Industrial Technologies Program — Boosting the Productivity and

Competitiveness of U.S. Industry

Industry consumes 33 percent of all energy used in the United States. By developing and adopting more

energy efficiency technologies, U.S. industry can boost its productivity and competitiveness while

strengthening national energy security, improving the environment, and reducing emissions linked to global

climate change.

The U.S. Department of Energy’s (DOE) Office of Energy Efficiency and Renewable Energy (EERE) works in

partnership with U.S. industry to increase the efficiency of energy and materials use, both now and in the

future. EERE’s Industrial Technologies Program (ITP) is working to build the Industries of the Future through

a coordinated program of research and development (R&D), validation, and dissemination of energy

efficiency technologies and operating practices to reduce energy intensity in the industrial sector. ITP

develops, manages, and implements a balanced portfolio that addresses industry requirements throughout

the technology development cycle. The primary long-term strategy is to invest in high-risk, high-return R&D.

Investments are focused on technologies and practices that provide clear public benefit but for which market

barriers prevent adequate private sector investment.

ITP focuses its resources on a small number of energy-intensive materials and process industries that account

for over 55 percent of industrial energy consumption.

ITP also conducts R&D projects on enabling technologies that are common to many industrial processes such

as industrial energy systems, combustion, materials, and sensors and process control systems. In addition,

ITP funds technical assistance activities to stimulate near-term adoption of best energy-saving technologies

and practices within industry. These activities include plant assessments, tool development and training,

information dissemination, and showcase demonstrations.

New technologies that use energy efficiently also lower emissions and improve productivity. By leveraging

technical and financial resources of industry and government, the ITP partnerships have generated

significant energy and environmental improvements that benefit the nation and America’s businesses.

Energy-intensive industries face enormous competitive pressures that make it difficult to make the necessary

R&D investments in technology to ensure future efficiency gains. Without a sustained commitment by the

private and public sectors to invest in new technology R&D and deployment, the ability to close the gap

between U.S. energy supply and demand will be severely compromised.

• Forest Products

• Glass

• Metal Casting

• Mining

• Steel

• Aluminum

• Chemicals

ITP uses a leveraging strategy that maximizes the energy and environmental benefits of its process-specific

technology investments by coordinating and cooperating with energy-intensive industries. By working

closely with the private sector, ITP is able to effectively plan and implement comprehensive R&D agendas and

help disseminate and share best energy management practices throughout the United States. The ITP publicprivate partnerships also facilitate voluntary efforts, such as the President’s Climate VISION initiative, to

encourage industry and government to reduce greenhouse gas emissions.
CONTENTS

Executive Summary ............................................................................................................................................ i

Industry Overview ............................................................................................................................................. 1

Glass Industry Shipments and Trade .................................................................................................................. 1

Energy Use .......................................................................................................................................................... 2

The Challenge ..................................................................................................................................................... 5

An Energy-Intensive Industry .............................................................................................................................. 5

Strategy for Improving Glass Industry Energy Efficiency .................................................................................... 6

FY 2004 Highlights & Accomplishments .......................................................................................................... 9

R&D Highlights .................................................................................................................................................... 9

Glass Projects with Completed Government Funding in FY 2004 ..................................................................... 10

Active Glass Projects in FY 2004 ......................................................................................................................... 10

Partnership Highlights ....................................................................................................................................... 12

Improving Energy Efficiency Today ................................................................................................................... 13

Disseminating Research Results to Industry ...................................................................................................... 13

Energy Analysis – Targeting Energy Efficiency ................................................................................................... 13

Tools, Publications, and Resources Available ................................................................................................. 15

How To Get Involved and Contact Information............................................................................................ 16

Partnership Information ................................................................................................................................... 16

Access to Resources and Expertise....................................................................................................................... 16

Where to Go to Get More Information............................................................................................................. 17

Sources ........................................................................................................................................................ 17

EXHIBITS

1. Industry Shipments by Segment, 2001 .......................................................................................................... 1

2. Energy Use in the Glass Industry3

3. Energy Footprint for the U.S. Glass Industry ................................................................................................ 4

4. Process and Technology Improvements Target Energy Efficiency ................................................................. 7

5. FY 2004 Glass IOF Partners ............................................................................................................................ 7
i

EXECUTIVE SUMMARY

The glass industry continues to face significant challenges in maintaining its competitive standing in global

markets. Competition from developing countries where energy and labor are cheaper is putting pressure on

U.S. producers. These difficult conditions are exacerbated by the increasing volatility of domestic energy

prices. Growing societal demands for environmental stewardship, and demand for short-term returns on

investment continue to impact the availability of R&D funds, especially for basic and applied research.

Productivity improvements and economic weakness have led to workforce reductions in the industry. These

challenges have led to a major change in this highly competitive industry. Companies are now more willing

to collaborate in strategic, pre-competitive areas to reduce costs, environmental impacts, and energy use.

The U.S. glass industry is a significant consumer of energy in the manufacturing sector, using an estimated

254 trillion Btu of energy in 1998. More importantly, the high proportion of energy costs (between 15 and 20

percent, depending on segment) as a percent of direct production costs in the industry makes the glass

industry a prime target for energy efficiency R&D. Increasingly stringent environmental regulations

associated with the combustion of fuels, used primarily for process heating in the glass industry, and the

growing volatility of energy markets are making investments in energy efficiency R&D more attractive.

Wellhead prices for natural gas, the glass industry’s fuel of choice, have roughly tripled since the beginning

of the decade. Furthermore, our growing dependence on imported energy threatens our national energy

security and makes a strong case for reducing energy use.

Significant advancements in melting technology are needed to revolutionize the way energy is used in glass

manufacturing. Energy consumed in manufacturing glass products is generally two to three times the

theoretical minimum. More efficient process heating technology can significantly reduce the use of fuels and

electricity required for glass processing.

Transformational R&D, such as that funded by the U.S. Department of Energy (DOE), Office of Energy

Efficiency and Renewable Energy (EERE), Industrial Technologies Program (ITP), is critical to maintaining the

global competitive position of the U.S. glass industry. Studies sponsored by EERE have quantified the

opportunity for saving energy in glassmaking (defined as the difference between today’s energy use and the

practical minimum energy use). DOE’s goal in this area is to develop transformational technologies that will

help the glass industry achieve a 50 percent reduction in the gap between

1995 melting energy use and the theoretical minimum by 2020.

A Successful Strategy with Industry

DOE’s Office of Energy Efficiency and Renewable Energy leads federal

development of advanced energy-efficient and environmentally friendly industrial technologies. Glass

industry R&D is a component of the overall EERE strategy, contributing to a reduction in energy intensity of

industry, a goal outlined in the National Energy Policy.

EERE/ITP is working to build the Industries of the Future through a strategy that is based on multi-year

planning, industry involvement and input during the planning process, and careful analysis and data-based

decision making. This strategy not only takes into consideration the interests of the industry as described in

their R&D Technology Roadmaps, but also consists of an agenda of analytical studies that provide the basis

for decision making. For instance, the Glass Industry Technology Roadmap, published in April 2002, has

provided the basis for focusing R&D by identifying industry research interests. The Glass Energy and

Environmental Profile, and Footprint study were developed using both government and industry data and

information, and industry expertise to provide the next level of prioritization for the portfolio. A bandwidth

analysis is currently underway to add to this analysis and provide support for the prioritization of the

portfolio. By using these studies, the portfolio is able to design a multi-year R&D plan based on the focus

area, barrier, and pathway approach. In this approach, a limited number of critical technology focus areas

are identified along with the technical barriers preventing their successful implementation. A multi-year plan

(called a “Pathway”) is then developed that will guide the R&D activities leading to a successful development

of the focus area technology. The “Pathways” are then the basis for solicitations of pre-competitive R&D

that addresses both energy efficiency goals outlined in the National Energy Policy and glass industry research

The Glass portfolio will help the glass industry

achieve a 50 percent reduction in the gap

between 1995 melting energy use and the

theoretical minimum by 2020.
ii

priorities. This successful strategy has now evolved to a point where it provides focus on potentially highimpact research to make revolutionary improvements in the glass industry. Improving energy efficiency in

glass manufacturing as well as improving glass products, will reduce the energy intensity of industry and

could directly reduce the amount of petroleum imported into the United States, two of EERE’s top priorities.

The EERE Industrial Technologies Program implements the Glass portfolio effort, which seeks to boost

efficiency and productivity of the energy- and resource-intensive glass industry by investing in a balanced

R&D portfolio with broad applicability in furnace operations. ITP works in partnership with the Glass

Manufacturing Industry Council, an organization representing the technology needs of the U.S. glass

industry. The groups involved in this partnership work with industry, academia, national laboratories, and

others to promote technology development of more environmentally sound energy efficiency technologies.

This partnership allows the Glass portfolio to leverage public and private resources and ensure the

application of research results.

Achieving Energy Savings: Portfolio Strategy

ITP supports a Glass portfolio of cost-shared, pre-competitive research addressing key technological needs that

have broad applicability throughout the glass industry. The strategy fosters both revolutionary technologies

and incremental improvement to existing processes, thereby addressing long-term goals without neglecting

short-term opportunities to improve energy efficiency. As the Glass portfolio shifts toward supporting a

smaller number of riskier and more costly high-impact projects, research activities are being organized into

the following categories: next generation melting systems, energy efficiency performance improvements,

advanced processing and environmental R&D, and technology deployment. The FY 2004 ITP Glass Portfolio

included seven R&D projects. Many other projects funded by EERE are applicable to the glass industry. More

information about the Glass portfolio is available on the Industrial Technologies Program Web site at http://

www.eere.energy.gov/industry/glass.

FY 2004 Highlights

• Advanced Glass Furnace Model Commercialized and Receives R&D 100 Award –An advanced glass

furnace model, developed by Argonne National Laboratory, has been commercialized successfully.

Accessible from Argonne’s software shop, the software has established licensure procedures. The model

received one of the prestigious R&D 100 Awards and 17 licenses were signed in 2004. To maximize

effectiveness and adoption, validation studies are continuing and an industry user group is being

formed.

• Furnace Energy Assessment Best Practice Now Available –This protocol for oxy-fuel furnaces,

developed by the Diagnostic Instrumentation and Analysis Laboratory (DIAL) at Mississippi State

University, identifies opportunities for optimizing furnace operations and reducing energy consumption.

Recommendations from the initial assessment of a PPG Industries furnace would improve energy

efficiency by at least 6 percent. DIAL has already received interest from two other glass manufacturers

about utilizing the protocol; a case study is also available.

• Oxy-Fuel-Fired Front-End System Readied for In-Plant Testing at Fiberglass Facility – Owens Corning

and project partners have conducted preliminary work and prepared the demonstration host site in

Jackson, Tennessee for installation of the technology. Analysis indicates that the technology will reduce

fuel use in the front-end system by over 60 percent and NOx emissions by over 90 percent, and will

provide attractive financial returns, with payback time of less than two years.

• Pilot-Scale Testing Underway for High-Intensity Plasma Glass Melter – Plasmelt has designed and

constructed the pilot-scale plasma melter and has operated the unit at 200 pounds of glass per hour with

stable operating conditions for over two hours. Researchers continue to test and improve plasma torches

toward their goal of 500 pounds/hour. In FY 2005, Plasmelt will validate energy efficiency targets and test

glass quality.
• Design of Pilot-Scale Submerged Combustion Melter Underway – In the first full year of this project,

the Gas Technology Institute has worked with project partners to design the pilot-plant unit, purchase

necessary equipment, determine modeling parameters, conduct laboratory-scale testing, and finalize the

consortium agreement. The pilot-scale unit will be constructed and testing will be initiated in FY 2005.

• Technical and Economic Assessment for Next Generation Melting Systems Completed – This

document highlights technical and economic barriers that have stifled innovation and change in glass

processes, including a detailed review of previous research efforts to improve glass melting and refining.

• Strong Collaborative Partnership Continues with Glass Research Community – The ITP Glass

portfolio continues to work closely with industry, university, and national laboratory partners to

maximize potential improvement in energy efficiency. ITP coordinates activities with the Glass

Manufacturing Industry Council (GMIC), which sponsored several workshops to support the Glass

portfolio efforts.

Additional research and partnership highlights can be found in the FY 2004 Highlights and

Accomplishments section (see pages 9-14).

iii
1

INDUSTRY OVERVIEW

Glass is an integral part of the American life style and a staple of the nation’s economic success. Its popularity

as a material stems from its transparent, durable, recyclable, and non-permeable qualities. The U.S. glass

industry is comprised of four major segments based on end products:

• Container glass (bottles, jars, packaging)

• Flat glass (windows, automobile windshields, picture glass)

• Fiberglass (insulation fiberglass, optical fibers, textile fibers)

• Pressed and blown glass (television tubes, light bulbs, table and ovenware, scientific and medical

glassware)

The U.S. glass industry employs over 140,000 workers at approximately 2,500 facilities throughout the nation,

including workers from a fifth glass industry segment, products of purchased glass. This segment includes

items such as mirrors, ornaments, art glass, and aquariums.

Competitive global markets and technological change have led to accelerated restructuring, joint ventures,

mergers, and acquisition activities throughout the industry. Glass companies today are often diversified into

other related products, such as ceramics, packaging, building materials, and other higher margin products.

Glass companies rely on technology, science, and innovation to create value-added products and gain ground

in new markets. However, large capital investments are required to keep glass manufacturing plants operating

at a competitive level. U.S. glass companies’ products compete both with foreign sources and, in many

segments, with other materials such as plastics and metals.

While all glass product segments have melting in common, there are both real and perceived differences in

which types of melting satisfy their individual business needs, such as production rate and compositional

flexibility. Another key attribute is glass quality, and requirements vary from sector to sector. The most

significant quality parameter between sectors is the amount of small gaseous inclusions, called seeds, which are

allowed to remain in the molten glass. Seeds influence the aesthetics and service performance of glass

products. For example, customers would not

tolerate bubbles in auto windshields, but would

not care about imperfections in residential

insulation fiberglass.

Glass Industry Shipments and Trade

In 2001, U.S. glass industry shipments totaled

nearly $28 billion. Exhibit 1 shows the value of

shipments for the major sub-sectors. Products of

purchased glass lead the industry in shipments

with 39 percent, followed by pressed and blown

glass (19 percent), mineral wool/fiber (17 percent),

container glass (15 percent), and flat glass (10

percent). Over the last decade, the industry has

grown at an average rate of about 1 to 2 percent

per year, with highest growth rates in the flat and

fiberglass segments. During the 1990s, industry

consolidation continued and high-value niche

industries such as fiber optics and glass for

electronics began to gain market share. Along with

consolidation has come an increase in foreign

ownership. Today, the U.S. industry has fewer major players in most industry segments. While commodity

glass products continue to form the core of the industry, the highest future growth is predicted to occur in

specialty applications. The U.S. glass industry has generally maintained a small trade deficit (around 1 to 2

percent of net shipments). Annual production of the U.S. glass industry is approximately 20 million tons.

Production of container and flat glass is estimated to be about 9 million tons and 5 million tons respectively.

Source: Annual Survey of Manufactures, DOC.

Exhibit 1

Industry Shipments by Segment, 2001

Products of

Purchased Glass

39%

Container

15%

Flat

10%

Fiber

17%

Pressed and Blown

19%
2

Energy Use

In 1998, energy consumption in the glass industry was estimated at approximately 254 trillion Btu. Energy in

the glass industry is used primarily for process heating. During the last decade, significant improvements

have been made in energy efficiency, reducing energy use per unit of output substantially from the early

1970s. Technologies such as advanced burners, improved refractories, and oxy-fuel firing have played a major

role in efficiency improvements.

Exhibit 2 (page 3) shows the glass industry’s energy inputs by source. Natural gas provides the largest share of

energy for process heat and power. Electricity is primarily used for machine-driven equipment, such as

motors, fans, pumps, and furnace heating.

The industry spent $1.8 billion in energy purchases for fuel and power in 2001, a nearly 30 percent increase

from energy costs in 1997. The dramatic increases in natural gas prices since 2000 have had a substantial

negative impact on the industry as the existing plant infrastructure has a limited ability for near-term

substitution of fuels.

Energy end-use patterns can be illustrated through the use of an energy footprint, shown in Exhibit 3 (see

page 4), which identifies both energy use and losses due to equipment and system inefficiencies. The total

primary energy associated with the glass industry is 372 trillion Btu, which includes energy losses associated

with the generation of power at off-site utilities, and the transport of fuels to the plant site. As shown in

Exhibit 3, these off-site losses are considerable, amounting to about 118 trillion Btu. Furthermore, within the

plant, about 18 percent of the energy delivered to the plant is lost prior to being used in specific processes.

Process heating, mostly from glass melting and refining, represents the largest use of fuels in the glass

industry (91 percent). Electricity use is primarily split between process heating (43 percent) and motor-driven

equipment (41 percent). While not estimated by the energy footprint, process operations represent

substantial energy sinks where new technology, as well as

incremental improvements, can have an impact.

In theory, 2.2 to 2.7 million Btu/ton are required to melt a

ton of glass, depending on the composition of the glass.

Energy is required for the heat of reaction, and enthalpy of

glass and gases emitted. However, inefficiencies cause the

process to consume considerably more energy than is

theoretically required. Glass furnaces, for example, the

mainstay of the industry, often operate with less than the

optimal thermal efficiencies. Much of the heat is lost

through furnace walls and exhaust gases. In practice, two

or three times the theoretical minimum energy is

consumed during the melting and refining of glass.

Glass Segment Average Melting/Refining

Energy Consumption, 1998

(million Btu/ton)

Flat Glass

Fiber Glass

Pressed and Blown Glass

Container Glass

8.6

8.4

7.3

5.5
3

Natural Gas

98% Glass Industry Forming 19%

Furnace

Operations

57%

Batch Preparation

and Charging

5%

The Glass portfolio will reduce 

energy use by 46 trillion Btu

per year in 2020.

Energy Use

Fuels

Electricity

166 trillion Btu

112 trillion Btu

54 trillion Btu

200 trillion Btu

254 trillion Btu

Transmission, distribution

and generation losses

Other

2%

 2001 shipments of $27.7 billion 254 trillion Btu of electricity and fuels

 consumed annually 

 Purchased energy costs in 2001 of

 $1.8 billion

 143,000 employees, of which 81 percent

 are production workers earning 17 percent more than the manufacturing average

Finishing

19%

Exhibit 2

Energy Use in the Glass Industry
4

Steam Plant

Glass Plant Boundary

Purchased 

Electricity 

54

Purchased 

Fuels 

200

Facilities/HVAC/Lighting 13

Losses 6

NAICS 3272 and 3296 Glass & Glass Products, Fiber Glass Total Associated Energy: 372 Trillion Btu

Losses

112

Boiler 

Losses 1

Distribution Losses 8

Process Use

Direct Fuel 195

254 232 187

7 6

Direct 

Electricity 54 

Pumps 4

Fans 3

Materials Handling 2

Motor-Driven 22 

(21 Electric, 1 Fuel)

Equipment 

Losses 32

Other 1

Motor Losses 1 

System Losses 12

Steam 3

Other Fuel 3 

Process Cooling 2

Process Heating 

204 (23 Electric)

253

Central Energy Plant Energy Distribution Energy Conversion Process Energy

4

Sources: Based on 1998 MECS data for 3272 and 1994 MECS data for Fiber Glass (NAICS 3296).

Electricity to 

Processes 

47

Materials Processing 7

Compressed Air 3

Refrigeration 2

Exhibit 3

Energy Footprint for the U.S. Glass Industry
5

THE CHALLENGE

Glass products are an integral part of the American economy and everyday life. These products are used in

food and beverage packaging, lighting, communications, transportation, and building construction.

Today, the U.S. glass industry faces significant challenges in maintaining its leadership position in the global

market. Competition from developing countries is putting increasing pressure on U.S. producers, particularly

countries where energy and labor are cheaper and government subsidies help to fuel new industry with less

stringent regulations. Growing societal demands for cleaner production and environmental stewardship

continue to place increasing pressure on limited R&D funds. Demand for short-term returns on investment in

recent years has also limited the amount of capital available for research activities, especially basic and

applied research. The workforce in the glass industry has dropped in recent years by more than 5 percent,

from 150,000 in 1997 to 143,000 in 2001.

The competitive demands facing glass companies have led to a major change within this highly competitive

industry. For the first time in several decades, glass companies are now willing to collaborate in strategic, precompetitive areas to reduce costs, environmental impacts and energy use. The industry has emphasized in the

Glass Industry Technology Roadmap that collaborative partnerships involving government, industry and

academia will be critical to meeting the technology challenges of the future and accelerating the pace of

technological innovation. Recognizing that R&D consortia could benefit both industry and the nation, the

industry organized the Glass Manufacturing Industry Council, an association of major U.S. glass companies

and supporting organizations. This group works with government and academia to promote the

development of more environmentally sound energy efficiency glass technologies.

An Energy-Intensive Industry

Energy is a major factor in the technology equation for the glass industry. The U.S. glass industry consumed

an estimated 254 trillion Btu of energy in 1998. The magnitude of energy consumed by the industry makes it

a prime target for energy efficiency R&D, with potentially large energy savings opportunities. In 2001, energy

costs accounted on average for about 19 percent of direct glassmaking production costs. The industry relies

primarily on natural gas to provide heating for the manufacture of glass products.

While tremendous advances have been made in energy efficiency since the oil crisis of the 1970s, the industry

still relies on many processes that are relatively inefficient and energy intensive. When energy costs are low

relative to the costs of processing and other inputs to production, investments in energy efficiency often take

a backseat to investments in environmental compliance or product development. However, increasingly

stringent environmental regulations associated with the combustion of fuels and the growing volatility of

energy markets are moving energy efficiency to the forefront. The record high prices for natural gas over the

last two years, for example, have forced plants to close and to move production out of North America to

locations where natural gas is cheap and plentiful.

The government and the glass industry have overlapping interests for improving energy efficiency. By

improving the efficiency of glassmaking, the glass industry benefits by reducing production costs and by

becoming more competitive. The government also desires both near- and long-term solutions for reducing

domestic energy consumption. Innovative glass products, such as advanced windows and lighting products,

which allow consumers to use less energy, will also help the United States reduce energy demand. However,

permanent technology changes, rather than short-term fixes, are needed to revolutionize the way energy is

used in glass manufacturing. Efforts have been initiated to develop a next-generation melting system to

significantly reduce energy requirements for glassmaking.

Glass industry R&D is a component of the overall EERE strategy to improve energy efficiency and contributes

to the goals outlined in the National Energy Policy. Specifically, improving energy efficiency in glass

manufacturing will reduce the energy intensity of industry and indirectly reduce the amount of petroleum

imported into the United States, two of EERE’s top priorities.
Strategy for Improving Glass Industry Energy Efficiency

The U.S. Department of Energy’s (DOE) Office of Energy Efficiency and Renewable Energy (EERE) leads the

federal role in developing advanced energy efficiency and environmentally friendly industrial technologies.

The EERE Industrial Technologies Program (ITP) implements the Glass portfolio effort, to boost efficiency and

productivity of the energy-intensive glass industry.

ITP’s Glass portfolio responds to the unique challenges in the glass

industry by supporting collaborative, innovative R&D

improvements in process technologies, design tools and

methodologies; promoting demonstrations of promising

technologies; and promoting the implementation of best practices

and emerging technologies that will contribute to the ITP goal of

helping industry achieve a 30 percent reduction in energy consumption per unit of output by 2020. The

objective of the Glass portfolio is to reduce energy use in the glass industry by 46 trillion Btu per year by

2020.

ITP’s Glass portfolio works in partnership with the Glass Manufacturing Industry Council (GMIC) on an

ongoing basis to identify research priorities with broad applicability in the glass industry. The GMIC was

established to represent the needs of the entire glass industry, bridging diverse interests and creating a unified

voice. By partnering with GMIC and fostering broad collaboration with glass industry partners, ITP’s Glass

portfolio leverages public and private resources and ensures the application of research results.

ITP’s Glass portfolio created the

impetus for the industry to

develop a long-term vision and

roadmap. Glass portfolio

solicitations reflect the priorities

in the vision and roadmaps, as

well as ITP’s analysis of

opportunities for energy savings,

national priorities and the

appropriate federal role. To assure

broad participation among glass

companies, Glass portfolio

solicitations are announced via

email to the GMIC listserv, in

trade society publications, Web

sites, meetings, the Commerce

Business Daily, FedBizOpps, and the

ITP Glass portfolio Web site.

Selection of projects follows meritbased criteria that emphasize

projected energy, environmental,

and economic benefits based on

sound analysis using a

standardized procedure available

through the On-line Glass Project

Evaluation Tool (http://

www.energetics.com/glasstool).

This rigorous solicitation

development and implementation

process ensures targeted,

competitive solicitations for precompetitive R&D.

ITP’s Glass portfolio strategy is

6

Fact sheets describing projects in the ITP

Glass portfolio are located at http://

www.eere.energy.gov/industry/glass/

portfolio.html.

The Glass Manufacturing Industry Council (GMIC) is a trade association of the

U.S. glass industry that includes among its members representatives of all four

sectors: Flat, Container, Fiber and Specialty. GMIC, incorporated in September

1998, is moving forward on a broad front to promote the interests and growth of

the U.S. glass industry as a whole. Its formation represents a milestone

development for the industry. Other industries (steel, aluminum, forest and paper

products, etc.) have had organizations that operated on behalf of the entire

industry and that were effective in consolidating benefits for the industry as a

whole. Until the formation of the GMIC, the U.S. glass industry has had no

“umbrella” body to represent its interests.

The mission of the Glass Manufacturing Industry Council is:

“To facilitate, organize, and promote the interests and growth of the U.S. glass

industry through cooperation in the areas of technology, productivity and the

environment.”

GMIC Members

Core

CertainTeed Corporation

Corning Incorporated

Johns Mansville

Leone Industries

Longhorn Glass Corporation

Owens Corning

PPG Industries - Fiberglass

Society for Glass Science and

Practices

Techneglas

Visteon - An Enterprise of Ford

Motor Company

Associate

Advanced Manufacturing Center

Air Liquide America

BOC Gases

Center for Glass Research

Eclipse Inc. /Combustion Tec

Gas Technology Institute

Glass Service, Inc.

Mississippi State University (Diagnostic

Instrumentation & Analysis Laboratory)

Praxair, Inc.

Siemens Energy & Automation

Unimin

U.S. Borax

U.S. Silica

Westinghouse Savannah River Company

GMIC
7

designed to have the greatest impact on reducing glass industry energy intensity. The strategy evolves over

time as R&D projects are funded and completed, as new opportunities to have a significant impact on the

industry are identified, and as

national priorities change. The

Glass portfolio organizes its

activities into four categories:

next generation melting systems,

energy efficiency performance

improvements, advanced

processing and environmental

R&D, and technology

deployment. Exhibit 4 shows the

target areas for each of these

research categories.

During FY 2004, the Glass

portfolio participated in ITP

Corporate and National Academy

of Science Peer Reviews. The ITP

Corporate Peer Review was held

March 9-10, 2004. This Peer

Review brought industry

stakeholders and government

partners together to review the

mission, strategies and future direction of the Industrial Technologies program, including a strategic overview

of the Glass R&D portfolio. Examples of some of the feedback the Glass portfolio received from the review

included:

• Impressed with number of industry partners on projects.

• Fundamental understanding of glass melting process is still insufficient.

• Consider more work in cullet area to potentially reduce energy use.

Subsequently, the National Academy of Sciences was briefed with similar presentations about ITP efforts and

is preparing a formal report of findings.

In FY 2004, the Glass portfolio

continued to transition to fewer,

yet higher-risk, higher-impact

research projects that will have the

opportunity to produce

revolutionary improvements in

glass processing efficiency. To

leverage available funding, the

Glass portfolio submits topics to

the Small Business Innovation

Research and Small Business

Technology Transfer Program

(SBIR/STTR), and tracks and

manages SBIR/STTR glass projects.

The Glass portfolio also encourages

other ITP elements and other EERE

programs to fund R&D priorities of

the glass industry. For example,

several sensors and automation

and industrial materials projects

are of great interest to the glass

industry.

Next Generation

Melting Systems

Energy Efficiency

Performance Improvement

Advanced Processing &

Environmental R&D

Technology

Deployment

Technical and Economic

Assessment

Innovative Melting

Concepts

Advanced

Refining

Modeling and

Optimization

Advanced Materials

and Refractories

Improved

Burners

Sensors

Process Control

Pollution Abatement

Recycling

Demonstration/Validation/

Implementation of

Emerging Glass

IOF Technologies

Best Practices

Energy Use: Reduce energy by 46 trillion Btu/year by 2020

Impact Targets

Exhibit 4

Process and Technology Improvements Target Energy Efficiency

Glass Portfolio 

Partner

Exhibit 5

FY 2004 Glass Portfolio Partners
The Glass portfolio includes projects and activities ranging from high-risk, high-return R&D and applied

research and development, to demonstrations and technology delivery activities. Most R&D projects in the

portfolio address technical needs in multiple glass industry segments. The duration of projects is two to five

years. Industry generally contributes between 30 and 50 percent of the funds for each R&D project. R&D is

conducted by glass companies, national laboratories, research institutes, and universities. Industry

involvement accelerates the dissemination of research results and technology transfer. The portfolio also

includes activities to highlight available opportunities that can immediately reduce glass industry energy use.

Project participants and partners are distributed across the United States, with the majority in areas densely

populated with glass industry manufacturing facilities, such as the Midwest and Mid-Atlantic states, and at

national laboratories. The map in exhibit 5 shows the distribution of the 34 Glass portfolio partners (FY

2004).

8
9

FY 2004 HIGHLIGHTS AND ACCOMPLISHMENTS

The ITP Glass portfolio supports a diverse portfolio of cost-shared, pre-competitive research that address highrisk, high-impact needs and have a broad application throughout the glass industry. In FY 2004, the Glass

portfolio included seven core R&D projects. Of these seven projects, two were completed in FY 2004. These

projects, along with the current Glass Project Laboratory User Services projects, one project with states, and

two SBIR projects are listed below. In addition, over 20 projects relevant to the glass industry that are funded

by other EERE programs are included in the Glass portfolio.

R&D Highlights

Advanced Glass Furnace Model Commercialized and Receives R&D 100 Award – An advanced glass

furnace model, developed by Argonne National Laboratory, has been commercialized successfully. Accessible

from Argonne’s software shop, the software has established licensure procedures. The model received one of

the prestigious R&D 100 Awards and 17 licenses were signed in 2004. To maximize effectiveness and adoption,

validation studies are continuing by industry partners and an industry user group is being formed.

Furnace Energy Assessment Best Practice Now Available –This protocol for oxy-fuel furnaces, developed by

the Diagnostic Instrumentation and Analysis Laboratory (DIAL) at Mississippi State University, identifies

opportunities for optimizing furnace operations and reducing energy consumption. Recommendations from

the initial assessment of a PPG Industries furnace would improve energy efficiency by at least 6 percent. DIAL

has already received interest from two other glass manufacturers about utilizing the protocol; a case study is

also available.

Oxy-Fuel-Fired Front-End System Readied for In-Plant Testing at Fiberglass Facility – Owens Corning and

project partners have conducted preliminary work and prepared the demonstration host site in Jackson,

Tennessee for installation of the technology. Analysis indicates that the technology will reduce fuel use in

the front-end system by over 60 percent and NOx emissions by over 90 percent, and will provide attractive

financial returns, with payback time of less than two years.

Pilot-Scale Testing Underway for High-Intensity Plasma Glass Melter – Plasmelt has designed and

constructed the pilot-scale plasma melter and has operated the unit at 200 pounds of glass per hour with

stable operating conditions for over two hours. Researchers continue to test and improve plasma torches

toward their goal of 500 pounds/hour. In FY 2005, Plasmelt will validate energy efficiency targets and test

glass quality.

Design of Pilot-Scale Submerged Combustion Melter Underway – In the first full year of this project, the

Gas Technology Institute has worked with project partners to design the pilot-plant unit, purchase necessary

equipment, determine modeling parameters, conduct laboratory-scale testing, and finalize the consortium

agreement. The pilot-scale unit will be constructed and testing initiated in FY 2005.

In-Plant Trials Successfully Conducted for On-line Coatings of Float Glass – Initial full-scale testing has

been completed at PPG Industries. Results indicated an improvement in the efficiency of precursor material

used in coating operations from 50 to 150 percent over current usage at standard conditions. Additional

trials are continuing under differing conditions and parameters to gain further insights on optimizing the

process.

LIBS Sensor Technique Successfully Tested in Plant Environment – Scientists from Energy Research

Company successfully tested a laser-induced breakdown spectroscopy (LIBS) sensor technique at PPG

Industries’ Chester, South Carolina plant for a 20 day-equivalent period, and a long-term trial is now

underway. Plant personnel were very satisfied with the method’s accuracy, repeatability and ease of use in

determining concentrations for their material of interest. Further development activities will expand the

method’s capabilities and applicable materials.
10

Glass Projects with Completed Government Funding in FY 2004

Energy Efficiency Performance Improvements

• Process Optimization Strategies, Models, and Chemical Databases for On-line Coating of Float Glass (PPG

Industries, Sandia National Laboratories)

Sandia National Laboratories and PPG Industries have developed modifications to atmospheric pressure

chemical vapor deposition to increase the efficiency of reactant utilization. Researchers are conducting

detailed theoretical and experimental studies of the underlying deposition process. Computational

models are being developed that can predict defects in coatings.

Advanced Processing and Environmental R&D

• Monitoring and Control of Alkali Volatilization and Batch Carryover for Minimization of Particulates and Crown

Corrosion (Sandia National Laboratories, Gallo Glass)

Researchers at Gallo Glass and Sandia National Laboratories are collecting data to determine the

conditions having the greatest influence on volatilization, batch carryover, combustion efficiency and

furnace efficiency. A prototype measurement instrument using laser-induced breakdown spectroscopy

has been designed and built. A control strategy and system for minimizing alkali volatilization and

batch carryover is being developed.

Active Glass Projects in FY 2004

Glass R&D Projects

Next Generation Melting Systems

• Energy-Efficient Glass Melting: The Next Generation Melter (Gas Technology Institute, Corning Incorporated,

PPG Industries, Owens Corning, Johns Manville, Schott Glass Technologies, CertainTeed Corporation,

Fluent, Praxair, Eclipse/Combustion Tec, A.C. Leadbetter and Son)

Researchers at the Gas Technology Institute are designing and fabricating a pilot-scale submerged

combustion glass melter. Two series of tests will be performed and product glass properties will be

analyzed.

• High-Intensity Plasma Glass Melter (Plasmelt Glass Technologies, LLC, Johns Manville, Advanced Glassfiber

Yarns)

Plasmelt is developing a plasma-melting system that is generically suited to melting a large variety of glass

compositions. A prototype system is being constructed and tested and product quality will be evaluated.

Energy Efficiency Performance Improvements

• Development/Demonstration of an Advanced Oxy-Fuel-Fired Front-End System (Owens Corning, Osram

Sylvania, BOC Gases, Eclipse/Combustion Tec)

Scientists at Owens Corning are developing a novel, oxy-fuel fired front-end system. After laboratory

design testing of burners and system control, the system will be demonstrated in a commercial fiberglass

production plant.

• Development and Validation of a Coupled Combustion Space/Glass Bath Furnace Simulation (Argonne

National Laboratory, Techneglas, Owens Corning, Osram Sylvania, Libbey, Visteon, Mississippi State

University, Purdue University)

Researchers have developed a validated glass melting furnace simulation model that incorporates

innovative features. The combustion space and glass bath models are coupled at their interface through

the use of appropriate heat flux and temperature continuity conditions. The combustion space model

incorporates a rigorous treatment of the radiative heat transfer to the glass bath.

Advanced Processing and Environmental R&D

• Measurement and Control of Glass Feedstocks (Energy Research Company, PPG Industries, Oak Ridge

National Laboratory, Fenton Art Glass Company)

Researchers at Energy Research Company are developing a probe based on laser-induced breakdown

spectroscopy to measure the chemical makeup of glass feedstocks in real time. The probe will quickly

detect contaminants and batch nonuniformity in the raw materials and cullet. Artificial neural network

software will be tested to provide high-speed analysis of data obtained by the probe.
11

GPLUS Projects

The Glass Project Laboratory User Services (GPLUS) program enables glass manufacturers to conduct smallscale scoping studies in collaboration with any of the DOE national laboratories. The program is cost-shared

by DOE and the glass manufacturer, and results are provided to the GMIC to enable technology transfer.

• Foaming of Glass (PPG Industries, Pacific Northwest National Laboratory)

• Study of Sulfate Fining Chemistry in Oxidized and Reduced Soda-Lime Silica Glasses (Visteon, Pacific Northwest

National Laboratory)

• Spectral Analysis and Imaging of Colored Glasses (Society for Glass Science and Practices, Judel Products, Oak

Ridge National Laboratory)

• Application of Furnace Model to an Oxy-Fuel Furnace for the Production of Amber Glass (Longhorn Glass,

Argonne National Laboratory, Metal Container Corp.)

• High-Temperature Thermocouple Study (Schott Glass Technologies, Idaho National Laboratory)

• Improvement of Oxy-Fuel Burner Design/Operations (Owens Corning, Sandia National Laboratories)

• Laser-Induced Laser Breakdown Spectroscopy (LIBS) as a Glass Melt Monitor (Corning, Sandia National

Laboratories)

• Strength Data and Design Method for Tempered Automotive Glazing Which is Subject to Stress Corrosion Cracking

(Visteon, Pacific Northwest National Laboratory)

• TV Glass Surface Problems (Techneglas, Oak Ridge National Laboratory)

Projects with States

• Improvement of Performance and Yield of Continuous Glass Fiber Drawing Technology (Cleveland State

University, PPG Industries, Johns Manville, Schott Glass, U.S. Borax)

This project is applying six sigma quality methodology and fundamental glass science to reduce fiber

breakage and resultant waste. During the project, instrumentation will be developed, simulation models

will be employed, and the process will be investigated and optimized.

SBIR Projects

• An Optical Fiber Probe for the Measurement of High-Temperatures (Hope Technologies, Inc.)

• Universal Photo-Acoustic Sensor System (Physical Optics Corporation)

Other ITP and EERE Projects Relevant to the Glass Industry

Advanced Industrial Materials Projects Relevant to Glass

• Advanced Thermoelectric Materials for Efficient Waste Heat Recovery in Process Industries

• Thermochemical Models and Databases for High-Temperature Materials

• Alkaline-Resistant Fe-Phosphate Glass Fibers as Concrete Reinforcement

• Development of Functionally Graded Materials for Manufacturing Tools and Dies and Industrial Processing

Equipment

• Advanced Nanoporous Composite Materials for Industrial Heat Applications

• Crosscutting Industrial Applications of a New Class of Ultra-Hard Borides

• Development and Demonstration of Advanced Tooling Alloys for Molds and Dies

Combustion Project Relevant to Glass

• Development of an Innovative Energy-Efficient, High-Temperature Natural Gas-Fired Furnace

Sensors and Automation Projects Relevant to Glass

• Boiler and Furnace Efficiency Improvement with Low-Cost CO Sensor and Burner Control System

• Diagnostics and Control of Natural Gas-Fired Furnaces via Flame Image Analysis Using Machine Vision and

Artificial Intelligence Techniques

• Fiber-Optic Sensor for Industrial Process Measurement and Control

• Thermal Imaging Control of Furnaces and Combustors

• Tunable Diode Lasers Sensors for Monitoring and Control of Harsh Combustion Environments

• Advanced Wireless Sensors for the Industries of the Future
12

Inventions and Innovations Projects Relevant to Glass

• Monitoring of Refractory Wall Recession Using High-Temperature Impact-Echo Instrumentation

• Monitoring of Refractory Wall Recession Using Radar Techniques

• Fiber-Sizing Sensor/Controller for Optimizing Glass and Polymer Fiber Manufacturing Processes

• Development of a Novel Frequency-Selective Solar Glazing System

• Enabling Tool for Innovative Glass Applications

• Energy-Saving Method of Manufacturing Ceramic Products from Waste Glass

• High-Throughput Vacuum Processing for Innovative Uses of Glass

• Low-Energy Alternative to Commercial Silica-Based Glass Fibers

• Thermophotovoltaic Electric Power Generation Using Exhaust Heat

Partnership Highlights

In addition to sponsoring R&D, the Glass portfolio achieved a number of noteworthy accomplishments in

FY 2004. These accomplishments are described below:

Allied Partnership Agreement Continues with GMIC – An Allied Partnership with the Glass Manufacturing

Industry Council (GMIC) was established in June 2003 and continued throughout FY 2004. Key activities

during FY 2004 included: conducting three Best Practices workshops (Process Heating, Compressed Air, and

20 Major Energy Savings Tips) in conjunction with Glassman America in Pittsburgh, promoting the

commercialization and adoption of ITP and EERE glass technologies, and distributing ITP and EERE literature

at numerous industry events.

Technical and Economic Assessment for Next-Generation Melting Systems Completed – This document

highlights technical and economic barriers that have stifled innovation and change in glass processes,

including a detailed review of previous research efforts to improve glass melting and refining.

Alternative Refining/Conditioning Technology Pathways Examined – As part of broader efforts to develop

next generation melting systems, two workshops were conducted to examine the potential for alternative

refining/conditioning technologies. The GMIC focused workshop discussions and analysis on four potential

technologies: vacuum refining, helium gas refining, sonic refining and centrifugal refining. Development of

advanced refining concepts may be necessary for broad adoption of next generation melting technology.

Glass Project Review Conducted – As part of its effort to ensure stewardship of public funds, the Glass

portfolio conducts a yearly evaluation of research projects to assess performance, including progress toward

technical, economic and market goals. The FY 2004 review was held in June 2004 near Washington, DC in

conjunction with the ITP Industrial Materials, and Sensors and Automation subprograms. Over 150

attendees heard presentations on ongoing research projects being conducted by industry, university, and

national laboratory researchers in order to evaluate each project’s progress, significance and relevance to the

industry’s needs.

Glass Resources CD-ROM Wins Communications Awards – The glass resources CD-ROM, released in FY

2003, provides tips and tools for spotting energy-saving opportunities in glass plants, as well as details on

energy efficiency technologies. This CD-ROM won two awards in 2004. First, the CD won an Award of Merit

from the Colorado Chapter of the International Association of Business Communicators. The CD was one

of only three award winners in the Electronic and Digital Communications, Multimedia CD category.

Second, the CD won an APEX Award of Excellence from Communications Concepts, Inc. Out of nearly 200

entries, the CD was one of five award winners in the Multimedia and Interactive Publications category. The

APEX awards are based on excellence in graphic design, editorial content, and the ability to achieve overall

communication excellence.

Guidebook on Commercialized Energy Efficiency and Supply Technologies for the Glass Manufacturing

Industry Completed – This document describes a variety of technologies that energy managers in the glass

industry can use to make their plants more efficient, self-reliant and profitable, creating less pollution.
13

Improving Energy Efficiency Today

Plant-wide assessments (PWAs) are cost-shared assessments of plant utility and process-related energy

efficiency opportunities across a plant. Plants are eligible through a competitive solicitation. In FY 2004, a

PWA was awarded for Owens Corning’s Santa Clara, California plant to evaluate all major energy-consuming

systems required for the glass-melting and fiber-forming processes. The assessment team will focus on

efficiency and identify opportunities for state-of-the-art and emerging technologies. The assessment includes

the adoption of best practices in the design, management, operation, and procurement of systems that

support production.

Additionally, the case study from an earlier Corning, Incorporated PWA assessment was published. The

assessment team developed 17 recommendations with the potential to save 123 billion Btu of natural gas and

72 million kWh of electricity annually. The average payback period for each recommendation was less than

one year.

Disseminating Research Results to Industry

ITP’s Glass portfolio conducts numerous outreach activities to disseminate R&D results and encourage

companies to reduce energy intensity of glass processing. Project reports submitted to DOE are available on

the ITP Glass portfolio Web site (http://www.eere.energy.gov/industry/glass) and on DOE’s Information

Bridge Web site (http://www.osti.gov/bridge). In addition, the Glass portfolio attended and participated in

several meetings and workshops in FY 2004, including:

• Glass Problems Conference

• Future Refining/Conditioning Needs Workshop

• Next Generation Refining/Conditioning Workshop

The Glass portfolio is also supporting focus group interactions for establishing distance learning from the

preeminent glass science degree-granting university, the Center for Glass Research at Alfred University. The

focus groups will determine industry interests relating to emerging energy efficiency technologies and

practices and glass science and engineering.

Two commercial technologies supported by the Glass portfolio continued to have great success in the U.S.

glass industry. Oxy-fuel firing, commercialized in the early 1990s, now represents over 30 percent of U.S. glass

industry capacity. The technology, while no longer tracked by ITP, was saving over 4 trillion Btu annually

industry-wide when last reported. Oxygen-Enriched Air Staging (OEAS), which provides a low-cost method

for glass manufacturers to reduce NOx emissions, is being utilized in 16 glass furnaces. Another technology,

the High-Luminosity Low-NOx Burner, has just entered the commercial marketplace. More information

about these and other ITP commercialized and emerging technologies of interest to the glass industry can be

found in ITP’s “Impacts” document (http://www.pnl.gov/impacts).

ITP’s Glass portfolio Web site underwent a significant improvement during FY 2004. It is now easier to

navigate and is more consistent with the other EERE Web sites. Other improvements include additional

information, highlights of activities and opportunities, and increased accessibility of final reports from R&D

projects.

In addition, an on-line stakeholder engagement tool was developed to allow better two-way interaction with

the glass research community. The tool allows stakeholders to share feedback on current activities and

research, suggestions for future collaborative activities, and sharing of best practices (http://

www.govforums.org/glass).

Energy Analysis – Targeting Energy Efficiency

The Energy Bandwidth Study continued in FY 2004 to show the magnitude of energy savings possible for

glass manufacture. The energy “bandwidth” will be used to provide a rationale for supporting R&D on new

technologies with the highest potential impact on glass industry energy consumption.
14

The Energy Footprint Study of the Glass Industry shows the flow of energy throughout the industry. The

energy flow and losses are shown for energy supply, central energy generation/utilities, energy distribution,

energy conversion, and process energy (see Exhibit 3, page 4).

A Project Evaluation Tool has been created to analyze energy and environmental benefits of glass research

projects. Applicants to ITP Glass portfolio solicitations are now required to use the project evaluation tool.

The Government Performance and Results Act (GPRA) Analysis was completed for projects considered in

the FY 2006 budget. The GPRA analysis estimates future benefits of emerging technologies in the Glass

portfolio based on market penetration, energy savings, and environmental emission reductions.
15

TOOLS, PUBLICATIONS, AND RESOURCES AVAILABLE

EERE offers valuable tools and publications to help glass companies improve productivity and energy

efficiency. Some of these resources are described below. See the Web site at http://www.eere.energy.gov/

industry/glass for a complete listing.

Glass: A Clear Vision for a Bright Future – This landmark document released in 1996 outlines a vision for

the glass industry in 2020 and identifies industry-wide goals for production efficiency, energy efficiency,

environmental performance, and innovative uses.

Glass Industry Technology Roadmap – The GMIC published the Glass Industry Technology Roadmap in

April 2002. The document describes technology challenges, research needs and priorities, and implementation

roles.

Fact Sheets and Success Stories – These brief publications describe the objectives, benefits, partners, and

accomplishments of RD&D projects in the Glass portfolio.

Resource CD-ROM – This award-winning CD-ROM provides tips and tools for spotting energy-saving

opportunities in glass plants today, as well as details on energy efficiency technologies. The CD-ROM

contains over 200 documents relevant to glass manufacturers.

Energy and Environmental Profile of the Glass Industry – This detailed report benchmarks the energy and

environmental characteristics of key technologies used in major processes of the glass industry.

Technical and Economic Assessment for Next Generation Melting Systems – This document highlights

technical and economic barriers that have stifled innovation and change in glass processes, including a

detailed review of previous research efforts to improve glass melting and refining.

Guidebook on Commercialized Energy Efficiency and Supply Technologies for the Glass Manufacturing

Industry – This document describes a variety of technologies that energy managers in the glass industry can

use to make their plants more efficient, self-reliant and profitable, creating less pollution.
16

HOW TO GET INVOLVED AND CONTACT INFORMATION

Partnership Information

Public-private partnerships are the foundation of ITP’s technology delivery strategy. ITP includes its partners

in every phase of the technology development process to focus scarce resources where they can have the

greatest impact on industrial energy efficiency. To learn more, please visit our Web site at http://

www.eere.energy.gov/industry.

• Collaborative, cost-shared research and development projects are a central part of ITP’s strategy.

Annual solicitations provide technology development opportunities in a variety of energy-intensive

industries.

• Industries of the Future Partnerships increase energy efficiency in the most energy-intensive

industries. In addition to cost-shared research and development projects, industry partners participate in

the development of vision and roadmap documents that define long-term goals, technology challenges,

and research priorities.

• Allied Partnerships provide an opportunity for ITP to reach a broad audience of potential customers by

allying with corporations, trade associations, equipment manufacturers, utilities, and other stakeholders

to distribute industrial energy efficiency products and services. By becoming an Allied Partner, an

organization can increase its value to clients by helping them achieve plant efficiencies.

• State energy organizations work with ITP in applying technology to assist their local industries. ITP

assists states in developing IOF partnerships to mobilize local industries and other stakeholders to

improve energy efficiency through best practices, energy assessments, and collaborative research and

development.

• EERE’s technical programs (ITP is one of 11) give manufacturers access to a diverse

 portfolio of energy efficiency and renewable energy technologies and bring advanced manufacturing

technology to the renewable energy community. For more information, access the EERE home page at

http://www.eere.energy.gov.

• The President’s Climate VISION (Voluntary Innovative Sector Initiatives: Opportunities Now) effort also

offers opportunities for manufacturers to pursue cost-effective actions that will reduce greenhouse gas

emissions. See http://www.climatevision.gov for details.

Access to Resources and Expertise

The Industrial Technologies Program provides manufacturers with a wide variety of industrial energy

efficiency resources to help your company reduce energy expending right away. Visit our site at: http://

www.eere.energy.gov/industry or call the EERE Information Center at 877-337-3463 to access these resources

and to get more information.

• ITP offers energy management best practices to improve energy efficiency throughout plant

operations. Improvements to industrial systems such as compressed air, motors, process heat, and steam

can yield enormous savings with little or no capital investment.

• Our suite of powerful system optimization software tools can help plants identify and analyze energysaving opportunities in a variety of systems.

• Training sessions are held several times per year at sites across the country for companies interested in

implementing energy-saving projects in their facilities. DOE software tools are used as part of the

training sessions.
17

• ITP’s qualified industrial energy specialists will work with your plant personnel to identify savings

opportunities and train staff in the use of ITP software tools.

• Our extensive library of publications gives companies the resources they need to achieve immediate

energy savings.

• Plant-wide energy assessments are available to manufacturers of all sizes interested in cutting their

energy use. Cost-shared solicitations are available each year for plant-wide energy assessments. In

addition, no-cost, targeted assessments are provided to eligible facilities by teams of engineering faculty

and students from 26 university-based Industrial Assessment Centers around the country.

• The DOE Regional Offices provide a nationwide network of capabilities for implementing ITP’s

technology delivery strategy. Regional Offices are located in Atlanta, Boston, Chicago, Denver,

Philadelphia, and Seattle. Visit http://www.eere.energy.gov/rso.html for more information.

Where to Go to Get More Information

Visit our Web site - http://www.eere.energy.gov/industry/glass

Learn about all EERE Programs - http://www.eere.energy.gov

EERE Information Center answers questions on EERE’s products, services and 11 technology programs, refers

callers to the most appropriate EERE resources, and refers qualified callers to the appropriate expert networks.

You may contact the EERE Information Center by calling 1-877-EERE-INF (1-877-337-3463) or by completing

the form at this site: http://www.eere.energy.gov/informationcenter. A customer service specialist or energy

expert at the EERE Information Center will respond to your inquiry.

For print copies of DOE, EERE and ITP Publications, contact the

Energy Efficiency and Renewable Energy Information Center

P.O. Box 43165

Olympia, WA 98504-3165

http://www.eere.energy.gov/informationcenter/

For questions regarding Glass portfolio, contact -

Elliott Levine

Industrial Technologies Program

Office of Energy Efficiency and Renewable Energy

EE-2F

U.S. Department of Energy

1000 Independence Avenue, SW

Washington, DC 20585-0121

Phone: 202-586-1476

Fax: 202-586-9234

Email: Elliott.Levine@ee.doe.gov

Sources

1997 Census of Manufacturers, U.S. Department of Commerce

U.S. Department of Commerce Annual Survey of Manufacturers, 2001

1998 Manufacturing Energy Consumption Survey (MECS), U.S. Department of Energy, Energy

Information Administration, 2002

Energy Footprint Analysis, Energetics, Inc., for the U.S. Department of Energy, May 2003
Glass Industry of the Future

Industrial Technologies Program

Boosting the productivity and competitiveness of U.S. industry

A Strong Energy Portfolio for a Strong America

Energy efficiency and clean, renewable energy will mean a stronger economy, a cleaner environment, and great energy

independence for America. By investing in technology breakthroughs today, our nation can look forward to a more

resilient economy and secure future.

Far-reaching technology changes will be essential to America’s energy future. Working with a wide array of state,

community, industry, and university partners, the U.S. Department of Energy’s Office of Energy Efficiency and

Renewable Energy invests in a portfolio of energy technologies that will:

• Conserve energy in the residential, commercial, industrial, government, and transportation sectors

• Increase and diversify energy supply, with a focus on renewable domestic sources

• Upgrade our national energy infrastructure

• Facilitate the emergence of hydrogen technologies as a vital new “energy carrier”

The Opportunities

Biomass Program

Using domestic, plant-derived resources to meet our fuel, power, and chemical needs

Building Technologies Program

Homes, schools, and businesses that use less energy, cost less to operate, and ultimately, generate as much power as

they use

Distributed Energy & Electric Reliability Program

A more reliable energy infrastructure and reduced need for new power plants

Federal Energy Management Program

Leading by example, saving energy and taxpayer dollars in federal facilities

FreedomCAR & Vehicle Technologies Program

Less dependence on foreign oil, and eventual transition to an emissions-free, petroleum-free vehicle

Geothermal Technologies Program

Tapping the Earth’s energy to meet our heat and power needs

Hydrogen, Fuel Cells & Infrastructure Technologies Program

Paving the way toward a hydrogen economy and net-zero carbon energy future

Industrial Technologies Program

Boosting the productivity and competitiveness of U.S. industry through improvements in energy and environmental

performance

Solar Energy Technology Program

Utilizing the sun’s natural energy to generate electricity and provide water and space heating

Weatherization & Intergovernmental Program

Accelerating the use of today’s best energy-efficient and renewable technologies in homes, communities, and

business

Wind & Hydropower Technologies Program

Harnessing America’s abundant natural resources for clean power generation

To learn more, visit www.eere.energy.gov

published February 2005