Overview of the U.S. DOE Industrial Technologies Program
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Overview of the U.S. DOE Industrial Technologies Program. James Quinn Energy Efficiency & Renewable Energy U.S. Department of Energy. Rio de Janeiro, Brazil August 9, 2011. U.S. Industrial Energy Use. U.S. industry accounts for about one-third of all U.S. energy consumption.

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Overview of the U.S. DOE Industrial Technologies Program

James Quinn

Energy Efficiency & Renewable Energy

U.S. Department of Energy

Rio de Janeiro, Brazil

August 9, 2011

U.S. Industrial Energy Use

U.S. industry accounts for about one-third of all U.S. energy consumption.

Reducing U.S. industrial energy intensity is essentialto achieving national energy and carbon goals.




Natural Gas


Coal and Coke

Renewable Energy












* Excludes losses

Source: Annual Energy Review 2009, EIA.

Source for pie chart: U.S. Energy Information Administration / Monthly Energy Review June 2011 (includes losses)

Energy Use by U.S. Manufacturing


Energy Consumption by Major U.S. Manufacturing Sector, 2006

Quadrillion Btu

Source: U.S. Energy Information Administration, Manufacturing Energy Consumption Survey 2006, 2009.

Role of Energy Efficiency

& Renewable Energy

Potential of Carbon Abatement Technologies to Achieve the 450 ppm Scenario by 2030

Carbon Capture & Storage: 10%

Nuclear: 10%

Renewables & Biofuels: 23%

Efficiency: 57%

“The industrial sector accounts for 35% of the end-use energy efficiency potential [by 2020].” – McKinsey, 2009

Source: World Energy Outlook 2009, presented at UNFCCC Meeting in Bangkok, Thailand

Section I: US DOE’s Industrial Technologies Program

DOE’s Industrial Technologies Program


Advance manufacturing science and technology to enable rapid, low-cost, energy-efficient manufacturing.

  • Objectives:

    • Develop innovative, energy-efficient processes and materials technologies that can improve energy diversity, resource efficiency, and carbon mitigation

    • Promote a corporate culture that values energy and carbon management

ITP Delivers Solutions

Research, Development & Demonstration

  • Develop and demonstrate more efficient next generation manufacturing processes and materials to address the top opportunities for saving energy across industry.

Energy Management

Help plants find opportunities to save energy today by adopting the best energy management practices and most efficient technologies.

Industrial Technologies Program

ITP: Delivering Results For 30 Years

Working with industry, we have successfully developed and moved cutting-edge technologies and energy-saving measures into practice.

  • Produced >220 commercialized technologies

  • Obtained 215 patents between1994 and 2009

  • Received 55 prestigious R&D 100 awards since 1991

  • Saved 9.3 quads and reduced emissions by 755 million metric tons of CO2

Energy Management

Resources to help manufacturers reduce energy use and carbon emissions today—and continue to improve.

Standards & Incentives





Energy Management Tool Suite

Energy Management System Implementation Self-Paced Module

System Area Tools, Calculators, & Scorecards

Corporate Analysis Tools

  • Create corporate baseline

  • Generate annual report

  • Motors

  • Process Heating

  • Compressed Air

  • Fans

  • Plant Energy Profiler

  • Pumps

  • Steam

  • Buildings & Facilities

  • Data Centers

  • Getting started

  • Profile your energy flow

  • Develop opportunities, objectives, resources

  • Reality check

  • Manage current state & improvements

  • Check the system

  • Sustain & improve the system

Facility Analysis Tools

  • Create facility baseline

  • Develop recommendations portfolio

  • Prioritize projects

  • Follow-up tool

Project Analysis Tools

  • Prioritize projects

  • Follow-up tool


Energy Management: Tools

Plant Energy Profiler (PEP)


  • Plant description

  • Utility supply data

  • Energy use information

  • Overview of plant energy

  • Energy cost distributions

  • Preliminary assessment

  • Areas for improvement

  • Energy reduction potential



Energy Management: Training

Training at several levels for:

  • Energy Management Training seminars

  • Webinars on relevant topics(1-2 hours)

  • Web-based Awareness Workshops(1-2 hours)

  • 1-day End-User BestPracticesTraining (soon to be offered as web-based training)

  • 3-day Advanced/Qualified Specialist Training

  • Data Center Workshops

DOE's 26 university-based Industrial Assessment Centers (IACs) conduct energy assessments of small and medium-size plants* at no charge.

Faculty-led teams of engineering students conduct the assessmentsas training for careers in industrial energy efficiency.

IACs serve 300 plants per year (under 1 TBtu/yr or 25ktoe/yr) and typically identify savings of 8%-10% or $115,000/plant (181,000 BRL/plant)

Energy Management: Small Plant Assessments

Crosscutting Assessments at Small and Medium-Size Plants: Industrial Assessment Centers


* IAC plants typically have gross annual sales of less than $100 million, fewer than 500 plant employees, and annual energy bills less than $2 million.

Section I: US DOE’s Industrial Technologies Program





Energy Management: Assessments

ITP provides two types of assessments, working with plants of all sizes.

Percent of Total U.S. Manufacturing Energy

U.S. Manufacturing Plants: By Size


Small 5%

Number of U.S. Plants




Mid-Size Plants

Small Plants

Large Plants

All Plants

System-Specific Assessments

Crosscutting Assessments

Energy Management: Small Plant Assessments

  • Industrial Assessment Center (IAC) Assessments:

  • 1-day assessments cover plant-wide energy systems, including process andnon-process energy use (e.g., lighting,HVAC)

    • Recommended energy-savingmeasures are entered in a searchable,on-line data base.

  • Since January 2006:

    • Over 1,900 assessments conducted at small- and medium-size plants

    • 44 trillion Btu of identified primary energy savings

    • Over $402 million in energy cost savings identified

    • 2.7 million metric tons of CO2 emissions reductions identified

Hands-on training in diagnostics, data collection, and analysis of energy savings opportunities

Exposure to a wide range of industries, energy systems, and solutions

Interaction with plant staff, utility representatives, and vendors

Expedited ability to obtain professional licensure and certification

Energy Management:

Workforce Development

Industrial Assessment Centers (IACs):Greening the Workforce

DOE energy expert teams visit plants, conduct analyses, and report to plant managers

Teams focus on fans, pumps compressors, steam, process heating, or other plant energy system using DOE software tools

The biggest savings come from improving process heating and steam systems

Energy Management:

System-Specific Assessments

Large Plants: System-Specific Improvements

  • Average plant found ways to reduce energy bill by about 8%

  • Over a three year period, industry had implemented approximately 1/6 of recommendations and 1/3 were either in progress or in planning stages

Section I: US DOE’s Industrial Technologies Program

Energy Management:

Assessment Results

  • Since Save Energy Now was initiated in January 2006:

    • Over 2,900 energy assessments conducted at US plants to date

    • Average plant has found ways to reduce energy bill by ~5-8%

    • Over $1.6 billion (2.5 billion BRL) in identified energy cost savings

    • 13.3 million metric tons of CO2 emissions reductions identified

Energy Management:

Information Resources



Web Resources


Industrial Companies

Non-Government Organizations

Interagency Coordination




International Collaboration



Energy Management : Partnerships

Energy Management: CHP

Combined Heat & Power (CHP)

Combined Heat & Power (CHP):

An integrated set of technologies for the simultaneous, on-site production of electricity and useful heat.

CHP simultaneously

  • Reduces GHG emissions

  • Promotes use of secure domesticand renewable energy sources

  • Reduces exposure to energyprice hikes and volatility

This market-based, ANSI-accredited plant certification program provides industrial facilities with a pathway to continuously improve energy efficiency while boosting competitiveness.

Energy Management: Superior Energy Performance

Superior Energy Performance

  • Uses ISO 50001 standard as foundational energy management system

  • Develops system to validate energy intensity improvements and management practices

  • Encourages broad participation throughout industry for sustained energy savings

Superior Energy Performance launches in 2012

Thank You

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