The energy data used in this report do not reflect adjustments for losses in electricity generation or transmission. 1

 The manufacturing sector is composed of establishments classified in Standard Industrial Classification 20 through 39 of the U.S. economy as defined 2

by the Office of Management and Budget. The manufacturing sector is a part of the industrial sector, which also includes mining; construction; and

agriculture, forestry, and fishing.

 The EIA also conducts energy consumption surveys in the residential, commercial buildings, and residential transportation sectors: the Residential Energy 3

Consumption Survey (RECS); the Commercial Buildings Energy Consumption Survey (CBECS); and, until recently, the Residential Transportation

Energy Consumption Survey (RTECS). 

Energy Information Administration/Manufacturing Consumption of Energy 1994 1

Manufacturing Consumption of Energy 1994 provides estimates on energy consumption in the manufacturing sector of the

U.S. economy. The estimates are based on data from the 1994 Manufacturing Energy Consumption Survey (MECS). The 1

MECS, administered by the Energy Information Administration (EIA), is the most comprehensive source of national-level

data on energy-related information about the manufacturing industries.

Manufacturing Energy Consumption Surveys

To determine how energy is used in the manufacturing sector, EIA gathers information from a national representative sample

of the manufacturing establishments that transform input materials or substances into new products, assemble components,

or perform blending operations. In 1994, of the approximately 380 thousand manufacturing establishments in the United 2

States, the MECS sample represented about 250 thousand of the largest establishments. Those establishments account for

approximately 98 percent of U.S. economic output from manufacturing and an expected similar proportion of manufacturing

energy use. The amount of energy an establishment uses is collected for all of its operations and not solely for the amount

of energy used in manufacturing its product.

The 1994 MECS is EIA's fourth survey of the manufacturing sector. Previous manufacturing surveys were conducted in

1986, 1989, and 1992 (for reporting years 1985, 1988, and 1991, respectively). The next manufacturing survey will be

conducted for reporting year 1998, with subsequent surveys being conducted every 4 years thereafter. 

The sample design of the 1985, 1991, and 1994 surveys differed somewhat from that of the 1988 survey, which necessitates

that care be exercised when comparing estimates from the four surveys. The 1988 sample represented 100 percent of

manufacturing energy use, but it included statistical adjustments to account for 2 percent of the population, namely the

smallest manufacturing establishments. The 1985, 1991, and 1994 samples represented 98 percent of the population,

without any statistical adjustment. 

The MECS is conducted under the authority of the Federal Energy Administration Act of 1974, Public Law 93-275, as

amended, and Section 205 of the Department of Energy Organization Act, Public Law 95-91, as amended by Section 3102

of the Omnibus Budget Reconciliation Act of 1986, Public Law 99-509. 3

On behalf of EIA, the Manufacturing and Construction Division of the Bureau of the Census collects and compiles the data.

All data reported to the Bureau of the Census are confidential under the provisions of Section 9, Title 13, of the U.S. Code.

EIA gratefully acknowledges the cooperation of the respondents in supplying the information used to produce the estimates

in this report.

Organization of This Report

This introductory chapter is followed by three more chapters:

 Chapter 2 presents the reader with a brief summary of what is new in the 1994 MECS, along with four questions

that demonstrate how the new data can be used to analyze energy consumption by the manufacturing sector.

 Chapter 3 presents profiles for the four major energy-consuming manufacturing industries: the petroleum refining,

chemical, paper, and primary metal industries. 
 To better serve the user community, EIA has made those tables and other, more detailed, tables available electronically at 4

http://www.eia.doe.gov/emeu/mecs/contents.html.

2 Energy Information Administration/Manufacturing Consumption of Energy 1994

A Guide to the Tables in This

 Report 

 Energy Table

Consumption A1-A6

 End Use A9, A10

 Management A24, A25

 Operating Ratios A23 

 Sources A44

 Technology A26, A27

Electricity

 Demand A11

 Generation A12, A13

 Sales A14

Purchased Energy

 Consumption A15, A16

 Expenditures A17-A19

 Average Prices A20-A22

Fuel Switching A28-A40

Square Footage A7, A8

Motors A41, A42

Wood A43

 Chapter 4 presents “How Changing Energy Markets Affect Manufacturing,” a feature article analyzing 

the effects of changes in the natural gas and electricity markets on the manufacturing sector.

Seven appendices follow the chapters:

 Appendix A presents detailed statistical tables that provide measures of data reliability (relative standard errors)

as factors in the rows and columns of the data tables. 4

The tables presented in this publication have been enhanced in two ways. First, additional data have been

incorporated into tables that were present in 1991. Most of the time, those additional data are “the number of

establishments,” collected for the first time in the 1994 MECS. An example is Table A1: a Part 5 has been added

to present the number of establishments. 

Secondly, new tables have been added. New tables are A7, “floorspace”; A29, “demand-side management”; A32,

A34-A36, A38-A40, and A45, “fuel switching”; and A47, “wood used as energy.” 

 Appendix B explains the sample design of and the

estimation and implementation procedures for the MECS.

 Appendix C discusses the quality of the data. 

 Appendix D provides copies of the forms used to collect

the MECS data, Forms EIA-846 A through C, on which the

estimates in this report are based, unless otherwise noted.

 Appendix E provides a map of the U.S. Census Regions

and Divisions.

 Appendix F describes the major industrial groups and

selected industries.

 Appendix G presents metric conversion factors.

 Appendix H lists related energy consumption publications

for readers interested in earlier MECS publications or

consumption reports for other sectors. 

A glossary of statistical and engineering terms used in this report

follows the appendices. 
What Type of Cogeneration Technologies Did the Largest

Cogenerator Use in 1994?

1994 MECS Sample

New 1994 Data

In 1994, the MECS sample size was increased by roughly 40 percent. The increase allows the Energy

Information Administration (EIA) to publish separate estimates for 52 industries and industry groups, nine

more than in the 1991 MECS. The larger sample also provided reliable data for energy consumption at

the geographic level of nine Census divisions.

In addition to the new data analyzed on these two pages, cogeneration technologies, biomass, number

of establishments, and square footage, other new data are available from the 1994 MECS. For the first

time, data on actual fuel switching between natural gas and fuel oil are available. Other newly available

data cover methods that manufacturers most commonly used to purchase and make modifications to

electric motor systems, participation in the U.S. Department of Energy's Motor Challenge Program, and

participation in the Environmental Protection Agency's Green Lights and Energy Star programs.

The largest cogenerator, the paper industry, cogenerated 51 billion

kilowatthours of electricity in 1994 (Table A12). The cogeneration

technology most used was the steam turbine supplied by bed boilers

(61 percent of the cogenerated electricity). Twenty-three percent of

the paper industry's cogeneration occurred in establishments where

two or more different types of cogeneration technologies were used

(Table A13).

Paper Industry

2. New in the 1994 MECS

Energy Information Administration/Manufacturing Consumption of Energy 1994 3

What Types of Biomass Are Used as an Energy Source, How Much

Is Used, and by Whom?

In the manufacturing sector, biomass, used as an energy source, consists of agricultural wastes, wood

directly harvested from trees, wood residues from mill processing, and wood-related and paper-related

refuse. In 1994, biomass accounted for 831 trillion Btu of energy used for heat, power, and electricity

generation, and wood residues from mill processing accounted for 61 percent of that amount. The paper

industry used the most biomass, 49 percent in 1994. The next largest user, the lumber industry, accounted for 33 percent, followed by the food industry, which accounted for 13 percent (Table A43).
Do the Industries That Consume the Most Energy Also Have the

Largest Number of Establishments?

No, there is not necessarily a correlation between the

amount of energy used and the number of establishments.

In 1994, the petroleum refining industry used 29 percent

of all the energy but accounted for only 1 percent of the

establishments. In contrast, the printing industry had the

largest percent of establishments, but used less than 1

percent of the energy (Table A1, Part 1 and Part 5).

Do the Industries That Have the Most Square Footage Also Have

High Energy Intensities?

No, in the manufacturing sector, there is not necessarily a

correlation between square footage and the intensity of

energy use. The chemical industry had the largest amount

of floorspace of any of the major users of energy (808 million

square feet). That amount of floorspace was only about 67

percent as much as the industry with the most floorspace--the

fabricated metal industries. The energy intensity for the chemical industry was 21 times higher than the energy intensity for

the fabricated metal industries (6.6 million Btu per square foot

versus .31 million Btu per square foot). The chemical industry

accounted for almost 25 percent of manufacturing energy use,

while the fabricated metal industries accounted for only 2 percent (Tables A7 and A1, Part 1).

Petroleum Refining

Industry

Chemical Industry

Energy Information Administration/Manufacturing Consumption of Energy 1994 4
Energy Information Administration/Manufacturing Consumption of Energy 1994 5

In 1994, there were 246,855 manufacturing establishments in the manufacturing population covered by the MECS that used

at least one energy source. Just 9 percent of the establishments accounted for almost 78 percent of all of the energy used

in the manufacturing sector as measured by “Total First Use of Energy for All Purposes.” Those establishments belong to

only four major industry groups, defined by 2-digit Standard Industrial Classification (SIC) codes. This chapter presents

individual profiles of each of the four major energy-consuming industries. 

The Four Major Energy Consumers in the Manufacturing Sector

Petroleum and Coal Products (SIC 29). The petroleum refining industry is the largest consumer of energy in the

manufacturing sector. Large amounts of energy are used to produce energy. Establishments in this group are engaged

primarily in refining petroleum, manufacturing paving and roofing materials, and compounding lubricating oils and greases

from purchased materials.

Chemicals and Allied Products (SIC 28). The chemical industry includes establishments producing basic chemicals.

It also includes establishments that use predominately chemical processes to manufacture products used in further

manufacture, producing such products as synthetic fibers and plastics; or as a final product for consumption, such as drugs

and cosmetics; or as materials and supplies, such as paints and fertilizers.

Paper and Allied Products (SIC 26). The paper industry includes establishments called pulp mills that are engaged

primarily in the manufacture of pulps from wood and other cellulose fibers, rags, wastepaper, and straw. It also includes

paper and paperboard mills, which manufacture paper and convert paper into products such as napkins and paperboard.

Primary Metal Industries (SIC 33). The metal industries include establishments engaged in smelting and refining

ferrous and nonferrous metals from ore, pig, or scrap. Also, refined metals, such as steel, iron, and aluminum, are rolled and

turned into basic shapes, such as plates, sheets, strips, rods, bars, and tubing. Establishments participating in the

manufacture of alloys and copper smelting also belong to this group.

Quantities of Energy and Expenditures for the Four Major Energy Consumers

In 1994, the four major energy consumers accounted

for 99 percent of all energy consumed as feedstock and

92 percent of the byproduct energy (a secondary

product from the feedstock use of energy or from the

processing of nonenergy materials) (Figure 3.1). With

feedstock excluded, these four industries accounted for

71 percent of the measure “Total Inputs of Energy for

Heat, Power, and Electricity Generation.” Although

they purchased 67 percent of all purchased energy, they

spent only 48 percent of all of the dollars spent on

energy in the manufacturing sector. The four industries

also generated the most electricity--69 percent of all

electricity generated by the manufacturing sector. 
How Much Energy Did the Petroleum Refining Industry Use in 1994?

Energy Expenditures:

Forty-seven percent of the expenditures were for natural gas, with an average price of $2.26 per

1,000 cubic feet--25 percent lower than the average price for the rest of the manufacturing sector.

Most of the remaining expenditures were for electricity--38 percent in 1991 (the most recent year

for which data were available).

First Use of Energy for All Purposes:

The petroleum refining industry used 6,339 trillion Btu of energy--29 percent of total manufacturing

energy use.

It used 50 percent as feedstock (a nonenergy use).

Expenditures and Average Prices (Annualized Rates):

Quantity of Purchased Energy (Annualized Rates):

Total expenditures decreased 2.7 percent.

Natural gas expenditures grew 2.1 percent and average prices grew 1.2 percent.

Total purchased energy decreased 2.3 percent.

End Use of Total Inputs of Energy for Heat, Power, and Electricity Generation:

Machine drives accounted for 80 percent of net electricity use.

Boiler fuel accounted for 52 percent of residual fuel oil use; process heating accounted for

40 percent.

Process heating accounted for 68 percent of liquefied petroleum gas use; boiler fuel accounted

for 21 percent.

Process heating accounted for 67 percent of distillate fuel oil use.

For Which Energy Sources Did the Petroleum Refining Industry Spend

the Most Dollars?

What Were the Most Important Energy End Uses?

Between 1991 and 1994, What Changed in the Amount of Energy

Purchased and Its Cost?

Petroleum and Coal Products (SIC 29)

6 Energy Information Administration/Manufacturing Consumption of Energy 1994
How Much Energy Did the Chemical Industry Use in 1994?

Energy Expenditures:

In 1994, the chemical industry accounted for 26 percent of all energy expenditures

in the manufacturing sector.

Of total expenditures, electricity accounted for 30 percent, LPG accounted for 30

percent, and natural gas accounted for 30 percent..

First Use of Energy for All Purposes:

The chemical industry used 5,328 trillion Btu of energy--25 percent of total

manufacturing energy use.

It used 46 percent as feedstock (a nonenergy use).

Ninety-five percent of all liquefied petroleum gas (LPG) used in the manufacturing

sector was used by this industry, mostly as feedstock.

Expenditures and Average Prices (Annualized Rates):

Quantity of Purchased Energy (Annualized Rates):

Total expenditures grew 1.7 percent, while average prices fell 4.2 percent.

Electricity expenditures grew 3.7 percent, while average prices fell 2.1 percent.

Natural gas expenditures grew 9.7 percent and average prices increased 3.4 percent.

Total purchased energy increased 6.7 percent.

Purchased electricity increased 6.2 percent.

Purchased natural gas increased 5.7 percent.

End Use of Total Inputs of Energy for Heat, Power, and Electricity Generation:

Machine drives accounted for 62 percent of net electricity use.

Boiler fuel accounted for 62 percent of residual fuel oil use.

Boiler fuel accounted for 49 percent of natural gas use; process heating accounted for

33 percent.

Boiler fuel accounted for 95 percent of coal use.

For Which Energy Sources Did the Chemical Industry Spend the

Most Dollars?

What Were the Most Important Energy End Uses?

Between 1991 and 1994, What Changed in the Amount of Energy

Purchased and Its Cost?

Chemicals and Allied Products (SIC 28)

Energy Information Administration/Manufacturing Consumption of Energy 1994 7
How Much Energy Did the Paper Industry Use in 1994?

First Use of Energy for All Purposes:

The paper industry used 2,665 trillion Btu of energy--12 percent of total

manufacturing energy use.

It used 35 percent of all residual fuel oil used in the manufacturing sector.

Expenditures and Average Prices (Annualized Rates):

Quantity of Purchased Energy (Annualized Rates):

Total expenditures grew 1.2 percent.

Electricity expenditures grew 1.0 percent, while average prices fell 2.7 percent.

Purchased electricity increased 4.1 percent.

End Use of Total Inputs of Energy for Heat, Power, and Electricity Generation:

Machine drives accounted for 80 percent of net electricity use.

Boiler fuel accounted for 80 percent of residual fuel oil use.

Boiler fuel accounted for 70 percent of natural gas use.

Boiler fuel accounted for 98 percent of coal use.

What Were the Most Important End Uses?

Between 1991 and 1994, What Changed in the Amount of Energy

Purchased and Its Cost?

Paper and Allied Products (SIC 26)

Energy Expenditures:

Almost half of the expenditures were for electricity, with an average price of 4.1 cents

per kilowatthour--8 percent lower than the average price paid by the rest of the

manufacturing sector.

Twenty-three percent of the expenditures were for natural gas with an average price of

$2.61 per 1,000 cubic feet--11 percent lower than the average price for the rest of the

manufacturing sector.

For Which Energy Sources Did the Paper Industry Spend the

Most Dollars?

8 Energy Information Administration/Manufacturing Consumption of Energy 1994

Purchased electricity increased 4.1 percent.

Residual fuel oil purchases increased 4.2 percent.
How Much Energy Did the Metal Industries Use in 1994?

Energy Expenditures:

Sixteen percent of all energy expenditures for the manufacturing sector were in this industry.

Almost two-thirds of the expenditures in this industry occurred in the blast furnace and

steel mills industry (SIC 331).

First Use of Energy for All Purposes:

The metal industries used 2,462 trillion Btu of energy--11 percent of total manufacturing

energy use.

It used 39 percent as feedstock (a nonenergy use).

Ninety-five percent of all coke and breeze used in the manufacturing sector was used by

this industry.

Forty percent of coal used in the manufacturing sector was used by the metal industries,

mostly as feedstock.

Expenditures and Average Prices (Annualized Rates):

Quantity of Purchased Energy (Annualized Rates):

Total expenditures grew 2.1 percent.

Coal expenditures grew 3.3 percent, while average prices fell 3.6 percent.

Coke and breeze expenditures grew 16.8 percent, while average prices fell 4.8 percent.

Purchased coal increased by 7.7 percent.

Purchased coke and breeze increased 25.2 percent.

End Use of Total Inputs of Energy for Heat, Power, and Electricity Generation:

Process heating accounted for 24 percent, machine drives accounted for 30 percent, and

electrochemical processes accounted for 36 percent.

Boiler fuel accounted for 70 percent of residual fuel oil use; process heating accounted

for 30 percent.

Boiler fuel accounted for 83 percent of coal use.

Process heating accounted for 76 percent of natural gas use.

For Which Energy Sources Did the Metal Industries Spend the

Most Dollars?

What Were the Most Important End Uses?

Between 1991 and 1994, What Changed in the Amount of Energy

Purchased and Its Cost?

Primary Metal Industries (SIC 33)

Energy Information Administration/Manufacturing Consumption of Energy 1994 9