Industrial Energy Efficiency:

Technology Delivery

“Thinking Globally, Saving Locally”

David S. GodfreyAtlanta Regional OfficeEnergy Efficiency and Renewable EnergyU.S. Department of Energy

Presentation to EPA Region IV P2 Conference Call September 1, 2004

• Oil for 40 years, w/ 77% in OPEC countries*

• Natural gas for 67 years, mostly from former USSR*

• Coal for 192 years from N. Am, Europe, Asia and Eurasia*

• World energy use up 2.9% in 2003 w/ 15% increase in Chinese coal use and doubling of oil use in decade

• Wind capacity at 40,000 MW worldwide; solar photo-voltaics up 10X in last 10 years

*At current rate of production

BP Statistical Review of World Energy, 2004The Global Look

Office of Industrial Technologies

Partner with industry and other stakeholders to:

• Increase energy savings

• Reduce environmental impacts

• Improve process yield/conserve resources

• Reduce reliance on foreign oil

• Increase use of renewable energy

• Improve competitiveness and quality of life

Improve the energy intensity of U.S. industry through coordinated research and development, validation, and dissemination of energy efficiency technologies & practices.

Delivering Technology Solutions

• Technical Assistance

• Plant-wide Assessments

• Industrial Assessment Centers

• Software Tools

• Training

• Information (Case Studies, Tip Sheets, etc.)

Technology Delivery: Saving Locally

Plant-wide Assessments : 32 representing Forest Products, Chemical, Petroleum and other industries

Attended Training : more than 4,500 employees

Received Decision Tools Software CD : 3150 distributed

Case Studies (at any stage of development): 85 completed

Summary of Technology Delivery Activities

Cost-shared assessments identify opportunities for energy and cost savings

• Up to $100,000 competitively awarded to plant through open solicitation process

• Summary assessment reportpublished to promotereplication

• Proprietary Informationfully protected

• Opportunity to promote findings and methodology

Plant-wide Assessments

Plant-wide Assessments: Examples

.

Annual Savings Opportunities Identified

• Anchor Glass Container $1,638,000 Metlab $518,000• Utica Corporation $1,880,000 Bayer $1,478,000• Equilon Enterprises $52,500,000 Weyerhaeuser $3,100,000• Neville Chemical $287,000 Corning $25,920,000• Appleton Paper $3,459,000 3M $1,094,000• Georgia Pacific $5,000,000 WR Grace $840,000• Alcoa $1,072,000 Ford $3,280,000• Boise Cascade $707,000 Inland $9,500,000• Caraustar $1,280,000 Alcoa $1,974,000• Akzo Nobel $1,170,000 AMCAST $3,600,000

How can a company benefit fromplant-wide assessments?

• Submit a proposal to next DOE solicitation (Mar. 2004). Watch www.oit.doe.gov/solicitations

• Access case studies to learn about recommended strategies to boost energy efficiency.

• Strengthen the corporate energy efficiency management team.

Pursuing a Plant-wide Assessment

Next Plant Wide Assessment solicitation expected Winter, 2005.

Industrial Assessment Centers (IACs)

• ~240 students in training each year

• Average 7-year savings per assessment: $74,000

Teams of engineering faculty and students from 26 university-based IACs around the country conduct no-cost, on-site industrial assessments at eligible facilities.

More than 12,000 assessments have been conducted by IACs.

Qualification Criteria

• Annual sales under $100 million

• 500 or less employees at plant

• No designated energy manager

• Energy bill less than $2 M/yr and greater than $100K/yr

• Plant located 150 miles or less from IAC school

Industrial Assessment Centers

To request an assessment, contact the nearest IAC university. See www.oit.doe.gov/iac

Replicate Savings

• Motor Master + – Assists in energy-efficient motor selection and management.

• Air Master+ - Provides comprehensive information on assessing compressed air systems.

• Pump System Assessment Tool - Helps industrial users assess the efficiency of pumping system operations.

• Steam System Scoping Tool - Profiles and grades steam system operations and management.

• Steam System Assessment Tool – Assists users in assessing potential benefits of specific steam-system improvements

• 3EPlus Insulation Assessment Tool – Helps to evaluate the thickness of insulation on steam lines.

Tools Available on the OIT Web Site

4,500 company employees are registered users of the Decision Tools CD.

EERE Industrial Energy Efficiency Training Opportunities

See OIT website to attend training sessions for relevant tools.

• Steam Systems Improvement

• Pump System Assessment

• Pump System Assessment Tool (PSAT) Specialist Training

• Advanced Management of Compressed Air Systems

• Insulation Assessment

• Motor Systems Management

• Optimization of Process Heating Systems

• Process Heating Assessment Tool (PHAST) Specialist Training

• AirMaster+ Specialist Training

• Fundamentals of Compressed Air Systems

On-call team of 17 professional engineers, scientists, research librarians, energy specialists, and communications information staff

• Fact Sheets

• Newsletters

• Tip Sheets

• Brochures

• Reports

• SoftwareDecision Tools

• Data

• Q & A

Voice:

Fax:

Email:

Web:

1-800-862-2086

360-586-8303

clearinghouse@ee.doe.gov

www.oit.doe.gov

Resources & Information

EERE Info Center

CentralJamey Evans303-275-4813

Mid-AtlanticBill Orthwein215-656-6957

MidwestBrian Olsen312-886-8579

NortheastStephen Costa617-565-1811

SoutheastDavid Godfrey 404-562-0568

WesternChris Cockrill816-873-3299

Regional Offices

Increased Accessibility