October 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.
Read the E-Bulletin and tap into opportunities to improve industrial energy efficiency today...and tomorrow! Subscribe now!
Some of the following documents are available as Adobe Acrobat PDFs. Download Adobe Reader.
2008 Save Energy Now Award Recipients Announced at World Energy Engineering Congress
Congratulations to the 128 U.S. manufacturers being recognized by DOE for the second annual Save Energy Now Awards! By implementing Save Energy Now energy assessment recommendations over the last year, these industrial plants and companies have implemented a combined total of more than $37 million in cost savings and 2.9 trillion Btu in energy savings. To qualify for an award, companies must report their assessment results and meet the criteria for either an Energy Saver or Energy Champion Plant award. A 2008 Save Energy Now Awards kick-off event took place on October 2, 2008, during the 31st World Energy Engineering Congress (WEEC) conference in Washington, DC. ITP's Douglas Kaempf and James Quinn presented awards to the following companies:
Energy Champion Plants
- Alcan Packaging Food Americas - Catoosa, OK
- CertainTeed Corp., Roofing Products - Shreveport, LA
- Northrop Grumman Corporation - St. Augustine, FL
- Pennex Aluminum Company - Wellsville, PA
- United States Steel Corporation (Steam) - Gary, IN
- United States Steel Corporation (Process Heating) - Gary, IN
Energy Savers
- CROWN Closures Americas - Connellsville, PA
- Eliokem - Akron, OH
- Lyondell Chemical Company - Clinton, IA
- Molson Coors Brewing Company - Elkton, VA
- Molson Coors Brewing Company - Golden, CO
- Ocean Spray Cranberries Inc. - Kenosha, WI
- Republic Engineered Products, Inc. - Lorain, OH
- Shaw Industries, Inc. - Dalton, GA
- Trojan Battery Company - Santa Fe Springs, CA
DOE will publicly recognize other companies throughout the year at industry events. View the full list of 2008 award recipients.
ITP Presentations Available from WEEC Conference
View presentations given by ITP representatives at the WEEC conference:
- Saving Energy in Industry (PDF 1.3 MB)
- Save Energy Now: Partnering with Industry Results to Date and Related Resources (PDF 1.6 MB)
- DOE Data Center Energy Efficiency Program (PDF 839 KB)
- Certifying U.S. Manufacturing Plants for Energy Efficiency (PDF 308 KB)
$5.54 Billion and Counting: New Report Summarizes ITP Impact on Industry in 2006
Every year, ITP tracks the amount of energy saved as well as the other benefits associated with successfully commercialized technologies that result from its research partnerships. The latest ITP Impacts Report summarizes the successes for 2006, including 104 commercially available technologies that have resulted in energy cost savings of $1.02 billion, and 141 emerging technologies that are in development. Check out the commercialized technology section, organized by industry type, to locate the benefits, application, and company contact information for technologies that your company can purchase now. Read the emerging technologies section to learn about projects such as the Super Boiler that are paving the way for improved industrial processes and are likely to be commercialized in the next 2 to 3 years. The Impacts Report also includes information on ITP's 99 historical technology successes and an overview of two ITP technical assistance programs: Industrial Assessment Centers and BestPractices. In 2006, ITP programs saved a total of 489 trillion Btu of energy at a cost savings of $5.54 billion. Download the entire Impacts Report (PDF 4.8 MB) or read it by section.
Steel Industry Reduces Energy Consumption Through Save Energy Now Assessments
Save Energy Now is helping steel manufacturers save money and energy by recommending steps they can take to improve the efficiency of their process heating and steam systems. Learn more about the results from these assessments by reading the following new case studies.
- 14 Ways to Cut Steel Energy Costs—A new steel industry case study (PDF 351 KB) highlights the top 14 identified savings opportunities based on payback period for 23 U.S. steel facilities that have participated in Save Energy Now. The companies have identified more than $105 million in potential energy cost savings, which represents an average reduction of 10.2% in overall energy costs.
- U. S. Steel Saves $760,000—A Save Energy Now assessment conducted at U. S. Steel, the largest producer of steel products in the country, resulted in annual energy cost savings of $760,000 and maintenance labor cost savings of $30,000. A DOE Energy Expert used DOE’s Process Heating Assessment and Survey Tool (PHAST) to quantify existing energy savings measures at the company's Minntac plant and identify nine additional opportunities. Download the U. S. Steel case study (PDF 599 KB). Also see other Save Energy Now case studies.
Qualified Specialist Recertification Forms Due November 28, 2008
Calling all DOE Qualified Specialists and training instructors! If you were certified by ITP before August 2006, you are required to complete a certification/requalification process. Forms must be submitted by November 28, 2008. The goal of the recertification process is to ensure that Qualified Specialists and instructors are active in their chosen field and up-to-date on all the latest changes and enhancements to ITP's software tools and materials. If you have questions or need additional information, please contact the ITP training coordinator.
Manage Energy Costs and Generate Revenue with Demand Response
The Demand Response Webcast presented by DOE on July 31, 2008, is now available online. Laurie Weigand-Jackson, President of North America Power Partners, discussed demand response as a solution to managing rising energy costs and a revenue generator. According to Weigand-Jackson, demand response resources are critical to maintaining grid reliability because they alleviate transmission congestion, offset the loss of major generation units, and maintain the balance of supply and demand on a real time basis. Demand response can also lead to reduced greenhouse gas emissions. View the Webcast to learn more.
Industry Invited to Help Develop Energy Management Standard
Industry representatives are encouraged to participate in the development of an International Organization for Standardization (ISO) 50001 working draft. ISO 50001 will establish a framework for industrial plants, commercial facilities, and corporations to manage energy. The working draft emphasizes the need to ensure compatibility with the existing suite of ISO management systems standards such as ISO 9001 for quality management and ISO 14001 for environmental management. The energy management standard is being developed by ISO project committee PC 242, which met for the first time September 8-10, 2008, in Washington, DC. Industry feedback is facilitated by the American National Standards Institute (ANSI) U.S. Technical Advisory Group. Contact Deann Desai at 770-605-4474 to get involved.
Stay Informed Through Superior Energy Performance Web Site
Superior Energy Performance is a voluntary partnership among industry, government, and other organizations focused on improving the energy intensity of U.S. industry. The partnership is guiding the development of an ANSI-accredited Plant Certification Program; a pilot program is currently underway at five Texas manufacturing plants. Visit the Superior Energy Performance Web site to find out what's new with the pilot program and keep up on the latest ISO energy management standard activities.
New Energy Assessment Draft Standards Trial Use Period Now Open
Organizations are invited to test four new draft standards issued by the American Society of Mechanical Engineers (ASME) for conducting energy assessments at industrial plants in four system areas: pumping, compressed air, steam, and process heating. The draft standards were issued on August 19, 2008, and ASME has asked for feedback by January 19, 2009. ITP has provided support to the ASME Project Teams throughout the development process. The standards will establish the requirements for organizing and conducting assessments, analyzing data, and reporting and documentation. They also provide a framework for conducting assessments that will help define the market for system assessment services. The Project Teams will review and revise the draft standards based, in part, upon experience obtained from the trial use period and resulting comments. It is intended that these draft standards will then be processed for approval as American National Standards in accordance with the ASME accredited procedures. If you are interested in testing the draft standards, please contact Paul Sheaffer at 703-356-1300 extension 215, or Ryan Crane at 212-591-7004.
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 PowerSaver™ technology, which works with existing High Intensity Discharge (HID) fixtures and components, can help industry conserve energy and reduce maintenance costs. |
Improve HID Lamp Efficiency by 40% with Energy-Saving Controls
Companies can conserve energy and reduce the maintenance costs of High Intensity Discharge (HID) lighting systems by utilizing a new technology called PowerSaver™. Ideal for industrial parking lots, yard operations and loading areas, and street lighting, the technology features inexpensive and compact controllers that can be mounted in existing HID fixtures of 70 to 2000 Watts. The PowerSaver technology was developed by Electronic Energy Solutions (EES) with support from DOE's Inventions and Innovation program. The technology consists of sensors, computerized programmable controllers, daylight-visible fault indicators, and illumination management devices, which offer the following benefits:
- Conserve HID lighting energy by up to 40%
- Decrease maintenance costs through “wear protecting” ballasts and igniters, and user-defined end-of-lamp-life indication
- Reduce greenhouse gas emissions
- Achieve a simple payback of 2 to 3 years.
With the PowerSaver technology, illumination levels can be adjusted to customer needs or applicable standards and programmed for timing and other variables. The controllers will automatically adjust for season (day length) and geographic location (latitude), and are designed to last for the rated service life of the fixture. Read more about this and other technologies designed to help improve industrial energy efficiency in ITP's new report, Impacts: Industrial Technologies Program: Summary of Program Results for CY2006 (PDF 4.8 MB).
Attend these key events to learn about the latest energy-efficient technologies and practices, and network with industry peers.
J.R. Simplot is hosting an Energy Symposium November 5-7, 2008, in Boise, Idaho. Industrial end users can attend the public event to learn about system efficiency and become DOE Qualified Specialists. Several DOE-sponsored workshops will be held, including Pumping System Assessment, Pumping System Specialist Qualification, and Motor Systems Management. To register for the DOE workshops, contact Tiffany Curtis at 208-389-7454. The Industrial Efficiency Alliance will also be sponsoring compressed air and motor workshops at the symposium. View their training calendar to learn more and register.
The Society of Plastics Engineers New Technology Symposium will take place November 11-12, 2008, in Philadelphia, Pennsylvania. Speakers from academia and industry will focus on emerging, leading, and cutting-edge technologies including nanotechnology, biotechnology, and advanced energy storage.
The Supplier Relationship Management for Utilities Conference and Seminar will be held November 17-18, 2008, in Denver, Colorado. Utility personnel can learn about the implementation of efficiencies in the creation, negotiation, and management of service contracts and the advantages of good supplier relations to the utility enterprise.
Attend the free Virtual Energy Forum December 10-11, 2008, to learn how leading organizations can adopt better energy management practices to cut costs, while at the same time adopting clean energy alternatives. The forum will feature a virtual exhibit floor and booths and live question-and-answer sessions with leading energy experts, including representatives from ITP.
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.
Thursdays with ITP: Sign Up for New No-Cost Webcasts
Attend an upcoming ITP Webcast to learn about industrial efficiency, find out about the latest tools and technologies, and get information on Save Energy Now assessment opportunities. ITP is offering the following new Webcasts at no-cost on Thursdays from 1:00 to 2:00 p.m. EST:
- October 16, 2008—Energy Assessments: What are the Benefits to Large Facilities?
- October 23, 2008—ITP Software Decision Tools Awareness
- October 30, 2008—Quick PEP Tool Demonstration and Results
- November 6, 2008—Energy Assessments: What are the Benefits to Small and Medium Facilities?
- November 13, 2008—Assessing Data Center Energy Use
- November 20, 2008—Super Boiler Technology
Sign up today!
Motor Sourcebook Offers Solutions to Enhance Motor and Drive System Performance
Are you looking for practical guidelines and information to boost efficiency and reliability of your electric motors and motor-driven systems? Download ITP’s newly revised Improving Motor and Drive System Performance: A Sourcebook for Industry (PDF 2 MB) to:
- Improve your knowledge about motor and drive systems
- Discover seven efficiency opportunities that address specific component and system issues
- Learn about motor system economics and get recommendations on presenting energy efficiency projects to management.
DC Pro Version 1.0 Incorporates User Comments
The Data Center Energy Profiler (DC Pro) is an online software tool that companies can use to quickly determine energy use in their data centers and potential cost and energy savings. The tool was developed as part of ITP's Save Energy Now effort. Over the past 3 months, the beta version of the tool was tested by 610 users. Comments received from many of those users, including 11 Green Grid Association member companies, have been incorporated into Version 1.0 of the tool. These new features include: an online tutorial, enhanced user interface, easier formats to enter data center input energy streams, answers to frequently asked questions, and the ability to create a PDF report of the results. The tool also enables users to customize the source energy factor for each energy stream to account for electricity produced from cogeneration, renewable sources, etc. Download Version 1.0.
Case Studies Highlight Small- and Medium-Sized Plant Successes
Six new case studies are now available featuring success stories from assessments performed at small- and medium-sized manufacturing companies through DOE's Industrial Assessment Centers (IAC). The case studies include energy efficiency improvement opportunities identified during the assessment and the results the company achieved from implementing those recommendations. University-based IACs have conducted more than 14,000 energy assessments resulting in energy savings of more than 400 trillion Btu in natural gas, or enough to power 3.1 million U.S. homes; and 22 million metric tons of carbon dioxide, or the equivalent to taking 4 million cars off the road. View the case studies. You can also apply for an IAC assessment.
Provide Your Feedback on New Version of Quick PEP Software Tool
ITP invites you to test the enhanced Quick Plant Energy Profiler (Quick PEP), Version 1.2.0, and provide comments on the new features. Quick PEP is an online software tool that can help you diagnose the energy usage in your plant and get recommendations for reducing energy and operating costs. Version 1.2.0 of Quick PEP includes these additions:
- Chinese language support for the entire software program
- Energy intensity spreadsheet
- Carbon dioxide footprint calculator
- Functionality improvements to correct user errors.
Download and test Quick PEP Version 1.2.0 and submit your feedback by October 22, 2008. Your comments will be used to further enhance the tool for final release. If you are currently using Version 1.1.3 of Quick PEP, you can test Version 1.2.0 simultaneously.
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.
Reminder: State Solicitation Applications Due October 16, 2006
Letters of intent for the "Save Energy Now: State, Regional and Local Delivery" funding opportunity were due September 15, 2008; applications are due October 16, 2008. Organizations that receive funding will work at local, regional, and state levels to increase awareness about ITP resources that can help industrial facilities save energy. Up to $9.5 million in total funding is available through this solicitation over three years; awards will range from $100,000 to $300,000 per year. Learn more about ITP's state activities.
Small Business Funding Opportunity Announced
DOE is seeking applications for a Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) funding opportunity. Applications are due November 20, 2008, at 8:00 p.m. EST for Phase I of the funding. The goal of the solicitation is to increase private sector commercialization of technology developed through DOE-supported research and development (R&D), stimulate technological innovation in the private sector, and improve the return on investment from federally-funded research for economic and social benefits to the nation. DOE will support high-quality research or R&D on advanced concepts concerning important mission-related scientific or engineering problems and opportunities that are likely to lead to significant public benefit if the research is successful. Phase I grants will be made during fiscal year 2009 to small businesses in amounts up to $100,000. Success in Phase I is a prerequisite to receiving further DOE support in Phase II, which is the principal R&D effort. Phase II awards are expected to be made in fiscal year 2010 in amounts up to $750,000. The Phase II period of performance will depend on the scope of the effort, but normally will not exceed a 12-month initial budget period with an option for continuation up to 12 months. In Phase III, small businesses will use non-SBIR capital to pursue commercial applications of the R&D. Learn more about this opportunity. Please note that you must be registered on grants.gov to apply.
To learn more about project opportunities, visit ITP's solicitation page.