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 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, the 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

public-private partnerships also facilitate voluntary efforts, such as the President’s Climate VISION initiative,

to encourage industry and government to reduce greenhouse gas emissions. 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
CONTENTS

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

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

Energy Use in the Chemical Industry .................................................................................................................. 2

The Challenge ..................................................................................................................................................... 4

An Energy-Intensive Industry .............................................................................................................................. 4

Strategy for Improving Chemical Industry Energy Efficiency ............................................................................. 5

FY 2004 Highlights & Accomplishments .......................................................................................................... 7

R&D Highlights.................................................................................................................................................... 7

Partnership Highlights ......................................................................................................................................... 9

Improving Energy Efficiency Today ................................................................................................................... 10

Disseminating Research Results to Industry ...................................................................................................... 10

Energy Analysis – Targeting Energy Efficiency ................................................................................................... 10

Tools, Publications, and Resources Available ................................................................................................. 12

How To Get Involved and Contact Information............................................................................................ 13

Partnership Information ................................................................................................................................... 13

Access to Resources and Expertise....................................................................................................................... 13

Where to Go to Get More Information............................................................................................................. 14
EXHIBITS

1. Value of Industry Shipments by Sub-Sector, 2003 ......................................................................................... 1

2. Energy Use in the Chemical Industry ............................................................................................................ 3

3. Process and Technology Improvements Target Energy Efficiency ................................................................. 6

4. Active Chemicals Portfolio Projects Map....................................................................................................... 6

5. Chemicals Projects with Completed Government Funding in FY 2004 ....................................................... 7

6. Core Chemicals Portfolio in FY 2004 ............................................................................................................ 7

7. Examples of Other EERE Projects Relevant to the Chemical Industry .......................................................... 8

8. Emerging Chemical Technologies ................................................................................................................ 11

9. Energy Footprint for the U.S. Chemical Industry ....................................................................................... 11
i

EXECUTIVE SUMMARY

Today the chemical industry faces significant challenges in maintaining its leadership position in global

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

pressure on U.S. producers, and is exacerbated by the increasing volatility of energy prices. Growing societal

demands for environmental stewardship and demand for shorter-term returns on investment continue to

impact the availability of R&D funds, especially for basic and applied research. The skilled workforce

conducting chemical R&D has dropped by at least 10 percent. These challenges have led to a major change

in this highly competitive industry. Companies are now more willing to collaborate in strategic, precompetitive areas to reduce costs, environmental impacts, and energy use.

The U.S. chemical industry is the second largest consumer of energy in manufacturing, using almost 6.1

quads of energy in 1998 (the largest industrial user of energy is the petroleum refining industry). The

magnitude of energy consumed by the industry makes it a prime target for energy efficiency R&D.

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

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

prices for natural gas over the last two years and growing dependence on imported oil threaten national

energy security and make a strong case for reducing the use of energy.

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. chemical industry. Permanent technology changes, rather than

short-term fixes, are needed to revolutionize the way energy is used in chemical manufacturing. New

catalysts, for example, can dramatically increase product yield (the amount of product obtained from every

barrel of oil) and reduce feedstock requirements. More efficient process heating technology can reduce the

use of fuels and electricity. DOE’s goal for the Chemicals portfolio will help the chemical industry achieve a

30 percent reduction in energy, water use, and toxic and pollutant dispersion per unit of output by 2020.

A Successful Strategy with Industry

The DOE/EERE leads the federal role in developing advanced energy-efficient and environmentally-friendly

industrial technologies. Chemical industry R&D is a component of the overall EERE strategy and contributes

to the goals outlined in the National Energy Policy. Improving energy efficiency in chemical manufacturing

could directly reduce the amount of petroleum imported into the United States and will reduce the energy

intensity of industry, two of EERE’s top priorities.

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 decision making 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

including analytical studies that provide the basis for decisionmaking. For instance, the Vision 2020: Reaction Engineering

Roadmap, published in 2001, has provided the basis for focusing

the R&D by identifying industry research interests. The

Chemicals Energy and Environmental Profile, Bandwidth study and

Footprint study were developed using both government and industry data, information and expertise to

provide the next level of prioritization for 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 chemical industry research priorities. This successful strategy has now evolved to

a point where it provided focus on potentially high-impact research to make revolutionary improvements in

chemicals manufacturing.

The ITP Chemicals portfolio will help

the chemical industry achieve a 30

percent reduction in energy, water use,

and toxic and pollutant dispersion per

unit of output by 2020.
ii

EERE/ITP directs the Chemicals portfolio, which seeks to boost efficiency and productivity of the energy- and

resource-intensive chemical industry by investing in a balanced R&D portfolio with broad applicability in

chemical processing. ITP works in partnership with the Chemical Industry Vision2020 Technology

Partnership (Vision2020, see http://www.ChemicalVision2020.org), a group of executives from major U.S.

chemical companies. This group works with government, academia, and national laboratories to promote

technology development of more energy-efficient and environmentally-sound chemical technologies. By

partnering with Vision2020 and fostering collaboration with chemical industry trade organizations, ITP

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

Achieving Energy Savings: Portfolio Strategy

The ITP Chemicals portfolio of pre-competitive research addresses technological needs that have broad

applicability throughout the chemical industry. The program 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. ITP also strives to expand the industry’s

fundamental base of knowledge to optimize key processes and resource efficiency.

As the ITP Chemicals portfolio continues to shift toward supporting a smaller number of high-impact

projects, research activities are organized into the following categories: reactions, separations, enabling

technology (materials, process heating, computations, and sensors and controls), and technology

deployment. The FY 2004 ITP Chemicals portfolio included 37 active and 32 SBIR projects. Many other

projects funded by EERE are applicable to the chemical industry. More information about the Chemicals

portfolio is available online at http://www.eere.energy.gov/industry/chemicals.

FY 2004 Highlights

• Solicitations Conducted for Innovative Chemical Processing Technologies – ITP conducted two

competitive solicitations in FY 2004 addressing the Chemicals portfolio, one for industry and one for

National Laboratories. Both solicitations primarily focused on catalytic oxidation and distillation

technologies, and nine award winners have been announced.

• Twelve Projects Received Final Funding, Several Technologies Appear Promising – During FY 2004,

twelve RD&D projects were funded to completion. Final results from these projects will be posted on the

Chemicals Web site.

• Membranes for Corrosive Oxidations, Argonne National Laboratory

• Mesoporous Membranes for Olefin Separation, Los Alamos National Laboratory

• Membranes for P-xylene Separations, Sandia National Laboratories

• Autothermal Reformer Kellogg Brown & Root

• Ethylene Process Design Optimization, BP

• High Throughput Catalyst Screening, TDA Research

• Short Contact Time Residence Reactors, Sandia National Laboratories

• Molecular Simulation for Chemical Industry, Sandia National Laboratories

• Research Consortium for Multiphase Fluid Dynamics, Sandia National Laboratories

• Solution Crystallization Modeling Tools, OLI Systems

• Alloys for Ethylene Production, Oak Ridge National Laboratory

• Distillation Column Flooding Predictor, 2nd Point Industries

• Energy Bandwidth Study Continued – This study was initiated to gain knowledge of inefficiencies for a

number of the highest energy-consuming processes employed in the chemical industry. The

“bandwidth” provides a snapshot of the energy losses that can potentially be recovered through

improvements in technology. The bandwidth analysis is based on calculation of the energy and exergy

losses associated with individual chemical processes. In FY 2004, the study looked at 25 different

manufacturing processes for high volume chemicals.

• Advanced Analytic Tools Developed – To better select and manage R&D projects, two tools were

significantly upgraded during FY 2004. The Chemicals Project Assessment Tool (CPAT) measures energy
iii

and environmental impacts, as well as the cost/benefit of projects. The Chemicals Portfolio Management

Tool (CPMT) addresses risk and performance for each project. Significant efforts are being made to

integrate and customize these tools for the proposal selection and portfolio review processes.

• Continued Refocusing Efforts to Better Meet Industry Needs – ITP strives to continually improve

performance. As part of these efforts, a crosswalk of industry priorities with Chemicals portfolio focus

areas was prepared and is depicted on page iii. In addition, feedback was received from several peer

reviews, which will allow the Chemicals portfolio to be more productive.

Climate VISION

• Industrial Technologies Program (ITP) continues to work in partnership with the DOE Office of Policy

and the U.S. chemical industry through the American Chemistry Council (ACC) to implement activities

in support of ACC achieving its ClimateVISION commitment. A ClimateVISION workplan is being

developed where ACC will be collaborating with the federal government on near-term energy efficiency

activities, cross-sector projects, and R&D to develop and commercialize advanced technology (see

ClimateVISION Web site at http://www.climatevision.gov).

Separations

Alternative fossil-based feedstock 

& chemistries

Technology for Alternative Energy Production, Storage & Transmission

New Materials

Energy-efficient process 

alternatives - (Leveraging with 

other programs)

Separations

Reactions

Enabling Technologies

ITP Chemical

Technical Focus Areas

Chemical Industry 

Priorities

Focus Areas Meet Chemical Industry’s Priorities
1

INDUSTRY OVERVIEW

The chemical industry is a vital part of the U.S. economy, transforming raw

materials into more than 70,000 diverse products that are integral to today’s

quality of life. Nearly every product in use today, from transportation to

plastics to paper, requires some input from the chemical industry.

The chemical industry is a global enterprise worth $1.9 trillion, and the

United States holds the largest market share (24 percent). In the U.S. alone

there are over 13,000 chemical establishments employing more than 900,000

people.2 In 2003, the domestic chemical industry provided 2 percent of the

U.S total GDP and invested almost $22 billion on R&D. Chemicals

manufacture is the second largest industrial consumer of energy, and the

industry spends almost $11 billion on environmental programs annually.1,2

Globalization and innovation are major influential forces in the chemical

industry. Dynamic global demand and rapid technological change have led to accelerated restructuring,

joint ventures, mergers, and acquisition activities throughout the industry. Chemical companies today are

highly diversified and knowledge-based, relying on technology, science and innovation to create value-added

products and gain ground in new markets. For example, leading companies are increasingly utilizing

biotechnology to produce value-added products, which also provides opportunities for more efficient use of

energy and environmental benefits.

In 2003, U.S. chemical industry shipments totaled

over $459 billion. 1 Exhibit 1 shows the value of

shipments for the major sub-sectors. Over the last

decade the industry has grown at an average real

rate of almost 2 percent per year, with some sectors

experiencing flat or negative growth, while others

are growing rapidly. The composition of the

industry has been steadily changing, with an

increasing emphasis on high technology and niche

markets such as the life sciences and specialty

chemicals. While commodity chemicals continue

to form the core of the industry, it is these specialty

markets where the highest future growth is

predicted.

The U.S. chemical industry has traditionally

maintained a trade surplus over the years. In 2003,

however, the U.S. chemical industry reported a $9.6

billion trade deficit, continuing a trend that began in 2002. The U.S. still remains the largest exporter of

chemicals in the world, with over $91 billion in products shipped to foreign trading partners in 2003, in large

part due to the research-intensive pharmaceutical sector. Canada, Mexico, Western Europe, and the AsiaPacific region account for over 88 percent of U.S. export markets. 1

In 2003, production of petrochemicals and organic chemicals was estimated at 273 billion pounds. That

same year, production of inorganic chemicals totaled 329 billion pounds. Plastics account for about 109

billion pounds per year of organic chemical production. 1

Products Requiring Chemical Inputs

Plastics Antifreeze

Paints Printing Links

Detergents Textiles

Adhesives Food Packaging

Solvents Carpets

Pharmaceuticals Insulation

Toys Auto Interior Parts

Film Paper

Plastic Bags Cell Phones

Medical Supplies Microwaves

Cosmetics Refrigerators

1 Guide to the Business of Chemistry 2004, American Chemistry Council.

2 2001 Census of Manufacturers, U.S. Department of Commerce.

Exhibit 1

Value of Industry Shipments by Sub-Sector,

2003 ($ in Billions) (1)

Basic Chemicals

$167.9

Specialties

$104.2

Consumer Products

$50.5

Pharmaceuticals

$117.7

Agricultural

Chemicals

$18.7
2

Energy Use in the Chemical Industry

In 1998, energy consumption in the chemical industry was an estimated 7.3 quads (with electricity losses),

which represents about 7 percent of all domestic energy use and over one-quarter of total U.S. manufacturing

energy use.1 Energy use in the chemical industry is split almost evenly between heat and power and feedstock

energy for the production of petrochemicals, plastics, and other products. During the last few decades,

significant improvements have been made in energy efficiency, reducing energy use per unit of output by

nearly 40 percent since 1974.4 Technologies such as cogeneration, advanced catalysts, and improved

separations have played a major role in efficiency improvements. Today one third of the electricity used by

the industry is produced onsite more efficiently, mostly through cogeneration, which provides both power

and process heat.

Exhibit 2 shows the chemical industry’s energy inputs by source. The industry is the second largest consumer

of natural gas, accounting for over one-third of total U.S. manufacturing use, and the largest consumer of

liquefied petroleum gas (LPG), at 95 percent of total manufacturing use.5 Natural gas provides the largest

share of energy for heat and power. The industry is fuel-intensive; electricity only provides about 16 percent

of heat and power requirements. Feedstock energy is a mix of LPG, natural gas liquids (NGL), heavy

petroleum liquids, and natural gas.

Energy consumption varies widely among the industry sectors. Petrochemicals and other organics account

for the largest share of energy use (35 percent), followed by plastics and resins (19 percent), and fertilizers (9

percent), as shown in Exhibit 2. Energy costs on average account for about 7 percent of the value of

chemical industry shipments. In 2001, the industry spent $31.4 billion in energy purchases for fuel, power,

and feedstocks, a 65 percent increase over energy costs in 1999. The dramatic increases in natural gas prices

since 2000 have had a substantial impact on certain sectors of the industry. For example, about 50 percent of

methanol capacity and 40 percent of ammonia capacity, both of which depend on natural gas for feedstock,

were idled during the early part of the decade.6

Within the plant boundary, about 37 percent of energy delivered to the plant is lost prior to being used in

specific processes. For example, steam is used extensively in the chemical industry for fluid heating and to

produce power. In the steam system, which includes boilers, steam distribution lines (pipes, valves, traps),

and energy conversion systems (heat exchangers, preheaters, etc.), about 45 percent of delivered energy is lost.

Process heating (both steam and fired heaters) represents the largest use of fuels in the chemical industry (77

percent), followed by motor systems (12 percent). Technologies that improve the efficiency of process

heating systems have significant potential to reduce overall industry energy use.

Process operations represent substantial energy sinks where new technology as well as incremental

improvements can have an impact. Distillation columns, for example, the mainstay of the industry, often

operate with thermal efficiencies as low as 20 percent.

Off-site losses for the industry are considerable, amounting to about 1345 trillion Btu. Over 93 percent of

these losses occur in electricity generation off-site. Technologies that produce electricity on-site, such as

cogeneration, have the potential to reduce these off-site losses by increasing thermal efficiency.

3 1998 Manufacturing Energy Consumption Survey (MECS), U.S. Department of Energy, Energy Information Administration, 2002.

4 Guide to the Business of Chemistry 2003, American Chemistry Council.

5 1998 Manufacturing Energy Consumption Survey (MECS), U.S. Department of Energy, Energy Information Administration, 2002.

6 Guide to the Business of Chemistry 2002, American Chemistry Council.
3

Chemical Industry

Other

28%

Plastics, Resin,

and Rubber

19%

Inorganics

6%

The Chemicals portfolio

will reduce energy use by

322 trillion Btu per year in 2020.

Energy Use Among Chemical Sectors

Fuels and Feedstocks

5,487 trillion Btu

Electricity

1,828 trillion Btu

1,251 trillion Btu

577 trillion Btu

6,064 trillion Btu

Transmission, distribution

and generation losses

 The chemical industry provides 2 

 percent of the U.S. GDP.

 In 2003, U.S. chemical industry shipments

 totaled $459 billion. 

 In 1998, energy consumption, including

 feedstocks and offsite losses, amounted  to over 7.3 quads.

 In 2003, total compensation (wages and

 benefits) for all workers in the business of chemistry averaged $82,000, or 50 percent higher than the average for  all manufacturing.

Fertilizers

9%

Organics

35%

Industrial

Gases

3%

Natural Gas

48%

Fuel Oil

2%

Coal

5%

LPG & NGL

32%

Other

12%

Feedstocks

2,772 trillion Btu

Non-feedstock Fuel Energy

2,715 trillion Btu

Exhibit 2

Energy Use in the Chemical Industry*

*Data from 1998 MECS
4

THE CHALLENGE

Chemicals are integral to nearly every sector of the economy. The products of the chemical industry are

essential raw materials for U.S. manufacturers, agriculture, construction, health care, communications,

transportation, and national security. It is a very complex industry, producing over 70,000 products using

thousands of different processes. The industry relies heavily on a highly skilled workforce and continuous

technological innovation to maintain competitiveness and economic growth.

Today the chemical industry faces significant challenges in maintaining its leadership position in global

markets. 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

shorter-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 of scientists and engineers engaged in

chemical industry R&D has dropped in recent years by more than 10 percent, from 91,000 to 81,000.

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

competitive industry. Companies are now more willing to collaborate in strategic, pre-competitive areas to

reduce costs, environmental impacts, and energy use. In Technology Vision 2020: The U.S. Chemical Industry, the

industry has emphasized 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 has

organized Chemical Industry Vision2020 Technology Partnership (Vision2020, see http://

www.ChemicalVision2020.org), a group of executives from major U.S. chemical companies. This group works

with government and academia to promote the development of more energy-efficient, environmentally

sound chemical technology.

An Energy-Intensive Industry

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

the second largest consumer of energy in manufacturing, using almost 7.3 quads of energy in 1998 and

accounting for around one-quarter of all manufacturing energy use. The magnitude of energy consumed by

the industry makes it a prime target for energy efficiency R&D, with potentially large energy savings

opportunities.

The industry relies primarily on petroleum and natural gas to provide feedstocks for the manufacture of

chemicals. Nearly 50 percent of the energy consumed by the industry is for feedstocks – about 2.8 quads, or

the equivalent of about 500 million barrels of oil. Transforming fossil energy and other raw materials into

saleable products also consumes large amounts of energy in the form of heating, cooling, and electrical

power.

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

still relies on many processes which are inefficient and energy-intensive (e.g., distillation). When energy

costs are low relative to the costs of processing and other inputs to production, investments in energy

efficiency often take a back-seat 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 is 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 new projects out of

North America to locations where natural gas is cheap and plentiful. The use of petroleum as a feedstock for

commodity chemicals has served to increase our dependence on imported oil and impacts our energy security.

Both government and industry agree that conservation, or improving the efficiency of energy use, is part of

the solution for reducing energy consumption of both fuels and feedstocks in the chemical industry7,

7 M. S. Reisch, “Running Low on Gas,” C&E News, July 14, 2003.
5

especially in the long term. Permanent technology changes, rather than short-term fixes, are needed to

revolutionize the way energy is used in chemicals manufacture. New catalysts, for example, can dramatically

increase product yield (the amount of product obtained from every barrel of oil) and reduce feedstock

requirements. More efficient process heating technology can reduce the use of fuels and electricity.

Alternatives to distillation could impact nearly 2 quads of energy use annually.

Chemical industry R&D is a component of the overall EERE strategy to improve energy efficiency worldwide

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

in chemicals manufacture could directly reduce the amount of petroleum imported into the United States

and will reduce the energy intensity of industry, two of EERE’s top priorities.

Strategy for Improving Chemical 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-efficient and environmentally-friendly industrial technologies.

The EERE Industrial Technologies Program (ITP) directs the Chemicals portfolio which seeks to boost

efficiency and productivity of the energy- and resource-intensive chemical industry.

The ITP Chemicals portfolio responds to the unique challenges in the chemical industry by: 1) supporting

collaborative, innovative R&D on chemical process technologies and design tools and methodologies; 2)

promoting demonstrations of promising technologies; and 3) promoting the implementation of best

practices and emerging technologies that will help the chemical industry achieve a 30 percent reduction in

energy, water use, and toxic and pollutant dispersion per unit of output by 2020. The overall goal is to

reduce energy use in the chemical industry by 322 trillion Btu per year in 2020.

ITP works in partnership with the Chemical Industry Vision2020 Technology Partnership (Vision2020, see

http://www.ChemicalVision2020.org) to identify research priorities with broad applicability in the chemical

industry on an ongoing basis. Vision2020 was formally established in 2001 to represent the needs of the

entire chemical industry, bridging diverse interests and creating a unified voice. By partnering with

Vision2020 and fostering

collaboration with chemical

industry trade organizations, the

ITP leverages public and private

resources and ensures the

application of research results.

The ITP Chemicals portfolio

strategy fostered the development

of Vision2020 and created the

impetus for the industry to

develop a long-term vision and

numerous roadmaps for diverse research areas (See project listing by topic area on page 7). ITP Chemicals

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 chemical companies, ITP Chemicals portfolio solicitations are announced to the

Chemicals portfolio Contacts database via email, in trade society publications, Web sites, meetings, the

Commerce Business Daily, FedBizOpps, and the Chemicals portfolio Web site. Selection of projects follows

merit based sound analysis using CPAT, a standardized Web-based procedure available online at the

Chemicals portfolio Web site. This rigorous development and implementation process ensures targeted,

competitive solicitations for pre-competitive R&D.

The ITP Chemicals portfolio strategy is designed to have the greatest impact on reducing chemical 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.

ITP organizes its Chemicals portfolio into four categories: reactions, separations, enabling technologies, and

technology deployment. Exhibit 3 shows the target areas of each of these research categories.

Vision2020 Members

• Air Products and Chemicals Incorporated

• American Chemical Society

• American Institute of Chemical Engineers

• BP

• Cargill

• Ciba Specialty Chemicals

• Council for Chemical Research

• The Dow Chemical Company

• Eastman Chemicals

• E.I. du Pont de Nemours and Company

• General Electric Company

• Honeywell International, Incorporated

• Materials Technology Institute of the

Chemical Process Industries

• Praxair Incorporated

• Rohm and Haas Company
6

In FY 2004, the ITP Chemicals portfolio continued to transition to higher-risk, higher-impact research

projects that have the opportunity to produce revolutionary improvements in chemical processing efficiency.

In addition, ITP also submits and manages technical topics for the DOE Small Business and Innovation

Research and Small Business Technology Transfer (SBIR/STTR) Program Solicitation each year relevant to the

Chemicals portfolio (see http://sbir.er.doe.gov/sbir). Recent topic areas include nanotechnology applications

in industrial chemistry, reactive separations, energy efficient membranes, materials for industrial energy

systems, sensors and controls, and innovative waste heat recovery. ITP also encourages other EERE programs

to fund R&D priorities of the chemical processing industries.

The projects in the portfolio have significant risk. The portfolio includes high-risk, high-return R&D, applied

research, applied development, demonstrations, and technology delivery projects. Most projects in the

portfolio address R&D needs in

multiple chemical industry

segments and chemical chains.

R&D is conducted by large and

small chemical companies,

national laboratories, research

organizations, and universities.

Industry involvement

accelerates the dissemination of

research results and technology

transfer.

Projects are distributed across

the United States, with

clustering at national

laboratories and areas densely

populated with chemical

industry manufacturing

facilities, such as Texas and the

northeast. The map shows the

distribution of projects

throughout the country.

Exhibit 3

Process and Technology Improvements Target Energy Efficiency

Reactions Separations Enabling Techology Technology Deployment

Chemical Synthesis

New Reaction Media

Catalysis

Reaction Engineering

Process Intensification

Dilute Liquids

Gaseous Mixtures

Similar Compounds

Computations

Materials

Process Heating & Cooling

Sensors

Demonstration of

Emerging 

Chemical IOF

Technologies 

Energy Use: Reduce energy by 322 trillion Btu/year by 2020

Environmental Benefits: Achieve 30 percent reduction in water use and toxic 

 and pollutant release per unit of output by 2020.

Impact Targets

Exhibit 4

Active Chemicals Portfolio Projects Map

Chemicals Partner

Chemicals Prime Recipient
7

FY 2004 HIGHLIGHTS AND ACCOMPLISHMENTS

The ITP Chemicals portfolio supports a diverse portfolio

of cost-shared, pre-competitive research that addresses

high-risk, high-impact needs that have a broad

application throughout the chemical industry. In fiscal

year 2004, the Chemicals portfolio included 37 core-active

projects – 12 projects were completed (see Exhibit 5) and 7

new projects have been selected to become part of the

portfolio in FY 2004. The core projects, organized by research categories, are listed in Exhibit 6. The

portfolio also includes 12 SBIR Phase II and STTR projects. In addition to the core portfolio, other EERE

programs support projects that address key R&D priorities in the chemical processing industries (see Exhibit

7).

In addition to sponsoring R&D, the ITP Chemicals portfolio achieved a number of noteworthy

accomplishments in FY 2004. These accomplishments are described below:

R&D Highlights

Solicitations Conducted for

Innovative Chemical

Processing Technologies – ITP

conducted two competitive

solicitations in FY 2004, one

for industry and one for

national laboratories. Both

solicitations primarily focused

on catalytic oxidation and

distillation technologies.

Factsheets describing projects in the

Chemical portfolio are located on the Web

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

industry/chemicals.

Separations

1. Separation of Olefin/Paraffin Mixtures with Carrier Facilitated

Membranes, Membrane Technology & Research, Inc.

2. Low-Cost Chemical Feedstocks Using an Improved and EnergyEfficient Natural Gas Liquids Removal Process, Gas Technology Institute

3. Advanced Membranes Technology Platform for Hydrocarbon

Separations, Air Products, and Chemicals

Reactions

4. Production and Separation of Fermentation-Derived Acetic Acid, BP

Chemical

5. Tackifier Dispersions to Make Pressure-Sensitive Adhesives, West

Virginia University

6. Microchannel Reactor System Design, Stevens Institute of Technology

7. New Sustainable Chemistries for Low-VOC Coatings, Rohm & Haas

Company

8. Microchannel Reactor System for Catalytic Hydrogenation of Olefins by

High-Intensity Oxidation, Stevens Institute of Technology

9. Advances in Process Intensification Through Multifunctional Reactor

Engineering, Chemical Research & Licensing Inc

10. Olefins by High-Intensity Oxidation, Velocys, Inc

11. A Novel Highly-Efficient and Economic Purification Process

Revolutionizing PTA Production, GTC Technology

12. Enhanced Chemical Processing Using Dense Fluidized Beds, Millennium

Chemicals

Enabling Technology

Computations

13. Computational Chemistry and Reaction Engineering Workbench,

Colorado School of Mines

Exhibit 6

Core Chemicals Portfolio in FY 2004

14. Distillation Column Modeling Tools, University of Texas and Oak

Ridge National Labs

Materials

15. Chemical Industry Corrosion Management, Honeywell, Inc.

16. Alloy Selection System (ASSET), Shell

17. Chemical Industry Corrosion Management – A Comprehensive

Information Management System (ASSET 2), Shell Global

Technologies

18. Metal Dusting Phenomenon, Argonne National Laboratory

Process Heating and Cooling

19. Enhanced Heat Exchangers for Process Heaters, Gas

Technology Institute

Sensors

20. Development of In-Situ Sensors for the Chemical Industry, Dow

Chemical Co.

21. Distillation Column Flooding Predictor, 2nd Point Industries

22. Instrumentation for Multiphase Flow Measurement, Washington

University at Saint Louis

Technology Deployment

23. Processes for the Production of Paraxylene that Utilize Waste

Heat Powered Ammonia Absorption Refrigeration, BP

24. LPG Recovery with Ammonia Absorption Refrigeration, Giant

Yorktown

25. Rotary Burner Demonstration, Calcpos

26. Process Heater Ultra Low Excess Air Control, Valero Energy

1. Membranes for Corrosive Oxidations, Argonne National Laboratory (Separations)

2. Mesoporous Membranes for Olefin Separation, Los Alamos National Laboratory (Separations)

3. Membranes for P-Xylene Separations, Sandia National Laboratories (Separations)

4. Autothermal Reformer, Kellogg Brown & Root (Reactions)

5. Ethylene Process Design Optimization, BP Amoco (Reactions)

6. High Throughput Catalyst Screening, TDA Research (Reactions)

7. Short Contact Time Residence Reactors, Sandia National Laboratories (Reactions)

8. Molecular Simulation for Chemical Industry, Sandia National Laboratories (Enabling-Computations)

9. Research Consortium for Multiphase Fluid Dynamics, Sandia National Laboratories (Enabling-Computations)

10. Solution Crystallization Modeling Tools, OLI Systems (Enabling-Computations)

11. Alloys for Ethylene Production, Oak Ridge National Laboratory (Enabling-Materials)

12. Distillation Column Flooding Predictor, 2nd Point Industries (Enabling-Sensors)

Exhibit 5

Chemicals Projects with Completed Government Funding in FY 2004
8

Four projects from the industry solicitation were awarded:

• Gold Catalyzed Cyclohexane Oxidation, Solutia, Inc.

• Heat-Integrated Distillation Through Use of Microchannel Technology, Velocys, Inc.

• Millisecond Oxidation of Alkanes, Rohm and Haas Co.

• Using Ionic Liquids in Selective Hydrocarbon Conversion Processes, California Institute of Technology

Three projects from the laboratory solicitation were awarded:

• Development of Highly-Selective Oxidation Catalysts by Atomic Layer Deposition, Argonne National

Laboratory

• Ethylene via Ethane Oxidative Dehydrogenation, Oak Ridge National Laboratory

Exhibit 7

Examples of Other EERE Projects Relevant to the Chemical Industry

Advanced Industrial Materials Projects Relevant to Chemicals

• Advanced Chlor-Alkali Technology

• Advanced Composite Coatings

• Advanced Integration of Multi-Scale Mechanics and Welding Process

Simulation in Weld Integrity Assessment

• Advanced Nanoporous Composite Materials for Industrial Heat

Applications

• Advanced Thermoelectric Materials for Efficient Waste Heat Recovery

in Process Industries

• Advanced Wear- and Corrosion-Resistant Systems through Laser

Surface Alloying and Materials Simulation

• Combinatorial Methods for Alloy Design and Optimization

• Development of a New Class of Fe-3Cr-W(V) Ferritic Steels for

Industrial Process Applications

• Development of Bulk, Nanocrystalline-Cemented Tungsten Carbide for

Industrial Applications

• Development of Cost-Effective Ceramic and Refractory Components

for Aluminum Melting and Casting

• Development of Materials Resistant to Metal Dusting Degradation

• Development of Stronger and More Reliable Cast Austenitic Stainless

Steels

• Fracture Toughness and Strength in a New Class of Bainitic ChromiumTungsten Steels

• High-Density Infrared Transient Liquid Coatings for Improved Wear and

Corrosion Resistance

• High Performance Oxide-Dispersion Strengthened Tubes for Production

of Industrial Chemicals

• Low-Temperature Surface Carburizing of Stainless Steels

• Novel Carbon Film for Next Generation Rotating Equipment Applications

• Novel Modified Zeolites for Energy Efficient Hydrocarbon Separations

• Physical and Numerical Analysis of Extrusion Process for BiMetallic

Tubes

• Prediction of Corrosion of Advanced Materials and Fabricated

Components

• Stress-Assisted Corrosion in Boiler Tubes

• Thermochemical Models and Databases for High Temperature

Materials

• Ultrahigh Magnetic Field Processing of Materials

• Ultrananocrystaline Diamond Coatings for Pump Seals

Combustion Projects Relevant to Chemicals

• Integrated Process Heater System

• Development of an Innovative, Energy-Efficient, High Temperature

Natural Gas-Fired Furnace

• Super Boiler: Packed Media/Transport Membrane Boiler Development

and Demonstration

• Ultra-Low NOx Burners with FGR and Partial Reformer

Forest Products Projects Relevant to Chemicals

• Bubble Size Control to Improve Oxygen-Based Bleaching

• High Selectivity Oxygen Delignification

• Improved Recovery Boiler Performance Through Control of Combustion,

Sulfur and Alkali Chemistry

• Increasing Yield and Quality of Low-Temperature, Low-Alkali Kraft Cooks

• Development of METHANE de-NOx® Reburning Process for Wood

Waste, Sludge, and Biomass-Fired Stoker Burners

• Particle Formation and Deposition in Recovery Boilers

Mining Project Relevant to Chemicals

• In-Plant Testing of High-Efficiency Hydraulic Separators

• Reducing Energy Consumption for Water Pumping at Limestone Quarries

Petroleum Projects Relevant to Chemicals

• Energy-Saving Separations Technology for the Petroleum Refining

Industry

• Micro-Gas Chromatography Controller

• Biocatalytic Desulfurization of Petroleum

Sensors and Controls Projects Relevant to Chemicals

• Advanced Wireless Sensors for the Industries of the Future

• Diagnostics and Control of Natural Gas-Fired Furnaces via Flame Image

Analysis Using Machine Vision and Artificial Intelligence Techniques

• Distributed Wireless Multisensor Technologies – A Novel Approach to

Reducing Motor Energy Usage

• Fiber-Optic Sensor for Industrial Process Measurement and Control

• Tunable Diode Lasers Sensors for Monitoring and Control of Harsh

Combustion Environments

• Wireless and Sensing Solutions Advancing Industrial Efficiency

Inventions and Innovation Projects Relevant to Chemicals

• Insoluable Titanium-Lead Anode for Sulfate Electrolytes

• Chemically Inert Membranes for Separation of Solvent/Oil Mixtures

EERE/Fossil Energy Science Initiative

• Atomic-Scale Design of Cobalt Fischer-Tropsch Catalysts: A Combined

Computational Chemistry Experiment and Microkinetics Modeling

Approach

• Design Synthesis and Mechanistic Evaluation of Iron-Based Catalysis for

Synthesis Gas Conversion to Fuels and Chemicals

• Separation of Fischer-Tropsch Wax Products from Ultra-Fine Iron

Catalysts

• A Novel Polymer-Derived Nano-Ceramic for Ultrahigh Temperature

MEMS
9

• Microchannel Catalytic Distillation for Efficient Chemical Manufacturing, Pacific Northwest National

Laboratory

Successful Conclusion for Multi-Phase Fluid Dynamics Research Consortium – This consortium was

established to support learning and fundamental research to better understand and model multi-phase flows.

Its members include Chevron Texaco, Dow Chemical, Dow Corning, DuPont, ExxonMobil, Millennium

Chemicals, Fluent, AEA Technology, seven universities, and six national laboratories. The team continues to

provide improved software and insightful modeling techniques, and continues to educate the scientific

community.

Alloy Selection and Corrosion Prediction System Software Entering Beta Testing – Data generation,

compilation and thermochemical modeling have been completed, and the final version of the software has

been released. Project partners are promoting the software through articles in trade publications and

presentations at industry conferences. The system will greatly improve the ability to predict corrosion for

high-temperature process equipment used in the petrochemical industries.

Dimpled-Tube Technology for Process Heaters Readied for Field Trial – The Gas Technology Institute has

successfully completed bench-scale testing and selected BP’s Cherry Point facility for field testing. The field

test unit has been designed and will be fabricated and installed in FY 2005. This promising technology

provides improved thermal efficiency without a significant increase in pressure drop.

Partnership Highlights

Chemical Industry R&D Roadmap for Nanomaterials by Design: From Fundamentals to Function

Published – This roadmap, written for the chemical industry by a Vision2020 team, was published in

December 2003 and was sponsored by ITP and the federal agencies participating in the National

Nanotechnology Initiative. Nanomaterials present a tremendous energy saving opportunity for the U.S.

chemical industry.

Chemical Peer Review Conducted – As part of ensuring stewardship of public funds, the ITP conducted an

evaluation of research projects to assess performance, including progress towards technical, economic and

market goals. This review was held in April 2004 in conjunction with the AIChE Spring Meeting. Meeting

attendees heard presentations detailing 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.

Chemicals Portfolio Participated in ITP Corporate and NAS Peer Reviews - The Chemicals portfolio was

reviewed as part of the ITP Corporate Peer Review that 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 Chemicals R&D portfolio.

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

preparing a formal report of findings.

Advanced Analytic Tools Developed – To better select and manage R&D projects, two tools were

significantly upgraded during FY 2004. The Chemicals Project Assessment Tool (CPAT) estimates future energy

and environmental impacts, as well as the cost/benefit of projects. The Chemicals Portfolio Management

Tool (CPMT) addresses risk and performance for each project. Significant efforts are being made to integrate

and customize these tools into the proposal selection and portfolio review processes

Ionic Liquids Roadmap Published – The roadmap, entitled “Accelerating Ionic Liquid Commercialization:

Research Needs to Advance New Technology” was published in June 2004. Ionic liquids offer the potential

for ground-breaking changes to synthesis routes and unit operations in the chemical industry.

Bioseparations ChemPlus Project Identifies State-of-the-Art – Bioprocessing means using a living organism

such as bacteria or yeast, or an enzyme secreted by the organism, for a chemical process. In some cases

bioprocessing can be more efficient than a process normally carried out at a higher temperature. Given the

copious amount of water currently required for bioprocessing, separations technology is the critical economic
10

driver for large-scale bioprocessing of chemical products. This project seeks to identify the state-of-the-art in

separations technologies that could be applied in bioprocessing and to identify the R&D needed to make the

technology more cost-effective.

The Plant Energy Profiler (PEP) Tool Begins Beta Testing – This tool will enable plant engineers to create a

benchmark energy map that defines how much and where energy is used in individual facilities. The tool

uses energy data developed through the chemical “energy footprint” as a starting point, and then allows

users to input actual utility data and nameplate capacity to create a plant-specific energy map. A scorecard is

ultimately created for each utility area and estimates energy losses, as well as potential opportunities for

energy and cost savings. Users are then directed to a possible suite of other tools or technologies that could

be used to achieve energy savings. During FY 2004, a third version of the beta test software was released and

evaluated by three industrial partners.

Five Allied Partnerships Continue, Sixth Initiated – The American Institute of Chemical Engineers (AIChE),

FMC Corporation, Millennium Chemicals Inc., Rohm & Haas, and Society of Plastics Industry continued to

be Allied Partners in FY 2004, and 3M initiated an Allied Partnership. Allied Partners undertake voluntary

activities that promote increased energy efficiency and productivity.

Green Power Market Development Group Exploring Biopower Options – Based on the Biopower Technical

Assessment, Green Power is exploring three areas of opportunity: onsite biomass-to-energy, purchase

agreements with biomass-to-electricity project developers, and options for purchasing the renewable energy

certificates from projects generating electricity using biomass residues.

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,

Solutia (Springfield, Massachusetts) was selected to receive funding for assessments, becoming the ninth

chemical plant to receive such funding. In addition, Rohm & Haas (Deer Park, Texas) completed their

assessment. Based on the experience of other manufacturers, these companies can expect to cut energy costs

by anywhere from $1 million to $10 million per year. Success stories from PWAs are available on ITP’s Web

site at http://www.oit.doe.gov/bestpractices/case_studies_pwa.shtml.

Disseminating Research Results to Industry

ITP conducts numerous outreach activities to disseminate R&D results and encourages companies to reduce

energy intensity of chemical processing. In addition, ITP participated in trade shows and annual meetings,

and updated its Web site to be more consistent with other EERE Web sites and better highlight activities and

opportunities. Emerging technologies of interest are shown in Exhibit 8 (following page). More information

about ITP emerging and commercialized technologies of interest to the chemical industry can be found in

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

Energy Analysis – Targeting Energy Efficiency

The Energy Bandwidth Study continued in FY 2004 to gain knowledge of inefficiencies for a number of the

highest energy-consuming processes employed in the chemical industry. The “bandwidth” provides a

snapshot of the energy losses that can potentially be recovered through improvements in technology. The

bandwidth analysis is based on calculation of the energy and exergy losses associated with individual

chemical processes. Exergy takes into account both the amount and quality of energy content of a stream

(based on conditions and composition). The study looked at 25 different manufacturing processes for high

volume chemicals, including ethylene and major derivatives, propylene, styrene, methanol, vinyl chloride,

ammonia, p-xylene, nitric acid, terephthalic acid, acrylonitrile, cumene, formaldehyde, and others. The

results identify top chemical targets for improvements in energy efficiency, identify key process steps where

energy consumption is highest, and provide recommendations for new technology approaches.

The Energy Footprint Study of the chemical industry shows the flow of energy for heat and power
11

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 9).

The Chemicals Project Assessment Tool (CPAT) provides a measure of the potential commercial deployment

of new processes, technologies, and practices. This tool projects energy, environmental, and economic

benefits of for chemical technologies. Applicants to Chemicals portfolio solicitations are required to use

CPAT.

The GPRA Analysis was completed for projects considered in the FY 2006 budget. The GPRA analysis

estimates future benefits of emerging technologies in the chemical portfolio based on market penetrations,

energy savings, and environmental emission reductions.

The Chemicals Portfolio Management Tool (CPMT) is an internal tool that allows an assessment of the

overall Chemicals portfolio. Risk and performance for each project is evaluated as part of the portfolio

review process.

Central 

Boilers

Energy Export 25

Plant Boundary

Purchased 

Electricity 

602

Purchased 

Fuels 

3127

Facilities 123

Losses 

94

NAICS 325 Chemicals Total Energy Input: 5074 Trillion Btu

Losses

1251 Boiler 

Losses 328 

Power 

Losses 54

Distribution Losses 322

Combined 

Heat/Power

Electricity 

Process Use

156

148

1164

Fuel 1277

3729 2877 2221

75

48

Electricity 

to 

Processes 

658

Pumps 120

Fans 55

Materials Processing 110

Motor-Driven 464 

(418 Electric, 46 Fuel)

Equipment 

Losses 355

Compressed Air 129

Refrigeration 36

Other 8

Motor Losses 26 

System Losses 275

Steam 1055 (5 Electric)

Electrochemical 136

Process Cooling 70

(15 Fuel, 55 Electric)

3347

Central Energy Plant Energy Distribution Energy Conversion Process Energy

1312

Materials Handling 6

Onsite Transport 5

Other 48 (1 Electric)

Fired Heaters 1099 

(17 Electric)

Fuel

Electricity

Exhibit 9

Energy Footprint for the U.S. Chemical Industry

Reactions

1. Selective Oxidation of Aromatic Compounds

2. Novel Catalyst for CH4-CO Conversion

3. Membrane Reactor Designs for the Production of Olefins

4. Sonic-Assisted Membrane Processing

Separations

5. Membrane for P-Xylene Separation

6. Economic and Self-Sustaining Production of Saleable Products from

Waste Anions Using Phase-Transfer Catalysis

Exhibit 8

Emerging Chemical Technologies

(Factsheets describing projects in the Chemical portfolio are located on the Web site at http://www.eere.energy.gov/industry/chemicals)

7. Novel Low-Cost Zeolite Ceramic Membrane Module

Enabling Technologies

8. Alloys for Ethylene Production

9. Metal Dusting Phenomena

10. Mixed Solvent Corrosion

11. Computational Chemistry and Reaction Engineering Workbench

12. Molecular Simulation for the Chemical Industry

13. Accelerated Characterization of Polymer Properties

Emerging Technologies are projects that are no longer receiving ITP funding, but are anticipated to be commercialized within the next three years. The

Emerging Technologies include:
12

TOOLS, PUBLICATIONS, AND RESOURCES AVAILABLE

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

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

industry/chemicals for a complete listing.

Technology Vision2020: The U.S. Chemical Industry – This landmark document, developed with

participation from over 300 companies and released in 1996, outlines a unified vision for the chemical

industry in 2020 and identifies industry-wide goals for making more efficient use of energy and raw materials,

better managing of the supply chain, and enhancing environmental performance (see http://

www.ChemicalVision2020.org).

R&D Roadmaps – Groups of chemical companies have come together to jointly develop R&D agendas, or

“roadmaps,” that outline priority R&D needs in critical technology areas. To date, the industry has

completed the roadmaps listed below.

• Biocatalysis • Materials Technology

• Combinatorial Chemistry • Nanomaterials

• Computation Chemistry • New Process Chemistry

• Computational Fluid Dynamics • Reaction Engineering

• Ionic Liquids • Separations

• Materials of Construction

Fact Sheets and Success Stories – Publications describing research, development, and demonstration

(RD&D) projects are available at http://eere.energy.gov/industry/chemicals/success.html.

Resources and Tools for Energy Efficiency and Cost Reduction Now CD – The CD provides tips and tools

for spotting the biggest energy-saving opportunities in chemical plants today, as well as details on energy

efficiency technologies. (contact the EERE Information Center at 877-337-3463 or eereic@ee.doe.gov).

Energy and Environmental Profile of the Chemical Industry – A detailed report benchmarking the energy

and environmental characteristics of key technologies used in major processes of the chemical industry (see

http://www.eere.energy.gov/industry/chemicals/tools_profile.html).

Beyond the Molecular Frontier – This National Research Council report examines the current state of

knowledge across the chemical sciences and outlines the challenges for the 21st century (see http://

www.oit.doe.gov/chemicals/pdfs/beyond_molecular_frontier.pdf).

Highlights of Biopower Technical Assessment – This report assesses the current status of the biopower

industry for producing electricity and heat from biomass (see http://www.nrel.gov/docs/fy03osti/33502.pdf).

A Pilot Study of Energy Efficiency Performance Levels for the U.S. Chemical Industry: A Methodology

for Determining Practical Minimum Energy Metrics – This study discusses preliminary results of a joint

study with AIChE to develop and implement tools and methodologies to estimate energy performance levels

(see http://www.bridgestos.org/PME_final_report.pdf).

Chemicals Project Assessment Tool (CPAT) – Software is available that can be used to estimate the potential

energy, environmental, and economic benefits of a proposed new chemical technology (see http://

www.bcstools.net/CPAT).
13

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 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 (of which ITP is one of eleven) 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 cut energy use 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 for 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.

• 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.
14

• 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, nocost, 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 nation-wide network of capabilities for implementing ITP’s

technology delivery strategy. Regional Offices are located in the Southeast, Northeast, Midwest, Central,

Mid-Atlantic, and Western regions. 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/chemicals

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 ITP Chemicals portfolio activities, please contact:

Dickson Ozokwelu

Industrial Technologies Program

Office of Energy Efficiency and Renewable Energy

EE-2F

U.S. Department of Energy

1000 Independence Ave. SW

Washington, DC 20585-0121

Phone: 202-586-8501

Fax: 202-586-9234

Email: Dickson.Ozokwelu@ee.doe.gov

Brian Valentine

Industrial Technologies Program

Office of Energy Efficiency and Renewable Energy

EE-2F

U.S. Department of Energy

1000 Independence Ave SW

Washington, DC 20585-0121

Phone: 202-586-1739

Fax: 202-586-9234

Email: Brian.Valentine@ee.doe.gov

Charles Russomanno

Industrial Technologies Program

Office of Energy Efficiency and Renewable Energy

EE-2F

U.S. Department of Energy

1000 Independence Ave SW

Washington, DC 20585-0121

Phone: 202-586-7543

Fax: 202-586-9234

Email: Charles.Russomanno@ee.doe.gov


Chemicals 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