest Products

    Petroleum Refining

    Iron & SteelFood ProcessingNon-Metallic Minerals


    Other Mfg.


    Fabricated Metals

    Plastic & Rubber











    Japan Total Energy C

    onsumption: 22.4 Q


    Industry: Key to National Energy Picture

  • 4

    Collaborative R&D

    Technology Delivery


    Energy-intensiveProcess Technologies

    Crosscutting Technologies

    Assessments Training & Tools

    Delivering Technology Solutions

  • 5

    Response to Energy Supply & Cost Issues

    Americas 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 nations 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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    Relatively Few Plants Use the Most Energy

    U.S. Manufacturing Plants: By Size

    Small Plants

    500 BBtu


    ber o

    f U.S

    . Pla


    2002 EIA MECS

    All Plants

    Percent of Total Industrial Energy

    Small &Medium


  • 7

  • 8

    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


    * Not including Mining 0 1000 2000 3000

    942 TBtu

  • 9

    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


    Potlatch Corp. Sappi Fine Paper Smurfit-Stone


    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


    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


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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


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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

  • 25

    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

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