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Overview of the U.S. DOE Industrial Technologies Program

Overview of the U.S. DOE Industrial Technologies Program. James Quinn Energy Efficiency & Renewable Energy U.S. Department of Energy. Rio de Janeiro, Brazil August 9, 2011. U.S. Industrial Energy Use. U.S. industry accounts for about one-third of all U.S. energy consumption.

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Overview of the U.S. DOE Industrial Technologies Program

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  1. Overview of the U.S. DOE Industrial Technologies Program James Quinn Energy Efficiency & Renewable Energy U.S. Department of Energy Rio de Janeiro, Brazil August 9, 2011

  2. U.S. Industrial Energy Use U.S. industry accounts for about one-third of all U.S. energy consumption. Reducing U.S. industrial energy intensity is essentialto achieving national energy and carbon goals. Transportation 28.1% Petroleum Natural Gas Electricity* Coal and Coke Renewable Energy 34.4% 34.8% 14.1%* 7.0% 9.7% Industry 30.8% Commercial 18.6% Residential 22.6% * Excludes losses Source: Annual Energy Review 2009, EIA. Source for pie chart: U.S. Energy Information Administration / Monthly Energy Review June 2011 (includes losses)

  3. Energy Use by U.S. Manufacturing Sectors Energy Consumption by Major U.S. Manufacturing Sector, 2006 Quadrillion Btu Source: U.S. Energy Information Administration, Manufacturing Energy Consumption Survey 2006, 2009.

  4. Role of Energy Efficiency & Renewable Energy Potential of Carbon Abatement Technologies to Achieve the 450 ppm Scenario by 2030 Carbon Capture & Storage: 10% Nuclear: 10% Renewables & Biofuels: 23% Efficiency: 57% “The industrial sector accounts for 35% of the end-use energy efficiency potential [by 2020].” – McKinsey, 2009 Source: World Energy Outlook 2009, presented at UNFCCC Meeting in Bangkok, Thailand Section I: US DOE’s Industrial Technologies Program

  5. DOE’s Industrial Technologies Program Mission: Advance manufacturing science and technology to enable rapid, low-cost, energy-efficient manufacturing. • 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

  6. ITP Delivers Solutions Research, Development & Demonstration • Develop and demonstrate more efficient next generation manufacturing processes and materials to address the top opportunities for saving energy across industry. Energy Management Help plants find opportunities to save energy today by adopting the best energy management practices and most efficient technologies.

  7. Industrial Technologies Program ITP: Delivering Results For 30 Years Working with industry, we have successfully developed and moved cutting-edge technologies and energy-saving measures into practice. • 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

  8. Energy Management Resources to help manufacturers reduce energy use and carbon emissions today—and continue to improve. Standards & Incentives Tools Assessments Training Information

  9. Energy Management Tool Suite Energy Management System Implementation Self-Paced Module System Area Tools, Calculators, & Scorecards Corporate Analysis Tools • Create corporate baseline • Generate annual report • Motors • Process Heating • Compressed Air • Fans • Plant Energy Profiler • Pumps • Steam • Buildings & Facilities • Data Centers • Getting started • Profile your energy flow • Develop opportunities, objectives, resources • Reality check • Manage current state & improvements • Check the system • Sustain & improve the system Facility Analysis Tools • Create facility baseline • Develop recommendations portfolio • Prioritize projects • Follow-up tool Project Analysis Tools • Prioritize projects • Follow-up tool www.eere.energy.gov/industry/

  10. Energy Management: Tools Plant Energy Profiler (PEP) INPUTS • Plant description • Utility supply data • Energy use information • Overview of plant energy • Energy cost distributions • Preliminary assessment • Areas for improvement • Energy reduction potential OUTPUTS eere.energy.gov/industry/quickpep_ml

  11. Energy Management: Training 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 BestPracticesTraining (soon to be offered as web-based training) • 3-day Advanced/Qualified Specialist Training • Data Center Workshops

  12. 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) Energy Management: Small Plant Assessments Crosscutting Assessments at Small and Medium-Size Plants: Industrial Assessment Centers 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. Section I: US DOE’s Industrial Technologies Program

  13. Mid-Size 37% Large 58% Energy Management: Assessments ITP provides two types of assessments, working with plants of all sizes. Percent of Total U.S. Manufacturing Energy U.S. Manufacturing Plants: By Size 200,710 Small 5% Number of U.S. Plants 112,398 84,298 4,014 Mid-Size Plants Small Plants Large Plants All Plants System-Specific Assessments Crosscutting Assessments

  14. Energy Management: Small Plant 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

  15. 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 Energy Management: Workforce Development Industrial Assessment Centers (IACs):Greening the Workforce

  16. 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 Energy Management: System-Specific Assessments Large Plants: System-Specific Improvements • 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 Section I: US DOE’s Industrial Technologies Program

  17. Energy Management: Assessment Results • 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

  18. Energy Management: Information Resources Outreach Technical Web Resources eere.energy.gov/industry

  19. Industrial Companies Non-Government Organizations Interagency Coordination STRATEGIC PARTNERSHIPS States Utilities International Collaboration Supply Chain Energy Management : Partnerships

  20. Energy Management: CHP Combined Heat & Power (CHP) Combined Heat & Power (CHP): An integrated set of technologies for the simultaneous, on-site production of electricity and useful heat. CHP simultaneously • Reduces GHG emissions • Promotes use of secure domesticand renewable energy sources • Reduces exposure to energyprice hikes and volatility

  21. This market-based, ANSI-accredited plant certification program provides industrial facilities with a pathway to continuously improve energy efficiency while boosting competitiveness. Energy Management: Superior Energy Performance Superior Energy Performance • 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 Superior Energy Performance launches in 2012

  22. Thank You

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