Industrial Technologies Program

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• Industrial Technologies Program
• Department of Energy Save Energy Now
• SPI Energy Efficiency Workshop
• June 20, 2006Chicago, Illinois

Paul Scheihing Industrial Technologies
ProgramOffice of Energy Efficiency and Renewable
Energy
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Challenges for Energy-Intensive Industries

• Volatile energy prices
• Industry concern about naturalgas costs and
  availability
• Influence of the emergingeconomies on energy
  andcommodity prices
• Difficulty for process industries to make needed
  investments in RD and commercialization
• Potential for game-changing scientific advances
  (e.g. nanotechnology) to transform industries

Natural Gas Prices, Henry Hub, LA
Dollars per Million Btu
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Industry Key to National Energy Picture
(Quadrillion Btu)
Industry is the largest energy using sector
2004 Energy Use 100.3 Quads

• 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

Industry 33
Transportation 28
Japan Total Energy Consumption 22.4 Quads
Commercial 18
Residential 21
Includes electricity losses
Source DOE/EIA Monthly Energy Review 2004
(preliminary) and estimates extrapolated from
MECS
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Delivering Technology Solutions
Collaborative RD

• Energy-intensiveProcess Technologies
• Crosscutting Technologies

Technology Delivery
Partnerships

• Assessments
• Training Tools

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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 Bodman
• National Press Club
• October 3, 2005

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Secretarial Initiative Save Energy Now

• Status to Date
• 200 plants selected in 39 States(14 of
  manufacturing gas useequivalent to 13 million
  typicalUS homes that use natural gas)
• 93 assessments completed as of May 19th, 2006
• Initial results from 50 assessments
• Potential savings over 15 trillion Btu
  naturalgas (equivalent to consumption by 207,000
  typical US homes)
• 153 million/year in potential energy cost
  savings
• Seven plants have reported immediate
  implementation of recommended ESA actions,
  leading to a total energy savings of 903,000 per
  year.

Secretary of Energy Samuel W. Bodman
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Energy Savings Teams

• Teams are 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

• Plastics Manufacturers
• Receiving Assessments
• Ball Corporation
• Bemis Company, Inc
• Formosa Plastics
• Sunoco

Completed andScheduled Assessments
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Save Energy Now Savings Potential

• Estimated savings potential for all 200 plant
  assessments
• Natural gas savings potential identified 63
  trillion Btu per year
• Cost savings potential identified 500 million
  per year
• Estimated impacts for all 200 plant assessments
• Natural gas savings implemented 25 trillion Btu
  per year (assume 40 percent implementation)
• Cost savings potential implemented 200 million
  per year

Additional energy savings will accrue as results
are replicated across plants and companies.
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Payback Periods

• 2 4 years
• Modify steam turbine operation
• Use oxygen for combustion
• Change process steam use

• 9 mo. 2 years
• Heat feed water with boiler blowdown
• Lower excess oxygen
• Flue gas heat recovery

2

• gt 4 years
• Install CHP system

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41
40

• lt 9 months
• Improve insulation
• Implement steam trap program
• Clean heat transfer surfaces

• Results from first 36 assessments

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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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Industrial Assessment Centers

• 26 centers located at accredited engineering
  schools
• Assessment teams include faculty and students
• Assessments usually entail aone-day site visit
• Integrated approach considersenergy, waste, and
  productivity

• Plant Qualification Criteria
• Annual sales under 100 million
• 500 or less employees at plant
• No designated energy manager
• Plant located lt150 miles from IAC school
• Energy bill less than 2 M/yr and greater than
  100K/yr

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Industrial Assessment Centers
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Improving Energy Efficiency at Plastics Plants
Joint study by SPI, DOE, IACs, and 11 U.S.
Plastics Manufacturing Plants

• IAC teams conducted assessments at 11 plastics
  plants in 2003
• 52 0f the 99 recommendations had been implemented
  by March 2005, saving an average of 68,500
  annually per plant.
• 9 of the 11 plants implemented energy-related
  recommendations to reduce energy costs by an
  average of 45K/yeara savings of 9.7 on their
  annual energy bills.

See http//www1.eere.energy.gov/industry/bestpract
ices/pdfs/plastics_report.pdf
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Improving Energy Efficiency at Plastics Plants
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Improving Energy Efficiency at Plastics Plants
Number of Recommendations
Average Annual Cost Savings per Category
(estimated)
Improvement Category
29
27,143
Compressed Air
17,012
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Lights
15
14,695
HVAC
13,460
Motors
8
7
16,845
Heat recovery
Insulation
6
19,480
Waste reduction
6
7,640
Load shedding/power factor
6
12,690
4
240,217
Productivity
Controls
3
15,570
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Plant Energy Profiler (PEP) Tool

• 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?

• 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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On-line Plant Energy Profiler QuickPEP

• OUTPUTS
• Overall picture of plant energy use
• Summary of energy cost distributions
• Preliminary assessment comparison
• Areas for energy efficiency improvement
• Energy cost reduction potential

• INPUTS
• Plant description
• Utility supply data electricity, fuel steam
• Energy consuming system information
• Scorecardresponses

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QuickPEP Results
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Tools Available via Our Web Site

• Air Master Provides comprehensive info on
  assessing compressed air systems.
• 3EPlus Insulation Assessment Tool Calculates
  most economical thickness of insulation for
  various operating conditions.
• Fan System Assessment Tool Assesses efficiency
  of fan system operations and quantifies benefits
  of system optimization.
• Plant Energy Profiler Helps plants assess
  plant-wide operation to identify savings and
  efficiency opportunities.
• Process Heating Assessment and Survey Tool
  Helps assess energy usein furnaces and
  identifies ways to improve performance.

• Motor Master Aids in energy-efficient motor
  selection and management.
• Pumping System AssessmentTool Assesses
  efficiency of pumping system operations.
• Steam System Assessment Tool Assists in
  assessing potential benefitsof specific
  steam-system improvements.
• Combined Heat Power Application Tool Enables
  users to evaluate the feasibility of CHP for
  heating systems.
• NOx and Energy Assessment Tool Assesses NOx
  emissions and applications of energy efficiency
  improvements at petroleum refiningand chemical
  plants.

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Training for Decision Tools
DOE and its partners conduct user training as
well as certify Qualified Specialists (via
rigorous testing) to apply energy management
decision tools at industrial facilities.

• Steam Systems
• Process Heating Systems
• Pump Systems
• Compressed Air Systems
• Fan Systems

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Immediate Suggested Actions

• Assign an Energy Manager Collect 12 months of
  energy bills, communicate energy costs to plant
  staff
• Use DOE QuickPEP to identify major energy costs
  http//www.eere.energy.gov/industry/quickpep/
• Manage compressed air systems with DOE tip
  sheets - Analyzing Your
  Compressed Air System
  - Determine the Cost of
  Compressed Air for Your Plant
  - Eliminate Inappropriate Uses of Compressed
  Air
• Survey infrequently used equipment that could be
  moved to off-peak electric periods.
• Start to manage your electric motors with DOE
  Motor Master
• Check to see if you can Replace V-Belts with
  Cogged or Synchronous Belt Drives.
• Get an energy assessment!

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Resources for Plants to Save Energy

• 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

877-337-3463 www.eere.energy.gov/industry
Info Center
Website
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Save Energy Now Website
Visitwww.eere.energy.gov/industry/saveenergynow