Transcript Slide 1

Industrial Technologies Program
State Energy Advisory Board Meeting
Arlington, VA
November 16-18, 2005
Jacques Beaudry-Losique, Program Manager
Industrial Technologies Program, EERE
U.S. Department of Energy
Overview
•
Industrial Energy Context
•
The Industrial Technologies Program’s (ITP’s) Focus
• Results & Highlights
•
Save Energy Now Initiative
•
State Outreach & Resources
2
Industrial Energy Context
3
Industry: Critical to National Energy Policy
• Uses more energy than any other single
sector; >1/3 of U.S. energy consumption
• Accounts for more than 40% of U.S.
natural gas demand
2004 Energy Use*
Transportation
27.9%
Industry
33.6%
• Accounts for 28% of U.S. electricity
demand
• Produces approximately 30% of U.S
greenhouse gas emissions
Residential
21.1%
Commercial
17.4%
*Includes electricity losses
Source: DOE/EIA Monthly Energy
Review 2004 (preliminary)
4
U.S. Energy Consumption by Industry
8000
Trillion Btu
All Energy
6000
Natural Gas
Natural Gas
Liquids
Computers
4000
2000
Plastics
Glass
Fabricated Metals
Transport
Equip.
Mining
0
Petroleum & Chemicals Forest
Iron & Steel Food &
Coal Products
Products
Beverage
Source: 1998 Manufacturing Energy Consumption Survey (MECS)
Other
Aluminum
Other
(1,922 TBtu NG)
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U. S. Consumption of Natural Gas
By Sector, 2004
Transportation
0.7 Quads
Industrial
8.8 Quads
Power
5.5 Quads
Commercial
3.1 Quads
Residential
5.0 Quads
Industry > 40% of total U.S. Natural Gas Use
Source: DOE/EIA Monthly Energy Review 2004 (preliminary)
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Challenges for Energy-Intensive Industries
• International technology/cost
competition
• Uncertain environmental
constraints
• Limited access to LT investment
capital
• Uncertain long-term economics
Industrial NG Prices
• Natural gas prices and supply
Henry Hub spot price on November 8
2005, was $11.89/MMBtu
• “Many companies have been
unable to pass higher energy
costs on to their customers, which
has sharply reduced their profit
margins” National Energy Policy,
pages 2-4
NG Cost
($/MMBTU)
–
10.0
8.0
6.0
4.0
2.0
0.0
1999
2001
US NG Prices
2003
2005YTD
WV NG Prices
7
ITP’s Focus
8
The Industrial Technologies Program (ITP)
Delivering Technology Solutions
Collaborative R&D
• Energy-intensive
Process Technologies
• Crosscutting
Technologies
Technology Delivery
Partnerships
• Assessments
• Training & Tools
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Types of R&D Supported by ITP
Process specific
• Hybrid Distillation
• Process Intensification
8000
• Advanced Water
Removal
• High-Efficiency
Pulping
6000
Trillion Btu
• Iso-thermal
Melting
Other
• Next
Generation
Steel-making
4000
Computers
Plastics
Glass
Fabricated Metals
2000
Crosscutting
• Inferential-based
Process Control
• Advanced ThermoElectric Materials
• Super Boiler
• Ultra-Hard Materials
• Natural Gas
Alternatives
Transport Equip.
Mining
0
Petroleum & Chemicals
Coal Products
Forest
Products
Iron & Steel
Food &
Beverage
Aluminum
Other
Manufacturing
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Emerging Topic: Fuel/Feedstock
Flexibility
ITP Strategies
Near-Term (0 – 2 years):
Redirect TD to pursue natural gas
saving opportunities via:
– Technology and market
assessments
– Application guides explaining
opportunities, implementation
strategies, permitting issues,
etc.
– Training and education
Total Nat Gas Displacement(1012 Btu)
Near Term
(<6
mnnth)
Mid
Term
(6 mnnth
– 2 yrs)
Long
Term
(>2 yrs)
TOTAL
--
--
700
700
Process
100
200
1,380
1,680
Boiler
200
750
800
1,750
TOTAL
300
950
2,880
4,130
Application
Feedstock
Longer-Term (>2 years): Significant process changes and permitting required
– Explore opportunities in FE and other EERE technologies
– Conduct applied R&D for industrial applications
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Technology Delivery Resources
• DOE-supported energy assessments
(IAC,CTA,PWA)
• Qualified specialists
• Energy efficiency training
for plant staff
• Energy analysis software tools
• Case studies and information
Info Center: 877-337-3463
Websites: www.eere.energy.gov/bestpractices
www.energysavers.gov/industry
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Technology Delivery Focus
U.S. Manufacturing Plants: By Size
Number of U.S. Plants
250,000
226,737
Percent of
Total Industrial Energy
200,000
Small &
Medium
47%
150,000
104,299
115,636
100,000
Large
53%
50,000
6,802
Focus of IAC
Teams
Focus of CTA,
PWA Teams
0
Category:
Annual
Energy
Costs
Small
Mid-Size
Large
AllUS
BP
Plants
Total
All
Plants U.S. Plants
Plants
<$100K $100K-$2M >$2M
Small
Plants IAC
Plants
Plants
Plants
1998 EIA MECS
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Results and Highlights
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2002 Program Results
•
Annual energy savings of 121 trillion Btu (87 commercial technologies currently
tracked)
•
Cumulative energy savings of 2.6 Quads since 1976
•
Cumulative production cost savings of $16.5 billion
since 1976
•
Initiated tracking of 11 new commercialized technologies
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Four “R&D 100” Award
Winners in 2004
• Enhancement of Aluminum Alloy
Forgings through Rapid
Preheating of Billets
• Imaging Ahead of Mining
• Smart Screening Systems
• Advanced Glass Furnace Model
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FY2006 ITP RD&D Solicitations
• Chemicals
through 1/11/06
~ $10 million
• SBIR
through 12/2/05
~ $10 million
• Materials for EE
Completed
~ $ 7.6 million
• Industrial Assessment Centers
through 1/24/06
~ $ 6 million
• Materials (Labs)
~ $ 5 million
Completed
• Innovative Energy Systems
through 1/25/06
~ $ 4 million
• Inventions & Innov.
~ $ 2 million
Completed
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Save Energy Now initiative
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“Save Energy Now” Initiative
Goals:
• Encourage industry to voluntarily
reduce its energy usage in a period
of tight supplies by working with
America’s largest energy-intensive
plants
• Create momentum to significantly
improve energy efficiency practices
throughout the manufacturing
sector
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Energy Savings Assessments
•
•
•
•
•
200 assessments of targeted industrial systems
Assessments done by teams composed of DOE Qualified Energy Experts
and plant personnel
Teams will focus on either steam generation or process heating
Plant personnel and affiliates will be trained on DOE efficient tools
ESA Report identifies potential energy and cost savings
Electrochemical - 2%
Other
4%
Facilities 8%
Process
Cooling
1%
Motor
Systems
12%
Note: Does not include off-site losses
Steam
35%
Process
Heating
38%
Manufacturing
Energy Use by
Type of System
(%)
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Robust Partnerships to Reach Plants
•
•
•
•
Allied Partners
States
Utilities
Equipment Suppliers & Service
Companies
• Trade Associations
• Replication within Industrial
Companies
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For the Latest Information …
Save Energy Now Website
www.eere.energy.gov/industry/saveenergynow
EERE Information Center - Call: 1-877-337-3463
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State Outreach & Resources
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Selected State and ITP Accomplishments
• Texas Technology Showcase
• Ohio Technology Showcase
• California Energy Fairs
• Saving Water; Saving Energy in Colorado
• Nevada Mining Energy Solutions Event
• Western US Food Processing Efficiency Initiative
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Recent SEP Special Project Industrial Awards
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Accelerating State and ITP Results
• Leverage market players (e.g., utilities, ITP
Allied Partners, Qualified Specialists, and
regional groups such as the Northwest
Energy Efficiency Alliance)
• Deliver SEP special projects through largest
energy consuming plants
• Facilitate cross-pollination of activities and
results across corporate facilities
• Increase awareness of ITP emerging
technologies and commercialization
capabilities
• Develop common impacts tracking system
and metrics
• Strategically communicate successes to
right audiences
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