Overview of the U.S. DOE Industrial Technologies Program

Program Name or Ancillary Text eere.energy.gov

Overview of the U.S. DOE Industrial Technologies Program

Rio de Janeiro, BrazilAugust 9, 2011

James QuinnEnergy Efficiency & Renewable Energy U.S. Department of Energy

2 | Industrial Energy Efficiency eere.energy.gov

U.S. industry accounts for about one-third of all U.S. energy consumption.

Petroleum

Natural Gas

Electricity*

Coal and CokeRenewable Energy

Residential22.6%

Industry30.8%

Commercial18.6%

Transportation28.1% 34.4%

34.8%

14.1%*7.0%9.7%

Reducing U.S. industrial energy intensity is essentialto achieving national energy and carbon goals.

* Excludes lossesSource: Annual Energy Review 2009, EIA.

U.S. Industrial Energy Use

Source for pie chart: U.S. Energy Information Administration / Monthly Energy Review June 2011 (includes losses)


Energy Use by U.S. ManufacturingSectors

0 2 4 6 8

Other Manufacturing

Refining

Chemicals

Forest Products

Food & Beverages

Iron & Steel

Energy Consumption by Major U.S. Manufacturing Sector, 2006

Source: U.S. Energy Information Administration, Manufacturing Energy Consumption Survey 2006, 2009.

Quadrillion Btu


“The industrial sector accounts for 35% of the end-use energy efficiency potential [by 2020].”

– McKinsey, 2009

Section I: US DOE’s Industrial Technologies Program

Carbon Capture & Storage: 10%

Nuclear: 10%

Renewables & Biofuels: 23%

Efficiency: 57%

Source: World Energy Outlook 2009, presented at UNFCCC Meeting in Bangkok, Thailand

Potential of Carbon Abatement Technologies to Achieve the 450 ppm Scenario by 2030

Role of Energy Efficiency & Renewable Energy


Objectives:• Develop innovative, energy-efficient

processes and materials technologies that can improve energy diversity, resource efficiency, and carbon mitigation

• Promote a corporate culture that values energy and carbon management

DOE’s Industrial Technologies Program

Mission:Advance manufacturing science and technology to enable rapid, low-cost, energy-efficient manufacturing.


Help plants find opportunities to save energy today by adopting the best energy management practices and most efficient technologies.

Develop and demonstrate more efficient next generation manufacturing processes and materials to address the top opportunities for saving energy across industry.

Research, Development & Demonstration

Energy Management

ITP Delivers Solutions


Industrial Technologies Program

• Produced >220 commercialized technologies

• Obtained 215 patents between1994 and 2009

• Received 55 prestigious R&D 100 awards since 1991

• Saved 9.3 quads and reduced emissions by 755 million metric tons of CO2

ITP: Delivering Results For 30 YearsWorking with industry, we have successfully developed and moved cutting-edge technologies and energy-saving measures into practice.

Harness Scientific Ingenuity

Spur Innovation

Leverage Resources

Change Corporate

Culture


Tools Training Assessments Information

Resources to help manufacturers reduce energy use and carbon emissions today—and continue to improve.

Energy Management

Standards & Incentives


Energy Management Tool Suite

Corporate Analysis Tools

Facility Analysis Tools

Project Analysis Tools

• Create corporate baseline• Generate annual report

• Create facility baseline• Develop recommendations

portfolio• Prioritize projects• Follow-up tool

• Prioritize projects• Follow-up tool

Energy Management System Implementation

Self-Paced Module

• Getting started• Profile your energy flow• Develop opportunities,

objectives, resources• Reality check• Manage current state &

improvements• Check the system• Sustain & improve the

system

System Area Tools, Calculators, & Scorecards

• Motors• Process Heating• Compressed Air• Fans• Plant Energy Profiler• Pumps• Steam• Buildings & Facilities• Data Centers

www.eere.energy.gov/industry/

http://www.eere.energy.gov/industry/


• Plant description• Utility supply data• Energy use

information• Overview of plant energy• Energy cost distributions• Preliminary assessment• Areas for improvement• Energy reduction potential

INPUTS

eere.energy.gov/industry/quickpep_ml

OUTPUTS

Plant Energy Profiler (PEP)

Energy Management: Tools

http://www1.eere.energy.gov/industry/quickpep_ml/default.aspx

http://www1.eere.energy.gov/industry/quickpep_ml/default.aspx


Training at several levels for:

• Energy Management Training seminars

• Webinars on relevant topics(1-2 hours)

• Web-based Awareness Workshops(1-2 hours)

• 1-day End-User BestPractices Training (soon to be offered as web-based training)

• 3-day Advanced/Qualified Specialist Training

• Data Center Workshops

Energy Management: Training


• DOE's 26 university-based Industrial Assessment Centers (IACs) conduct energy assessments of small and medium-size plants* at no charge.

• Faculty-led teams of engineering students conduct the assessmentsas training for careers in industrial energy efficiency.

• IACs serve 300 plants per year (under 1 TBtu/yr or 25ktoe/yr) and typically identify savings of 8%-10% or $115,000/plant (181,000 BRL/plant)


Crosscutting Assessments at Small and Medium-Size Plants: Industrial Assessment Centers

Energy Management: Small Plant Assessments

eere.energy.gov/industry/bestpractices/iacs.html

* IAC plants typically have gross annual sales of less than $100 million, fewer than 500 plant employees, and annual energy bills less than $2 million.

http://www.eere.energy.gov/industry/


Percent of Total U.S. Manufacturing Energy

Small 5%

Mid-Size37%

Large58%

0

50000

100000

150000

200000

250000

U.S. Manufacturing Plants: By Size

Small Plants

Mid-Size Plants

Large Plants

Num

ber o

f U.S

. Pla

nts

All Plants

84,298112,398

4,014

200,710

ITP provides two types of assessments, working with plants of all sizes.

Energy Management: Assessments

System-Specific AssessmentsCrosscutting

Assessments


Industrial Assessment Center (IAC) Assessments:• 1-day assessments cover plant-wide

energy systems, including process andnon-process energy use (e.g., lighting,HVAC)

• Recommended energy-savingmeasures are entered in a searchable,on-line data base.

Since January 2006:• Over 1,900 assessments conducted at small- and medium-size plants• 44 trillion Btu of identified primary energy savings• Over $402 million in energy cost savings identified• 2.7 million metric tons of CO2 emissions reductions identified

Energy Management: Small Plant Assessments


• Hands-on training in diagnostics, data collection, and analysis of energy savings opportunities

• Exposure to a wide range of industries, energy systems, and solutions

• Interaction with plant staff, utility representatives, and vendors

• Expedited ability to obtain professional licensure and certification

Industrial Assessment Centers (IACs):Greening the Workforce

Energy Management: Workforce Development


• DOE energy expert teams visit plants, conduct analyses, and report to plant managers

• Teams focus on fans, pumps compressors, steam, process heating, or other plant energy system using DOE software tools

• The biggest savings come from improving process heating and steam systems


Large Plants: System-Specific Improvements

Energy Management:System-Specific Assessments

• Average plant found ways to reduce energy bill by about 8%

• Over a three year period, industry had implemented approximately 1/6 of recommendations and 1/3 were either in progress or in planning stages


Since Save Energy Now was initiated in January 2006:

• Over 2,900 energy assessments conducted at US plants to date

• Average plant has found ways to reduce energy bill by ~5-8%

• Over $1.6 billion (2.5 billion BRL) in identified energy cost savings

• 13.3 million metric tons of CO2 emissions reductions identified

Energy Management: Assessment Results


Technical Outreach Web Resources

eere.energy.gov/industry

Energy Management: Information Resources

http://www.eere.energy.gov/industry


STRATEGIC PARTNERSHIPS

Interagency Coordination

Utilities

International Collaboration

Industrial Companies

Non-Government

Organizations

States

SupplyChain

Energy Management : Partnerships


An integrated set of technologies for the simultaneous, on-site production of electricity and useful heat.

Combined Heat & Power (CHP)

Energy Management: CHP

Combined Heat & Power (CHP):

CHP simultaneously• Reduces GHG emissions• Promotes use of secure domestic

and renewable energy sources• Reduces exposure to energy

price hikes and volatility


This market-based, ANSI-accredited plant certification program provides industrial facilities with a pathway to continuously improve energy efficiency while boosting competitiveness.

Superior Energy

Performance launches in 2012

• Uses ISO 50001 standard as foundational energy management system

• Develops system to validate energy intensity improvements and management practices

• Encourages broad participation throughout industry for sustained energy savings

Energy Management: Superior Energy Performance

Superior Energy Performance


Thank You

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Overview of the U.S. DOE Industrial Technologies Program

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