March 2008
Industrial Technologies Program E-Bulletin: Your Online Connection
Welcome to this edition of the E-Bulletin — your connection to news and resources from DOE's Industrial Technologies Program (ITP). Each monthly edition brings you the latest industrial news highlights, and announcements about new tools and resources, training events, and project opportunities.
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Industry Solicitations Abound
ITP is seeking solicitations from industry, labs, and Qualified Specialists to help meet the Energy Policy Act (EPAct) Section 106 goal, which calls for voluntary reduction of energy intensity of U.S. manufacturing industries by 25% over the next 10 years. Learn more about the following solicitations:
- Energy-Intensive Processes 2008 Lab Call
- Funding Opportunity for Transformational Technologies
- Energy Expert Request for Quotes
New Case Study Reveals How Chrysler Saves More Than $627,000 in Energy Costs Annually After Receiving Save Energy Now Assessment
Optimizing boiler operation, reducing boiler blowdown, and implementing an ongoing steam trap maintenance program are just some of the steps Chrysler's St. Louis complex took to save approximately $627,000 per year in energy costs. The complex, which produces mainly cars and light-duty trucks, received a DOE Save Energy Now energy assessment from Energy Expert Riyaz Papar of Hudson Technologies. Papar worked with two Chrysler employees to analyze the complex's steam system utilizing DOE's Steam System Assessment Tool (SSAT) software. By implementing several of the assessment recommendations, the complex achieved a simple payback of just over two months and is saving more than 70,000 MMBtu in natural gas annually. To learn more and see which Save Energy Now energy savings recommendations can be applied to your plant, read the case study (PDF 578 KB). Locate Business Incentives for Improving Energy Efficiency Through ITP's New States Incentives and Resources Database
If you're looking for cost-effective ways to decrease energy use at your facility or business, check out the new ITP States Incentives and Resources Database. Part of the recently updated State Activities Web site, the database features information on incentives available at the state, local, utility, and non-profit levels—including rebates, waived fees, tax credits, and loans. Search by one or more states, program name, and organization, assistance, and energy type. In addition to the incentives database, the State Activities Web site features state energy statistics, economic indicators, events and training, and R&D. Access a list of contacts for ITP's Industrial Assessment Centers, Manufacturing Extension Partnerships through the National Institute of Standards and Technology, and Regional Application Centers that facilitate the deployment of combined heat and power technologies. You can also see which companies have completed a Save Energy Now assessment and been recognized by DOE.
New ISO Energy Management Standard Development Underway
The International Organization for Standardization (ISO) Technical Management Board recently accepted a proposal from the American National Standards Institute (ANSI) and Brazil's Associacas Brasileira de Normas Technicas to develop a new ISO energy management standard. The two organizations were allocated the secretariat of the standard Project Committee and will also be working with the British Standards Institute and the Standardization Administration of China in leading the international initiative.
ITP is partnering with U.S. industry, other Federal agencies such as the Environmental Protection Agency and National Institute of Standards and Technology, and the ANSI to develop an ANSI-accredited plant certification program to promote improvements in industrial energy efficiency and management practices. Once available, the ISO energy management standard will be a key element of the voluntary plant certification process; U.S. manufacturing facilities will need to demonstrate that they have adopted the standard, as well as other energy system standards currently under development. Applying standards can help companies engage employees in technically sound and sustainable energy efficiency improvement processes; integrate those efforts into existing industrial management systems such as Six Sigma and ISO 9001 or 14001; and gain market value for their accomplishments. The first ISO Project Committee meeting will most likely take place in September. Industrial plants can start improving industrial system efficiency today by applying for a Save Energy Now energy assessment and utilizing ITP's BestPractices tools and resources.
Key Industries Cut Emissions Intensity by 9.4% in Four Years
The power and energy-intensive industrial sectors improved their combined emissions intensity by 9.4% from 2002 to 2006 according to the recently released DOE Climate VISION Progress Report 2007 (PDF 1.9 MB). Energy-intensive industries, which represent about 45% of U.S. greenhouse gas emissions, are working with their business associations and trade groups to participate in Climate VISION (Voluntary Innovative Sector Initiatives: Opportunities Now). This public-private partnership initiative was launched five years ago to contribute to President Bush's goal of reducing greenhouse gas intensity by 18% from 2002 to 2012. The Climate VISION Progress Report includes highlights, results, and success stories from industry. For example, the energy intensity per ton of steel shipped improved by about 15% from 2002 to 2006. See the DOE press release.
The emissions intensity reductions reported by the power and industrial sectors is also reflected in greenhouse gas intensity data for the U.S. economy as a whole. A recent report from DOE's Energy Information Administration (EIA) estimated that from 2002 to 2006, U.S. greenhouse gas intensity fell by an average of 2.5% per year, for a total of nearly 10%. The report concludes that the drop in emissions intensity is due mainly to using less energy per unit of production rather than using lower-carbon fuels. Learn more about ITP's energy management tools and resources that can help you improve productivity and save energy.
IAC Students Meet to Discuss Role in Energy Efficiency and Innovation
Thirty-five of the top engineering students representing university-based Industrial Assessment Centers (IACs) across the United States came together for a two-day meeting to discuss their role in energy efficiency and innovation. The IAC Lead Student Meeting was held February 7-8, 2008, in Washington, D.C., and featured speakers from DOE, Oak Ridge National Laboratory (ORNL), IAC Program Administration at Rutgers University, and the American Public Power Association (APPA). Participants in the IAC program receive hands-on training in energy assessments and provide no-cost plant assessments to mid-size manufacturers while supporting ITP's Save Energy Now campaign. In 2007, IACs conducted 300 plant assessments and found an average of more than $115,000 in energy cost savings annually per plant. Learn more about the IAC program and check out presentations from this year's meeting.
ITP-sponsored technologies help U.S. industry save energy, boost productivity, and reduce emissions. Below you will find new technologies to help increase energy efficiency at your company.
The Laser Contouring System measures refractory lining thickness of furnace vessels 10 times faster than prior units. |
Laser Contouring System Boosts Cost Savings for Steelmakers
Refractory vessels in steelmaking operations require constant monitoring of lining conditions to prevent equipment failure in this extreme industrial environment. The Laser Contouring System (LCS) (PDF 1.09 MB), developed by Process Metrix and American Iron and Steel Institute with ITP support, is a high-speed, laser-based technology that measures refractory lining thickness of furnace vessels used to manufacture steel, copper, and aluminum. With a laser scan rate of more than 8,000 points per second, the LCS provides exceptionally detailed contour resolution and accurate bath height determination. Moreover, measurement time ranges between 1 and 6 minutes, or 10 times faster than prior units. Quick, online feedback eliminates downtime costs due to inspection and unnecessary relining, increases equipment life, and ensures operational safety. Cost savings for manufacturers are estimated to be $500,000 to $1 million per year.
The system is available in both mobile and fixed-position platforms. Mobile platforms are typical in applications where multiple vessels must be analyzed with a single instrument. Fixed-position systems are used in ladle applications or in any situation where the vessel is brought to instrument. Currently, there are 30 units of the LCS in operation worldwide. In addition to several installations in the United States, the system is also in China, Korea, Germany, and Mexico. The rapid growth of commercial sales reflects industry-wide interest in the technology.
Attend these key events to learn about the latest energy-efficient technologies and practices, and network with industry peers.
Mark Your Calendar for These Upcoming Industry Events
Manufacturing Outreach Workshops, hosted by the Nuclear Energy Institute, will be held March 27, 2008 in
The Spring 2008 American Chemical Society National Meeting & Exposition, co-sponsored by the American Institute of Chemical Engineers, will be held April 6-10, 2008, in New Orleans, Louisiana. The theme for this year's meeting is "Energy and the Environment." The event, which attracts thousands of chemists, chemical engineers, and professionals, will feature more than 300 exhibitors showcasing new technological developments and offering free workshops.
Learn about the market drivers, technologies, financing structures, and regulatory issues affecting the energy efficiency industry at the 2nd Annual Energy Efficiency Finance Forum, April 10-11, 2008, in Arlington, Virginia. Forum highlights include an investor roundtable packed with venture capital, private equity, and institutional investors, opportunities for green building technologies, and a states and utilities roundtable.
The 79th Annual Meeting of the Industrial Heating Equipment Association will be held April 13-16, 2008, at the Sand Pearl Resort in Clearwater Beach, Florida. The three-day meeting will include roundtable discussions and presentations that emphasize energy efficiency and green technologies.
The Association for Iron & Steel Technology Conference and Exposition (AISTech) will be held May 5-8, 2008, at the David L. Lawrence Convention Center in Pittsburgh, Pennsylvania. AISTech 2008 conference programs will focus on iron making, steelmaking, engineering, finishing processes, technologies, and equipment. Attendees can also choose to tour the Wheeling-Pittsburgh Steel Corporation or U.S. Steel Mon-Valley Works plants on May 8.
Industrial innovations, energy use and waste reduction programs, and the latest in various state and federal programs affecting industry will be discussed at the Industrial Energy Technology Conference, May 6-8, 2008, in New Orleans, Louisiana. Hosted by the Energy Systems Laboratory of the Texas A&M University System, the event will feature 16 sessions, including one on ITP's Save Energy Now initiative.
ITP offers technical publications, software tools, and other resources to help you address your company's industrial energy needs. Here are the latest products from ITP.
Metric Version of Steam System Assessment Tool Now Available
The Steam System Assessment Tool (SSAT) Version 3 is the latest in ITP's Save Energy Now industrial software tools suite with measurement capabilities in both English and metric units. This new version gives steam analysts more options for developing approximate models of steam systems and quantifying the magnitude of potential steam improvement opportunities. The SSAT is now compatible with Microsoft Excel 2007 and Microsoft Vista, and important upgrades have been made to address all known problems with the previous version of the software. For example, the User Calculations sheet has been updated to allow for better access to Microsoft Excel functionality. Download SSAT Version 3 today.
In addition to SSAT Version 3, ITP has already introduced AIRMaster+ Version 1.2.0, MotorMaster+ International, and the Pumping System Assessment Tool 2008 with metric measurement capabilities. Learn more about these and ITP's entire suite of free software tools to help you assess key energy savings opportunities in your plant.
Winter 2008 Issue of Energy Matters Focuses on Energy-Efficient Solutions for Industrial Competitiveness
The complex workings of the Super Boiler technology are put into motion in the latest issue of Energy Matters.
Energy concerns are front and center as U.S. industry strives to stay competitive in the face of escalating energy costs. Rising and volatile fuel prices, global warming concerns, and dependence on foreign oil all accelerate the drive toward energy-efficient, clean technologies and practices. How is ITP meeting these challenges? Find out in the latest issue of Energy Matters, ITP's BestPractices quarterly online newsletter, which also features the following articles:
- Super Boiler: A Hero of Steam Generation—this ultra-high efficiency, low emissions revolutionary steam generation technology could save industry more than 185 trillion Btu of natural gas by 2020, and about $10 billion in annual energy costs. See an animation of how it works!
- Ask an Energy Expert: Assessing Compressed Air Systems—DOE Energy Expert Tom Taranto answers common questions about compressed air in this new Q&A column.
Quick and Easy Tip Sheets Offer Ways to Improve System Efficiency
Are you looking for ways to keep your systems running at maximum efficiency? Check out ITP's popular tip sheets. Quick and easy to read, each two-page tip sheet includes examples and suggested actions you can take to save energy, reduce costs, and improve productivity in your plant. Choose from 70 tip sheets covering steam, process heating, compressed air, motors and fans, and pumps.
Visit the ITP Web site for more BestPractices technical publications, software tools, and case studies to help you improve efficiency, productivity, and the bottom line.
ITP awards cost-shared funding for R&D and plant assessment projects through a competitive merit review process.
Proposals Being Accepted for Energy-Intensive Processes 2008 Lab Call
ITP is soliciting proposals from DOE national laboratories to develop innovative technologies that, when deployed commercially, would reduce the energy requirements for energy-intensive processes across many industrial sectors. The Energy-Intensive Processes 2008 Lab Call opened on February 14, 2008; proposals are due April 1, 2008. The solicitation is in direct support of the EPAct Section 106 goal of voluntary reduction of energy intensity of U.S. manufacturing industries by 25% over the next 10 years, while at the same time reducing industry's carbon footprint. Proposed R&D projects should clearly address one of the focus areas under any of the four technology platforms identified in the Industrial Technologies Program Research Plan for Energy-Intensive Process Industries (PDF 3.8 MB). Industrial collaboration and cost sharing are required. DOE anticipates selecting six to 12 projects to receive funding, depending on the scope of the projects. Read the full Program Announcement (PDF 221 KB) for more information.
Funding Opportunity for Transformational Technologies Announced
ITP is also seeking industry applications on transformational technologies for the Industries of the Future and energy-intensive processes, in conjunction with the Energy-Intensive Processes 2008 Lab Call mentioned above. The "Collaborative Energy Efficiency and Carbon Footprint Research and Demonstration for U.S. Manufacturing Industry" Funding Opportunity Announcement (FOA) opened on March 6, 2008. Applications are due by May 7, 2008. The areas of interest are:
- Transformational Iron and Steel Technologies: New or improved iron and steelmaking technologies; Technologies to improve energy efficiency and to reduce carbon footprint
- Alternative Chemical Process Technologies: Use of ionic liquids for the production of commodity chemicals; Improved heat exchange technologies for the chemical processing industry
- Forest Product Technologies: Advanced water removal for the forest products industry; Advanced pulping technologies.
- Energy-Intensive Processes:
- High-Temperature Processing Platform: Lower-energy, high-temperature material processing
- Industrial Reactions and Separation Platform: Advanced water removal; Advanced gas separation
- Sustainable Manufacturing Platform: Net and Near-net shape design and manufacturing; Advanced joining and assembly
- Waste Heat Minimization and Recovery Platform: Ultra-high efficiency furnace, Waste heat recovery systems.
Read the full Program Announcement (PDF 245 KB).
Energy Expert Solicitation Scheduled to Open March 17, 2008
DOE is soliciting Qualified Specialists interested in becoming Energy Experts through a Request for Quotes (RFQ) scheduled to open March 17, 2008. Energy Experts perform energy assessments at large manufacturing plants as part of ITP's Save Energy Now effort to reduce industrial energy intensity. Qualified Specialists who are already trained in the use of the DOE's software tools can become Energy Experts and help plants identify efficiency improvements in compressed air, fan, process heating, pumping, and steam systems. Once certified, Energy Experts are placed on a Qualified Bidders List (QBL) for future procurement opportunities in calendar year 2008 and 2009. Energy Experts on the QBL may be considered for individual awards for performing Save Energy Now assessments as determined by DOE. Watch ITP's active solicitations Web site or the Grants.gov Web site for more information on this opportunity.
To learn more about project opportunities, visit ITP's solicitation page.