Transcript U.S. Department of Energy’s Industrial Technology Program

U.S. Department of
Energy’s Industrial Technology
Program and Its Impacts
Presented by:
Steve Weakley
Pacific Northwest National Laboratory
Outline
Background, Strategies, and Program Areas of the
Industrial Technologies Program (ITP)
Technology Tracking Data Gathering
Program Results
Value of Technology Tracking
New Commercial Technologies
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Background
ITP has been working with industry since 1976 to
encourage new, energy-efficient technologies to be
developed and adopted.
Over the past 30 years, ITP has supported more than 600
separate RD&D projects, producing >200 technologies in
commercial use.
ITP Program Areas: Energy Intensive Industries,
Crosscutting Technologies, and Technology Delivery.
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ITP Strategies
Strengthen planning and analysis to identify opportunities
with greatest potential.
Exploit fuel and feedstock flexibility to give manufacturers
options.
Investigate cross-cutting R&D to save energy in top
energy-consuming processes.
Invest in “next-generation” technologies adaptable to
processes throughout industry.
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ITP Strategies
(Cont’d)
Encourage private investment in energy efficiency
through new partnerships and ways to reach industry.
Drive ambitious reductions in industrial energy intensity
through the Save Energy Now initiative.
Promote energy-efficiency improvements throughout the
supply chain.
Help drive development of energy management
standards and a certification program.
Emphasize commercialization planning throughout the
R&D life cycle.
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ITP Strategies (Cont’d)
Institute rigorous stage-gate project and portfolio
management procedures.
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Program Areas: Energy-Intensive Industries
In 1994, ITP implemented an innovative, customer-driven
research strategy known as Industries of the Future (IOF).
Each industry team develops a vision of its desired future
and a “technology roadmap” to guide collaborative
partnerships between ITP and industry.
Industry teams:
Aluminum
Chemicals
Forest
Products
Glass
Metal Casting
Mining
Steel
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Program Areas: Crosscutting Technologies
ITP also funds technology development spanning the
seven identified energy-intensive industries.
Widespread use of these technologies can mean
substantial energy and cost savings.
Cross-Cutting Programs:
Combustion
Distributed Energy/Combined Heat and Power
Energy Intensive Processes
Fuel & Feedstock Flexibility
Industrial Materials for the Future
Nanomanufacturing
Sensors & Automation.
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Program Areas: Technology Delivery
Program Purpose: To help industry assess and adopt
energy-efficient technologies and practices that are
currently available on the market to obtain immediate
energy savings.
Industrial Assessment Centers (IACs) provide free audits
to small- and medium-sized manufacturers and recommend
techniques to save energy and boost efficiency.
The BestPractices Program help industrial firms assess the
potential benefits of maximizing efficiency using a systems
approach, targeting electric motor, compressed-air, steam, and
other plant utility systems.
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Former Program Areas: Financial
Assistance
Two programs provided grants to help industry develop
and demonstrate energy-efficient, waste-reducing
technologies.
Inventions and Innovation (I&I) provided up to $200,000 to
inventors and small companies with promising ideas/inventions for
improving energy efficiency and environmental performance.
National Industrial Competitiveness through Energy,
Environment, and Economics (NICE3) provided matching
funding to state-industry partnerships for projects that developed
and demonstrated energy-efficient and pollution-preventing
technologies.
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Technology Tracking Data Gathering
PNNL tracks ITP program results and quantifies the
technologies’ energy, environmental, and other benefits.
PNNL coordinates with program staff to determine
commercial successes and emerging technologies from
each industry and cross-cutting program.
A technology is considered commercial when a full-scale
unit becomes operational. After 10 years in operation, the
technology is considered historical and is no longer
actively tracked. A technology is considered emerging if it
is under development and expected to commercialize in
2-3 years.
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Technology Tracking Data Gathering (Cont’d)
Industrial vendors and end users are contacted to obtain
the following information:
technical description
capabilities
applications
benefits
contact information
installations and units sold
type of fuel saved
energy savings and the associated calculation methodology
history
marketing information.
Data are stored in a database and made available to ITP
personnel.
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Technology Tracking Database Information
For each commercial technology, the following information is collected from the industry partner
and reported in our database.
►Overview:
Technology Title
Name of industry partner, year commercialized and number of
operating units
►Applications:
Industrial areas where technology can be applied
►Description:
Summary description of the technology, research development
activities, and its benefits
►Benefits:
Qualitative description of technology improvements including
environmental, quality, productivity, safety, etc.
►Graphic:
►Capabilities:
Operational characteristics that display improvement over the
baseline technology
►Energy Savings:
Btu’s saved in the current year and cumulative since technology
inception
►Emissions Reductions:
Current year decrease in SOX, NOX, CO2, and particulates
►Contacts:
DOE and industry partner name, address, and phone number
►IOF Team:
Primary and related industry areas impacted
►Status:
Industry supplied update on technology activities
►Installations and Savings:
Information on each technologies location and energy savings
►Fuel Types:
Type of fuel saved by the technology
►Calculation Methodology:
Description of how the energy savings were derived including
assumptions
►History:
Summary of prior year efforts
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Technology Tracking Database Information
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Program Results
PNNL engineers work with technology developers to
determine a specific energy-savings’ methodology.
Annual fuel savings are used to calculate each
technology’s current and cumulative energy savings and
air pollutant reductions.
In 2008, the 104 current commercial industrial
technologies saved 75 trillion Btu of energy.
Commercial technologies since 1976 cumulatively saved
3.63 quad through 2008.
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Program Results (Cont’d)
IAC Program: Since 1977, cumulatively saved 1.96 quad
from energy assessments performed by university
engineering students for small- and medium-sized
business.
BestPractices Program: Since 1998, cumulatively saved
1.14 quad by providing software decision tools, training,
and technical assistance to industrial firms.
CHP Program: Since 1990, cumulatively saved 2.54
quad from the aggregate reduction in overall fuel
consumption based on a percentage of capacity additions
since 1990.
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Program Results (Cont’d)
Cumulative Production Cost Savings are based on the
Btu of the various industrial fuels saved multiplied by
inflation adjusted fuel prices.
$21.5 billion through 2008
Cumulative Program Costs are the appropriations for
R&D adjusted for inflation.
$3.00 billion through 2008
Cumulative Implementation Costs are the capital costs
of adopting the new technology (assuming industry
requires a two-year payback period on investments so the
first two years of energy cost savings are excluded).
0.63 billion through 2008
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Program Results (Cont’d)
Cumulative Production Cost Savings Minus Cumulative Program and Implementation Costs
69000.0
59000.0
$ Millions
49000.0
39000.0
29000.0
19000.0
9000.0
-1000.0
1976
1978
1980
1982
1984
1986
1988
1990
1992
Years
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1994
1996
1998
2000
2002
2004
2006
2008
Program Results (Cont’d)
Results are in the ITP Impacts report on the ITP website:
www.eere.energy.gov/industry/about /brochures.html.
Technology tracking database and hard-copy program
files contain the following:
104 commercial industrial and 23 non-industrial technologies
135 emerging industrial and 4 non-industrial technologies
118 historical technologies
260 archived technologies.
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Value from Tracking
Effective management of R&D programs
Budget defense
Strategic planning
Portfolio management
Institutional memory.
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New Commercial Technologies
Six technologies added to the Impacts report this year,
with the following funding sources:
1 Materials
1 Sensors & Automation
1 Distributed Energy
1 Crosscutting
2 IOF: 1 Chemicals and 1 Forest Products.
Types of technologies are as follows:
1 Chemicals: Emission Control
1 Forest Products: Emission Control System
4 Crosscutting: Distributed Power Generation System, Computer
Modeling Program, New Material, Advanced Wireless Sensor.
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Titania-Activated Silica System for Emission
Control
Developed at the University of Florida.
Commercialized and marketed by Sol-gel
Solutions, LLC, in 2006.
Two units operating at a U.S. chlor-alkali
facility
Reduces the cost per pound of mercury
removed compared with activated carbon
Eliminates the risk associated with disposing of mercuryladen activated carbon.
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Biological Air Emissions Control
Developed by
BioReaction
Industries, LLC,
with assistance
from Texas A&M.
Commercialized by BioReaction Industries with 10 units
operating in 2008
Decreases greenhouse gas and ancillary emissions.
Saves energy by eliminating use of natural gas in thermal
oxidation process.
Reduces operating costs by 90% from thermal oxidation.
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Advanced Reciprocating Engine Systems
(ARES)
Developed and being
marketed by Caterpillar,
Inc., Cummins, Inc., &
Dresser Waukesha.
Sold >500 engines in U.S. and >1600 internationally.
Eliminates transmission costs from utility-provided
electricity.
Achieves higher power density and improved fuel
efficiency.
Work continues to improve the efficiency and reduce
emissions.
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Barracuda® Computational Particle Fluid
Dynamics (CPFD®) Software
Developed by
CPFD Software, LLC
ExxonMobil
Millennium Inorganic
Chemicals, Inc.
Sandia National Laboratories.
Marketed by CPFD Software.
Accurately models complex mixing and chemical reaction
processes with liquid-solids or gas-solids.
Models biomass and coal gasification systems and the
production of white pigment, gasoline, plastics, nylon, and
polysilicon.
Allows users to design more energy-efficient and
environmentally friendly processes.
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Ultrananocrystalline Diamond (UNCD) Seal
Faces
Developed by Argonne National
Laboratory with John Crane, Inc.,
and Advanced Diamond
Technologies (ADT).
Commercialized in 2008 and
sold by ADT.
Applies thin UNCD coating to seal face of a silicon
carbide ring for industrial pumps and mixers.
Reduces seal face temperature and friction between seal
faces and improves wear resistance.
Increases seal life and energy efficiency; allows sensitive
food, biological, and pharmaceutical media to
be handled.
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Wireless Sensors for Condition Monitoring of
Essential Assets
Developed by GE Global Research &
GE Energy; commercialized in 2008.
Monitors the condition of motordriven industrial equipment (e.g.,
pumps, fans, compressors).
Wireless nodes powered by battery or energy harvester
technology using the machine’s vibration as the power
source.
Reduces outage times and occurrences, lowering outage
costs.
Increases safety by remotely monitoring assets in
areas unsafe for humans to enter.
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