Industries of the Future: BestPractices

1. Industries of the Future: BestPractices Chris Cockrill U.S. Dept. of Energy, Seattle Reg. Off. Energy Efficiency & Renewable Energy Ph. 816-873-3299 Email: chris.cockrill@ee.doe.gov

2. Industries of the Future Strategy Technology for Today BestPractices Glass Aluminum Forest Products Technologyfor theFuture Metalcasting Chemicals Agriculture Steel Mining Petroleum

3. BestPractices Program Provides integrated delivery of energy-saving measures to the nine IOF sectors Energy management best practices • Motors and drives • Steam systems • Compressed air systems • Pump systems • Process heating systems Emerging technologies • Verification • Implementation Delivers OIT products and services by integrating: Addresses energy-saving needs and value from a plant-wide perspective by conducting: • Industrial assessments • Showcases

4. Industrial Assessment • Energy audit and industrial assessment by Industrial Assessment Centers (IACs) – Done for Plant • No cost to small/medium manufacturers • Conducted by university-based team of engineering faculty/students • 26 participating universities across the country Three levels of Energy-Use Assessment 1 • Collaborative Targeted Assessments – Done with Plants • Available to Showcase plants and those sponsoring corporate training • BP experts work with plant personnel (pumps, steam, air, process heat, insulation) 2 • Cost-shared, plant-wide assessment – Done by Plant • Up to $100 K OIT funds for each plant available through open solicitation or for Showcase plants • Summary assessment report published by OIT to promote replications of recommended energy conservation strategy 3

5. IAC Assessments Eligibility Requirements Results: Approx. 750 Assessments Annually, $55,000 in potential, average annual savings from each IAC assessment • Small/Medium size Manufacturing plants • Located within 150 Miles of IAC Host Campus • Gross Annual Sales less than $100M. • Fewer than 500 Employees • Annual Utility Bills >$100K & <$2M • No In-House Professional Staff to Perform Audit

6. Collaborative Targeted Assessments • Systems: • Motors and drives • Pump systems • Compressed Air Systems • Steam Systems • Process Heat Systems Purposes Assisting plant operators in use of industrial process application tools Developing a potential showcase site

7. Plant-wide Assessment Impact Expected Outcomes Payback of plant investment within one year through implementation of assessment recommendations Assessment recommendations applicable to an average of 7-8 similarly scaled plants for replication • Example: Boise Cascade (Round I Awardee) • 4 of 17 potential projects were implemented to reduce effluent heat load • $707,000 savings /yr with 3-year payback • reduce heat load by 45 million Btu/hr • reduce steam use by 28,100 lb/hr • reduce effluent flow by 2.2 million gals/day (8% reduction)

8. Plant-wide Assessment Solicitations • Round I: Six plants awarded in FY00, out of 17 applications • Alcoa, Amcast, Boise Cascade, Caraustar, Crucible, Inland Paper • All assessments completed • Five success story reports completed • Available in pdf format at www.oit.doe.gov/bestpractices • Round II: Seven plants awarded in FY00-01, out of 15 applications • Akzo Nobel, Anchor Glass Container, Appleton, Metlab, Paramount Petroleum, Utica Corporation, Weyerhaeuser • Assessments and reports scheduled for completion in FY01 All but Agriculture and Mining IOFs were represented through Round I & II awards

9. Plant-wide Assessment Solicitations • Round III: Nine plants awarded in FY01, out of 15 applications • Alcoa, Bayer, Blue Heron, Corning, Equilon, Neville Chemical, Rohm & Haas, 3M, W.R. Grace

10. Plant-wide Assessment Solicitations • Round IV • Solicitation Released: • June 29, ‘01 • Closing Date: • October 15, 2001

11. FY01 Initiative – Technology Implementation Promotion of Multiple Implementations • Cost-shared support to mitigate industry risk associated with use of emerging technologies • Provide verified performance data to ease hurdle of new technology acceptance • Eligibility: technologies beyond full-scale demonstration and preferably from those supported by NICE3, I&I, SBIR/STTR, and IOF partnerships • Costs shared by IOF programs, the BestPractices Program, and industry • Aiming to follow through to document realized savings to determine impact of OIT technology successes • Financial assistance solicitation was released on July 20, 2001 to close October 19, 2001; 4-6 awards expected in January 2002

12. Best Practices Software Tools Motor Master+ 3.0 • Comprehensive motor management software with 25,000 motors in database • Repair/replace decision-making • Self-training CD Pump System Assessment Tool (PSAT) • Calculation of energy use and efficiency of pumping system • Comparisons with optimal system for potential energy and cost savings ASD Master • Screening for Adjustable Speed Drive (ASD) upgrades • Energy, non-energy, and economic analysis • ASD specification

13. Best Practices Software Tools 3E Plus • Optimization of the insulation of boiler steam lines • Determination of the most economical thickness of insulation materials under varying operating conditions AirMaster+ • Compressed air systems assessment and evaluation designed for use with the training program Integrated Tool Suite • Under development for plant profiling to identify energy-saving opportunities • Will integrate the software tools above with OIT information products when fully developed in FY02

14. Best Practices Training Currently Available: • Steam Systems Improvement (1day) • Adjustable Speed Drive Application (1 day) • Pump System Assessment (1 day) • Fundamentals of Compressed Air Systems (1 day) • Advanced Management of Compressed Air Systems (2 days)

15. Best Practices Training Soon to be available: • Fan System Performance Assessment (1 day) • Optimization of Process Heating Systems (1 day) • Motor Systems Management (4 hours) Soon to be available through Allied Partners • Insulation Assessment (2 days) • Pump Systems Assessment (1 Day) • AirMaster+ Training (2 days)

16. Allied Partnership • Since the inception of Allied Partnership in 1995, 226 Allied Partners have been established, including • Suppliers of industrial equipment and services • Engineering and design consultants • Energy utilities • State agencies • Industrial and professional associations In aggregate, Allied Partners have distributed 10 times the amount of information/tool products as the amount distributed by all other OIT channels combined.

17. OIT Clearinghouse • A first stop for valuable OIT products and services • Experts help thousands of industrial customers: • “Can you help me justify a preventative maintenance program for our steam system?” --Facility Manager at a Petroleum Refinery • “Will the government cost-share with us to demonstrate an innovative melting technology that is more energy efficient?” --R&D Manager for a glass company • Voice: 1-800-862-2086 • Fax: 360-586-8303 • Email: clearinghouse@ee.doe.gov • Web: www.oit.doe.gov/clearinghouse “The real-world expertise of your organization places you in a unique position to provide solid advice and guidance. Keep up the good work.” --customer

18. OIT Home Page: www.oit.doe.gov