Michaela Martin, PE Program Manager Save Energy Now Initiative Oak Ridge National Laboratory

1. Michaela Martin, PE Program Manager Save Energy Now Initiative Oak Ridge National Laboratory U.S. Assessment Approachesand Resources U.S.-Brazil Industrial Energy Efficiency Workshop Rio de Janeiro, Brazil August 8-11, 2011

2. Discussion Overview • Targeting Energy End-Uses and Savings Potential • U.S. DOE Assessments • Crosscutting • System-specific • Assessment Resources • Experts • QuickPEP, or ePEP • Assessment Standards • Large Plant Assessment Results • Compressed Air Assessments (Dr. Kissock) • Process Heating Assessments (Dr. Muller)

3. U.S. Energy Footprint for Industry US Manufacturing Energy Consumption Survey (MECS) • Surveys a sample of US plants every 4 years • Inventory of fuel usage • Maps end-uses of energy • Overview of current energy management practices by US industry • Statistical sample representing 200,000 manufacturing plants • www.eia.doe.gov

4. End-Use Footprints in US Plants Top Energy Consuming End-Use Systems Process Heating Steam Pumps Fans Compressed Air

5. System-Based Consumption Fired heating systems Steam Process heating Electrical systems Pumps Compressed air Fans Why System Energy Efficiency Matters 5

6. Targeting Savings Potential by System Type Process Heating/ Steam Systems Typical Energy Consumption Rates 60 – 80% Electric MotorSystems Pumping Systems 8-15% CompressedAir Systems 7-15% Other* 2-7% < 2% * Other ancillary energy usages such as lighting represent less than 2% of energy consumption 10% to 30% 5% to 10% 10% to 20% 10% to 20% 5% to 10% Potential Energy Saving Opportunities

7. Mid-Size 37% Large 58% Industrial Energy Assessments ITP uses two types of general assessment approaches, to meet the needs of 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 >>0.5 TBtu/yr Crosscutting Assessments0.026 – 0.49 Tbtu/yr

8. Small 5% Mid-Size 37% Large 58% Plant Energy (Size) based Approach Industrial Assessment Centers (IAC) Cross-Cutting Energy Assessments 4,014 large plants use 58% of the energy Energy Saving Assessments(System focused)

9. U.S. DOE Industrial Energy Assessments Recap

10. DOE Qualified Energy Experts • U.S. DOE Industrial Technologies Program conducts a qualification training program to provide qualified energy experts by system area • Qualification workshops include classroom and hands-on instruction by highly experienced energy professions, written exams, and certificates • Energy Experts are available for system-specific areas (e.g., compressed air, pumping, process heating, steam, and fan systems)

11. PEP Tool Can Be Used to Determine Initial Approach 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 http://www1.eere.energy.gov/industry/quickpep_ml

12. ASMESystem Assessment Standards • Developed by US energy experts from utilities, industry, DOE, university IACs, national labs, consulting organizations • Based on DOE’s system-based approach • Provides comprehensive approach for holistic assessments of energy-intensive systems: • Pumping • Compressed Air • Steam • Process Heating • Sets requirements for • organizing and conducting assessments • collecting and analyzing data • reporting results • Standards and Guidance Documents available at:http://www.asme.org/kb/standards#des=EA

13. Save Energy NowSystem-BasedLarge Plant 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 Train Plant Staff Successful Project Implementation Gather Preliminary Data Conduct Plant Visit Analyze & Report Results Implementation Follow-up

14. DOE Save Energy Now System Assessment Results

15. TOP TEN FREQUENTLY IDENTIFIED PROCESS HEATING OPPORTUNITIESSAVE ENERGY NOW ASSESSMENTS - 2006 to 2011 * Based on Save Energy Now assessments conducted between 2006 to 2011. Numbers are as of July 1, 2011.

16. TOP TEN FREQUENTLY IDENTIFIED STEAM OPPORTUNITIESSAVE ENERGY NOW ASSESSMENTS - 2006 to 2011 * Based on Save Energy Now assessments conducted between 2006 to 2011. Numbers are as of July 1, 2011.

17. TOP TEN FREQUENTLY IDENTIFIED COMPRESSED AIROPPORTUNITIESSAVE ENERGY NOW ASSESSMENTS - 2006 to 2011 * Based on Save Energy Now assessments conducted between 2006 to 2011. Numbers are as of July 1, 2011.

18. TOP TEN FREQUENTLY IDENTIFIED PUMPING SYSTEMOPPORTUNITIESSAVE ENERGY NOW ASSESSMENTS - 2006 to 2011 * Based on Save Energy Now assessments conducted between 2006 to 2011. Numbers are as of July 1, 2011.

19. TOP TEN FREQUENTLY IDENTIFIED FAN SYSTEMOPPORTUNITIESSAVE ENERGY NOW ASSESSMENTS - 2006 to 2011 * Based on Save Energy Now assessments conducted between 2006 to 2011. Numbers are as of July 1, 2011.

20. Majority of Assessments Conducted In 6 Major Industries

21. TOP TEN FREQUENTLY IDENTIFIED OPPORTUNITIES FOR IRON & STEEL INDUSTRY 2006 to 2011 * Based on Save Energy Now assessments conducted between 2006 to 2011. Numbers are as of July 1, 2011.

22. TOP TEN FREQUENTLY IDENTIFIED OPPORTUNITIES FOR CHEMICAL INDUSTRY 2006 to 2011 * Based on Save Energy Now assessments conducted between 2006 to 2011. Numbers are as of July 1, 2011.

23. TOP TEN FREQUENTLY IDENTIFIED OPPORTUNITIES FOR PULP & PAPER INDUSTRY 2006 to 2011 * Based on Save Energy Now assessments conducted between 2006 to 2011. Numbers are as of July 1, 2011.

24. System-Assessment Examples • Compressed Air (Dr. Kissock) • Process Heating (Dr. Muller)