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Industrial Technologies Program State Energy Advisory Board Meeting Arlington, VA November 16-18, 2005 Jacques Beaudry-Losique, Program Manager Industrial Technologies Program, EERE U.S. Department of Energy Overview Industrial Energy Context

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Industrial Technologies Program

State Energy Advisory Board Meeting

Arlington, VA

November 16-18, 2005

Jacques Beaudry-Losique, Program Manager

Industrial Technologies Program, EEREU.S. Department of Energy



  • Industrial Energy Context
  • The Industrial Technologies Program’s (ITP’s) Focus
  • Results & Highlights
  • Save Energy Now Initiative
  • State Outreach & Resources

Industry: Critical to National Energy Policy

2004 Energy Use*

  • Uses more energy than any other single sector; >1/3 of U.S. energy consumption
  • Accounts for more than 40% of U.S.natural gas demand
  • Accounts for 28% of U.S. electricity demand
  • Produces approximately 30% of U.S greenhouse gas emissions







Residential 21.1%

*Includes electricity losses

Source: DOE/EIA Monthly Energy Review 2004 (preliminary)


U.S. Energy Consumption by Industry


All Energy

Natural Gas


Natural Gas Liquids


Trillion Btu





Fabricated Metals

Transport Equip.




Petroleum &


Food &



Iron & Steel


Coal Products



(1,922 TBtu NG)

Source: 1998 Manufacturing Energy Consumption Survey (MECS)

u s consumption of natural gas by sector 2004
U. S. Consumption of Natural GasBy Sector, 2004

Transportation 0.7 Quads

Industrial 8.8 Quads

Power 5.5 Quads

Commercial 3.1 Quads

Residential 5.0 Quads

Industry > 40% of total U.S. Natural Gas Use

Source: DOE/EIA Monthly Energy Review 2004 (preliminary)

challenges for energy intensive industries
Challenges for Energy-Intensive Industries
  • International technology/cost competition
  • Uncertain environmental constraints
  • Limited access to LT investment capital
  • Uncertain long-term economics
  • Natural gas prices and supply
    • Henry Hub spot price on November 8 2005, was $11.89/MMBtu
  • “Many companies have been unable to pass higher energy costs on to their customers, which has sharply reduced their profit margins” National Energy Policy, pages 2-4
the industrial technologies program itp
The Industrial Technologies Program (ITP)

Delivering Technology Solutions

Collaborative R&D

  • Energy-intensiveProcess Technologies
  • Crosscutting Technologies

Technology Delivery


  • Assessments
  • Training & Tools

Types of R&D Supported by ITP

Process specific

  • Hybrid Distillation
  • Process Intensification


  • Iso-thermal Melting
  • Advanced Water Removal
  • High-Efficiency Pulping
  • Inferential-based Process Control
  • Advanced Thermo- Electric Materials
  • Super Boiler
  • Ultra-Hard Materials
  • Natural Gas Alternatives


Trillion Btu


  • Next Generation Steel-making



Fabricated Metals

Transport Equip.


emerging topic fuel feedstock flexibility
Emerging Topic: Fuel/Feedstock Flexibility

Total Nat Gas Displacement(1012 Btu)

ITP Strategies

  • Near-Term (0 – 2 years):
  • Redirect TD to pursue natural gas saving opportunities via:
    • Technology and market assessments
    • Application guides explaining opportunities, implementation strategies, permitting issues, etc.
    • Training and education
  • Longer-Term (>2 years):Significant process changes and permitting required
    • Explore opportunities in FE and other EERE technologies
    • Conduct applied R&D for industrial applications
technology delivery resources
Technology Delivery Resources
  • DOE-supported energy assessments (IAC,CTA,PWA)
  • Qualified specialists
  • Energy efficiency trainingfor plant staff
  • Energy analysis software tools
  • Case studies and information


Info Center:


technology delivery focus
Technology Delivery Focus

Percent of Total Industrial Energy

U.S. Manufacturing Plants: By Size

Small &



Number of U.S. Plants



Focus of CTA, PWA Teams

Focus of IAC Teams

Small Plants<$100K

Mid-Size Plants$100K-$2M

Large Plants>$2M

Category:Annual EnergyCosts

All U.S. Plants


2002 program results
Annual energy savings of 121 trillion Btu (87 commercial technologies currently tracked)

Cumulative energy savings of 2.6 Quads since 1976

Cumulative production costsavings of $16.5 billionsince 1976

Initiated tracking of 11 new commercialized technologies

2002 Program Results
four r d 100 award winners in 2004
Enhancement of Aluminum Alloy Forgings through Rapid Preheating of Billets

Imaging Ahead of Mining

Smart Screening Systems

Advanced Glass Furnace Model

Four “R&D 100” Award Winners in 2004
fy2006 itp rd d solicitations
Chemicals through 1/11/06 ~ $10 million

SBIR through 12/2/05 ~ $10 million

Materials for EE Completed ~ $ 7.6 million

Industrial Assessment Centers through 1/24/06 ~ $ 6 million

Materials (Labs) Completed ~ $ 5 million

Innovative Energy Systems through 1/25/06 ~ $ 4 million

Inventions & Innov. Completed ~ $ 2 million

FY2006 ITP RD&D Solicitations
save energy now initiative goals
“Save Energy Now” Initiative Goals:
  • Encourage industry to voluntarily reduce its energy usage in a period of tight supplies by working with America’s largest energy-intensive plants
  • Create momentum to significantly improve energy efficiency practices throughout the manufacturing sector
energy savings assessments
Energy Savings Assessments
  • 200 assessments of targeted industrial systems
  • Assessments done by teams composed of DOE Qualified Energy Experts and plant personnel
  • Teams will focus on either steam generation or process heating
  • Plant personnel and affiliates will be trained on DOE efficient tools
  • ESA Report identifies potential energy and cost savings


Facilities 8%

Electrochemical - 2%


Manufacturing Energy Use by Type of System (%)

Steam 35%

Motor Systems 12%

Process Heating 38%

Note: Does not include off-site losses

robust partnerships to reach plants
Robust Partnerships to Reach Plants
  • Allied Partners
  • States
  • Utilities
  • Equipment Suppliers & Service Companies
  • Trade Associations
  • Replication within Industrial Companies
for the latest information
For the Latest Information …

Save Energy Now Website

EERE Information Center - Call: 1-877-337-3463


Selected State and ITP Accomplishments

  • Texas Technology Showcase
  • Ohio Technology Showcase
  • California Energy Fairs
  • Saving Water; Saving Energy in Colorado
  • Nevada Mining Energy Solutions Event
  • Western US Food Processing Efficiency Initiative

Accelerating State and ITP Results

  • Leverage market players (e.g., utilities, ITP Allied Partners, Qualified Specialists, and regional groups such as the Northwest Energy Efficiency Alliance)
  • Deliver SEP special projects through largest energy consuming plants
  • Facilitate cross-pollination of activities and results across corporate facilities
  • Increase awareness of ITP emerging technologies and commercialization capabilities
  • Develop common impacts tracking system and metrics
  • Strategically communicate successes to right audiences