Industrial Energy Efficiency: U.S. Policy , Initiatives, & Opportunities

1. James QuinnIndustrial Technologies ProgramEnergy Efficiency and Renewable EnergyU.S. Department of Energy Industrial Energy Efficiency:U.S. Policy, Initiatives, & Opportunities

2. Global Consumption: Projected Growth World Total Primary Energy Consumption by Region, 2005-2035 Asia Europe North America Middle East, Central & South America Africa Source: Table A1, EIA International Energy Outlook 2010

3. Global Consumption The world relies on fossil energy. Total World Energy Consumption, 2008 Note: Chart presents total primary energy supply. Source: International Energy Agency, 2010 Key World Energy Statistics.

4. Global Energy Solutions End-use efficiency and renewable energy are key to abatement of GHG emissions from energy consumption. World abatement of energy-related CO2 emissions in the 450 Scenario, 2007-2030 End-useefficiency End-use potential Gt CO2 Power plants Renewables Renewables potential Biofuels Nuclear CCS Source: OECD/IEA 2009, World Energy Outlook 2009. Notes: Gt refers to gigatons of carbon dioxide. “End-use efficiency” includes Buildings, Appliances, Lighting, Transportation, and Industry.

5. Global Energy Challenges • Overarching Challenges: • Carbon reduction • Market delivery of clean energy technologies • Research anddevelopment needs • Economic growth • Workforce development Security Clean Energy Solutions Environment Economy Energy efficiency and renewable energy provide solutions to global energy challenges.

6. Solution: Building a Clean Energy Economy Building the clean energy economy requires a planned, systematic approach: • Drive high-impact innovation • Move innovation to the marketplace rapidly and at scale • Attract the best and brightest people • Communicate plans and achievements to engage the public

7. Opportunities: Innovation Focus Areas • Renewable Energy • Solar • Wind • Biomass/Biofuels • Water Power • Geothermal • Energy Efficiency • Building Technologies • Weatherization • Vehicle Technologies • Industrial Technologies • Fuel Cells • Federal Energy Management

8. Renewable Energy Opportunities Capturing Sunlight Converting Biomass Water Power Harnessing the Wind

9. Building Efficiency Opportunities Building technologies available today can lower energy use and reduce pollution—at a low or negative net cost. • Building energy codes and appliance standards • Cost-effective, energy-efficientbuilding technologies and practices • Building envelopes • Equipment • Lighting, daylighting, windows • Cool roofs • Advanced sensors and controls  • Combined heating and power • Whole building design • Better Buildings Challenge • Catalyze private sector investment in commercial building upgrades • Part of plan to make America's commercial buildings 20% more efficient over next decade

10. Vehicle Efficiency Opportunities Energy efficiency can improve fuel efficiency, reduce GHG emissions, and reduce national dependence on imported oil. • Research and development • Electric vehicles and components • Nonconventional fuels and lubricants • Advanced engine technologies • Lightweight, high-performance materials • Partnerships with state and local organizations • Deployment and education

11. Federal Energy Management Opportunities The Federal government is the nation’s largest energy consumer, providing an enormous opportunity to save energy. • Federal Facilities and Operations • High-performance building design, operation, and maintenance • Water efficiency and conservation best practices • Renewable energy technology deployment • Data center energy efficiency • Project funding tools • Laboratory energy efficiency • Energy efficient product procurement • Federal Fleet and Mobility • Acquisition of alternative fuel vehicles • Acquisition of plug-in hybrid electric vehicles • Development of alternative fuel infrastructure

12. Advanced Manufacturing Partnership • In June of this year, President Obama launched the Advanced Manufacturing Partnership (AMP). • Brings together industry, universities, and the federal government to invest more than $500 million in emerging technologies • Will create high quality manufacturing jobs and enhance U.S. global competitiveness • Designed to provide platform for breakthroughs in the next decade by: • Building a roadmap for advanced manufacturing technologies • Speeding ideas from the drawing board to the manufacturing floor • Scaling-up first-of-a-kind technologies • Developing the infrastructure that will enable small and mid-sized manufacturers to innovate and compete. President Barack Obama delivers remarks following a tour of the National Robotics Engineering Center at Carnegie Mellon University in Pittsburgh, Pa., June 24, 2011.

13. Industrial Efficiency Opportunities Energy efficiency can yield cost, productivity, energy supply resiliency, and competitiveness benefits to industry. • Develop Next-Generation Manufacturing Processes & Materials • Manufacturing processes that limit energy intensity • Materials technologies that lower life-cycle energy consumption and provide low-cost, high performance. • Foster the Energy Management Services Industry • Identify, deploy, certify, and reward effective energy management • Develop tools and protocols to enable industry to measure and manage energy usage • Promote education and hands-on training for a new generation of energy management engineers. 28 MW, roll-to-roll manufacturing line for triple-junction amorphous silicon modules

14. 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)

15. Industrial Technologies Strategy Energy efficiency can yield cost, productivity, energy supply resiliency, and competitiveness benefits to industry. • Develop Next-Generation Manufacturing Processes & Materials • Manufacturing processes that limit energy intensity • Materials technologies that lower life-cycle energy consumption and provide low-cost, high performance. • Foster the Energy Management Services Industry • Identify, deploy, certify, and reward effective energy management • Develop tools and protocols to enable industry to measure and manage energy usage • Promote education and hands-on training for a new generation of energy management engineers. 28 MW, roll-to-roll manufacturing line for triple-junction amorphous silicon modules

16. R&D: Innovative Manufacturing Initiative Solicitation Released in June 2011—as part of the Administration’s AMP—to develop transformational manufacturing technologies and innovative materials that reduce time, cost, and energy requirements associated with manufacturing. • Innovative Manufacturing Processes topics: • Reactions and Separations • High Temperature Processing • Waste Heat Minimization and Recovery • Sustainable Manufacturing • Innovative Materials topics: • Thermal and Degradation Resistant Materials • Highly-Functional, High-Performance Materials • Lower Cost Materials for Energy Systems • Cost-shared projects with up to $120 million in DOE funding expected to be available over three years.

17. Industrial Technologies Program (ITP) 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.

18. R&D Successes: Examples Isothermal Melting (ITM) Process for Aluminum • Continuous flow system with immersion heaters converts electricity to melting energy with 97% efficiency. SuperBoiler • Gas-fired package offers >94% fuel-to-steam conversion efficiency • Demonstration at fruit processing facility in California.

19. R&D Partnerships Other R&D Collaborations • Partnerships to leverage R&D resources: • National Laboratories – leverage intellectual property and knowledge. • DOE’s Basic Energy Sciences – take scientific discoveries in nanotechnology, chemistry, and materials science and translate them into technology solutions for the Nation’s manufacturers. • DOE’s Office of Fossil Energy – work to ensure the provision of clean, affordable energy from traditional fuel sources. • Other EERE programs – develop viable manufacturing technologies for advanced energy technologies, including Wind Energy and Vehicle Technologies. • National Science and Technology Council interagency working group on nanomanufacturing, and with NIST, DOD, and other agencies – collaborate on areas of common interest such as advanced materials.

20. Industrial Related R&D in the U.S. Department of Energy • DOE’s Office of Science Research Valuable to Industry • Basic R&D improves understanding of chemical reactivity. • Industrial Reaction and Separation: improved catalysts for clean and efficient production of fuels and chemicals; better separations and analytical methods for applications in energy processes • Energy Conversion Systems: more efficient combustion systems with reduced emissions of pollutants • Biological Processing: potential for materials synthesis, chemical catalysis, and materials synthesized at the nanoscale

21. Industrial Related R&D in the U.S. Department of Energy • Office of Fossil Energy: Carbon Sequestration R&D and Initiatives In 2009, industry accounted for slightly more than ¼ of U.S. carbon dioxide (CO2) emissions from energy consumption (5,405 million metric tons per EIA data). Recovery Act funds were allocated to more than 25 projects that capture and sequester CO2 emissions from industrial sources (e.g., cement plants, chemical plants, refineries, paper mills, and manufacturing facilities) into underground formations. Three large-scale projects are expected to capture and store a total of 6.5 million tons of CO2 per year, and increase domestic production of oil by more than 10 million barrels of oil per year by September 2015. Another seven projects seek ways to convert captured industrial CO2 emissions into useful products, e.g., fuel, plastics, cement, and fertilizers. Numerical simulation of geologic carbon sequestration: the ability to simulate CO2 flow and transport in deep subsurface formations is critical for assessing injectivity, capacity, trapping mechanisms, brine displacement, and long-term impacts of injected CO2.

22. Industrial Technologies Strategy Energy efficiency can yield cost, productivity, energy supply resiliency, and competitiveness benefits to industry. • Develop Next-Generation Manufacturing Processes & Materials • Manufacturing processes that limit energy intensity • Materials technologies that lower life-cycle energy consumption and provide low-cost, high performance • Foster the Energy Management Services Industry • Identify, deploy, certify, and reward effective energy management • Develop tools and protocols to enable industry to measure and manage energy usage • Promote education and hands-on training for a new generation of energy management engineers 28 MW, roll-to-roll manufacturing line for triple-junction amorphous silicon modules

23. Energy Management Resources • Information • Website • EERE Information Center • Tip Sheets • Case studies • Webcasts • Supply chain guidance • Software Tools • Process heating, steam, motors and pumps, fans • Plant Energy Profiler • Energy and carbon baselining • Energy management • Training • Basic and advanced • Qualified Specialist • Certified Practitioners • Standards • SEP plant certification • ISO 50001 • System assessments • Savings Assessments • In-plant, peer-to-peer • Industrial Assessment Centers (IACs)

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

25. Energy Management: Training Training at several levels: ITP Quality Assurance • Control the quality of training courses and materials • Make sure training efforts are useful and effective • Manage trainings and monitor results through Training Management System. • Energy Management seminars • Webinars on relevant topics(1-2 hours) • Web-based Awareness Workshops(1-2 hours) • 1-day End-User BestPracticesTraining (soon to be offered online) • 3-day Advanced/Qualified Specialist Training • Data Center Workshops

26. 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

27. Energy Management: System-Specific Assessments Teams are DOE Energy Experts and plant personnel Teams focus on fans, pumps compressors, steam or process heating systems. Plant personnel trained on DOE software tools TrainPlant Staff Successful Project Implementation Gather Preliminary Data Conduct Plant Visit Analyze & Report Results Follow-up & Technical Assistance 27 Section I: US DOE’s ITP Activities for US Industry

28. 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 up to 300 plants per year (under 1 TBtu/yr or 25ktoe/yr) and typically identify savings of 8% to 10% or $115,000/plant (181,000 BRL/plant) Energy Management: Small/Medium Plant Assessments 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

29. Energy Management: IAC Transition and Deployment • Who benefits? • IACs focus on an underserved sector – small to medium companies with no technical staff that has energy analysis as a primary duty • IAC grads are in demand – nearly 60% have jobs in energy fields before they leave Why it works • IAC students follow-up 60 days after the assessment report and debrief to assist with implementation • Implementation saves companies money and promotes a culture of energy efficiency – lays the foundation for additional technology deployment and continuous improvement

30. Monitoring and Measuring Results • DOE monitors and measures results from its industrial energy efficiency programs. • Administers consistent and reliable collection and recording systems • Performs analyses and uses sophisticated calculation models to estimate impacts • Conducts participant surveys to help in vetting estimated impacts and improving program resources • Generates consistent, defensible estimates of program performance.

31. Energy Management: Technical Assessment 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

32. Global Energy Management System Standard ISO 50001: New energy management standard for buildings and industry • Developed by ISO Project Committee 242; U.S. and Brazil led effort with the UK and China • 58 countries participated, 14 as observers • Published June 2011 • ISO TC 242 will meet Oct. 31-Nov. 4, 2011, in Washington, D.C. • Potential Impacts: • Could influence up to 60% of the world’s energy use across many economic sectors • Companies will implementthe standard in response to: • Corporate sustainability programs • Energy cost reduction initiatives • Demand created along themanufacturing supply chain • Carbon and energy legislation and international climate agreements

33. ISO 50001: New DOE Website Sign up to receive announcements about new tools, webinars, and more. l Website: eere.energy.gov/energymanagement.html

34. Superior Energy Performance Superior Energy Performance is a market-based certification program designed to: • Drive continual improvement in energy performance • Develop a transparent system to validate energy performance improvements and management practices • Encourage broad participation throughout industry • Support and build the energy efficiency market and workforce Superior Energy Performance for industry will launch nationwide next year (2012). • Certification Requirements: • An ANSI/ANAB-accredited verification body will conduct a third-party audit to verify that that the facility meets the following requirements: • Conformance to ISO 50001 Energy Management Standard • Energy Performance Improvement

35. U.S. Council for Energy-Efficient Manufacturing • Acts as champion of U.S. industry in pursuing national energy efficiency goals. • Seeks to improve the energy intensity of U.S. manufacturing through a series of initiatives. • Guides development of Superior Energy Performance.

36. U.S. Facilities Are Adopting ISO 50001 Through Superior Energy Performance pilot projects, 24 U.S. manufacturing facilities are implementing an energy management system that conforms with ISO 50001: • 3M • Alcoa • Allsteel • Amcor PET • Bentley Prince Street • Bridgestone Tire • Cook Composites & Polymers • Cooper Tire • Didion Milling, Inc • Dow Chemical • Eaton • General Dynamics • Haynes International • Holcim • JR Simplot • Kenworth Trucks • Lockheed Martin • Neenah Foundry Company • Nissan • Schneider Electric • Spirax Sarco • Traco • Volvo • World Kitchen June 2011

37. Value of Superior Energy Performance and ISO 50001 • Provides a framework for continual improvementof energy performance across an entire facility • Identify more projects • Collect data to support systematic decision-makingand prioritization of projects • Implement a broader range of operational andcapital projects • Implementing an energy management system… • Provides greater persistence of energy savings andhigher return on energy efficiency investments—increased net present value • Encourages operational changes that generateadditional energy savings beyond capital projects—deeper savings at lower cost.

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

39. Utility Partnerships DOE Partners with Utilities • With EPA, facilitates a 30-member Utility Motivation and Energy Efficiency Working Group • Helps utilities develop and implement industrial-efficiency programs • Transfers resources and knowledge to utility stakeholders • Policy Analyses • Case Studies • Webinar Series • Training • Software tools • Regional Demand-side Management (DSM) Reports Total ratepayer-funded energy efficiency program spending in the United States is projected to increase from $5.4 billion in 2010 to $12 billion per year or more in 2020. Source: Institute for Electric Efficiency. Summary of Ratepayer-Funded Electric Efficiency Impacts, Expenditures, and Budgets. The Edison Foundation. Updated January 2011.

40. Inter-Agency Initiative E3: Economy, Energy, and Environment • Brings together local manufacturers, utilities, local government, and federal resources to address sustainability challenges • Provide training, assessments, and implementation support, and continuous improvement. • Benefits include: – Create green jobs – Stimulate the local economy – Foster sustainability • Enables economic growth in local communities • Joint effort by U.S. Departments of Energy, Commerce, and Labor and the Environmental Protection Agency • Pilots are finding funding and opportunities forenergy-saving projects. • International projects planned

41. ENERGY STAR for Industry A voluntary program that enables organizations of all types to achieve their best in environmental and energy performance Companies agree to: • Institute a policy to continuously improve energy performance • Measure, track, and benchmark energy use in all facilities • Develop and implement a plan to improve energy performance • Educate employees about energy efficiency and ENERGY STAR EPA agrees to: • Support corporateenergy managers • Provide energymanagement resources • Promote networking, recognition, and sharing of best practices • Offer specialized energy efficiency focus groupsfor specific industries

42. Supply Chain Energy Efficiency “Analysis suggests that for consumer goods makers, high-tech players, and other manufacturers, between 40% and 60% of a company’s carbon footprint resides upstream in its supply chain…For retailers, the figure can be 80%.” -- McKinsey Quarterly, 2008 • Upstream suppliers may account for 2-4 times greater energy use. • Opportunities are often dispersed and difficult to tap with limited resources. • ITP resources can assist buyer companies in working with their suppliers to capture these energy and carbon reduction opportunities. • Improves sustainability, reduces risk,builds partnership with suppliers

43. Global Superior Energy Performance In July 2010, at the Clean Energy Ministerial, the U.S. launched a Global Energy Efficiency Challenge with initiatives in appliances, buildings, industry, vehicles, and the Smart Grid. Canada Australia Brazil Belgium EU China Germany Denmark India Indonesia France Italy Japan Korea Mexico Norway Russia United Arab Emirates United Kingdom Spain United States South Africa

44. GSEP Objective and Organizational Structure • GSEP objective is to reduce global energy use by: • Encouraging industrial facilities and commercial buildings to pursue continuous improvements in energy efficiency • Promoting public-private partnership GSEP CERTIFICATION WORKING GROUP (Lead: U.S.) POWER WORKING GROUP (Lead: Japan (P)) CHP WORKING GROUP (Lead: Finland) STEEL WORKING GROUP (Lead: Japan) COOL ROOFS WORKING GROUP (Lead: U.S.) CEMENT WORKING GROUP (Lead: Japan)

45. Bottom Line Energy efficiency is our cleanest, cheapest energy resource. U.S. Secretary of Energy Steven Chu, Testimony to U.S. Senate, 2010. Energy efficiency improvements exist in all sectors, but some of the biggest are in industry and transport U.N. Secretary General Ban Ki-moon, 2009 The potential to increase [industrial] efficiency is huge—the sector could reduce energy use by 14% to 22% by 2020 by using financially attractive technologies. Excerpt from National Research Council report Real Prospects for Energy Efficiency in the United States, 2009 Existing technologies with an attractive internal rate of return can cut the growth in global energy demand by half or more within 15 years. -- Curbing Global Energy Demand Growth, McKinsey & Co., May 2007 Industrial Energy Efficiency is a Key Solution to Building a Clean Energy Economy

46. Thank you James Quinn U.S. Dept. of Energy

47. Thank you James Quinn U.S. Dept. of Energy Michaela Martin Oak Ridge National Laboratory