Partnering 

bi-Consolidated • Boise Cascade • Georgia Pacific • Weyerhaeuser • Owens Corning • PPG Industries • AMCAST • Hitchiner • Mercury Marine, Brunswick

Steel • Delphi Automotive • Kaeser Compressors • Pneumatic/ ConservAIR • Emerson electric ITT Fluid Technologies • Fairbanks Morse • Spirax Sarco •

can Petroleum Institute • National Petroleum and Refiners Association • American Iron and Steel Institute • Steel Manufacturers Association • Compressed

Excellence • Materials Technology Institute • Metal Powder Industry Foundation • Alliance to Save Energy • ASSERTI • Energy Center of Wisconsin • Iowa

cal • Alcoa • Commonwealth Aluminum • Energy Research Company • Air Products • Dupont • FMC • Rohm & Haas • Abitibi-Consolidated • Boise Cascade

um • Imerys • Kennecott Utah Copper Corporation • Chevron • Flying J Refinery • Silver Eagle • Timken • • Weirton Steel • Delphi Automotive • Kaeser

n • Aluminum Association • SECAT • AlChE • TAPPI • GMIC • Cast Metal Coalition • National Mining Association • American Petroleum Institute • National

or Distributor Association • National Insulation Association • Forging Industry Association • WPI Center for Heat Treating Excellence • Materials Technology

titute • NASEO • Idaho • Maine • Texas Energy Coordination Council • Utah • West Virginia • Cargill Dow, LLC • Dow Chemical • Alcoa • Commonwealth

aeuser • Owens Corning • PPG Industries • AMCAST • Hitchiner • Mercury Marine, Brunswick Corporation • Superior Aluminum • Imerys • Kennecott Utah

ervAIR • Emerson electric ITT Fluid Technologies • Fairbanks Morse • Spirax Sarco • National Corn Growers Association • Aluminum Association • SECAT

n • American Iron and Steel Institute • Steel Manufacturers Association • Compressed Air and Gas Institute • C compressor Distributor Association • National

y Foundation • Alliance to Save Energy • ASSERTI • Energy Center of Wisconsin • Iowa State University • Hydraulic Institute • NASEO • Idaho • Maine •

ompany • Air Products • Dupont • FMC • Rohm & Haas • Abitibi-Consolidated • Boise Cascade • Georgia Pacific • Weyerhaeuser • Owens Corning • PPG

• Flying J Refinery • Silver Eagle • Timken • • Weirton Steel • Delphi Automotive • Kaeser Compressors • Pneumatic/ ConservAIR • Emerson electric ITT

ast Metal Coalition • National Mining Association • American Petroleum Institute • National Petroleum and Refiners Association • American Iron and Steel

ging Industry Association • WPI Center for Heat Treating Excellence • Materials Technology Institute • Metal Powder Industry Foundation • Alliance to Save

ncil • Utah • West Virginia • Cargill Dow, LLC • Dow Chemical • Alcoa • Commonwealth Aluminum • Energy Research Company • Air Products • Dupont •

• Mercury Marine, Brunswick Corporation • Superior Aluminum • Imerys • Kennecott Utah Copper Corporation • Chevron • Flying J Refinery • Silver Eagle

orse • Spirax Sarco • National Corn Growers Association • Aluminum Association • SECAT • AlChE • TAPPI • GMIC • Cast Metal Coalition • National Mining

ation • Compressed Air and Gas Institute • C compressor Distributor Association • National Insulation Association • Forging Industry Association • WPI Center

of Wisconsin • Iowa State University • Hydraulic Institute • NASEO • Idaho • Maine • Texas Energy Coordination Council • Utah • West Virginia • Cargill

Consolidated • Boise Cascade • Georgia Pacific • Weyerhaeuser • Owens Corning • PPG Industries • AMCAST • Hitchiner • Mercury Marine, Brunswick

Delphi Automotive • Kaeser Compressors • Pneumatic/ ConservAIR • Emerson electric ITT Fluid Technologies • Fairbanks Morse • Spirax Sarco • National

roleum Institute • National Petroleum and Refiners Association • American Iron and Steel Institute • Steel Manufacturers Association • Compressed Air and

ence • Materials Technology Institute • Metal Powder Industry Foundation • Alliance to Save Energy • ASSERTI • Energy Center of Wisconsin • Iowa State

T OF ENERGY

DEPARTMEN

U

E

NITED STAT S OF A

ERICA

M

U.S. Department of Energy

Office of Energy Efficiency and Renewable Energy

for

Success
Partnering for Success features companies and organizations that have not only worked in

partnership with DOE’s Office of Energy Efficiency and Renewable Energy (EERE)

during the last year, but have also gone the extra mile to raise awareness of the benefits of

industrial energy efficiency. EERE partners with hundreds of companies and organizations

during the year, and they all make substantial contributions to our energy efficiency goals.

We acknowledge their efforts, and regret that we cannot feature all of them here.

However, EERE also offers partners other opportunities for recognition, such as case

studies and articles in our newsletters that highlight successes; Showcases and other

energy events that demonstrate new technologies and improvements; and our Web site that

contains news and information on EERE and partner activities.

In addition, EERE presents three special awards at our bi-annual Expo:

• Partner of the Year recognizes an individual who exhibits extraordinary initiative and

commitment to advancing the goals of Industry of the Future partnerships. He or she

promotes and advances energy efficiency as a national goal beyond the needs of his or

her organization or industry, and engages in innovative approaches to joint publicprivate partnerships. 

• Technology of the Year goes to an EERE-supported technology that exhibits

exceptional commercialization potential and significant potential for energy

efficiency improvement, and economic or environmental benefits. 

• Plant of the Year is based on documented energy savings, replication

of emerging technologies, the plant’s history of progressive efforts

to reduce energy use, strategies for continuous improvement for

energy efficiency, and use of a project implementation plan that

includes funding commitments and ongoing validation of completed

projects.

The nomination period for the 2003 awards is May 9, 2002 to

September 15, 2002. See the EERE Partnership Awards

brochure for information about the process and how to submit a

nomination. Visit our Web site at www.eren.doe.gov or call the

Clearinghouse at 800-862-2086 for copies of the brochure and

nomination forms.

Partnering 
Welcome. The companies and organizations featured

here all have one thing in common. They are

working in partnership with the U.S. Department

of Energy’s (DOE) Office of Energy Efficiency

and Renewable Energy (EERE) toward a

more competitive future. Collectively, they

contribute to significant advances in the

development of energy efficiency technologies, increased productivity, and

enhanced environmental performance for

U.S. industry. Their actions have

contributed substantially to improving

the energy intensity of the U.S. economy

as called for in the President’s National

Energy Policy.

The participation and activities of these

companies and others are wide-ranging.

Through the Industries of the Future (IOF)

strategy, they are involved in charting future visions

for their industries and creating roadmaps to ensure

these visions are realized. They lead research and development projects that often find competitors collaborating. They perform

comprehensive energy assessments at their facilities that result in substantial

energy savings. 

These companies promote awareness of the benefits of industrial energy efficiency

through industry showcase events, regional energy events, training sessions, Web

sites, and publications. They not only carry this message to their customers, but

they practice it every day. Many of these companies have created a corporate

culture that rewards energy efficiency awareness and innovation. Some have

worked to develop industry standards for efficient performance of energyintensive systems, such as motors and pumps. Others have replicated initial

findings at multiple facilities with impressive results.

Please join me in recognizing our partners’ dedication and commitment to

increasing industrial energy efficiency and productivity, and reducing waste, while

helping to strengthen our economy and national energy security. We are proud of

our mutual accomplishments and invite your company’s participation in future

activities. Visit our Web site at www.eren.doe.gov to see how you can help us

partner for success!

Sincerely,

Denise Swink

Office of Energy Efficiency

and Renewable Energy

for

Success 
Founded in 1908 and today boasting over 50,000 members, the

American Institute of Chemical Engineers (AIChE) is the original

association focused on advancing the chemical engineering profession.

AIChE dedicates itself to fostering and disseminating chemical engineering knowledge to industries including energy, chemical, biotechnology, food, electronic, and pharmaceutical, while applying the

expertise of its members to societal issues such as sustainable development, the environment, human health, and water management and reuse.

As the global leader of the chemical engineering profession, AIChE

stresses the development and exchange of relevant knowledge

throughout the world. The institute works to stimulate collaborative

efforts among industry, universities, government, and professional

societies, while encouraging other engineering and scientific professionals and entities to participate in its own R&D ventures.

Working as an Office of Energy Efficiency and Renewable Energy

(EERE) Allied Partner, AIChE offers the time and expertise of its

members to review the EERE research project portfolio and the development and application of promising technologies. The institute

conducts BestPractices training events in its regional chapters

throughout the United States and assists the Chemical Industries of the

Future (IOF) with BestPractices outreach to chemical plants.

In the past year, AIChE assisted in the development of the Vision2020

Separations and Reaction Engineering Roadmaps and arranged a

topical conference held in March 2002 to showcase technologies being

developed under the Chemical IOF portfolio. Currently, the institute is

collaborating in the development and standardization of new energy

efficiency metrics and benchmarks, as well as a CD-ROM for the

chemical industry that includes energy efficiency tools and resources

for training programs and new technology developments.

Advanced Ceramics Research Inc. (ACR) develops state-of-the-art,

high-temperature, high-performance ceramic materials and processes.

It has have been an outstanding collaborator in all aspects of Mining

Industries of the Future (IOF) implementation. ACR’s participation

with the Mining IOF is led by its President and CEO, Anthony

Mulligan. Advanced Ceramics Research has:

• Provided industry expertise in Mining Roadmap workshops.

• Hosted a 2001 brainstorming forum of mining executives, university professors, and others to discuss opportunities for application

of advanced materials to save energy in the U.S. mining industry.

• Championed the Mining IOF strategy in Arizona and throughout

the industry. For example, ACR is working with a local community

college, owned by the Tohono O’odham Tribe in Tucson, to train

individuals how to manufacture advanced ceramics.

• Assisted in technology transfer. For example, during the 2001

National Mining Association’s MineExpo, the largest exposition

in the mining industry, ACR participated with the Mining IOF to

demonstrate advanced materials that hold energy saving potential

in mining.

In current Mining IOF research and development, ACR is developing

fibrous monolith wear-resistant components to increase the wear life of

mining drill bit inserts, point-attack tools, dozer teeth, and hydrocyclone apex tools. This will significantly improve energy efficiency

by increasing the duty-life of these components. Estimated energy

savings for the industry are 2.7 trillion Btu per year in 2010 and 

7.8 trillion Btu per year in 2020. It also will reduce operating costs 

in U.S. mines, thereby improving competitiveness.

Advanced

Ceramics

Research is 

developing 

fibrous

monolith

wearresistant

components

that will bring 

estimated energy 

savings of 2.7 trillion Btu per year 

in 2010 and 7.8 trillion Btu per year in 2020.

Advanced Ceramics Research AIChE

Collaborative

efforts that leverage

resources of industry, 

universities, government, and other

professional societies are crucial for the

identification of R&D needs and the

development of technology 

that can be applied to societal

issues in all parts of the world.

—Joseph Rogers 

AIChE

2
As the world’s only supplier of both gas and chemical products, Air

Products and Chemicals, Inc. is a leader in global electronics and

chemical processing industries and a long-time innovator in the steel,

metal, glass, and food processing manufacturing sectors. 

Air Products conducts fundamental research across various technology

platforms in the fields of materials, chemistry, processing, and

chemical engineering. The company actively seeks out long-term

research partnerships with individual researchers, universities, other

companies, industrial consortia, and U.S. and foreign government

agencies and laboratories, including the U.S. Department of Energy.

Among these research partnerships are two with EERE:

Catalytic Hydrogenation Retrofit Reactor—Working with Johnson

Matthey developing a new reactor system to serve as a catalyst in

industrial hydrogenation processes. The new system will be easily

retrofitted onto existing commercial batch stirred-tank reactors to

replace slurry catalysts used during hydrogenation processes in the fine

and specialty chemical industries. Projected benefits include:

• Elimination of problems in areas of environmental contamination,

waste production, industrial hygiene, and process safety

• 12 percent reduction in energy use

• Improved yield

• Reduced operational costs.

Pressure Swing Adsorption for Product Recovery—Working to

identify existing adsorbents and develop new adsorbents and processes

for the recovery of products such as

hydrogen from processing

waste streams. Projected

benefits include:

• Potential recovery

of 80,000 metric

tons of hydrocarbons per year, 

saving 336,000

standard cubic feet

per day of natural

gas from U.S. 

polyolefin plants

• Decreased NOx, CO2,

and VOC emissions.

Along with these partnerships, Air

Products is working on two Chemical Plus projects—direct capture 

of products and computation methods for chemical and physical 

properties—and, as a founding member of the Chemical Industry

Vision2020 Partnership, holds a chair on the Vision2020 steering

committee. The company also has participated in all four DOE-EEREsponsored Industrial Energy Efficiency Exposition and Symposiums

held to date.

Air Products and Chemicals, Inc. Alcoa

Alcoa, Inc. is the world’s largest producer of primary aluminum,

finished aluminum products, and alumina. In addition, Alcoa’s

aluminum products and components are used worldwide in aircraft,

automobiles, beverage cans, buildings, chemicals, and a wide variety

of industrial and consumer applications.

Alcoa is a long-time partner with DOE’s Office of Energy Efficiency

and Renewable Energy (EERE) and an important participant in 

the development of industry roadmaps and vision documents. Alcoa 

is currently the principal partner in three EERE research projects 

and a partner/contributor to ten R&D projects. Alcoa is a world class

R&D organization that contributes research efforts with EERE on

high-risk, industry changing technologies (i.e. carbothermic reduction

and inert anodes).

Alcoa recognizes the benefits of partnering with EERE on

BestPractices, Industrial Energy Assessments, and the 2001 Utah

Industrial Showcase. During the Showcase, Alcoa demonstrated new

energy-saving and environmentally friendly technologies implemented

with EERE support at its Spanish Fork, Utah, facility. Alcoa’s recent

activities with EERE include:

• DOE BestPractices Training—Alcoa and EERE held a three-day

training session on pumping systems and motors, adjustable

speed drives, and compressed air systems for over 30 Alcoa

employees.

• Energy Assessments—Alcoa has conducted energy assessments

that identified significant saving opportunities. EERE’s plantwide energy efficiency assessments at Alcoa’s Lafayette, Indiana,

and Bauxite, Arkansas, facilities identified potential annual 

savings of $1.9 million and $1.1 million, respectively. Colorado

State University, one of EERE’s Industrial Assessment Centers,

completed an assessment of Alcoa’s Spanish Fork plant and 

identified more than $800,000 in potential savings.

• Emerging Technologies—Alcoa has evaluated the use of air/oxyfuel furnace burner technology and the vertical flotation furnace

for melting recycled aluminum that were developed by other

EERE partners.

• Broadcasting Energy Benefits—Alcoa wrote a white paper on

“Energy Conservation in its Extrusion Operation” for its plants,

and it produces a quarterly energy conservation newsletter for its

operations worldwide. In addition, Alcoa developed an energy

efficiency self-assessment on its intranet, which allows Alcoa

locations to measure themselves against industry best practices.

Alcoa is a longtime partner

with EERE and

an important 

participant in

the development of industry

roadmaps 

and vision 

documents.

We can increase

and strengthen our technological options for the

future through early-stage

participation in

partnerships with EERE.

—Phil Winkler

Air Products and

Chemicals, Inc.

3

Carbothermic reduction of alumina

is a new aluminum production process 
The Aluminum Association, Inc. is the U.S. trade association for

producers of primary aluminum, recyclers, and producers of semifabricated aluminum products. The Association provides leadership to

the industry through its programs and services, which aim to enhance

aluminum’s position in a world of proliferating materials, increase its

use as the “material of choice,” remove impediments to its fullest use,

and assist in achieving the industry’s environmental, societal, and

economic objectives. Member companies operate about 200 plants in

the United States and many conduct business worldwide.

The Aluminum Association is an instrumental partner in the DOE

Office of Energy Efficiency and Renewable Energy (EERE) Industries

of the Future strategy. In 1996, the Aluminum Association signed a

compact with the Secretary of the U.S. Department of Energy agreeing

to work together to promote energy efficiency. The Aluminum

Association leads in the development of the Aluminum Industry Vision

and Technology Roadmaps. Recent efforts include:

• Aluminum Industry Vision—November 2001

• Alumina Technology Roadmap—November 2001

• Aluminum Industry Technology Roadmap—Revision currently in

progress

• Applications for Advanced Ceramics in Aluminum Production—

February 2001.

The Aluminum Association is partnering with Cornell University on

the EERE R&D project Integrated Numerical Methods and Design

Provisions for Aluminum Structures. The focus of this project is on

developing numerical methods for structural analysis and design of

complex aluminum structures. The project results will be integrated

into the aluminum design manual and should enable improved structural efficiency, which will result in significant energy savings. The

Association also partners on the aluminum scrap sorting and prevention of molten aluminum water explosions EERE R&D projects. These

projects will lead to more economical scrap sorting and improved

worker safety.

The Aluminum Association promotes EERE’s goals through extensive

dissemination of EERE products and information to its members and

the public. Its Web site disseminates EERE program and project information. In addition, the Aluminum Association works with EERE to

develop booklets and other materials relating to efficient energy use.

Alliance to Save Energy Aluminum Association

The Alliance to Save Energy and DOE’s Office of Energy Efficiency

and Renewable Energy (EERE) have collaborated for nearly a decade

in advancing energy efficiency in manufacturing. Both organizations

recognize the key roles played by industrial technology and energy

management in our economy, environment, and national security. 

As a non-profit organization, the Alliance mobilizes a progressive

coalition of Associate Members that participate in the market for

energy efficiency. By conducting trade shows, seminars, and media

presentations, the Alliance leverages the resources of these associates,

and effectively extends EERE’s outreach efforts. It has advanced the

energy efficiency dialog both within and beyond U.S. borders.

Industrial sector collaboration between EERE and the Alliance has

primarily focused on steam systems. This partnership created the

Steam Challenge, now known as “BestPractices Steam,” and generates

technical steam references and media for the benefit of industry.

As a precursor to the steam program effort, the Alliance conducted a

series of roundtables with industry in several locations across the

country. The resulting report, Understanding the Energy Efficiency

Investment Decisions of Smaller Manufacturers, was released in April

1995. This study identified the barriers to implementing energy efficiency in manufacturing. Its findings influenced EERE’s ensuing

program and outreach to industrial plant managers.

The Alliance extends industrial technologies and practices beyond the

United States through its International Programs division. In general,

this entails the presentation of materials through educational trade

missions. Alliance Associates play a key role in filling out the agendas

of these missions. 

Other collaborative activities in recent years include the FEMP steam

workshop, conducted in 2001 for the benefit of over 100 federal and

military facility managers, and the Industrial Energy Benchmarking

Forum. Read more about the Alliance’s industrial activities at

www.ase.org/programs/industrial.

The project results

will be integrated

into the 

aluminum

design manual

and should

enable

improved

structural 

efficiency,

which will result

in significant 

energy savings. 

The Alliance to

Save Energy and

EERE have 

collaborated

for nearly a

decade in

advancing

energy 

efficiency in

manufacturing.

4

Recently updated Vision and

Alumina Roadmap

A Steam best practice, color-coded

piping supports Connectiv’s

Steam Operations
For over a century, North American steel producers have left their dayto-day rivalries behind to work as partners and members of the

American Iron and Steel Institute (AISI), in furthering its mission to

promote steel as the material of choice and to enhance the competitiveness of the North American steel industry. AISI’s overall mission

centers around common goals and a clear vision for the future: 

• To provide high-quality, value-added products to a wide array 

of customers 

• To produce steel in a safe and environmentally friendly manner

• To increase the market for North American steel in both traditional

and innovative applications 

• To lead the world in innovation and technology in the production

of steel.

AISI engages in a wide range of collaborative research projects through

a partnership with the Office of Energy Efficiency and Renewable

Energy (EERE). As an EERE partner, AISI lends its industry expertise

to EERE-sponsored studies focusing on improving energy efficiency,

reducing emissions, and enhancing product properties. In 2001, AISI

led the revision of the Steel Industry Technology Roadmap, a guide for

identifying the technological advances needed to achieve steel’s vision

of the plant of the future. Results of this partnership help establish

baseline data that will provide the foundation for future energy savings

and productivity improvements to achieve these goals. Examples of

EERE and AISI collaborative projects include:

Commercial Alternative to Chrome—Addressing a major environmental concern by finding a commercially acceptable alternative to

chrome before the steel industry is required by regulation to do so.

Active Molten Metal Flow Control System—Working to implement

active electromagnetic control of the flow of molten metal during

manufacture. An electromagnetic control device could improve the

quality of metal by reducing turbulence, reoxidation, and impurity

entrapment in molten flow and increase overall yield, thus decreasing

energy use. Projected benefits include: energy savings on the order of

2 x 1,012 Btu/year across the industry and savings of several dollars

per ton, or possibly $500 million/year, across the steel continuous

casting industry.

Thermally Efficient Steel Stud—Developing a thermally efficient steel

stud for energy-efficient residential and light commercial constructions. Projected benefit includes savings of 10 percent on heating costs.

Playing a pivotal role in 

the steel industry’s ongoing 

renewal and realizing its vision of the

future, the AISI engages in a wide variety

of collective and collaborative activities,

such as those carried out with EERE.

—Larry Kavanaugh

American Iron and Steel

Institute

AMCAST American Iron & Steel Institute

Founded in 1866, AMCAST is a major supplier of performance critical

aluminum permanent-mold cast suspension components for the automotive industry. It also serves the construction industry and other

industrial sectors. 

In 2000, a plant-wide energy assessment was performed at AMCAST

Industrial Corporation’s Wapakoneta, Ohio, manufacturing facility by

DOE’s Office of Energy Efficiency and Renewable Energy

BestPractices team. The assessment identified how saving energy can

improve the bottom line. It resulted in 12 separate recommendations

that would improve the efficiency of the plant’s production process and

decrease energy consumption. These 12 recommendations required an

investment of $1 million and will save up to $3.6 million per year,

resulting in a simple payback of just three months. AMCAST was

quick to begin implementation on several of the 12 recommended

projects. Four are currently underway and one is complete. Some of

the recommendations included simple tasks such as making improvements to electrical, lighting, motor drive, compressed air, and process

heating systems. Implementation of these projects alone would result

in a total annual savings of $600,000. 

The assessment found that a majority of the improvements to be made

were in the manufacturing process. As a result of material modifications to process equipment, AMCAST will realize reductions in maintenance, scrap, downtime, and improve product quality. The total

savings to AMCAST through making improvements to the manufacturing process would be an additional $3 million. AMCAST is demonstrating to the industry the value and the importance of the industry

government partnership, while at the same time improving the

company’s bottom line.

The twelve recommendations that followed the

Wapakoneta facility’s

plant wide

assessment

required an

investment

of $1 million

and will

save up to

$3.6 million

per year,

resulting in a 

simple payback 

of just three months.

5

AMCAST staff install aluminumtitanate riser tube
The American Petroleum Institute (API) is a national trade association

representing more than 400 corporations involved in all aspects of the

oil and gas industry. Among its many activities, API serves as a focal

point for addressing oil and natural gas industry issues, including the

R&D needs of its refineries through their semiannual Refining

Meetings. API supports its public policy positions with scientific,

technical, and economic research programs.

API 's Technology Committee is charged with identifying the technical

areas of greatest concern to the downstream industry and with developing technology strategies to address those concerns. The API

Technology Committee, in cooperation with EERE, developed the

Technology Vision 2020—A Report on Technology and the Future of

the U.S. Petroleum Industry, and the Technology Roadmap for the

Petroleum Industry. These documents focus on the research needed to

strengthen the industry over the next two decades. The documents

recognize that government-industry collaboration and effective use of

the scientific capabilities of the national laboratory system can

leverage scarce funds for research to ensure that technology advances

are identified and adopted.

API is a partner with EERE on a number of R&D projects including:

“Gas Imaging for Advanced Leak Detection,” and “Rotary Phase

Burner Technology.” The gas imaging project provides accelerated and

simplified leak detection by optical imaging of hydrocarbon plumes,

while the rotary burner project reduces emissions of carbon dioxide

and nitrogen oxides. Members of the API Technology Committee have

reviewed EERE proposals and projects and will participate in the June

2002 portfolio review. 

API is committed to improving the energy efficiency and economic

competitiveness of the U.S. petroleum industry. API President Red

Cavaney testified in the Congressional Forum at the EERE 2001 Utah

Showcase and stated that "collaborative efforts such as Industries of

the Future are important to developing some of the technologies that

will enhance our quality of life in the 21st century."

API

is actively engaged in, and

supportive of, DOE’s Industries of the

Future initiative—both in Utah and nationwide...collaborative efforts such as Industries

of the Future are important to developing some of

the technologies that will enhance our quality

of life in the 21st century.

—Red Cavaney

American Petroleum Institute

American Petroleum Institute Applied Proactive Technologies

Applied Proactive Technologies, Inc. (APT) provides energy efficiency

programs to utilities and clients throughout the United States. We

provide complete planning, managerial, implementation and evaluation

services for conservation and load management, demand side management, energy efficiency, and market transformation programs. 

The Motors division, headed by Program Director Bruce Benkhart,

designed and ran the Southern California Edison Next Step Motor

Program and currently runs the MotorUp Premium Efficiency Motor

Initiative in New England, New Jersey, and Long Island, NY. 

MotorUp promotes NEMA PremiumTM efficient motors in the

commercial and industrial sectors with rebates, DOE MotorMaster+

software and training, technical documents, newsletters, and other

energy efficiency tools. MotorUp also gives Effective Motor

Management seminars focused on the benefits, energy savings, and life

cycle costing of premium motors and quality repair.

MotorUp has helped implement NEMA PremiumTM purchasing specifications for numerous companies including Anheuser-Busch, Crane

Paper, Verizon, Suffolk County Water Authority, and many others.

MotorUp has successfully encouraged motor manufacturers to develop

NEMA Premium Efficient lines.

Mr. Benkhart sits on the Motor Decisions Matter (MDM) committee,

which spearheaded the development of a Premium Efficient motor

standard (NEMA PremiumTM) adopted nationally. MDM promotes

motor management policy development nationally to upper level

management at commercial and industrial companies.

As an Allied Partner, APT relies heavily on the resources and expertise

of DOE’s BestPractices program. As a result of that relationship,

MotorUp had these successes in 2001:

• Distributed 440 MotorMaster+ 3.0 software CDs

• Gave 26 “Energy Savings Through Motor Management” seminars

including MotorMaster+ training

• Trained more than 250 individuals on MotorMaster+ 3.0 

• Distributed more than 100 DOE Energy Management for Motor

Driven Systems booklets

• Electronically distributed more than 100 DOE technical 

documents.

MotorUp has resulted in approximately 3,600 MWh annual savings to

the region, representing approximately 146,500 barrels of oil and over

100 million tons of carbon emissions avoided annually.

As an Allied

Partner, APT

relies heavily 

on the

resources

and 

expertise of

OIT and the

Best Practices

program.

6
Established in 1990, the Association of State Energy Research and

Technology Transfer Institutions, Inc. (ASERTTI) is a confederation of

state and regional organizations with energy research and development

and technology transfer responsibilities. ASERTTI members have a

demonstrated track record of supporting high-impact R&D and

applying the resulting new technologies in cooperation with utilities

and other private and public organizations in their states. ASERTTI

members, managing more than $200 million in energy research

annually, are major contributors to our nationwide energy research

capabilities.

ASERTTI’s goal is to increase the effectiveness of energy research

efforts in contributing to energy security, environmental quality, and

economic growth. ASERTTI does this by:

• Collaborating on research projects with state, federal, and 

private partners

• Sharing technical operation information among members 

and associates

• Speaking with one voice on energy R&D policy issues to 

national, state, and local decision-makers.

ASERTTI and its individual members have had a long, productive

working relationship with DOE’s Office of Energy Efficiency and

Renewable Energy (EERE). This relationship was recently formalized

in an Allied Partners Memorandum of Understanding (MOU), which is

intended to promote communications and collaboration and leverage

state and DOE energy research, development, demonstration and

deployment (RDD&D)

resources. Participating

in this MOU are

ASERTTI, EERE,

and the National

Association of

State Energy

Officials

(NASEO).

Representatives of

the states that are

members of ASERTTI

and NASEO work together

with EERE’s representative to

enhance communications between

EERE and the states. This team also identifies areas of mutual interest

and develops collaborative energy RDD&D programs and projects.

ASERTTI Augusta Newsprint

Augusta Newsprint’s roots go back to 1965, when, as Cox Newsprint,

it consisted of one paper machine and a groundwood mill. Today, the

mill’s facilities include two paper machines, a wood yard, a thermomechanical pulp (TMP) mill, a recycled newsprint mill, a bark boiler,

utilities, and support areas. It employs 390 people and produces 1,200

tons of newsprint per day. 

In May 2000, the Institute of Paper Science and Technology introduced Augusta Newsprint to EERE. EERE subsequently assisted mill

management with assessing energy use and identifying energy-saving

opportunities, plus sharing costs and providing technical assistance for

improvements, helping Augusta save $1.4 million and approximately

130 billion Btu per year. 

The Augusta Newsprint Energy Showcase Event, held in March 2002,

showcased some of the technologies that helped Augusta save energy

and money, including:

Compressed Air—After doing a compressed air survey, management

decided to increase system storage capacity, tie two mill systems

together with improved controls, and repair leaks. These actions, which

cost $75,000, are saving the mill $60,000 per year. “It showed us that,

even though we’re experienced, we were unaware of some important

issues,” said Chuck Amos, Augusta Newsprint’s Engineering Manager.

TMP LD Transfer Pump Upgrade—This project involved removing a

10-inch control valve and installing a variable frequency drive. It

required a $15,000 investment, but will save the mill $12,000 per year

in energy costs on one pump. 

#1 Paper Machine Fan Pump Motor Replacement—Augusta

Newsprint replaced a 1,250-hp (900-rpm) motor with an 800-hp (720-

rpm) motor. A total of 500 hp is being saved; the mill invested

$123,000 on this project and will save $93,500 per year in energy

costs.

Advanced Quality Control Project—This project aims to improve

TMP quality. After investing $1.4 million, the AQC project is expected

to save Augusta Newsprint $1.12 million per year and reduce

consumption of kraft pulp by 2,000 metric tons. Furthermore, energy

use may be cut by 7,200 MWh per year.

EERE assisted mill 

management 

with assessing 

energy use 

and identifying

savings 

opportunities,

shared costs,

and provided 

technical 

assistance.

Representatives of the

states that are members 

of ASERTTI and NASEO work

together with EERE to enhance

communications between 

EERE and the states.

7

New 10,000-gallon compressed

air storage tank
Cargill Dow LLC has received much acclaim for the development of

polylactic acid (PLA), a novel polymer made from annually renewable

resources. PLA is the first commercially viable, biobased polymer that

offers performance equal to or greater than traditional polymers while

being fully compostable in industrial and municipal composting facilities.

The success of PLA sparked an outpouring of industrial recognition 

in 2001 led by Industry Week’s Top Technology of the Year for 2000

and Popular Mechanics’ 2001 Design and Engineering Award. These

were followed by the U. S. Department of Energy Office of Energy

Efficiency and Renewable Energy’s Technology-of-the-Year Award 

and recognition of Dr. Pat Gruber, vice president and chief technology

officer of Cargill Dow, for his work on PLA with the Discover Award

for Environmental Innovation.

As a strong, outspoken advocate for biobased products and bioenergy,

Cargill Dow has been a valuable partner of the Office of Energy

Efficiency and Renewable Energy’s Agriculture Industry of the Future

(IOF) and the Federal Interagency Biobased Products and Bioenergy

Initiative. They are currently collaborating on three Agriculture IOF

projects and a biomass refinery project funded by the Office of Energy

Efficiency and Renewable Energy. Cargill Dow has also been active in

the effort to create a Biobased Products and Bioenergy Industry Vision

and Roadmap.

In November 2001, Cargill Dow began PLA production at its new

plant in Blair, Nebraska, which has a capacity of its more than 300

million pounds per year. Initially used in textile, fiber, and film

packaging applications, the PLA market is expected to expand with the

development of new applications to approximately 8 billion pounds

per year by 2020, with a potential annual fossil energy savings of 210

trillion Btu.

Boise Cascade Cargill Dow

Boise Cascade has a long history of energy management policies

aimed at eliminating waste, minimizing consumption, and maximizing

self-generation. Over the years, the company has advanced these goals

through collaborative efforts with the Office of Energy Efficiency and

Renewable Energy (EERE), national laboratories, and other visionary

organizations. Today, Boise Cascade generates 54 percent of its energy

needs from renewable resources.

In 2000, Boise Cascade won a prestigious American Forest and Paper

Association Annual Environmental and Energy Achievement Award

for demonstrating Methane DeNOx, a technology that improves woodfired boiler efficiency while reducing emissions. In 2001, the company

followed up with investigations to utilize this same technology at other

locations and currently plans to implement a modified version at its

DeRidder, Louisiana, paper mill. Boise Cascade is also working

toward demonstration of an advanced gasification power generation

process along with other EERE emerging technologies. 

Boise Cascade is a strong supporter of plant-wide assessments. All

five of its fully integrated pulp and paper facilities have been modeled

and audited. A follow-up case study was completed in 2001, for one

such project at the International Falls, Minnesota, paper mill, that was

done in cooperation with Oak Ridge National Laboratory. The

company estimates saving 45 MMBtu/hr from six successfully implemented projects and process modifications, and is presently investigating similar approaches at other facilities.

Progress is also being made in less energy intensive divisions

throughout the company. The container and wood products facilities

have benefited from case studies presented on the EERE Web page.

Several plants have completed compressed air studies and many more

are working on lessons learned from participation in EERE

BestPractices for Steam. One of Boise Cascade’s plywood plants

performed upgrades on a wood-fired boiler that reduced emissions and

decreased natural gas consumption by 46 percent.

In addition to optimization studies and technology demonstrations,

Boise Cascade is actively involved in the development and review of

its industry strategy and business plan. In 2001, the company participated in industry merit and program reviews, technology roadmapping,

and planning for the Washington State Industries of the Future event to

be held in April 2002. It anticipates continued joint success from

participation in IOF programs.

DOE has been a key

organization 

in the 

development 

of the 

technology

behind

NatureWorksTM

PLA. With

assistance from

this organization,

and others, Cargill

Dow was able to bring the 

technology to market sooner.

—Dr. Pat Gruber 

Cargill Dow Boise Cascade is a strong

supporter of plant wide

assessments. All five 

of its fully integrated pulp and

paper facilities have been

modeled and audited.

8

Cargill Dow’s PLA plant in 

Blair, Nebraska
The Chevron refinery in North Salt Lake was built in 1948, and it is

the largest marketer of gasoline in Utah. The Chevron refinery

produces a variety of finished products including fuels, finished lubricants, base oils, process oils, and fuel additives. The refinery was one

of three Office of Energy Efficiency and Renewable Energy (EERE)

Showcase refineries to allow industry experts, researchers, colleagues,

and EERE staff to learn first-hand about the technologies that are

reducing costs and improving the efficiency of refinery operations.

The participants exchanged ideas that will encourage attendees to

adapt innovations in their own facilities. 

Chevron showcased five different technologies and best practices at

the August 2001 event. They included an improved compressor system

configuration, enhanced steam system management, better pipe insulation using EERE’s 3E Plus software, and an effective statistical

analysis and tracking program for oxygen in refinery furnaces and

boilers. Chevron also broke new ground with an analysis of air pollutants emitted through combustion of refinery fuel gas. The analysis

found that the fuel gas emissions were essentially the same as the

emissions from natural gas. The benefits of these technologies and of

Chevron’s work with EERE include reduced electricity usage, reduced

use of water treatment chemicals, reduced consumption of fuel gas,

operating cost savings, and savings on capital expenditures for

pollution abatement and control. 

At the August 

2001 event,

Chevron 

showcased 

five 

different 

technologies

and best 

practices.

Technology poster-board used for

Chevron Tour

Cast Metals Coalition Chevron

The Cast Metals Coalition (CMC) facilitates DOE’s partnership with

industry in the Metal Casting Industry of the Future (IOF) program.

The CMC is comprised of the Steel Founders’ Society of America

(SFSA), American Foundry Society (AFS), North American Die Casting

Association (NADCA), and the Advanced Technology Institute (ATI).

AFS, NADCA, and SFSA are the leading technical societies for the

industry and collectively represent the majority of U.S. metal casters.

ATI, a leading technology organization, provides management support

on CMC activities and is involved in all stages of the partnership. 

The CMC is an outstanding partner, enthusiastically supporting all

aspects of the partnership from the original Metal Casting Compact,

Vision, and Roadmap to successfully implementing research and

development (R&D) and disseminating results to industry. CMC

continues to provide leadership

as it renews its Compact

with DOE and updates

its Vision and

Roadmap. The

CMC provides

technical

oversight on

metal casting

R&D. 

CMC members

provide outreach and

dissemination of R&D

results to the industry

through conferences, seminars, Web

sites, and trade journals. They actively communicate opportunities

available from DOE technical and financial assistance programs,

demonstrated by metal casting industry participation in BestPractices,

NICE3, Inventions and Innovation, and State IOF. 

Since the beginning of its partnership with DOE, CMC has helped to

implement and manage nearly 100 R&D projects involving dozens of

universities and laboratories, more than 300 industry partners and

hundreds of students. CMC has consistently participated in biennial

DOE Energy Efficiency Expos, Customer Day, and other events. CMC

has sponsored showcases to demonstrate the tangible difference that

DOE research is making in the metal casting industry. It facilitates

advances in innovative casting techniques such as lost foam, and

disseminates R&D results including casting guidelines, design tools,

energy manuals, and mechanical properties data to reduce energy

consumption and simultaneously produce higher quality castings. 

It is currently sponsoring a benchmarking study on energy use in 

the industry to identify new opportunities for saving energy and

measuring progress.

CMC has sponsored 

showcases to demonstrate the

tangible difference that DOE

research is having in the metal

casting industry.

9
Commonwealth Aluminum is one of North America’s leading manufacturers of aluminum sheet and tubing. Commonwealth Aluminum

has unmatched cost-efficiency and manufacturing flexibility. The

company manufactures more than 3,800 variations of aluminum sheet

and tubing products in accordance to exacting customer specifications.

Its production exceeds one billion pounds of aluminum products.

These products are sold to distributors and end-users, principally for

use in building and construction products such as roofing, siding,

windows, and gutters; transportation equipment such as truck trailers

and bodies and automotive parts; and consumer durables such as

cookware, appliances, and lawn furniture.

Commonwealth Aluminum has helped establish a history of collaboration with DOE’s Office of Energy Efficiency and Renewable Energy

(EERE) as a charter member of the aluminum research consortium,

Secat, Incorporated. Commonwealth participates in six EERE

Aluminum cost-shared R&D projects that address industry-defined

priorities as well as national goals for energy and the environment.

Projects include isothermal melting, reduction of oxidative melt loss,

evaluation and characterization of in-line annealed continuous cast

sheet, modeling optimization of direct chill casting to reduce ingot

cracking, and structural factors affecting formability of continuous 

cast aluminum.

Commonwealth Aluminum will host an EERE Showcase at its

Uhrichsville, Ohio, facility in September 2002. The Showcase is a

public event designed to highlight the benefits of adopting new energy

efficiency and resource productivity technologies. The Showcase

allows the public to view technologies applied in real-use conditions in

a manufacturing environment.

Commonwealth Aluminum is currently conducting an EERE plantwide assessment. It is assessing two aluminum sheet production operations (chill casting and continuous casting) at its Uhrichsville facility

and providing direct comparisons of energy requirements and future

savings opportunities for the different process technologies.

Commonwealth hosted BestPractices training sessions in March 2002

at the Uhrichsville facility.

Commonwealth

Aluminum will

host an

EERE

Showcase

at its

facility in

the city of

Uhrichsville,

Ohio, in 

September 2002.

Commonwealth Aluminum Compressed Air & Gas Institute

The Compressed Air & Gas Institute (CAGI), a trade association of

manufacturers of compressed air systems equipment, joined with the

U. S. Department of Energy in 1996 to improve the effectiveness and

efficiency of compressed air systems. The Institute is focusing on

education and training of users and purchasers of compressed air systems.

As part of its training and education initiative, CAGI has participated

as a founding member of the Compressed Air Challenge in developing

two training courses, Fundamentals of Compressed Air Systems and

Advanced Management of Compressed Air Systems. The recommendations and knowledge provided in these courses will help users reduce

the cost of operating their compressed air systems while simultaneously

improving the performance of those systems. CAGI plans to offer this

training opportunity in 16 cities throughout the country this fall. 

The institute has also

developed a series of

videos as a resource

about compressed

air systems.

CAGI and DOE 

cooperated 

on the latest

installment in

the series, How

to Select an Air

Compressor,

which helps buyers

identify the items that

will affect their decision.

The video shows how approaching

the purchase of a compressor with the entire system in mind, and 

using life cycle costs to analyze the many available choices, will 

allow purchasers to minimize overall cost and maximize performance

of their systems.

To fulfill its mission of delivering information to users and purchasers,

CAGI has created a standardized format for reporting performance.

CAGI members have agreed to supply performance data on the standardized data sheets upon request. The members of CAGI have been

determining performance according to recognized international

standards for many years, and the standardized forms will clarify the

data for easier comparison.

The Compressed Air & Gas

Institute joined with DOE 

to improve both the efficiency 

and effectiveness of 

compressed air systems.

10

Commonwealth’s Showcase will

feature plant tours
A little known benefit to the formation of the Compressed Air

Challenge in 1998 was the idea that compressed air equipment 

distributors had a vested interest in working together as a single 

voice to make U.S. industry more competitive in a world market. 

The Compressor Distributor Association (CDA) was formed to share

the expenses of becoming one of the original program sponsors. 

The CDA is an association of associations representing over 600 

independent businesses across North America. 

Historically very fierce competitors, the notion that representatives of

the Gardner Denver, Quincy, Sullair, CompAir and Atlas-Copco

equipment distributors could meet in the same room would be

followed by jokes about a 911 phone call to the local authorities.

Acronyms identify most of the syndicate families: Gardner Denver

Distributors are represented by the ICDA (Industrial Compressor

Distributor Association), the Quincy Distributors group is the AICD

(Association of Independent Compressor Distributors), Sullair

members are represented by their Distributor Council, CompAir

members are represented by the NAACD (North American Association

of Compressor Distributors) and the Atlas Copco members are represented by the ACIDA (Atlas Copco Industrial Distributors

Association). The organization is successful in its third year. 

In early 2000, as part of its Allied Partner agreement with DOE, the

CDA agreed to organize a program that combined fundamentals 

and advanced compressed air training for its member and industry

representatives. CDA members from all five associations were

assigned host duties for each 

of ten training sites.

Between September 27

and December 7,

2000, 638 people

attended a

two-and-ahalf-day

training

program.

The training

sites were

Atlanta,

Baltimore,

Boston,

Chicago, 

Denver, Louisville,

Milwaukee, Newark,

San Francisco and St. Louis.

The training was co-sponsored by DOE and Advisory Board Utilities.

More than 30 distributors agreed to become Allied Partners in response

to an invitation issued by the CDA as part of the CDA/DOE training

partnership.

Compressor Distributor Assoc. ConservAIR

Established in 1987 to help manufacturers use compressed air more

efficiently, ConservAIR Technologies Company, LLP develops

products and application technologies to improve the performance of

industrial compressed air systems. At the inception of the Compressed

Air Challenge (a group that EERE also participates in), ConservAIR

recognized the need to actively participate in the process. 

Teaming with DOE, ConservAIR has shared the knowledge and 

experience gained over a decade to save industry millions of dollars in

energy costs. EERE has completed three studies utilizing ConservAIR

application technologies with annual savings reported: Caterpillar

Fuel Systems 5,280,000 kWh ($226,000/year); Sanmina Corporation

742,000 kWh ($63,000/year); and Modern Forge 2,400,000 kWh

($120,000/year). 

Tom Taranto and Bob Wilson of ConservAIR are Qualified

AIRMaster+ Specialists and have contributed extensively to the

AIRMaster training curriculum. Tom is also a Qualified AIRMaster+

Instructor and was involved in formulating the exam. Both are

Compressed Air Fundamentals Training Instructors for CAC, and Tom

is qualified to conduct the Advanced Management Training for

Compressed Air. 

Joe Fresch of ConservAir served as President of Compressed Air

Challenge, Inc., in its first year as a corporation. ConservAIR has 

co-sponsored several CAC training sessions and recently participated

in a DOE industrial energy event conference in Sacramento, California.

ConservAIR works with its distributors to promote the various DOE

initiatives and disseminate information, including the recently

published EERE Assessment of the Market for Compressed Air

Efficiency Services. ConservAIR is committed to working in partnership

with DOE and EERE to establish standards for the compressed air

industry and implementing its BestPractices Program. 

Teaming with EERE,

ConservAIR 

has shared the

knowledge and

experience

gained over a

decade to

save millions

of dollars in 

energy costs.

Modern Forge of Tennessee evaluated its

compressed air system, and then 

implemented several 

optimization changes.

A little known benefit

to the formation of the

Compressed Air Challenge in

1998, was an idea that, compressed

air equipment distributors as a technical resource, could contribute to

and had a vested interest in working

together as single voice to make

U.S. industry more competitive in a world market.

11
Multi-national Delphi Corporation is a world leader in mobile electronics and transportation components and systems technology.

Headquartered in Troy, Michigan, Delphi’s three business sectors—

Dynamics and Propulsion; Safety, Thermal and Electrical Architecture;

and Electronics and Mobile Communication—provide comprehensive

production solutions for its customers. 

Delphi has a long history of partnering with DOE’s Office of Energy

Efficiency and Renewable Energy (EERE). Delphi and EERE signed

an initial cooperative research and development agreement in 1992 for

Delphi to apply nickel aluminide alloys, including alloy development,

welding, melting, and casting technologies in its manufacturing facilities. The new alloy enables a more energy-efficient manufacturing

process not only for Delphi, but also for other U.S. manufacturers with

similar needs. 

More recently, Delphi engineers worked with the Oak Ridge National

Laboratory, the inventors of the alloy, to apply the material in their

heat treating facilities, changing more than 500 fixtures used in their

carburizing furnaces. Carburizing furnaces are very large gas-fired

systems that heat treat many tons of steel per day. The nickel

aluminide fixtures last 3-5 times longer than current high performance

steel alloys, and are at least three times stronger at operating temperatures than conventional alloys. These properties enable improved

energy and production efficiencies of up to 33 percent.

Delphi’s plant in Saginaw, Michigan, was the site of a Success event to

highlight the commercialization and use of nickel aluminide fixtures in

its heat treating furnaces.

Delphi also participates in the Green Power Market Development

Group, which is developing strategies to reduce green power costs,

reduce market barriers, and help articulate the business case for green

energy use including wind, solar, landfill gas, and fuel cells. 

CONSOL Energy Delphi Corporation

CONSOL Energy Inc. is among the nation’s top energy companies,

producing coal and natural gas. CONSOL Energy mines more highBtu bituminous coal than any other producer in the United States and

is one of the largest U.S. producers of coalbed methane. CONSOL

Energy’s Research & Development Department is a private research

organization devoted to energy production and use. With an annual

R&D budget of $7 million, CONSOL Energy performs research to

enhance safety, improve productivity, control emissions and byproducts, and improve efficiency in energy production and use.

Led by the efforts of Frank Burke, vice president for Research and

Development, CONSOL Energy has been a champion for the Mining

Industry of the Future (IOF) since the inception of the program.

CONSOL Energy has provided leadership and technical expertise in

all aspects of Mining Industries of the Future (IOF) implementation.

CONSOL Energy has:

• Provided industry perspective and technical expertise in developing the Mining IOF Vision and three subsequent Mining IOF

Technology Roadmaps

• Participated in EERE’s Mining IOF Annual Portfolio Reviews

and sponsored an independent project review to evaluate promising mining technologies

• Championed the State IOF strategy and is currently working with

industry and government leaders in West Virginia to translate the

benefits of the IOF strategy to companies in the state.

Most importantly, CONSOL Energy is contributing its R&D expertise

to improve energy efficiency and competitiveness in U.S. mining. This

includes R&D on advanced sensors to perform real-time stress

measurement as well as technologies to perform imaging ahead of

mining. These technologies will significantly reduce excavation

requirements in mining, resulting in significant improvements in mine

safety as well as reduced energy requirements. On one project alone,

development of an advanced sensor to improve the machine’s ability

to measure and analyze mineral seams will save an estimated 6.4

trillion Btu per year by 2020.

CONSOL Energy is assisting in technology transfer of R&D results

through participation in industry meetings and a wide range of other

activities.

One project alone, an

advanced sensor

to improve 

the ability to

measure and

analyze 

mineral

seams, will

save an 

estimated 6.4

trillion Btu per

year by 2020.

Delphi has a long 

history of partnering with

DOE’s Office of Energy Efficiency

and Renewable Energy (EERE). Delphi

and EERE signed an initial cooperative

research and development agreement 

in 1992 for Delphi to apply nickel 

aluminide alloys, including alloy 

development, welding, melting, 

and casting technologies in its 

manufacturing facilities. 

12

Sensors will be placed on a continuous

mining machine to measure the

machine’s position, orientation,

and motion.
Two hundred years after its inception, DuPont is a global leader in

science-based solutions in food and nutrition, health care, apparel,

home and construction, electronics, and transportation. DuPont is an

active partner with the Office of Energy Efficiency and Renewable

Energy (EERE), heading two Vision2020 projects—direct capture of

products and biomass to energy. DuPont also leads development of

American Institute of Chemical Engineers (AIChE) and EERE energy

metrics and benchmarks, supports technology roadmap development,

and participates on the Vision2020 steering committee. DuPont also

collaborates with EERE in several research partnerships:

• Corrosion Prediction in Mixed Solvents—Helps to develop software to predict alloy corrosion in organic and mixed-solvent solutions. Projected benefits include estimated energy savings of 33

million Btu/year per unit installed and elimination of shutdowns

associated with overly complicated equipment.

• Molecular Simulation—Developing software tools with molecular

modeling capabilities for design of improved membrane separation techniques. Projected benefits include elimination of certain

steam-driven chemical separations and significantly reduced 

separation energy use.

• Resistance to Metal Dusting—Collaborating with a host of partners researching materials resistant to corrosion associated with

metal dusting in the high-temperature, high-carbon environments

prevalent in many chemical and petrochemical processes. Projected

benefits include operational savings of $50,000/year per plant and

savings of $200-290 million/year in the hydrogen industry.

• Computational Chemistry and Reaction Engineering Workbench—

Developing a suite of graphical user interface modeling software

that will replace the array of complicated, often unused chemical

modeling tools existing today. Projected benefits include

improved design of chemical processes and processing equipment

and increased energy savings and efficiency.

With more than 40 R&D and

customer service labs in the United

States and 35 in 11 other countries, DuPont

is dedicated to innovation. An important

aspect of that is research partnerships such

as our projects with EERE.

—John Carberry

DuPont

The Dow Chemical Company DuPont

The Dow Chemical Company is a leading provider of chemical,

plastic, and agricultural products and services to essential markets such

as food, transportation, health and medicine, personal and home care,

and building and construction. As a leader in innovation and development, Dow collaborates with the Office of Energy Efficiency and

Renewable Energy (EERE) Agriculture and Chemicals Industries of

the Future program. Dow’s activities include participation on the

Vision2020 steering committee, the Vision2020 Chemicals Plus project,

the Vision 2020 Challenge initiative, and the Technical Advisory

Committee for the Biobased Products and Bioenergy Initiative. 

The company represented cross-cutting engineering science from the

chemical industry at the Utah 2001 Industry Showcase and chairs the

Texas Industry of the Future Technology Showcase steering

committee. Dow has also joined with EERE in organizing a consortium of ten companies, seven universities, and six national laboratories

researching multi-phase fluid dynamics.

Dow is the lead partner on one of EERE’s new biobased products

projects that integrate the biobased product value chain from plant

science and crop production through processing and product utilization. Dow also volunteered to play a leadership role and co-moderate

the Agriculture IOF-sponsored workshop on plant sciences recently

held in Chicago. 

Dow collaborates with EERE on several ongoing partnership projects:

• Corrosion Prediction in Mixed Solvents

• Solution Crystallization Tools

• Distillation Column Modeling Tools

• Improved Chemicals and Plastics from Oilseeds.

The company has also improved its manufacturing operations with

seven new cogeneration power facilities since 1994. The combined

facilities have replaced less efficient energy generating facilities,

reducing energy usage by approximately 23 trillion Btu per year and

eliminating approximately 1.2 million metric tons of CO2 emissions.

The Dow Chemical

Company is a 

leading partner

with DOE’s

Office of

Energy

Efficiency

and

Renewable

Energy in 

both the agriculture and chemical

sectors.

Castor Seed Pods

13
As a charter partner of the DOE Motor Challenge program in 1993,

and a recent sponsor of the Motor Decisions Matter campaign,

Emerson Motor Technologies has long understood the value of

advancing industrial energy efficiency, and partnering with EERE to

help make its energy efficiency goals a reality.

Emerson Motor Technologies has made it a primary mission to seek

out and participate in energy efficiency programs that make business

sense to the motor industry, and economic sense to its customers. By

looking at factory operations as a whole, instead of one motor at a

time, Emerson Motor Technologies is helping its customers identify

real energy reducing solutions and process improvements.

This major focus is driving Emerson Motor Technologies’ present and

future energy efficiency efforts. It is through previous involvement in

energy programs that Emerson Motor Technologies has gained insights

that help Emerson move forward with new premium motor programs.

In 1989, Emerson Motor Technologies became an original founder of

EERE’s Motor Challenge program, later renamed BestPractices. The

program focused on energy efficiency within an entire motor system,

looking at each element of a motor system, such as the motors, drives,

controls and pumps, rather than just the motor.

Emerson Motor Technologies continued its dedication to energy efficiency in 1997 by becoming one of the first motor manufacturers to

conform to the federal Energy Policy Act (EPAct), which set the

standards for energy efficient motors.

In June 2001, Emerson Motor Technologies introduced its line of

NEMA PremiumTM motors. The extensive line of industrial, commercial, and HVAC motors meet or exceed the new National Electrical

Manufacturers Association premium efficiency standards—the most

comprehensive in the industry. 

In 2001, Emerson Motor Technologies also became a sponsor of the

nationwide Motor Decisions Matter (MDM) campaign, which

promotes sound motor management and the use of NEMA PremiumTM

motors. The campaign has 29 sponsors, which also include DOE and

the U.S. Environmental Protection Agency.

Emerson Motor

Technologies

has made it

a primary

mission to

seek out

and 

participate

in energy 

efficiency programs.

Emerson Electric Energy Center of Wisconsin

The Energy Center of Wisconsin is the leading Wisconsin organization

providing objective research, information, and education on energy

issues to businesses, professionals, and policymakers. To fulfill this

mission, the Energy Center manages programs to help industry, hosts

educational workshops, and makes information available through its

Web site. The Energy Center is a private, non-profit organization. 

As an Allied Partner, the Energy Center of Wisconsin works with DOE

to raise awareness of energy efficient technologies and practices for

industry by leveraging the DOE’s Industries of the Future strategy and

BestPractices. For example, the Energy Center is working with the

state’s metal casters to adopt the DOE Metal Casting Roadmap and

pursue priority projects. It recently developed a roadmap for

Wisconsin papermakers, and now facilitates action teams working to

accelerate deployment of advanced papermaking technologies.

In 2001, the Energy Center of Wisconsin was selected to design and

manage an expanded Wisconsin Industries of the Future Program 

for seven industries, funded by $2.3 million of state public benefits

charge money.

Other recent collaborative activities include:

• Hosting training in the advanced management of compressed air

systems and a session in specialist training for DOE’s AirMaster+

software. The Energy Center is very active in Compressed Air

Challenge (in which DOE also participates).

• Providing a series of one-day steam training workshops.

• Facilitating Industries of the Future roundtable discussions for the

Wisconsin printing, agricultural biotechnology, food processing,

and plastics industries.

• Managing events such as the Annual Governor’s Business

Roundtable on Energy and the Environment that promote EERE

programs, products, and services.

• Creating new curricula modeled on DOE’s BestPractices, including Industrial Energy Management, Ammonia Refrigeration, and

Industrial Process Controls.

We leverage EERE’s

industrial 

programs for

Wisconsin.

Our success

is market

proof that

EERE does

valuable

work.

—Kevin Grabner

Senior Project

Manager, Energy Center of Wisconsin

Wisconsin metal casters discuss DOE’s

Metal Casting Roadmap

14
Energy Research Company (ERCo) has successfully partnered with

DOE’s Office of Energy Efficiency and Renewable Energy (EERE),

industry, and state agencies to develop and provide innovative technologies and services for industry’s use. These projects have resulted

in actual energy savings of 62,000 million Btu per year and aluminum

production increases of 46 million pounds per year. In addition,

projects under development and further deployment of existing technologies will provide additional benefits. ERCo has achieved its first

commercial success with 14 scrap decoaters (NICE3 Project) sold

throughout the world. Other projects are on the verge of commercial

introduction. ERCo has participated in the following EERE programs:

National Industrial Competitiveness Through Energy, Environment and

Economics (NICE3)

• Demonstrated a decoating kiln now being commercially sold. It

meets EPA standards and reduces energy use by 24 percent

• Developed corrosion resistant coatings for recuperators. A pilotscale test was successfully completed and a full-scale demonstration is underway.

Inventions and Innovation (I&I)

• Inert anodes for the primary aluminum industry are being

developed. These replace the traditional carbon anodes thus

reducing energy use by 25 percent and eliminating greenhouse

gas emissions. 

• Started initial development of Laser Induced Breakdown

Spectroscopy (LIBS) work.

Sensors and Controls

• Continued developing and testing an LIBS probe.

Aluminum

• Pilot-tested a Vertical Floatation Melter (VFM) and decoater for

the aluminum industry that reduces energy by 60 percent. 

• Applied the LIBS technology for in-situ, real-time measurement

of melt constituents. 

Glass

• The LIBS technology was also adapted for measuring glass feedstocks and identifying cullet contaminants and cullet color. 

Plant Assessments

• Participated in plant assessments at Crucible Specialty Metals,

Charter Steel, Utica Corporation, and Metlab. 

Energy Research Company Fairbanks Morse

For over a century, Fairbanks Morse has been manufacturing a wide

range of pumps for applications in public works and industrial 

installations. The Fairbanks Morse manufacturing facility provides

advanced engineering and technology, a major testing facility for

product performance evaluation, and computerized machining centers

for high-quality manufacturing techniques. Fairbanks Morse sales and

service facilities are located across the United States and throughout

the world.

As a DOE Allied Partner, Fairbanks Morse works with its customers to

reduce energy consumption. Arnie Sdano, Director of Engineering for

Fairbanks Morse, is involved in a number of activities with DOE.

Through his involvement in the Hydraulic Institute’s (HI) Education

Committee, he was able to guide the development of the Energy

Reduction video program developed by HI and sponsored by DOE.

When DOE initiated its program to qualify instructors in the use of its

Pumping System Assessment Tool (PSAT) software tool, Arnie was the

first DOE qualified instructor. He uses PSAT as part of his own

presentations to pump users.

Fairbanks Morse has sponsored several training sessions in Virginia

and Texas on pump energy reduction where the focus was on the use

of PSAT. Through these sessions approximately 300 people have been

trained in the use of PSAT and were provided with DOE’s Decision

Tools Software CD. This type of training is an exemplary model of

partnering that helps to leverage limited resources and facilitates the

dissemination of important energy efficiency materials to industry.

Furthering its commitment to energy reduction for its customers,

Fairbanks Morse has also developed a graphical method of selecting

pump control set points that allow for the efficient application of

variable speed pumps.

Energy Research

Company has 

successfully 

partnered 

with EERE, 

industry, 

and state 

agencies to

develop and

provide innovative technologies

and services for

industry’s use.

Fairbanks Morse has 

sponsored several training 

sessions in Virginia and Texas 

on pump energy reduction 

where the focus was on the 

use of PSAT.

15

ERCo’s innovative Vertical

Flotation Melter Furnace
The FMC Corporation is a focused chemical company supplying the

agricultural, specialty, and industrial chemical markets. Utilizing

advanced technologies and customer-specific R&D, FMC provides

solutions to food and agricultural, pharmaceutical, pulp and paper,

textile, glass and ceramic, rubber and plastic, lubricant, structural pest

control, turf and ornamental, specialty, and other related industries. 

In August 2001, three divisions of FMC’s Industrial Chemicals Group

formed the first end-user Allied Partnership with the Office of Energy

Efficiency and Renewable Energy (EERE). FMC Alkali Chemicals is

the world’s largest producer of natural soda ash and the market leader

in North America, also producing sodium bicarbonate, sodium cyanide,

sodium sesquicarbonate, and caustic soda. FMC Hydrogen Peroxide is

a worldwide producer of hydrogen peroxide with manufacturing sites

in the United States, Canada, Mexico, Spain, the Netherlands, and

Thailand. FMC Active Oxidants is the world’s leading supplier of

persulfate products and a major producer of peracetic acid and other

specialty oxidants. 

FMC focuses heavily on improving resource efficiency, using site

energy reduction teams and energy-focused interdivisional technology

support teams in the company’s energy conservation efforts. As an

EERE Allied Partner, FMC reviews the entire R&D project portfolio

for opportunities to participate in the development and application of

promising technologies. The company engages in plant energy site

surveys and enrolls its employees in EERE BestPractices training to

improve the energy efficiency of its operations. The company also

incorporates EERE products,

tools, and services into its

operations and

promotes the use of

those tools and

strategies within

the chemical

industry. 

The FMC

Allied

Partnership with

EERE focuses

on the following

initiatives:

• Disseminating 

information on EERE 

and its resources

• Conducting energy assessments at multiple facilities

• Providing training workshops on energy efficiency

• Participating in Texas Industries of the Future activities

• Evaluating opportunities to implement emerging technologies.

Flying J Refinery FMC Corporation

Flying J converts approximately 25,000 barrels per day of crude oil,

natural gas liquids, and other feedstocks into diesel fuel, propane,

gasoline, jet fuel, and specialty wax. The refinery has made great

strides in keeping pace with advancing technology.

Flying J has demonstrated its commitment to improving process efficiency by making new capital investments in equipment and advanced

process control and by participating in Office of Energy Efficiency and

Renewable Energy (EERE) BestPractices activities and energy assessments. It was the first Utah refinery to agree to act as a Showcase host

and to open its gates to display what can be accomplished when

government and industry work together. The on-site tour enabled

Showcase attendees to view the new energy-saving, environmentally

friendly technologies that Flying J has implemented. Learning firsthand about these new innovations and exchanging ideas with industry

experts, researchers, colleagues, and EERE staff encouraged attendees

to adapt these innovations in their own facilities. 

Flying J’s readiness to adopt new technologies and willingness to open

its facilities says volumes about Utah’s attitude toward business innovation, its concern for industry, and its understanding of the nation’s

energy needs and resources. The refinery was instrumental in

obtaining the participation of the Utah Congressional delegation for a

field hearing. Flying J also participated in the briefing for high school

students on professional careers in the refinery industry. 

Flying J highlighted six different applied technologies and best

practices at the Showcase. Together these technologies have resulted in

increased liquid volume yield of approximately 4 percent, reduced

energy consumption of 53 billion Btu per year, reduced costs by more

than $320,000 per year, reduced carbon dioxide emissions by more

than 4,600 tons per year, reduced SOx emissions of almost 6,400

pounds per year, reduced NOx emissions by more than 11,300 pounds

per year, and reduced fugitive emissions of VOCs of 10-12 tons per

year. 

Flying J was the first

Utah refinery to

agree to act as a

Showcase host

and open 

its gates 

to display

what can be

accomplished

when 

government 

and industry 

work together.

The

strong market positions held by our Alkali

Chemicals, Hydrogen Peroxide,

and Active Oxidants 

divisions are largely the result of

innovative process technologies

such as those developed through

our partnership with EERE.

—Brian Wimer

FMC Corporation

16

Flying J Refinery hosted one of the

2001 Utah Showcase tours
In 2001, the Gas Technology Institute (GTI) and the U.S. Department

of Energy’s Office of Energy Efficiency and Renewable Energy

(EERE) continued their partnership toward advancing energy-efficient

technologies for industry. 

Selected project highlights include:

• A two-day Industrial Natural Gas Vision and Technology

Roadmap workshop hosted by GTI. The 50 attendees included

industrial end-users, Southern California Gas Company, 

manufacturers, and researchers. Participants identified research,

development, and demonstration needs related to more efficient

uses of natural gas and began development of a vision and

roadmap document that will serve as a planning tool for both

industry and government. GTI is coordinating the effort, supported

by the American Gas Association and the Industrial Center, in

cooperation with DOE.

• A GTI-DOE partnership with Peabody Engineering Corporation

to demonstrate a Forced Internal Recirculation (FIR) burner for

applications firing mixtures of natural gas, coke oven, and blast

furnace gases. Developed with GTI, DOE, and gas industry 

support, the FIR burner has achieved less than 10 ppmv NOx

with natural gas in watertube boilers without external flue gas

recirculation (FGR). External FGR requires parasitic (fan) energy

and degrades boiler thermal efficiency. GTI licensed Johnston

Boiler Company and COEN for different applications.

• Testing and evaluations of the METHANE de-NOX® process for

environmental and energy efficiency benefits in wood waste and

sludge-fired stoker boilers used extensively in the paper and forest products industry. Results of earlier testing at a boiler in

Minnesota documented 50-70 percent NOx reductions and boiler

efficiency improvement of between 1-2 percent. GTI and its 

commercial partners are seeing significant industry interest in 

the technology.

• Field trials on oxy/gas burners at glass furnaces that provided

positive preliminary data that a High Luminosity Burner could

provide increased energy efficiency and reduced NOx emissions.

Commercial introduction by Combustion Tec is anticipated in 2002.

A GTI-DOE 

partnership 

with Peabody

Engineering

to demonstrate a

Forced

Internal

Recirculation

(FIR) burner for

applications firing 

mixtures of natural gas, 

coke oven, and blast furnace gases.

FIR burner for steel application firing mixed

fuels (courtesy of Peabody

Engineering Corporation)

Forging Industry Association Gas Technology Institute

The Forging Industry Association (FIA) provides its members with

management, marketing, engineering, environment and safety, and

regulatory assistance services. Its outreach programs include assistance

to end-use customers, taking part in trade shows, and acquainting

students at the university level with the forging process and production. FIA committees conduct conferences and seminars to assist

members in the total operation of their organizations. FIA hosts Webbased interactive educational courses on forging technology and

company management. Its Web site provides important information

about the forging process, the North American forging industry, and

the producers of forged products. The Forging Industry Educational

and Research Foundation is a supporting organization that promotes

formal education and scientific research.

Through cooperative efforts with DOE’s Office of Energy Efficiency

and Renewable Energy (EERE), FIA has provided the leadership

needed for the development and distribution of the Forging Industry

Vision and Technology Roadmap. This roadmap established the

strategy to ensure the forging industry’s growth in the world markets,

through improvements in its energy efficiency, productivity, product

quality, and environmental performance. 

Since 2000, the successes that have resulted from the FIA-EERE partnerships for implementing the forging industry TRP, have included: (1)

Formation of Center for Excellence in Forging Technology at Ohio

State University; (2) Development of an Infrared Heating System for

Dies and Billets; (3) Defense Logistics Agency Forging Initiative to

significantly reduce lead time and component cost (4) System for the

Non-Contact Dimensional Inspection of Elevated Temperature Parts

which accurately predicts Room Temperature Dimensions; (5)

Galvanneal Temperature Measurement System; (6) Development of

Replacement for Phosphate Coating Lubes; (7) Formation of a

Precision Forging Consortium; and (8) three EERE plant-wide assessment awards.

To leverage resources, FIA formed a Joint Industry Alliance with the

American Iron and Steel Institute and the ASM Heat Treatment

Society, with Oak Ridge and Sandia National Laboratories as the key

technical partners.

The Forging Industry

Vision and

Technology

Roadmap

established

the strategy

to improve

energy 

efficiency,

productivity,

product quality, 

and environmental

performance.

17

Isothermal turbine disk
The Glass Manufacturing Industry Council (GMIC) and its members

in all sectors of the glass industry have been very active in their work

with EERE in the last year in many areas. A major achievement of the

collaboration has been the completion of the Glass Industry Roadmap,

which describes the path the industry is following to improved energy

efficiency and productivity. Additional publications developed through

this partnership include a glass industry CD that provides complete

information on tools, resources, and literature available in support of

the industry and a set of “Cost Reduction How-To” fact sheets that

provide step-by-step approaches to identifying and eliminating energy

inefficiencies in plant operations.

To expand possible opportunities for energy efficiency improvements

in the industry, the GMIC is supporting developing EERE State

Industry of the Future programs in Florida, Indiana, New Jersey, North

Carolina, Ohio, West Virginia, and Wisconsin with information and

contacts in the local glass industry and guidance in establishing their

programs. An Ohio proposal recently obtained a competitive award to

support research in productivity developments in fiberglass forming.

Capital costs and energy use are two of the major concerns regarding

glass industry profitability. The GMIC last year initiated a long-term

program to address these issues: the Next Generation Melting System

(NGMS) Project was launched in early 2001 as a 15–20 year effort to

identify a new “Glass Business Model” that will lead to step changes

in the efficiency and profitability of the industry. An initial Technical

and Economic Assessment, currently underway in collaboration with

EERE, will determine the current state of melting technologies as well

as examine past efforts to improve the technologies that will serve as a

baseline for exploring new directions for the industry.

The 2-year old G+ Program permits individual member companies to

pursue improvements in selected areas of their operation with DOE

national laboratory support. Through a simplified application and

administrative process, companies can obtain up to $25,000 worth of

research work to resolve specific problem areas in their operations.

Results from these short-term projects are then shared with other

members to obtain maximum effects.

The collaboration

between

GMIC and

EERE has

achieved

the 

completion

of the Glass

Industry

Roadmap, which

describes the path the industry is following 

to improved energy efficiency and productivity.

GMIC Hitchiner

The Hitchiner Manufacturing Co., Inc., has been an important partner

with the Metal Casting Industry of the Future (IOF) and is taking a

leadership role in advancing the state IOF efforts in New Hampshire

and Massachusetts as well as in disseminating information on

BestPractices and other EERE services. The company has been an

advocate for the IOF process and has championed the IOF strategy in

national and state-level conferences and other events. 

Hitchiner has invested the valuable time and expertise of the

company’s leadership, which has proven integral to the success of this

research program. Senior executives from Hitchiner have participated

in numerous EERE and program activities, including EERE Expos,

Customer Days, State IOF ceremonies and other events. 

Executive Vice President of

Operations Paul Mikkola

has been a champion

of the program

since its

inception,

serving on both

the Industrial

Advisory Board

and the

Industrial

Oversight Panel.

In this capacity he

has provided expert

input on the program’s R&D

portfolio, stressing foresight and

energy efficiency. He has provided his leadership to the industry’s

long-term visioning and roadmapping activities. He helped facilitate

the Metal Casting “Future Think Forum,” in which over 30 leaders

from industry provided critical insights on the future of the industry. It

was the first step in updating the Metal Casting Vision and Compact. 

Moreover, Dr. Mikkola has long been an advocate of Metal Casting

IOF lost foam casting research. This has been a major EERE success

and was recently commended by the National Research Council. He

has been a leader in applying the results of lost foam and other metal

casting research and has championed the application of advanced metal

casting processes throughout the industry. These efforts are leading to

significant improvements in casting productivity and are helping the

industry to improve energy efficiency in casting processes.

Senior Hitchiner 

executives have participated

in numerous EERE and program

activities, including EERE Expos,

Customer Days, State IOF 

ceremonies and 

other events. 

18

GMIC Executive Director,

Michael Greenman
As the largest association of pump producers in North America, the

Hydraulic Institute (HI) is committed to raising awareness of new

methods for increasing energy efficiency among manufacturers,

purchasers, and users of pumps and pumping systems. HI has done so

successfully by collaborating with DOE’s Office of Energy Efficiency

and Renewable Energy (EERE) on numerous projects since 1993 when

HI joined the Motor Challenge Program as a charter member.

HI and Europump, with support of DOE, developed and published

Pump Life Cycle Costs: A Guide to LCC Analysis for Pumps and

Pumping Systems. Europump is spokesperson for 15 European pump

associations. In 2001, more than 1,000 hard copies of this guide were

distributed, with a downloadable version also made available on the HI

and DOE BestPractices Web sites. In addition, more than 10,000

copies of the LCC Guide’s Executive Summary were downloaded

from the HI Web site alone. Over 2,500 copies of the LCC Guide have

been sold and distributed to manufactuers and users. Copies have been

translated into French, German, and Polish.

A highlight of the HI Web site continues to be the extensive Energy

Savings section, featuring many downloadable DOE tools, resources,

software and case studies. Here, HI has helped promote DOE’s

MotorMaster+ and the Pumping System Assessment Tool (PSAT)

software as well as information on BestPractices and Web links to

Allied Partnership information. HI also makes available an excellent

“Energy Reduction in Pumps and Pumping Systems” video-based

education program, developed with DOE support.

HI has encouraged its members to become Allied Partners, with

several regularly participating in DOE sponsored events and activities.

In fact, two HI member organizations have committed to energy efficiency by holding “in-house” sessions of the PSAT Qualified

Specialist training at their facilities. Through these sessions, engineers

and facility operators are learning how to accurately assess the

operating efficiency of their pumping systems. 

For 85 years, HI has been developing pump industry standards,

defining components, installation, application, operation, and test

procedures. Increasingly, HI standards are addressing systems issues.

HI is proud to partner with DOE. The Institute looks forward to a

strong partnership, and helping to make pump energy efficiency and

life cycle cost both a widely-accepted business strategy and an

industry standard.

Hydraulic Institute Idaho

The Idaho State Industry of the Future (IOF) is improving the energy

efficiency and competitiveness of key industries in Idaho, including

agriculture, forest products, and mining. In 2000, Idaho Governor

Dirk Kempthorne became the nation’s first governor to sign an MOU

with DOE’s Office of Energy Efficiency and Renewable Energy.

Idaho received a $200,000 State Energy Program Special Project grant

in FY2000 to develop its IOF Program. Activities completed by the

program include:

• Publishing the Idaho Forest Industry Strategic Technology

Development Plan in May 2001

• Conducting the Idaho Industrial Summit on November 13, 2001,

with participation from Idaho industry, government, and academia

• Organizing a meeting in Twin Falls in December 2001 to 

demonstrate a working pilot plant of the acid recovery phase 

of a biorefinery—a key agriculture project

• Creating and presenting the first Idaho Innovation in Industry

Awards for technological advances in Idaho agriculture, forest,

and mining industries

• Producing two Best Practices workshops in pump efficiency with

the Idaho Mining Association and NW Mining Association in

June 2001. These workshops led to a project at Hecla Mining

with Oak Ridge National Laboratory to generate power from

cooling water as it falls from the surface.

A number of other activities and relationships have emerged as a result

of the State IOF. Specifically, the State Energy Division has expanded

its working relationship with Idaho National Engineering and

Environmental Laboratory, the University of Idaho, and Idaho’s 

agriculture, forest products, and mining industries. 

The University of Idaho College of Agriculture, the Idaho Food

Producers Commission, and the Ad Hoc Committee worked to

integrate the Industries of the Future strategy into the Ag Initiative

2001, a legislative effort to create a state research grant agency for

agriculture. The initiative failed to pass, but forged working relationships for future efforts. 

More than 10,000

copies of the

LCC Guide’s

Executive

Summary

were downloaded from

the HI 

Web site:

www.pumps.org.

19

In 2000, Idaho

Governor Dirk

Kempthorne

became the

nation’s first

governor to

sign an 

MOU with

DOE’s Office 

of Energy

Efficiency and

Renewable Energy.
IMERYS offers the most comprehensive selection of kaolins for 

paper. Located in Georgia, IMERYS supplies nearly 4 million 

tons of kaolin worldwide annually for the paper industry, more than

twice that of the nearest competitor. IMERYS continues to invest

heavily in production and process control technology to reduce costs,

develop new products, and extend crude reserves. Over the past 2–3

years, they have become a major supporter of the EERE Mining

Industry of the Future (IOF) initiative. 

Dr. Robert Pruett, of IMERYS, has been a large supporter of the

Mining Industry of the Future. IMERYS has participated in the

following EERE activities:

• Hosted an EERE BestPractices training workshop

• Participated in technical reviews of proposals for solicitations 

• Formed a working relationship with the DOE Savannah 

River laboratory 

• Attended Mining IOF roadmap workshops.

More importantly, IMERYS has agreed to host a Georgia Mining

Showcase scheduled for April 2004. This showcase will highlight and

demonstrate Mining IOF research. In addition, the Georgia showcase

will demonstrate implemented energy saving practices that were

recommended by EERE’s BestPractices Program.

IHEA IMERYS

The Industrial Heating Equipment Association (IHEA) is a national

trade association representing the major segments of the industrial heat

process equipment industry. The organization counts among its

members the leading designers and manufacturers of all types of

heating equipment used for the melting, refining, and heat processing

of ferrousand non-ferrous metals, and certain non-metallic materials. 

It is the common goal of IHEA and DOE to promote increased energy

efficiency for industrial process heating applications. 

IHEA is excited about progress made in the past year on a range of

DOE-EERE sponsored projects. Cooperation with DOE was initiated

with the development of a process heating roadmap document. Since

its publication, areas of activity have been expanded and significant

progress has been made. Primary among the activities are:

• Assessment tool development

• Tip sheets and fact sheets

• Training to support the systems approach

• Sensor and process controls

• Materials forum

• Web site coordination.

IHEA members have been actively supporting the above activities

through committee membership. Three committees presently exist.

The first is in support of the Process Heating Assessment and Survey

Tool (PHAST). This committee counts members from end-user

companies, energy producers, and the national labs. The second

committee is in the Sensors and Controls cross-cutting technology

segment. Finally, a Materials Task Group has been assembled to

address materials needs for process heating equipment and the 

role of the national laboratories in helping to meet the future needs 

of the industry. 

The Georgia 

showcase 

will demonstrate

implemented

energy 

savings 

practices 

that were 

recommended

by EERE’s

BestPractices

Program.

It is the common

goal of IHEA and

DOE to promote

increased

energy 

efficiency for

industrial

process 

heating 

applications. 

20

Calciner at Imerys
ITT Industries’ Fluid Technology business, the world’s leading pump

producer, is dedicated to excellence in engineering, manufacturing,

and applying pumping equipment. ITT Industries, Inc.

(http://www.itt.com) supplies advanced technology products and

services in key markets including electronic interconnects and

switches; defense communication, opto-electronics, information technology, and services; fluid and water management; and specialty

products. Headquartered in White Plains, New York, the company

generated $4.7 billion in 2001 sales.

As one of the industry’s forerunners and premier advocates for life

cycle costing, the company has educated thousands of pump users on

the subject. ITT has published multiple articles on the topic, and

played a pivotal role in the development of a 200-page guide entitled,

Pump Life Cycle Costs: A Guide to LCC Analysis for Pumps and

Pumping Systems. The guide was published jointly by the Hydraulic

Institute and Europump, an organization comprised of various national

pump associations in Europe. 

ITT has also been a driving force behind the Hydraulic Institute’s work

with the U.S. Department of Energy, which focuses on reducing industrial energy consumption and greenhouse gases. These efforts have

also strengthened the Hydraulic Institute’s ties with DOE’s Office of

Energy Efficiency and Renewable Energy (EERE).

ITT has also been active in developing and participating in the DOECalifornia Energy Commission’s Energy Solutions for California

event. Together with DOE, ITT has implemented several breakthrough showcases.

ITT is especially proud of its six employees that have become

qualified Pump System Assessment Tool specialists. 

ITT has been a

driving force

behind the

Hydraulic

Institute’s

work with

the U.S.

Department

of Energy,

which focuses on

reducing industrial energy 

consumption and greenhouse gases.

Iowa State University ITT Industries

Iowa State University (ISU) is very active in the arena of biobased

products and bioenergy, partnering with EERE for two biobased

products, R&D projects, and receiving two Education Initiative grants,

in addition to being a key player in the Iowa State-Level Industries of

the Future efforts. ISU also houses the Center for Sustainable

Environmental Technologies whose mission is to develop, demonstrate, and promote sustainable environmental technologies such as

biobased products and bioenergy. The Biorenewable Resources

Consortium, a partnership among the Ames Laboratory, the

Experiment Station and the Plant Sciences Institute, is developing

biobased alternatives to fossil fuel-derived products.

As the recipient of two Education Initiative grants, ISU is helping to

train the next generation of scientists for the biobased products

industry. The development of biobased products cuts across the 

boundaries of scientific disciplines such as agronomy, plant science,

chemistry, engineering, and economics. This results in the need for

researchers with both in-depth knowledge of their primary discipline,

and significant exposure to these other disciplines. The Education

Initiative programs are designed to provide graduate students multidisciplinary training and a systems perspective of the biobased

products industry with an appreciation of problems in plant sciences,

production, conversion, and utilization.

For the first R&D project, “Multi-Component Harvesting Equipment

for Inexpensive Sugars from Crop Residues,” ISU is involved in developing a single-pass harvester to collect the wheat straw components

desired as feedstocks for chemicals. The new harvester will reduce the

time, energy, and cost of collecting wheat straw while enabling the

maximum use of wheat straw components in value-added products.

The sale of wheat straw will help boost domestic farm profitability,

and the displacement of products derived from imported fossil fuels

will increase national energy security. ISU is also contributing their

expertise and facilities for harvesting machinery development to the

second project, “Collection, Commercial Processing, and Utilization of

Corn Stover,” led by BioMass Agri-Products LLC. 

The new harvester will reduce 

the time, energy, 

and cost of 

collecting

wheat straw

and enable

the maximum use 

of wheat

straw 

components

in value-added 

products. 

21

Conceptual illustration of the

single-pass harvester

Sample life cycle costs for 

an industrial pump
Kaeser Compressors, Inc. has been in business for more than 85 years,

providing quality compressed air products to the worldwide market.

The company specializes in individually evaluating each customer’s

compressed air application, and providing the most efficient and

effective air system solution. In addition to equipment, its solutions

approach includes services that evaluate air consumption, storage

capacity, air wasted to leaks, artificial demand caused by over pressurization and misapplication, and varying demands in flow and pressure. 

Kaeser’s proprietary developments and equipment designs have also

helped many customers save thousands of dollars in energy costs every

year. The company knows that 70 percent of compressed air cost is

the electricity to run the compressor, and that getting more air for less

energy can make a big impact on the facility’s bottom line. That’s why

Kaeser’s extensive research and development team is committed to

designing equipment that is energy efficient, reliable, and requires

minimal maintenance.

Furthering its commitment to providing end users with the most

energy efficient air systems, Kaeser Compressors is a proud member

of the Compressed Air and Gas Institute (CAGI). The company was

the first equipment manufacturer to publish its compressor’s total

package performance on the World Wide Web according to CAGI

standards. Kaeser’s Technical Director, Wayne Perry, was unanimously

selected by the CAGI’s Energy Awareness Committee to be CAGI’s

representative to the board of the Compressed Air Challenge. Wayne

Perry also serves as CAGI’s representative to the Office of Energy

Efficiency and Renewable Energy Best Practices Steering Committee.

In May of 2001, Kaeser Compressors, Inc. became the only

compressor manufacturer designated as an Allied Partner of the U. S.

Department of Energy. The company helped DOE and the California

Energy Commission develop “Solutions for California Industry” a

series of informational seminars and conferences for industrial end

users seeking to reduce energy consumption while improving operations

and profitability. 

Kaeser is a global force in the compressed air industry and continues

to be committed to energy efficient air systems through training,

education and innovative product designs.

Kaeser became the

only compressor

manufacturer

designated

as an

Allied

Partner of

the U. S.

Department 

of Energy in 

May of 2001.

Kaeser Compressor Kennecott Utah Copper

Every year, Kennecott Utah Copper produces about 310,000 tons of

refined copper—along with 450,000 ounces of gold, 4 million ounces

of silver, about 22 million pounds of molybdenum, and over 1 million

tons of sulfuric acid, a by-product of the smelting process. Kennecott

Utah Copper is the second largest copper producer in the United

States, providing 15 percent of the country’s copper needs. The copper

comes from the Bingham Canyon Mine, the largest open pit copper

mine in the world, located near Salt Lake City, Utah.

Kennecott Utah Copper was a key player in the Utah 2001 Industry

Showcase in August 2001. One of the research projects showcased was

the EERE Mining IOF project “Three-Dimensional Simulation of

Charge Motion in Semiautogenous Grinding (SAG) and Ball Mills for

Energy Efficiency.” This project is developing a three-dimensional

simulation software application that optimizes the operating conditions

of grinding mills and can save an estimated 10.5 trillion Btu annually

by 2020. Kennecott Utah also worked with the EERE BestPractices

program to initiate energy saving practices throughout its facilities to

become more energy efficient. David George is the Mining IOF

contact at Kennecott Utah Copper, and was instrumental in organizing

the Utah 2001 Industry Showcase. 

Kennecott Utah also

worked with EERE

Best-Practices

program to

initiate

energy 

saving

practices

throughout

its facilities 

to become more

energy efficient.

22

Member:

SAG Mill at Kennecott

Copper
Kentucky began its effort by focusing on its aluminum industry, with

nearly 80 mostly small- and medium- sized facilities throughout the

state. “With all the mergers in the aluminum industry, it was clear that

R&D is taking a backseat—often it’s the first thing that’s cut,” said 

Dr. Subodh Das, President of SECAT, Inc., and Director of the Center

for Aluminum Technology at the University of Kentucky in Lexington.

“EERE is helping us ensure that the industry in Kentucky and around

the country stays strong.” 

A consortium involving aluminum firms, the University of Kentucky,

the Kentucky Economic Development Cabinet and DOE’s Office of

Energy Efficiency and Renewable Energy sponsored a Kentucky

aluminum industry roadmap session in early 1999. The effort brought

together industry representatives and researchers to discuss common

needs. They ultimately contributed to the award of four R&D projects

(involving about $15 million) to Kentucky companies. Recently,

Kentucky firms brought together by DOE’s States Industries of the

Future effort won a fifth aluminum-related project through an EERE

program for university-led R&D projects. 

Kentucky is now expanding its success to other industries in the state.

A new State Energy Program grant will target the agriculture, forest

products, chemicals, mining, and steel industries. A well-attended

roadmapping workshop for the state’s chemical industry was held in

June, and mining industry representatives have joined forces to submit

R&D proposals to EERE-sponsored programs.

“That seed money from DOE’s State IOF program and access to

outstanding resources is the impetus that will help us achieve great

things in Kentucky,” said Dr. Das.

For more information, visit

www.nr.state.ky.us/nrepc/dnr/energy/doeiof.html.

Kentucky Maine

Measures of success for the Maine IOF Program are related to the

goals of the DOE Industries of the Future (IOF) to broaden the impact

of investments in advanced industrial technologies and practices for

energy savings and waste reduction. Accordingly, the Maine IOF

Program’s measures of success are:

• Enthusiastic support and participation from three targeted 

industry sectors, the pulp and paper, wood products, and 

metals industries 

• Enthusiastic support from key state agency commissioners and

the university system and subsequent staff participation on the

steering committee 

• Identification of Maine IOF as an important resource in the state’s

economic development strategy stated by the Maine Department

of Economic Development (DECD). 

• Two facilitated roadmapping events with all three industry sectors 

• A Successful Energy & Technology EXPO

• Development of Maine IOF communication systems through a

monthly electronic newsletter and Web site www.maineiof.org.

Extensive industry involvement has been a key to the program’s

success. An implementation plan will be presented at the June 2002

Maine DECD annual Energy Conference. Issues and goals that cut

across all industry sectors include:

• Reduction in energy use per unit of output 

• Secondary market development and R&D for waste streams

• R&D leading toward new products, processes, and services

• Improved access to technology transfer 

• Improved rail, highway, and inter-modal shipping systems 

• Best practices implemented throughout industry.

At the 2001 Energy and Technology EXPO held at the University of

Maine (UM), the positive benefits companies derive from utilizing

new technologies were publicized, emerging technologies were

demonstrated, and the UM research and development facilities were

featured. 

The Maine IOF continues to work with its three industry sectors to create

visions that lead to the development of the critical technologies required

by each industry sector to meet future demands in the marketplace. 

Kentucky’s industries 

are very energyintensive, so

everything we

can do to

reduce energy

use helps 

us be more

competitive.

DOE’s States

IOF program is

helping us do that.

—Geoff Young

Kentucky Division of Energy

The Maine IOF continues

to work with its three

industry sectors to

create visions

that lead to the

development

of the critical

technologies

required by

each industry

sector to meet

future demands

in the marketplace.

23

Denise Swink and Governor Angus

King signing the MOU,

April 2001.
The Materials Technology Institute (MTI) is a non-profit technology

organization that has served the chemical process and allied industries

for 25 years. Corporate membership numbers 62, including chemical,

petroleum, forest products, materials suppliers, and welding service

companies, which collaborate to leverage resources for non-proprietary

activities of interest to the entire membership. 

In 1997 MTI took the lead in preparation of the Technology Roadmap

for Materials of Construction, Operation, and Maintenance in the

Chemical Process Industries and subsequently submitted five proposals

to the Chemical Industry Solicitation. All were highly rated and funded.

MTI is now working with EERE to revise the Roadmap to include

other industries such as petroleum, forest products, and agriculture. 

MTI is a member of the Vision2020 steering committee that promotes

collaboration across the chemical process industry. MTI has recently

agreed to become an Allied Partner with EERE to raise awareness of

EERE resources and information; promote Best Practices; develop

Showcases; participate in States IOF programs; and participate in

workshops and topical conferences.

Mercury Marine, Brunswick MTI

Mercury Marine has been a consistent and valued partner since the

inception of the Metal Casting Industry of the Future (IOF). The

company promotes and advances energy efficiency as a national goal.

It has provided the technical expertise of its management and staff as

well as valuable industry cost share on a long list of advanced metal

casting research projects including Lost Foam, Clean Steel, Alternative

Granular Molding Media, and many others. 

Mercury Marine has been instrumental in applying and validating the

results of this research through experiential data. For example, it

helped demonstrate that lost foam casting has the potential to reduce

energy consumption by as much as 27 percent, compared to sand

casting. It shared the results of its innovative applications for alternative granular molding media, calling it “one of the most significant

advancements in lost foam since unbonded sand was patented in

1964.” It has provided data to support outside reviews by the Centre

for the Analysis and Dissemination of Demonstrated Energy

Technologies and the National Research Council. Mercury Marine

champions the Metal Casting IOF and has been an enthusiastic

supporter of the industry Compact, Vision, and Roadmap. This support

has continued throughout 2001 and 2002 as the industry updates these

guidance documents. 

Recently, Mercury Marine invited Deputy Assistant Secretary Denise

Swink to participate with the Governor of Wisconsin at the dedication

of its Fon du Lac, Wisconsin, Pressurized Lost Foam Facility. The

company’s participation has been led by Senior Director for Advanced

Materials and Foundry Technology, Dr. Raymond Donahue. He has

consistently stressed the importance of national energy security and

improved energy and environmental performance. He has participated

in all industry vision, roadmapping, and compact activities, and shown

leadership in State IOF activities in Wisconsin. He was Chairman of

the Metal Casting Industrial Advisory Board and currently volunteers

on the Industrial Oversight Panel. He has championed the IOF strategy

and promotes EERE and Metal Casting IOF activities industry-wide. 

Mercury Marine helped

demonstrate that lost foam

casting has the potential to

reduce energy consumption by

as much as 27 percent 

compared to sand casting.

MTI is now working with EERE

to revise the Roadmap to

include other industries such as

petroleum, forest products, and

agriculture. 

24
For more than a decade, the National Association of State Energy

Officials (NASEO) has provided leadership on energy issues, guiding

regional, state and federal government officials toward a deeper understanding of energy’s pivotal role in the economy and environment, and

informing them about the specific energy priorities and concerns of the

states and territories.

Affiliated with the National Governor’s Association, NASEO members

are officials from the State and Territory Energy Offices and affiliates

from the private and public sectors. NASEO was created by the

governors to improve the effectiveness and quality of state energy

programs and policies, and to be a collector and repository of energyrelated information. NASEO meetings and communications offer a

forum for energy officials, policymakers and others to exchange information and discuss issues with

regional and national

implications.

NASEO has

partnered with

DOE’s Office

of Energy

Efficiency and

Renewable

Energy’s

Industries of the

Future Program

(IOF) to assist State and

Territory Energy Offices and

their industry partners. NASEO has

become an EERE Allied Partner and recently signed a memorandum of

understanding with EERE to increase cooperation and leverage

resources.

A part of this effort was the establishment of NASEO’s Industrial

Committee at the February 2002 NASEO Energy Outlook Conference.

State members of this new committee will work with NASEO and

EERE staff to identify needs and opportunities and work to make new

State Energy Program Special Project activities a success.

In addition, NASEO is undertaking a number of activities to promote

the EERE State Industries of the Future program and emerging industrial technologies by facilitating electronic and print communications

with the states. NASEO is also increasing efforts to include important

industrial topics on the agendas of NASEO’s Annual and Energy

Outlook meetings.

In 1996, the National Corn Growers Association (NCGA) approached

DOE’s Office of Energy Efficiency and Renewable Energy (EERE)

with the goal of establishing an Agriculture Industries of the Future as

a way of catalyzing the development of the biobased products industry.

With the signing of a Compact in 1998 with EERE and 14 other

national organizations to establish the partnership commitment

between the private sector and government, and involvement in the

development of the Plant/Crop-Based Renewable Resources Vision

2020 and accompanying Industry Roadmap, NCGA has proven to 

be a staunch supporter of EERE and the Agriculture IOF and this 

partnership continues to flourish.

NCGA provides a link between corn growers, the researchers developing new biobased products, and industrial companies looking for

opportunities to produce biobased products. They are a partner on

three projects funded by EERE. Technologies under development

include the conversion of corn glucose to chemicals such as ethylene

and propylene glycol and the synthesis of 1,3-propanediol, the

chemical precursor of a novel polymer. The 2020 market potential for

these technologies is estimated at 1 billion pounds per year and 500

million pounds per year, respectively, and would yield total fossil fuel

energy savings of 19.2 and 10.4 trillion Btu per year. The third project

focuses on the use of corn fiber as feedstock for a biorefinery that

could produce ethanol, ethylene, and propylene glycol, and other

value-added chemicals. 

NCGA has recently elected to become an Allied Partner with EERE.

This will further its ability to advance energy conservation in agriculture, as well as its support for the development of new biobased

product technologies.

With EERE and

the Industries

of the

Future, 

we found

people

who were

willing to

listen to our

needs and work

with us to address them. It is so 

refreshing to find someone in government 

who is truly interested in what industry needs.

—Lee Klein 

National Corn Growers Association Chairman

M. Alnajjar, of PNNL, works on corn

oil recovery and analyses

NASEO National Corn Growers Assoc.

NASEO is undertaking

a number of activities to 

promote the EERE State Industries

of the Future program and 

emerging industrial technologies

by facilitating electronic 

and print communications

with the states.

25
The National Mining Association (NMA) was created in 1995 as a

result of the merger of two major organizations representing the

mining industry at the national level: the National Coal Association

and the American Mining Congress. NMA’s current members include

coal, metal, and mineral hardrock mining operators, mineral processors,

bulk transporters, mining equipment manufacturers, financial and 

engineering firms, and other businesses and associations related to 

the mining industry. 

NMA is the industry partner of the EERE Mining Industry of the

Future (IOF) initiative. Since signing its Compact with DOE in 1998,

NMA has enthusiastically supported the Mining IOF, including the

development of an industry vision, three technology roadmaps, and

four research and development (R&D) solicitations. NMA coordinates

broad industry participation in the program, including the 28 R&D

projects that involve over 110 industry, university, and national 

laboratory partners. NMA, through its Technology Committee and

Industry Oversight Panel, offers technical and portfolio guidance 

to the Mining IOF. 

NMA has participated in events such as the EERE Energy Efficiency

Expos, Customer Days, and the Utah 2001 Industry Showcase. NMA

promotes the Mining IOF and disseminates R&D results to the

industry and public through conferences, seminars, its Web site, and

various publications. 

The National

Mining

Assoc. has 

enthusiastically 

supported

the Mining

IOF, including

the development

of an industry vision,

three technology roadmaps, and four 

research and development solicitations.

National Mining Association NIA

The National Insulation Association (NIA), a northern Virginia based

trade association representing the mechanical and specialty insulation

industry, was founded in 1953. It has approximately 450 member

companies consisting of contractors, manufacturers, distributors, 

laminators, and fabricators. 

NIA developed the Insulation Energy Appraisal Program (IEAP) in the

fall of 2000. This program is a major industry initiative designed to

give facility/energy managers a better understanding of the true dollar

and performance value of an insulated system. The program is a tool

that quantifies the amount of energy and actual dollars a facility is

losing with its current in-place insulation system. To date, 215 industry

professionals have earned the title of “Certified Insulation Energy

Appraiser.”

Students learn how to: determine the optimal insulation thickness and

corresponding energy and dollar savings; interview customers to gather

information for the appraisal; conduct a facility walkthrough; use the

3E Plus® computer software program; determine the amount of greenhouse gases saved through the use of insulation; analyze and complete

the appraisal spread sheet; complete a final customer report; and

market their new skills to potential customers.

There are a number of reasons why facility managers want to consider

an insulation energy appraisal at their location. These reasons include

the potential for hundreds of thousands of Btu savings, the opportunity

to improve process control and efficiency, contributing to a cleaner

environment through the reduction of emissions into the atmosphere,

and saving money through reduced fuel costs.

Bill Pitkin, NIA executive vice president and chairman of DOE’s

EERE Steam BestPractices believes that “the partnership of trade 

associations and government, such as NIA and EERE, has been one 

of the most outstanding successes of promoting the greater use of 

insulation. Because of this partnership, the recognition of industrial

insulation’s contribution to industry has risen significantly.”

Because of this 

partnership, 

the recognition

of industrial 

insulation’s 

contribution 

to industry 

has risen 

significantly.

—Bill Pitkin

NIA 

26

Materials for NIA’s Insulation Energy

Appraisal Program
The National Petrochemical and Refiners Association (NPRA) represents approximately 460 companies. Primarily, these are the companies

and suppliers that provide consumers with transportation fuels, home

heating oil, and the petrochemicals that serve as “building blocks” in

making everything from plastics and clothing to medicine and

computers. 

A number of NPRA activities support technical advancement and

continued progress in safety and environmental performance. NPRA

participates in the Responsible Care® Partnership Initiative designed

to continually improve the industry’s health, safety, and environmental

performance. NPRA’s Maintenance and Manufacturing Committees

focus on the application of new technologies, technology

transfer, and sharing of best practices to improve the operations of

member companies. NPRA holds an annual Question and Answer

Conference designed to provide for the discussion of issues, trends,

and challenges focusing on the refining and petrochemical industries. 

NPRA worked with EERE on the development of the Technology

Vision 2020—A Report on Technology and the Future of the U.S.

Petroleum Industry, and the Technology Roadmap for the Petroleum

Industry. These documents focus on the research needed to strengthen

the industry over the next two decades. The vision advocates cooperation among the petroleum industry, the U.S. Department of Energy, the

national laboratories, and academia. NPRA members contribute to

EERE activities in a number of ways. Members supported the EERE

2001 Utah Showcase, they provide sites for project demonstrations,

and they provide valuable input on the portfolio of projects. EERE and

NPRA continue to work together to develop joint strategies that

address the needs of the refining industry and promote the adoption of

technologies that will make the industry safer and more energy efficient.

NPRA Northeast Utilities

The Northeast Utilities System (NU), at the forefront of energy 

efficiency programs for more than two decades, helps customers in

Connecticut, Massachusetts, and New Hampshire save energy, money,

and the environment while bolstering the local economy in each state. 

Last year, by leveraging effective alliances such as its affiliation with

DOE’s Office of Energy Efficiency and Renewable Energy (EERE),

sponsorship of the Compressed Air Challenge (CAC), and partnerships

in the Motors Decisions Matter and Motor-up Program, NU, in cooperation with other New England utilities, hosted the first Qualified

AIRMaster Specialist Training sessions and a number of CAC sessions

and workshops that successfully trained 216 people. As a result of

these efforts and the design and implementation of innovative energysaving programs, NU has helped industrial customers save over 81,000

megawatt hours with their 2001 projects.

Examples of these programs include The Connecticut Light and Power

Company’s (CL&P) PRIME (Process Reengineering for Increased

Manufacturing Efficiency) program. CL&P, NU’s Connecticut

subsidiary, through PRIME and in partnership with CONNSTEP, a

state-sponsored agency that helps manufacturers increase productivity

by adopting LEAN-manufacturing processes, helped industrial

customers increase throughput by $44 million and preserve more than

20,000 jobs. Through its Custom Services Incentive program, CL&P

showed Johnson and Johnson’s Medical, Inc. how to transform an 

inefficient compressed air system into a state-of-the-art system that 

is saving the Southington, Connecticut-based company $120,000

annually. CL&P’s Research Development and Demonstration (RD&D)

program supports new, cutting-edge technologies that might otherwise

not get to market. One RD&D project, scheduled to be ready for

market in 2003, combines traditional manufacturing processes with

fuel cell plate production and could cut production costs by 50 percent. 

These programs, partnerships, and initiatives are consistent with NU’s

promotion of its “energy efficiency ethic,” encouraging customers to

use energy wisely with an eye on the environment.

EERE and NPRA 

continue to 

work together 

to develop

joint 

strategies 

that address 

the needs of 

the refining 

industry and 

promote the 

adoption of 

technologies that will make

the industry safer and more energy efficient.

Already,

thousands of 

customers participate 

in our energy-efficiency 

programs. But, as we move to fully

deregulated environment and the

price of electricity takes on more

significance, so will NU’s energy

efficiency programs and services.

—Colin G. Odell

Senior Program

Administrator

27

NPRA’s Q & A sessions provide

refiners with the latest 

technology news
As a leading global supplier of flat glass, fiber glass, and coated glass

products, PPG Industries has long been a technological leader in the

glass industry. PPG business units are supported by a comprehensive

program of research and development. Finding techniques that

improve efficiency is a pillar of PPG’s research efforts, as are ongoing

efforts to make its production processes environmentally-friendly. 

PPG conducts glass research in technical centers for both flat and fiber

glass production. The company actively seeks research partnerships

with universities and U.S. government agencies and laboratories,

including the U.S. Department of Energy. Among these partnerships

are three with EERE:

• Diagnostics and Modeling of Refractory Corrosion in Oxy-Fuel

Furnaces—Working with Sandia National Laboratories, PPG is

determining corrosion factors and developing mathematical 

models that can predict corrosion rates, identify operating 

conditions that minimize corrosion, and define the attributes of

improved refractories for oxy-fuel firing. Projected benefits

include extended refractory lifetime, which reduces production

costs, and increased industry conversion to oxy-fuel firing, which

reduces energy consumption and NOx emissions and increases

productivity.

• Process Optimization Strategies, Models, and Chemical Databases

for On-Line Coating of Float Glass—Also working in conjunction

with Sandia National Laboratories, PPG is developing new control

strategies and process models to 

significantly improve the 

efficiency of depositing

coatings on float glass.

Modifications to the

existing deposition

technique as well as

new coater designs

are being evaluated.

Projected benefits

include higher yield

of coated products,

which reduces

remelting energy 

use and costs, reduced

raw material usage, and

more efficient use of costly

chemical precursors.

• Clean, Efficient Glass Production Using High-Luminosity 

Oxy-Gas Burners—During a planned conversion of a float glass

furnace to oxy-fuel firing, PPG will demonstrate a new burner

technology. Developed by the Gas Technology Institute and its

marketing partner Combustion Tec, the burner increases luminosity and radiant heat transfer in the glass furnace. Projected benefits

include increased thermal efficiency, which reduces energy 

consumption, reduced NOx emissions, and increased furnace 

productivity.

Along with these efforts, PPG was a founding member of the Glass

Manufacturing Industry Council (GMIC), and is supporting GMIC

efforts to evaluate the potential for a next generation glass melting system.

Owens Corning PPG Industries

Since inventing glass fiber insulation more than 50 years ago, Owens

Corning has been a technological leader in the glass industry. With its

leading position in the production of glass fiber materials for insulation and composites, Owens Corning has an impressive history of

promoting and supporting the rational and productive use of energy, and

has developed a comprehensive understanding of energy second to none.

Owens Corning promotes the development of new technology with its

world-class science and technology team. Parallel engagements aimed

at reducing energy waste and costs, at increasing efficiencies and

advancing technology are at the core of Owens Corning’s efforts.

Owens Corning also understands the value and power of partnerships,

whether with suppliers, customers, or others. Among these partnerships are two with DOE’s Office of Energy Efficiency and Renewable

Energy (EERE):

• Development and Validation of a Coupled Combustion

Space/Glass Bath Furnace Simulation—Along with Argonne

National Laboratory and other project partners, Owens Corning is

participating in the development of a three-dimensional model

that provides a more accurate representation of the entire melting

process. Projected benefits include the optimization of melter

operation and combustion process, improved production efficiency, and reduced costs and emissions.

• High-Luminosity, Low-NOx Burner—Owens Corning recently

hosted the first full-scale demonstration of a new burner developed by the Gas Technology Institute. The burner increases luminosity and radiant heat transfer in the glass furnace, and was successfully tested at an Owens Corning facility in New York.

Projected benefits include increased thermal efficiency, thereby

reducing energy consumption; reduced NOx emissions; and

increased furnace productivity.

Along with these efforts, Owens Corning was a founding member of

the Glass Manufacturing Industry Council (GMIC), has made significant contributions to implementing the EERE glass portfolio by evaluating research projects and serving on GMIC technical subcommittees,

and is supporting GMIC efforts to evaluate the potential for a next

generation glass melting system.

Owens Corning

understands

the value and 

power of 

partnerships. 

PPG research has

resulted in improved

understanding of the thermodynamics and corrosion of

refractors in an oxy-fuel 

environment. 

—Dr. Amar Mishra

PPG Industries. Inc. 

28

GTI’s high luminosity burner firing 

at 3 MMBtu per hour in a

fiberglass furnace
Rohm and Haas Company is one of the largest producers of specialty

chemicals in the world. Manufacturers in an array of industries use the

Philadelphia-based company’s chemicals in the production of paint

and coatings, electronics, household products, detergents, personal

care goods, water treatment products, adhesives, plastics, and salts.

Rohm and Haas stresses innovation in its 140 research and manufacturing sites around the globe. As a partner with the Office of Energy

Efficiency and Renewable Energy (EERE), the company has

performed plant-wide energy efficiency assessments in its Knoxville

plant and elsewhere to identify cost savings potential.

The Rohm and Haas facility in Deer Park, Texas, is the company’s

largest monomer manufacturer, accounting for 35 percent of all Rohm

and Haas corporate energy use. In 1996, a plant-wide assessment identified 125 areas in which the plant could implement cost-saving best

practices. Over the past 6 years, EERE’s BestPractices energy management techniques have reduced overall energy use at the facility by 17

percent and saved the company an average of $15 million per year. In

February of 2001, the Deer Park facility was named runner-up for the

EERE’s 2001 Plant-of-the-Year award.

In addition to its BestPractices efforts, Rohm and Haas is a member of

several EERE initiatives, including:

• Initial Vision2020 Challenge

• BestPractices for Steam

• Vision2020 Steering Committee.

Praxair Rohm and Haas Company

Praxair, Inc. conducts cutting-edge R&D in connection with its

position as a leading global supplier of atmospheric, process, and

specialty gases; high-performance coatings; and related services and

technologies. In addition, the Fortune 500 company designs, engineers,

and builds advanced cryogenic and non-cryogenic supply systems.

Founded in 1907, the company was the first to commercially separate

oxygen using cryogenics. In 1992, it adopted the name Praxair, which

combines the Greek word for “practical application” with “air”—the

company’s primary raw material.

Praxair complements its robust internal technology development

program with a range of collaborative technology partnerships,

including several ongoing R&D partnerships with the Office of Energy

Efficiency and Renewable Energy (EERE):

• Advanced Sorbents for Gas Separation—Working to develop a

commercially viable oxygen-selective sorbent for separating commercial gases using pressure swing adsorption. This technology

requires less energy for gas separation and provides high-purity

gases at lower prices. Projected benefits include 4.2 trillion Btu

per year saved from industrial use of low-cost gas and 25- to 30-

percent reduction in production costs of industrial gases.

• Short-Contact-Time Reactors—Working with Sandia National

Laboratories and Reaction Design, Inc. in applying computational

technologies and catalyst characterization to develop a new

process for making syngas from methane. Projected benefits

include reduction in capital costs and fuel consumption and elimination of NOx and significantly lowered CO2 emissions.

• Oxidation Olefin Reactor—Developing a novel process to replace

energy-intensive steam cracking. The process employs a short

reaction-time catalyst and advanced gas-mixing technology to

lower energy use and production costs in ethylene manufacture

and similar operations. Projected benefits include a 20-percent

cost reduction and reduction in CO2 emissions.

• In addition, Praxair Director of R&D, Jack Solomon, is chairing

the Chemical Industry Vision2020 Technology Partnership steering group, while the company is participating in Chemicals Plus

projects and in the first Vision2020 Challenge initiative.

We need to think broadly

about the chemical

enterprise and

involve all of

the components that

can bring

or gain 

benefit.

Each element

of the enterprise

adds to the ultimate

value of Chemical Industry 

Vision2020 Technology Partnership. 

—Jack Solomon

Praxair, Inc. 

29

Because our Deer

Park facility

accounted

for such a

large 

portion

of the

company’s

total energy

use, it was an ideal

place to apply BestPractices techniques. 

With the help of EERE’s assessment project, 

we were able to reach our energy expenditure 

reduction goals 5 years ahead of schedule.

—Jeffrey Hackworth

Deer Park Plant Energy Manager

The 99- and 93- percent acid towers and

converter exchanger at Deer Park’s

sulfuric acid facility
SECAT, Inc. is a research consortium dedicated to facilitating cuttingedge research and development of innovative technologies and

products for the aluminum industry. SECAT was established in August

1999 in Lexington, Kentucky, and became the first Aluminum Industry

of the Future (IOF) Allied Partner in November 2001.

SECAT provides financial, project, and intellectual property management for aluminum research projects. SECAT and its sixteen

aluminum industry members, in partnership with land grant universities, other academic institutions, and national laboratories, have

quickly established their places as collaborative partners with DOE’s

Office of Energy Efficiency and Renewable Energy on research and

development of innovative processing technologies for the aluminum

industry. SECAT, Inc. currently partners with EERE on four projects

that include over 13 industries, three national laboratories, and two

university partners. SECAT is an active participant in updating the

Aluminum Vision. It is a leader in the Kentucky State IOF program. 

As an Allied Partner, SECAT applies and promotes EERE programs

and services to assist its members in the achievement of their longrange energy reduction, pollution abatement, and economic goals.

SECAT helps increase awareness of and disseminates EERE resources

and information. SECAT encourages BestPractices energy assessments

and training opportunities and facilitates the dissemination and replication of assessment results and recommendations throughout the

industry. SECAT builds awareness of EERE to the aluminum and

aluminum casting industries by promoting appropriate EERE emerging

technologies through its Web site and other communications methods

that focus on improving energy-efficiency. SECAT promotes and

assists in planning Showcases to highlight energy efficiency technologies and best practices, and encourages its members to participate in

updating the Aluminum Industry Vision and Roadmaps. 

SECAT actively participates in EERE’s State Industries of the Future

Programs in those states where its member companies have production

facilities for the manufacture of primary aluminum, semi-fabricated

aluminum products, and aluminum castings.

SECAT conducts R&D for improving energy efficiency in 

aluminum melting.

As an Allied

Partner, 

SECAT

applies 

and promotes 

EERE 

programs 

and services 

to assist its 

members in the achievement of 

their long-range energy reduction, 

pollution abatement, and economic goals.

SECAT President and CEO with Denise Swink

and DOE Industries of the Future staff at

Allied Partnership signing event

SECAT Silver Eagle

Silver Eagle refines crude oil and markets refined petroleum products,

including various grades of gasoline, kerosene, diesel fuel, waxes, and

asphalt. It processes approximately 10,000 barrels per day of crude oil. 

Silver Eagle was one of three Utah refineries to open its doors during

the 2001 Utah Showcase. The technologies on display at Silver Eagle

highlighted the advantages of government-industry cooperation. They

also showed how EERE resources such as 3E Plus insulation evaluation software and pump assessments can impact the operations of a

refinery. The success of the technologies in use at the refinery encouraged attendees to adopt these innovations in their own facilities. 

Silver Eagle showcased six different applied technologies and best

practices at the Showcase. Together these technologies have resulted in

increased product yield of approximately one and a half percent,

reduced energy use by more than 175 billion Btu per year, reduced

operating costs by more than $700,000 per year, and reduced carbon

dioxide emissions by more than 10,000 tons per year. The technologies

that produced these results include a boiler that uses waste heat, a new

catalyst that reduces the use of platinum catalyst by two-thirds, an

improvement to tank insulation using DOE’s 3E Plus software, and the

applied results of a DOE pump assessment. The facility also

showcased two emerging technologies: a cryogenic cooling system,

which will improve waste stream recovery; and a waste heat recovery

system, which will reduce the fuel required for steam production. 

The technologies 

on display 

at Silver

Eagle highlighted the

advantages

of cooperation

between 

government 

and industry.

Silver Eagle Facility Manager Gil Higham 

introduces a new energy-saving 

catalyst technology at the 2001 

Utah Showcase

30
The Sacramento Municipal Utility District (SMUD) has been an active

Allied Partner for years. Sacramento’s industrial customers have

adopted many of the energy and cost saving strategies fostered by

DOE’s Office of Energy Efficiency and Renewable Energy (EERE).

Industrial programs that contributed to the intense conservation efforts

of 2001 included numerous compressed air and motor system

workshops and seminars hosted by SMUD’s Energy & Technology

Center (E&TC) and the Commercial Services Department. These

included Energy Management for Water and Wastewater Treatment

Plants, two Motor Systems Management workshops, a workshop on

Correction of Existing Compressed Air Systems, and Pump System

Assessment Tool workshop. These events rely heavily on materials and

expertise available through EERE programs.

Lighting, architecture, manufacturing, and industrial processes are also

featured in workshops throughout the year at the E&TC. The E&TC

enables customers to take advantage of energy-efficient design,

equipment, and facility management practices. Seminars are also

offered on advanced processes that improve their bottom line and

enhance their competitiveness.

A primary means of assisting industrial customers is the performance

of system audits. SMUD maintains a staff of Commercial Services

Account Representatives, assisted by other trained professionals, to

assist customers in managing their energy use through retrofit projects.

Compressed air and other motor system audits have resulted in a

number of energy saving projects. Projects in 2001 included conversion of an electric boiler humidification system to air atomization,

resulting in annual savings of 2.36

GWh and 637 kW on this

project. SMUD is a

member of the

Consortium for

Energy Efficiency

(CEE), and participates in a number

of CEE managed

programs,

including the

Motor Decisions

Matter campaign.

SMUD was a proud

supporter and participant in

the first Energy Solutions for

California Industry, held in August in

Sacramento, an energy event organized by EERE and the California

Energy Commission. Other events where EERE materials were

featured and made available to customers included the Sacramento

Plant Engineering and Maintenance Show and Conference.

SMUD Spirax Sarco

SMUD’s industrial customers

have adopted many of the 

energy and cost saving strategies

fostered by DOE’s Industrial

Technologies Program.

31

Through its globally 

distributed Spirax

Sarco News, the

company has 

published six

articles 

highlighting

EERE and

BestPractices

Steam to raise

awareness

nationally 

and in European 

efficiency programs.

Spirax Sarco Headquarters

Spirax Sarco has 3,900 employees in 32 countries who provide

expertise and products for safe control and efficient use of steam and

other industrial fluids. Through its mutually beneficial Allied

Partnership with DOE’s Office of Energy Efficiency and Renewable

Energy (EERE), Spirax Sarco has distributed EERE Tip Sheets and

Case Studies in over 80 percent of the training it conducts. (Two case

studies highlight Spirax Sarco customers). Through its globally distributed Spirax Sarco News, the company has published six articles highlighting EERE and BestPractices Steam to raise awareness nationally

and in European efficiency programs.

Spirax Sarco integrates EERE information and products in its

workshops. Spirax Sarco also includes EERE personnel in its

workshops given to individual customers, often firms with multiple

plants. Additionally, Spirax Sarco’s all-day workshops for organizations such as the Association of Energy Engineers feature EERE

personnel and state representatives and other BestPractices Steam

partners, such as the National Insulation Association and ONDEO

Nalco. New fruitful working partnerships for Spirax Sarco and further

communications with individuals at national laboratories, Industries of

the Future Teams, and BestPractices have revealed new resources and

champions that strengthen Spirax Sarco’s marketing and credibility.

Spirax Sarco is presently co-developing software for a Steam Systems

Awareness program. Previously it helped develop EERE’s Steam

Scoping Tool software. The forthcoming Steam System Awareness

Tool will help plant managers determine project priorities for plant

improvements while taking into account costs, emissions, reliability,

and efficiency for a variety of options. Spirax Sarco is also developing

accompanying training aids to augment those already being used (e.g.

a video on internal boiler operation) by nearly all of EERE’s Industrial

Assessment Centers.

Glenn Hahn, Energy Services Group Manager, has been an extremely

active partner with EERE’s BestPractices. He currently Co-Chairs the

BestPractices Steam Technical Subcommittee and serves on the

BestPractices Steam Steering Committee Executive Board. Glenn also

Chairs the BestPractices Steering Committee, represents BestPractices

Steam on the Committee, and has served on the Editorial Board for

EERE’s Energy Matters newsletter.
The Superior Aluminum Company has championed the Metal Casting

Industry of the Future (IOF) since its inception. Moreover, Superior

has implemented many of the results and process improvements

resulting from Metal Casting IOF research leading to opportunities for

improved energy efficiency and productivity. As a champion of the

Metal Casting IOF, Superior has consistently shared and disseminated

the results of metal casting research at national conferences and other

events. Superior demonstrates to the industry the value of participating

in this industry-government partnership and applying clean and energy

efficient technologies on the plant floor. 

Superior has enthusiastically dedicated the time and expertise of its

employees to participating in EERE activities. The success of EERE’s

partnership with Superior is due in large part to the dedication and

hard work of Dwight Barnhard who led Superior and now shares his

time as Executive Director of the American Foundry Society. Mr.

Barnhard signed the original metal casting industry Compact, which

established the partnership between DOE and industry. He has been

instrumental in all facets of this successful partnership since its implementation, participating on both the Industrial Advisory Board and the

Industrial Oversight Panel. In this role he has provided expert insights

on technical R&D and helped to ensure a balanced portfolio focused

on improving energy efficiency in the industry. He was a key individual in hosting the “Future Think Forum.” It was at this forum that

over 30 industry leaders came together and provided critical insight

into stating the various challenges that face the metal casting industry

as a whole. The Forum laid the groundwork for the updated Metal

Casting Vision and new industry

Compact. The continued partnership with Superior is

helping to lead the

Metal Casting IOF

into the 21st century.

Steel Manufacturers Assoc. Superior Aluminum

The Steel Manufacturers Association (SMA) brings together 57 North

American companies that operate more than 130 steel plants and

employ approximately 120,000 workers, as well as nine member

companies outside of North America. In 2000, the SMA membership

accounted for 59 percent of domestic carbon steel manufacturing and

included a number of integrated (ore-based) steel makers and producers

of hot-rolled steel products. The organization is the primary trade 

association for scrap-based electric arc furnace (EAF) steel makers.

The SMA focuses its activities in the areas of international trade, environmental control, energy policy, workforce matters, new materials,

and products and technology. Towards that end, the association

engages in a range of collaborative research projects in partnership

with the Office of Energy Efficiency and Renewable Energy (EERE).

As an EERE partner, the SMA lends its industry expertise to EEREsponsored studies that analyze energy use and emissions in steelmaking processes to establish baseline data that will provide the foundation for future energy savings and productivity improvements in the

U.S. steel industry. The association provided input into the development of the U.S. Steel Industry Technology Roadmap and currently

collaborates with EERE on other ongoing projects:

• Improving Refractory Wear of Furnaces—Working to extend the

refractory service life of EAFs and achieve additional goals in

metallurgy, noise suppression, and energy savings. Projected 

benefits include reduced refractory consumption per ton of steel

produced and increased reuse of materials and energy efficiency

• Fellowship Cooperative Education Initiative—Leading the design

and establishment of a cooperative education program for selected college students who have completed the first or second year 

of a 4- or 5-year program. Selected students will participate on

projects designed to increase their interest and experience in the

steel industry. Projected benefits include an increased number 

of college graduates entering the steel industry and a more 

experienced entry-level steel industry workforce.

Superior has enthusiastically

dedicated the time and 

expertise of its employees to 

participating in EERE activities.

32

The

SMA seeks a

grass-roots involvement

with the federal government

as a way of advancing our 

segment of the steel industry.

Partnerships with offices 

such as EERE are important 

to our goals.

—Tom Danjczek 

SMA
The Technical Association of the Pulp and Paper Industry (TAPPI) and

EERE have a long-standing relationship dating to 1994 that included

the early development of the Forest Products Industry of the Future

Agenda 2020 activities. They took that relationship a step farther on

March 6, 2002 with the signing of an Allied Partnership agreement. As

Allied Partners, TAPPI and EERE will work together to help the pulp

and paper industry capture a part of the large energy savings opportunities that exist within mills throughout the United States, and to help

focus the industry on issues such as energy and environmental

concerns.

In May 2001, TAPPI, DOE and the American Forest and Paper

Association co-sponsored the Forest, Wood, and Paper Industry

Technology Summit. A group of 147 pulp and paper industry experts

gathered to determine the path for research to be pursued under the

Agenda 2020 program to deliver commercially viable systems by

2008. The industry’s vision is that integrated paper manufacturing will

one day require no fossil fuel energy and even be a net exporter of

electricity. Efforts currently underway as a result of this conference

will provide the direction for an effective, industry-led public/private

partnership for many years to come. 

TAPPI is helping this partnership come to life by communicating

Summit results through publications and conferences so it reaches the

largest possible audience in the most efficient way. A series of articles

on the technical and direction-setting substance of the Summit began

running in the TAPPI journal Solutions! in September 2001 and will

continue in the months to come.

Most recently, TAPPI and EERE created the Energy Results Showcase,

held March 5-7, 2002, with presentations and sessions in Atlanta and 

a DOE showcase at Augusta Newsprint in Augusta, Georgia. The 

two groups identified topics and coordinated promotion efforts to

deliver a complete program focused on methods to manage and 

lower energy costs. 

The Texas Industries of the Future (IOF) program, sponsored by the

Texas Energy Coordination Council, leverages the programs and tools

of the U. S. Department of Energy’s Industries of the Future. Three

IOF sectors, chemicals, refining, and forest products, account for 86

percent of the energy used by industry in Texas, and Texas industrial

energy use accounts for 20 percent of all energy used by industry in

the United States.

Texas IOF activities include:

• Forming an executive steering committee early on, consisting of

industry and academic advisors in chemicals, refining, forest

products, and agriculture.

• Introducing national and state IOF programs to 75 attendees from

industry, academic institutions, and government agencies at a

two-day conference, which included roadmapping R&D needs

(May 2001).

• Organizing a Texas IOF and EERE conference on energy efficiency strategies and emerging technologies to reduce NOx emissions

from industrial facilities (July 2001). EERE contractors introduced a model that incorporates best energy management practices into a facility’s NOx reduction strategy. To follow up on

this very positive reception, Texas IOF will develop a computerized tool to assist facility engineers to evaluate tradeoffs among

technology capital and operating costs, NOx reductions, and energy usage.

• Publicizing Texas IOF Best Practices training sessions to its mailing list and through trade associations. The training sessions are

well received by industry. 

• Holding a 1-day workshop held in February 2002 with the Texas

forest products industry to identify needs. One of the group’s

conclusions was that the Texas forest products industry would

benefit from cross-industry interaction. 

• Planning a Texas Technology Showcase to be held in March 2003

in Houston that will focus on energy-efficient technologies and

best practices that reduce NOx and VOCs in the chemical and

refining industries. 

Three IOF sectors

account 

for 86 

percent of

industrial 

energy

use in 

Texas,

which 

accounts for 

20 percent of all energy 

used by industry in the United States.

TAPPI Texas Energy Coordination Council

TAPPI and EERE will

work together to help the pulp 

and paper industry capture a part of

the large energy savings opportunities

that exist within mills throughout the

United States, and to help focus 

the industry on issues such as

energy and environmental

concerns. 

33

Percentage of total Texas 

industrial energy use

Chemicals 42%
The Timken Company’s commitment to innovation in the area of

energy conservation drives the company’s involvement in partnerships

with outside organizations. Timken serves a leadership role in strategic

planning initiatives to further broad-based energy reduction efforts

throughout the steel industry. Timken Project Manager of Process

Technology, Dr. Robert V. Kolarik, currently chairs the American Iron

and Steel Institute’s (AISI) Strategic Planning for R&D Group, which

advises AISI’s Committee on Manufacturing Technology. 

Timken also engages in several collaborative partnerships with the

Office of Energy Efficiency and Renewable Energy (EERE), including

revising and re-issuing the U.S. Steel Industry Technology Roadmap.

The company participates in eight projects funded by the U. S.

Department of Energy, including demonstrations of a newly developed

off-gas sensor for electric-arc furnaces at its Faircrest Steel Plant in

Canton, Ohio.

Timken collaborates with EERE on other projects including:

• Laser Ultrasonic Technology—Developing laser ultrasonic 

technology to measure the wall thickness of seamless mechanical

steel tubing for use by mill operators in process control. Projected

benefits include increased yield, reduced scrap and rework, and

annual savings of $4 million.

• Controlled Thermo-Mechanical Processing—Developing controlled thermo-mechanical processing technology in steel production to reduce heat-treatment cycles through control of the

microstructure of steel. Projected benefits include more efficient

processes and annual savings of $16 million.

The Timken Company is a leading international manufacturer of

bearings, alloy, and specialty steels and components, as well as related

products and services. The company employs approximately 18,900

associates in 24 countries around the globe.

The Timken Company’s

commitment to energy conservation

makes partnerships with outside 

organizations necessary to achieve 

broad-based conservation objectives.

—William A. Fladung

The Timken Company 

The Timken Company U.S. Steel

Over a century after its founding, the United States Steel Corporation

remains the largest integrated steel producer in the United States.

Headquartered in Pittsburgh, Pennsylvania, the company manufactures

and sells a wide variety of steel sheet, plate, tubular and tin product,

coke, and taconite pellets to customers around the world.

To maintain its station as an industry leader, the U.S. Steel invests

heavily in advanced technologies and continuous improvements in its

operations. Working in conjunction with the Office of Energy

Efficiency and Renewable Energy (EERE), the U.S. Steel conducted

plant-wide assessments of energy use and implemented several

improvement projects at the company’s Irvin and Edgar Thomson

Plants in Pennsylvania’s Mon Valley. In 2001 the Edgar Thomson

Plant was named the EERE Plant of the Year for its energy 

conservation improvements. 

In addition to these

efforts, the U.S. Steel

was the leading

contributor to the

development 

of the U.S. 

Steel Industry

Technology

Roadmap, with

U.S. Steel 

representative

Mark Atkinson 

co-chairing the project.

The company is also 

a participant in several collaborative 

projects with EERE:

• Blast Furnace Hot Oxygen Injection—Collaborating on an effort

to develop a system for direct injection of hot oxygen into blast

furnaces to create improved mixing and combustion conditions

for blast furnace coal injection. Projected benefits include

reduced operating costs, energy consumption, and emissions, and

savings of $2.24 million/year per furnace.

• Increased Uniformity of High-Strength, Low-Alloy Sheet

Steels—Helping to investigate the factors that reduce variability

in yield strength and grain size of hot-rolled steel to strengthen

the market for high-strength, low-alloy sheet steels, which are

used primarily for automobile parts. Projected benefits include

improved production yield and quality, and resulting savings, and

increased fuel efficiency in automobiles.

In 2001 the Edgar Thomson Plant

was named the EERE Plant of the

Year for its energy conservation

improvements. 

34
The theme of Utah Industries of the Future award-winning Web site

(www.uiof.org) is “What IF.” We have been asking industries “What

IF you had a clear vision of the future? What IF you had a technology

roadmap to take you there? What IF you could reduce your steam costs

by 20 percent? What IF?”

The Utah Industries of the Future (Utah IOF) is working on the ground

in Utah to develop partnerships to turn these and other possibilities

into realities. Since its launch in November 1999, Utah IOF has

delivered training and workshops, sponsored meetings and conferences, provided technical training, developed leadership partners, and

assisted with the Utah 2001 Industry Showcase. Early industry assessment identified the mining and metals industries as key components of

Utah’s IOF industries. The Utah Mining and Processing Industries

Collaborative (UMPIC) is working to address the needs of these 

industries (www.umpic.utah.edu).

In January 2001, Utah IOF and UMPIC hosted an Industry Roundtable

which brought together high-level participants from crosscutting industries. The crosscutting format—including coal mining, metals mining

and refining, petroleum, metal casting, steel, cement, and other large

Utah industrial businesses—was based on the advice and suggestions

from the industries themselves. Participants representing 23 industries

ranged from the President of Andalax Coal, to the Director of

Engineering and Technology at Geneva Steel, to the Director of

Technology for Kennecott Utah Copper. All the participants said that

the roundtable was “worth my time.” Comments included, “The most

valuable aspect of the roundtable was the cross-company (industries)

information passed and discussed.”

Utah Virginia Tech

Virginia Polytechnic Institute and State University (Virginia Tech)

Department of Mining and Minerals Engineering is home to two major

mining and energy research centers. These are the Virginia Center for

Coal and Energy Research (VCCER) and the Center for Advanced

Separation Technologies. Major areas of research include:

• Mining Systems Simulation

• Virtual Reality Applications in Mining 

• Energy Planning and Management

• Rock Mechanics and Ground Control

• Solid-Solid Separation

• Solid-Liquid Separation

• Environmental Management and Control.

Research in these areas is helping to improve safety, energy efficiency,

productivity, and environmental performance in the mining industry. 

Virginia Tech brings this technical expertise to the Mining Industry of

the Future partnership on a number of R&D programs. For example,

Dr. Erik Westman of the Department of Mining and Minerals

Engineering assembled an outstanding project team to develop and test

innovative engineering tools to improve coal recovery. These tools

include R&D with technologies to perform imaging ahead of mining

and sensors to perform real-time stress measurement. These technologies have the potential to reduce mining costs, improve mine safety,

and reduce energy requirements. 

Virginia Tech is also leading R&D on cyclone technologies to improve

energy efficiency in separating coal and minerals from ore. As a result

of the Mining IOF collaborative partnership with Massey Coal, Precision

Testing Laboratory, and Partition Enterprises Ltd., Dr. Gerald Luttrell

of the Department of Mining and Minerals Engineering is implementing

new operating and maintenance standards for the coal industry.

Michael Karmis, Stonie Barker Professor of Mining and Minerals

Engineering and Director of the VCCER, is a State IOF champion in

Virginia and at the national level. As president of the Society for

Mining, Metallurgy, and Exploration, Inc., Dr. Karmis is working

closely with EERE to communicate Mining IOF research priorities.

Through a State IOF grant, Virginia Tech is holding seminars for the

Virginia mining industry on energy management, reforestation, 

environmental remediation, novel training concepts, mining systems

optimization, and implementation of fuel cell technologies in underground mining. This work supports vital

technology transfer from research

institutions to industry. 

Virginia Tech is

helping to

improve 

safety, 

energy 

efficiency, 

productivity,

and environmental performance in the 

mining industry.

35

Bank of three dense medium

cyclones in operation at a coal 

preparation plant

What IF you had a

clear vision of the

future? What IF

you had a

technology

roadmap to

take you

there? What

IF you could

reduce your

steam costs by 20

percent? What IF?

Industry leaders address Utah congressional

representatives at a field hearing during

the Utah 2001 Industry Showcase
Founded in 1909, the Weirton Steel Corporation is the nation’s seventh

largest integrated steel company and second largest manufacturer of

tin-plated steel. The company embraces innovation and partnerships

dedicated to the advancement of the industry, including collaboration

with the Office of Energy Efficiency and Renewable Energy (EERE) in

a range of activities.

In May 2000, Weirton partnered with EERE in a demonstration of

energy efficiency and productivity advancements in the Pittsburgh

Regional Technology Showcase. The company provided guided tours

and technical presentations of the cutting edge technologies in use at its

Weirton Steel Plant. The plant tours demonstrated how EEREsupported R&D and BestPractices are increasing the energy efficiency

of steel production and improving its quality.

More recently, Weirton has undertaken a number of EERE-supported

efforts directed at improving energy efficiency in its operations,

including:

• Plant-wide Energy Efficiency Assessments—Evaluating its plant

processes to uncover areas in which modifications in procedures

or technologies could improve energy efficiency in the areas of

compressed air system design, utilities automation, and water

pumping. Projected benefits include: $1 million/year from

improved utilities automation and at least $150,000/year from

reconfigured compressed air systems.

• Infrared-based Steel Strip Preheating—Working with the Oak

Ridge National Laboratory to implement a system using infrared

technology to preheat steel strip entering the furnace. Projected

benefits include reduced energy use and increased throughput.

• Boiler Panel Overlay—Weld-overlaying boiler panels with new

materials that will improve overall boiler efficiency and greatly

reduce maintenance requirements. Projected benefit include 

savings of $5.2 million in operating and maintenance costs.

In addition to these projects, Weirton is currently investigating efficiency

improvements through the use of innovative materials in galvanizing

pot hardware and recycling and/or marketing iron-bearing mill wastes,

among other areas.

Weir Specialty Pumps Weirton Steel

Weir Specialty PumpsTM (WSP) is part of the WEIR Group PLC in

Glasgow, Scotland. The Group, founded in 1871 and today one of the

world’s top pump manufacturers, has nearly 10,000 employees with an

extensive global network of manufacturing plants and service operations.

The Group serves a number of global markets including power,

oil/gas, water/sewage, marine, minerals processing, and general industrial. 

Headquartered in Salt Lake City, Utah, Weir Specialty Pumps has been

providing the world with specialized pumps and equipment for nearly

a century. Municipal waste water and sludge, power generation,

chemical processing, pulp and paper, phosphate and fertilizer, oil

drilling, food handling, and high-pressure cleaning are just a few of

the many industries served by Weir Specialty Pumps products.

Through its partnership with DOE, Weir Specialty Pumps has

promoted energy efficiency in a number of ways in the past 3 years:

• In December 1999, WSP co-hosted a Pump Systems Assessment

Tool (PSAT) workshop in Houston.

• In April 2001, Tom Angle, Director of Engineering and R&D,

participated in PSAT training to become certified as a Qualified

PSAT Specialist.

• In June 2001, Weir Specialty Pumps became an Allied Partner

with the DOE’s Office of Energy Efficiency and Renewable

Energy (EERE). 

• In November 2001, WSP co-hosted a PSAT workshop in Baton

Rouge, Louisiana, distributing 50 copies of the DOE Decision

Tools CD. 

• During the past 3 years, WSP supported Mr. Angle’s efforts as

one of the editors of the Hydraulic Institute’s Pump Life Cycle

Costs: A Guide to LCC Analysis for Pumping Systems guide.

• WSP is in the process of making major design changes to its

Roto-Jet® line of pumps, significantly increasing hydraulic 

efficiency and reducing energy consumption. This effort will 

be completed in 2002.

Through its 

partnership 

with DOE, 

Weir Specialty

Pumps has

promoted

energy 

efficiency 

in a number 

of ways in 

the past 3 years.

36

Roto-Jet pumps manufactured by Weir

Specialty Pumps will be used for

NOx suppression on gas

turbine generators

When spot natural gas

prices hit $10 per

thousand cubic

feet not too

long ago, we

were very

lucky to 

have a 

project

pipeline and

network of 

technology support

already in place.

—Phil Elbaz

Weirton Steel 

Weirton’s Dave Yelegol (l) and Rick

Martin (r) observe a slab exiting

hot mill reversing rougher.
In 1994, the forest products industry signed a Compact with DOE’s

Office of Energy Efficiency and Renewable Energy (EERE) and the

industry’s technology visioning process, Agenda 2020, was born.

Weyerhaeuser scientists, engineers, and executives have participated in

all of the six task groups of Agenda 2020 and have provided leadership to five of these during much of this period. Currently the

Sustainable Forest Productivity, Environmental Performance, and

Recycling task groups are co-chaired by Weyerhaeuser staff as is the

Chief Technology Officers Committee.

Weyerhaeuser has benefited in many ways from this important partnership. In 1994, the company received a grant from DOE to study the

possibility of locating a biomass gasification combined cycle technology at its mill in New Bern, North Carolina. As part of the same

study the potential of producing ethanol from biomass was also 

thoroughly evaluated. A follow-on grant in 1996 focused on a detailed

feasibility study of the gasification plant and scoped the conditions

that would be necessary for such a project to be economically sustainable. The results of this effort are still used as a primary reference for 

evaluating possible gasification applications in Weyerhaeuser mills. 

In 2001, Weyerhaeuser began to work with DOE in carrying out

thermal and electrical conservation assessments. Currently, two

assessments are underway at mills in Longview, Washington and

Plymouth, North Carolina. The company is an active participant in

DOE’s BestPractices activities and has taken advantage of best

practice training in selected areas. An Allied Partner agreement is

currently under consideration in order to allow a wider dissemination

of the products offered by EERE.

Most recently, the company has cooperated with EERE in hosting a

Washington State Industry of the Future event at its technology center

in Federal Way, Washington. Since the mid-seventies the relationship

between Weyerhaeuser and EERE has been an excellent example of an

effective and efficient partnership between industry and government

that has benefited Weyerhaeuser, its customers, and its stakeholders.

In 1994, the forest products

industry signed a compact with

EERE and the industry’s technology

visioning process, Agenda 

2020, was born.

West Virginia Weyerhaeuser

The West Virginia Industries of the Future (IOF) program was established in 1997 by West Virginia University and a coalition of industry

and state government representatives. The initiative is part of DOE’s

Office of Energy Efficiency and Renewable Energy’s (EERE) States

Industries of the Future program, which aims to increase industrial

energy efficiency by encouraging and sponsoring collaborative R&D

partnerships at the local and state levels. 

The West Virginia IOF has developed industry-specific roadmaps that

identify critical paths for adopting energy efficiency and pollutioncontrol strategies, increasing asset productivity, and strengthening the

state economy. As a result of these roadmaps, industry members are

participating in energy-saving projects worth over $13 million. The

West Virginia IOF is focused on the steel, aluminum, glass, chemical,

forest products, mining, and metal casting industries. The West

Virginia effort is considered a “model” State IOF program because it

was well-conceived and has been energetically implemented by

members of West Virginia Industry and academia. The program has

gained strong support from prominent federal, state, and local officials

such as Senator Jay Rockefeller, West Virginia Governor Cecil

Underwood, and the President of West Virginia University David

Hardesty, Jr. Most importantly, the West Virginia program is considered successful because it has produced quantifiable energy-savings for

state industry. At the last symposium, in December 2001, the state

signed a Memorandum of Understanding (MOU) with DOE to

formalize and celebrate the West Virginia IOF. Because the West

Virginia program has been so effective, other states are using the

program as a guide.

The West Virginia IOF has resulted in numerous benefits for the state.

One benefit has been retention of industry in the state, which is at risk

due to increasing global competition. The West Virginia IOF is the

foundation of the state’s technology-based industrial retention activities

because identifying and implementing new technologies are key to

keeping a strong manufacturing base in the state.

The West Virginia

effort is 

considered a

“model”

State IOF

program

because it

was wellconceived

and has been

energetically

implemented by 

members of West Virginia Industry and academia.

37

From Left: Denise Swink, Carl Irwin,

Governor Underwood at MOU

signing event
Shortly after Wisconsin became a State Industries of the Future (IOF),

the state government was given the responsibility for promoting

energy efficiency–a task usually performed by public utilities. The

change was timely, according to Preston Schutt of the Wisconsin

Division of Energy. “The IOF provided an outreach model to help us

get our industrial programs off the ground quickly,” he said. Key to the

effort is promoting DOe’s office of Energy Efficiency and Renewable

energy (EERE) BestPractices to Wisconsin’s industries. “Our goal is to

work with our firms to institutionalize energy efficiency best practices.

We will also work with suppliers to ensure the marketplace provides

those goods and services,” said Schutt. “We’re about to kick this effort

into high gear.”

Wisconsin began its state IOF program by focusing on metal casting

and forest products, two of its largest industries. About 80 of the

state’s 260 metal casters came together for the first time to create a

roadmap with 14 action items. Enthusiasm was so high for one item

that work began right away. About 10 small foundries are working to

pool their waste foundry sand to attain sufficient volume and consistency for aftermarket uses. This pilot project could lead to other

regional collaborations where several foundries band together to

provide sand suitable for reuse in asphalt production. This could save

significantly on disposal costs and landfill space. 

The first forest products roadmap sessions brought together more than

40 representatives, whose effort resulted in its completion at the end of

2001. Partnerships forged at the meeting have already led to the

submission of a number of proposals to EERE’s NICE3 technology

demonstration grant program, one of which won funding in 2002 for

an alternative biopulping process. 

In 2001, Wisconsin received funding to begin work on the state’s agriculture industry, and they hosted their first biotech roadmapping

session in March, 2002. Biotechnology is a growing industry in the

state with more than 3,000 organizations in the Madison area alone.

Future plans for Wisconsin IOF include expanding participation in

other key industries such as glass and chemicals, with the state also

working on non-IOF projects in the printing, food processing, and

plastics industries. 

The IOF provided

an outreach

model to

help us

get our

industrial 

programs 

off the 

ground quickly.

— Preston Schutt

Wisconsin Division of Energy

Valri Robinson, DOE Industrial

Technologies, at the Wisconsin Forest

Products Roundtable

Wisconsin WPI

The Center for Heat Treating Excellence (CHTE) located at Worcester

Polytechnic Institute (WPI) is dedicated to the advancement of heattreating processes through collaborative research and development in

accordance with the Heat Treating Technology Roadmap and the

Current R&D Plan and Vision 2020 Document. Both of these

documents were established through industry workshops sponsored by

DOE’s Office of Energy Efficiency and Renewable Energy. The Center

was established in 1999 within the Metal Processing Institute (MPI) at

WPI as an alliance between the industrial sector consisting of heat

treaters, heat-treating suppliers and manufacturers of industrial

products, and university researchers. 

MPI’s vision is to be the premier university-based research facility

dedicated to advancing the state of the art in near-net-shape manufacturing. Through its focus on metal processing, MPI brings fundamental

understanding to existing processes, develops new methods, and

addresses management-technology interface issues with input from its

industrial partner. The CHTE member companies define and direct the

needed research, whereas the WPI faculty members, and their respective research team members, address fundamentals that are needed to

establish the knowledge base for the heat treating sector.

CHTE develops innovative processes to control micro-structure and

properties of metallic components, reduce energy consumption, reduce

process time, reduce production costs, achieve zero distortion, increase

furnace efficiency and achieve zero emissions. The Center’s consortium funded and launched four research projects in year 2000. These

are: Analytical Tools for Parts Loading Design and Temperature

Control; Quenching Control Process; Distortion and Residual Stress

Control; and Solution Heat Treatment of Aluminum Alloys. The

following two new projects were added to CHTE’s research portfolio

in 2002: Quenching–Understanding, Controlling and Optimizing the

Process, Phase II; and Enhancement of the Computer-Aided Heat

Treatment Planning System. Visit www.wpi.edu/+mpi for more information.

The

Center for Heat Treating

Excellence (CHTE) located at

Worcester Polytechnic Institute

(WPI) is dedicated to the advancement

of heat-treating processes through collaborative research and development in

accordance with the Heat Treating

Technology Roadmap and the

Current R&D Plan and Vision

2020 Document.

38
Advanced Ceramics Research, 2

AIChE, 2

Air Products and Chemicals, Inc., 3

Alcoa, 3

Alliance to Save Energy, 4

Aluminum Association, 4

AMCAST, 5

American Iron and Steel Institute, 5

American Petroleum Institute, 6

Applied Proactive Technologies, 6

ASERTTI, 7

Augusta Newsprint, 7

Boise Cascade, 8

Cargill Dow, 8

Cast Metals Coalition, 9

Chevron, 9

Commonwealth Aluminum, 10

Compressed Air and Gas Institute, 10

Compressor Distributor Association, 11

ConservAIR, 11

CONSOL Energy, 12

Delphi Automotive, 12

Dow Chemical, 13

Dupont, 13

Emerson Electric, 14

Energy Center of Wisconsin, 14

Energy Research Company, 15

Fairbanks Morse, 15

Flying J Refinery, 16

FMC Corporation, 16

Forging Industry Association, 17

Gas Technology Institute, 17

GMIC, 18

Hitchiner, 18

Hydraulic Institute, 19

Idaho, 19

IHEA, 20

Imerys, 20

Iowa State University, 21

ITT Industries, 21

Kaeser Compressor, 22

Kennecott Utah Copper, 22

Kentucky, 23

Maine, 23

Mercury Marine, Brunswick, 24

MTI, 24

NASEO, 25

National Corn Growers Association, 25

National Mining Association, 26

NIA, 26

NPRA, 27

Northeast Utilities, 27

Owens Corning, 28

PPG Industries, 28

Praxair, 29

Rohm and Haas Company, 29

SECAT, 30

Silver Eagle, 30

SMUD, 31

Spirax Sarco, 31

Steel Manufacturers Association, 32

Superior Aluminum, 32

TAPPI, 33

Texas Energy Coordination Council, 33

The Timken Company, 34

U.S. Steel, 34

Utah, 35

Virginia Tech, 35

Weir Specialty Pumps, 36

Weirton Steel, 36

West Virginia, 37

Weyerhaeuser, 37

Wisconsin, 38

WPI, 38

Profiled Partners 

39
About the Office of 

Energy Efficiency 

and Renewable 

Energy (EERE)

Through partnerships with industry,

government, and non-governmental

organizations, the office develops and

delivers advanced energy efficiency,

renewable energy, and pollution 

prevention technologies for industrial

applications. 

EERE encourages industry-wide efforts to

boost resource productivity through the

Industries of the Future (IOF) strategy. The

industry-led IOF strategy focuses on these energy and

resource intensive industries:

These nine industries account for more than 80 percent of the manufacturing sector’s

energy use. In addition, they account for more than 80 percent of the volume of all

waste and pollution generated in manufacturing, and about two-thirds of all

pollution control expenditures in manufacturing.

To help industries begin saving energy, reducing costs, and cutting pollution right

away, EERE offers a comprehensive portfolio of emerging technologies, practices,

tools, information, and resources in a variety of application areas. Visit our Web 

site at www.eren.doe.gov to find out more about EERE and how your company 

can get involved.

Notice

This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United

States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes

any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or

process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific

commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute

or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and

opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency

Agriculture

Aluminum

Chemicals

Forest

Products

Glass

Metal Casting

Mining 

Petroleum

Steel
About BestPractices 

BestPractices is part of the Industries of the Future (IOF) strategy.

BestPractices assists the nine Industries of the Future—agriculture, aluminum,

chemicals, forest products, glass, metal casting, mining, petroleum, and steel—

in identifying and realizing their best energy efficiency and pollution 

prevention options from a system and life-cycle cost perspective. 

Through activities such as plant-wide energy assessments, implementation of

emerging technologies, and energy management of industrial systems,

BestPractices delivers energy solutions for industry that result in significant

energy and cost savings, waste reduction, pollution prevention, and enhanced

environmental performance. In addition, EERE’s Industrial Assessment

Centers provide comprehensive industrial energy evaluations to small and

medium-size manufacturers.

BestPractices also works with an extensive network of Allied Partners to help

deliver energy efficiency information to industry. Allied Partners enhance the

IOF strategy by working with these industries to adopt proven technologies

and best energy management practices. 

BestPractices offers a wide range of resources—software, training, tip sheets,

case studies, sourcebooks, and a bi-monthly newsletter—to industry on how 

to take advantage of energy and cost saving opportunities in their facilities.

To learn more about BestPractices, visit our Web site at www.oit.doe.gov/

bestpractices.

For Additional Information Please Contact:

Industrial Technologies Clearinghouse

Phone: (800) 862-2086

Fax: (360) 385-8303

Clearinghouse@ee.doe.gov

Photo Credits

Page 1, Industry executives at Utah Showcase; courtesy of Rolf Butters, DOE.

Inside Back Cover, Left, Biomass power plant; courtesy Wheelabrator Shasta 

Energy Co., PIX 07163.

Inside Back Cover, Right, Flying J staff, Utah Showcase; courtesy Rolf 

Butters, DOE.

Outside Back Cover, Denise Swink, DOE, and TAPPI President Mike Wallace;

courtesy Grace Ordaz, DOE.
Cargill Dow, LLC • Dow Chemical • Alcoa • Commonwealth Aluminum • Energy Research Company • Air Products • Dupont • FMC • Rohm & Haas • Abitib

Corporation • Superior Aluminum • Imerys • Kennecott Utah Copper Corporation • Chevron • Flying J Refinery • Silver Eagle • Timken • USX • Weirton S

National Corn Growers Association • Aluminum Association • SECAT • AlChE • TAPPI • GMIC • Cast Metal Coalition • National Mining Association • Americ

Air and Gas Institute • C compressor Distributor Association • National Insulation Association • Forging Industry Association • WPI Center for Heat Treating E

State University • Hydraulic Institute • NASEO • Idaho • Maine • Texas Energy Coordination Council • Utah • West Virginia • Cargill Dow, LLC • Dow Chemic

• Georgia Pacific • Weyerhaeuser • Owens Corning • PPG Industries • AMCAST • Hitchiner • Mercury Marine, Brunswick Corporation • Superior Aluminu

Compressors • Pneumatic/ ConservAIR • Emerson electric ITT Fluid Technologies • Fairbanks Morse • Spirax Sarco • National Corn Growers Association

Petroleum and Refiners Association • American Iron and Steel Institute • Steel Manufacturers Association • Compressed Air and Gas Institute • C compresso

Institute • Metal Powder Industry Foundation • Alliance to Save Energy • ASSERTI • Energy Center of Wisconsin • Iowa State University • Hydraulic Inst

Aluminum • Energy Research Company • Air Products • Dupont • FMC • Rohm & Haas • Abitibi-Consolidated • Boise Cascade • Georgia Pacific • Weyerha

Copper Corporation • Chevron • Flying J Refinery • Silver Eagle • Timken • • Weirton Steel • Delphi Automotive • Kaeser Compressors • Pneumatic/ Conse

• AlChE • TAPPI • GMIC • Cast Metal Coalition • National Mining Association • American Petroleum Institute • National Petroleum and Refiners Association

Insulation Association • Forging Industry Association • WPI Center for Heat Treating Excellence • Materials Technology Institute • Metal Powder Industry

Texas Energy Coordination Council • Utah • West Virginia • Cargill Dow, LLC • Dow Chemical • Alcoa • Commonwealth Aluminum • Energy Research Co

Industries • AMCAST • Hitchiner • Mercury Marine, Brunswick Corporation • Superior Aluminum • Imerys • Kennecott Utah Copper Corporation • Chevron 

Fluid Technologies • Fairbanks Morse • Spirax Sarco • National Corn Growers Association • Aluminum Association • SECAT • AlChE • TAPPI • GMIC • Ca

Institute • Steel Manufacturers Association • Compressed Air and Gas Institute • C compressor Distributor Association • National Insulation Association • Forg

Energy • ASSERTI • Energy Center of Wisconsin • Iowa State University • Hydraulic Institute • NASEO • Idaho • Maine • Texas Energy Coordination Cou

FMC • Rohm & Haas • Abitibi-Consolidated • Boise Cascade • Georgia Pacific • Weyerhaeuser • Owens Corning • PPG Industries • AMCAST • Hitchiner •

• Timken • • Weirton Steel • Delphi Automotive • Kaeser Compressors • Pneumatic/ ConservAIR • Emerson electric ITT Fluid Technologies • Fairbanks Mo

Association • American Petroleum Institute • National Petroleum and Refiners Association • American Iron and Steel Institute • Steel Manufacturers Associa

for Heat Treating Excellence • Materials Technology Institute • Metal Powder Industry Foundation • Alliance to Save Energy • ASSERTI • Energy Center 

Dow, LLC • Dow Chemical • Alcoa • Commonwealth Aluminum • Energy Research Company • Air Products • Dupont • FMC • Rohm & Haas • Abitibi-C

Corporation • Superior Aluminum • Imerys • Kennecott Utah Copper Corporation • Chevron • Flying J Refinery • Silver Eagle • Timken • • Weirton Steel • D

Corn Growers Association • Aluminum Association • SECAT • AlChE • TAPPI • GMIC • Cast Metal Coalition • National Mining Association • American Petr

Gas Institute • C compressor Distributor Association • National Insulation Association • Forging Industry Association • WPI Center for Heat Treating Excelle

For more information, please contact:

Industrial Technologies Clearinghouse

Phone: (800) 862-2086

Fax: (360) 385-8303

clearinghouse@ee.doe.gov

Visit our Web site at www.oit.doe.gov

Energy Efficiency and Renewable Energy

U.S. Department of Energy

Washington, DC 20585

DOE/GO-102002-1550

April 2002

Printed with a renewable-source ink on paper containing at least 50% wastepaper,

including 20% postconsumer waste.