# Presentation: 089284

## Industries of the Future:

- BestPractices

- Chris Cockrill
**U.S. Dept. of Energy, Seattle Reg. Off.**
**Energy Efficiency & Renewable Energy**
**Ph. 816-873-3299****	****Email: chris.cockrill@ee.doe.gov**

**Notes:**
This presentation is not about a government program.  
It is about a strategy that modern businesses and forward-thinking organizations are using to focus the combined resources and talents of industry, academia, and government to tackle tough technical challenges.
It is about how companies and industries are saving money, becoming more efficient, reducing emissions, and  positioning themselves for future market growth through precompetitive partnerships.
Government has a role in facilitating and nurturing the process, both at the Federal and state level, but it is industry’s strategy and the technologies should be identified, developed, and implemented by industry.
State governments are using this strategy to promote smart growth, strengthen the competitiveness of industries within their boundaries, and attract new businesses.

## Industries of the Future Strategy

***Technology for Today***
***BestPractices***

- Steel

- Mining

- Petroleum

- Aluminum

- Metalcasting

- Forest Products

- Glass

- Agriculture

- Chemicals

***Technology******for the******Future***

**Notes:**
Message: Under the IOF strategy, OIT seeks to improve the energy and materials efficiency of 9 energy-intensive industries today and tomorrow.
The Industries of the Future strategy helps U.S. industrial plants become as efficient as possible today and prepared to meet the market challenges of tomorrow.
To create the greatest impact with a finite budget, OIT focuses on nine energy- and waste-intensive industries. (Shown)
Collectively, these industries account for 3/4 of industrial energy use and directly account for more than 3 million well-paying jobs. They supply over 90% of the materials required by the U.S. economy.
These are high-paying, high-tech industries critical to U.S. productivity and competitiveness. They account for over $40 billion in capital expenditures and roughly $1 trillion in product shipments.
OIT supports collaborative RD&D in technologies and processes specific to these industries as well as enabling technologies that are important to a large cross-section of U.S. industry.
We want to keep feeding the technology pipeline to keep U.S. industries on the cutting edge.
Of immediate interest, OIT also provides plants with assistance in applying the best technologies and practices available right now. This includes making industry aware of the technologies just emerging from R&D.

## The Vision Process

**Industry Today**

***Visions***

***Roadmaps***

***Collaborative ***
***Partnerships***

**GOALS**

**PRIORITIES**

**PROJECTS**

- Industries of the Future

**Notes:**
Industry leadership is a defining characteristic of the IOF model.
Industry develops its own vision, which establishes long-term economic, energy, and environmental goals for the industry.
Based on its vision, each industry then defines its priority needs in technology roadmaps--detailed research agendas for achieving the vision goals.
A broad range of public and private organizations have a role in implementing priority projects through collaborative research partnerships.
OIT facilitates the entire process, but industry takes the lead.

## OIT Programs Span Continuum

**BestPractices**

**Notes:**
The OIT programs provide opportunities for research development, demonstration, and deployment of advanced industrial technologies.
The IOFs and crosscutting R&D programs tend to focus on projects in the mid- to long-term stage of development, though some projects have moved to the demonstration stage.
The NICE3 and Inventions and Innovations grant programs focus on more near-term applications.
And the BestPractices programs focus on helping industry make better use of technologies that area available today.

## BestPractices Program

- Delivers OIT products and services by integrating:

**Energy management best practices**
- Motors and drives
- Steam systems
- Compressed air systems
- Pump systems
- Process heating systems
**Emerging technologies**
- Verification
- Implementation

**Provides integrated delivery of energy-saving measures to the nine IOF sectors**

**Industrial ****assessments**
**Showcases**

## Industrial Assessment

**Three levels of Energy-Use Assessment**

**   ****Energy audit and industrial assessment by Industrial Assessment Centers (IACs) – Done for Plant**
- No cost to small/medium manufacturers
- Conducted by university-based team of engineering faculty/students
- 26 participating universities across the country

**1**

**Collaborative Targeted Assessments – Done with Plants**
- Available to Showcase plants and those sponsoring corporate training
- BP experts work with plant personnel (pumps, steam, air, process heat, insulation)

**  ****Cost-shared, plant-wide assessment – Done by Plant**
- Up to $100 K OIT funds for each plant available through open solicitation or for Showcase plants
- Summary assessment report published by OIT to promote replications of recommended energy conservation strategy

**2**

**3**

##   IAC Assessments 

-   Eligibility Requirements
-  Results: Approx. 750 Assessments Annually,
-  $55,000 in potential, average annual savings    from each IAC assessment

-  Small/Medium size Manufacturing plants
-  Located within 150 Miles of IAC Host Campus
-  Gross Annual Sales less than $100M.
-  Fewer than 500 Employees
-  Annual Utility Bills >$100K & <$2M
-  No In-House Professional Staff to Perform Audit

## Collaborative Targeted  Assessments

**Purposes**
- Assisting plant operators in use of industrial process application tools
- Developing a potential showcase site

- Systems:
-  Motors and drives
-  Pump systems
-  Compressed Air    Systems
-  Steam Systems
-  Process Heat Systems

## Plant-wide Assessment Impact

**Example:  Boise Cascade (Round I Awardee)**
- 4 of 17 potential projects were implemented to reduce effluent heat load
- $707,000 savings /yr with 3-year payback
-  reduce heat load by 45 million Btu/hr
-  reduce steam use by 28,100 lb/hr
-  reduce effluent flow by 2.2 million gals/day (8% reduction)

**Expected Outcomes**** **
- Payback of plant investment within one year through implementation of assessment recommendations
- Assessment recommendations applicable to an average of 7-8 similarly scaled plants for replication

## Plant-wide Assessment Solicitations

**Round I:  Six plants ****awarded in FY00, ****out of 17 applications **
- Alcoa, Amcast, Boise Cascade, Caraustar, Crucible, Inland Paper
- All assessments completed
- Five success story reports  completed
- Available in pdf format at  www.oit.doe.gov/bestpractices

**Round II:  Seven ****plants awarded in ****FY00-01, out of 15 applications **
- Akzo Nobel, Anchor Glass Container, Appleton, Metlab, Paramount Petroleum, Utica Corporation, Weyerhaeuser
- Assessments and reports scheduled for completion in FY01

***All but Agriculture and Mining IOFs were represented through Round I & II awards***

## Plant-wide Assessment Solicitations

**Round III:  Nine plants ****awarded in FY01, ****out of 15 applications **
- Alcoa, Bayer, Blue Heron, Corning, Equilon, Neville Chemical, Rohm & Haas, 3M, W.R. Grace

## Plant-wide Assessment Solicitations

**Round IV **
**Solicitation Released: **
**June 29, ‘01**
-  Closing Date:
- October 15, 2001

## FY01 Initiative – Technology Implementation

- Promotion of Multiple Implementations

- Cost-shared support to mitigate industry risk associated with use of emerging technologies
- Provide verified performance data to ease hurdle of new technology acceptance
- Eligibility: technologies beyond full-scale demonstration and preferably from those supported by NICE3, I&I, SBIR/STTR, and IOF partnerships
- Costs shared by IOF programs, the BestPractices Program, and industry
- Aiming to follow through to document realized savings to determine impact of OIT technology successes
- Financial assistance solicitation was released on July 20, 2001 to close October 19, 2001; 4-6 awards expected in January 2002

## Best Practices Software Tools

- 	**Motor Master+ 3.0 **
- Comprehensive motor management software with 25,000 motors in database
- Repair/replace decision-making
- Self-training CD
-        **Pump System Assessment Tool (PSAT)**
- Calculation of energy use and efficiency of pumping system
- Comparisons with optimal system for potential energy and cost savings
-        **ASD Master**
- Screening for Adjustable Speed Drive (ASD) upgrades
- Energy, non-energy, and economic analysis
- ASD specification

**Notes:**
The software tools are available from the website, the Clearinghouse, or through a training session.

## Best Practices Software Tools

-        **3E Plus**
- Optimization of the insulation of boiler steam lines
- Determination of the most economical thickness of insulation materials under varying operating conditions
- 	**AirMaster+**** **
- Compressed air systems assessment and evaluation designed for use with the training program
-  **	****Integrated Tool Suite**
- Under development for plant profiling to identify energy-saving opportunities
- Will integrate the software tools above with OIT information products when fully developed in FY02

**Notes:**
The software tools are available from the website, the Clearinghouse, or through a training session.

## Best Practices Training

- Currently Available:
- Steam Systems Improvement (1day)
- Adjustable Speed Drive Application (1 day)
- Pump System Assessment (1 day)
- Fundamentals of Compressed Air Systems (1 day)
- Advanced Management of Compressed Air Systems (2 days)

## Best Practices Training 

- Soon to be available:
- Fan System Performance Assessment (1 day)
- Optimization of Process Heating Systems (1 day)
- Motor Systems Management (4 hours)
- Soon to be available through Allied Partners
- Insulation Assessment (2 days)
- Pump Systems Assessment (1 Day)
- AirMaster+ Training (2 days)

## Allied Partnership

**   ****Since the inception of Allied Partnership in 1995, 226 Allied Partners have been established, including**
**Suppliers of industrial equipment and services**
**Engineering and design consultants**
**Energy utilities**
**State agencies**
**Industrial and professional associations**

**In aggregate, Allied Partners have distributed 10 times the amount of information/tool products as the amount distributed by all other OIT channels combined.**

## OIT Clearinghouse

-  A first stop for valuable OIT products and services
-  Experts help thousands of industrial customers:
-  “Can you help me justify a preventative maintenance program for our       steam system?” *	**--Facility Manager at a Petroleum Refinery*
-  “Will the government cost-share with us to demonstrate an      innovative melting technology that is more energy efficient?”*	**	**	**--R&D Manager for a glass company*
- Voice: 	**1-800-862-2086**
- Fax: 	**360-586-8303**
- Email:	**clearinghouse@ee.doe.gov**
- Web:	**www.oit.doe.gov/clearinghouse**

***“******The real-world expertise of your organization places you in a unique position to provide solid advice and guidance. ******Keep up the good work.”***
*--customer*

## OIT Home Page: www.oit.doe.gov