A

JOINT

INDUSTRY

-

GOVERNMENT

COMMITMENT TO

PROMOTE INCREASED

USE OF INDUSTRIAL

ENERGY

-

EFFICIENT

MOTOR SYSTEMS

.

C

ost-saving technology for today —

bringing practical energy-efficient and

pollution-preventing solutions to U.S. industry

U.S. DEPARTMENT OF ENERGY

OFFICE OF INDUSTRIAL TECHNOLOGIES • ENERGY EFFICIENCY AND RENEWABLE ENERGY

Technical Assistance

TECHNICAL ASSISTANCE

OPENS THE DOOR TO

IMMEDIATE COST-SAVING

OPPORTUNITIES AND

PRODUCTIVITY IMPROVEMENTS

FOR U.S. MANUFACTURERS

THE OPPORTUNITY

2

THE PROGRAMS

Industrial systems targeted

for energy savings

U

.S. manufacturers are constantly looking for

bottom-line improvements. There are many

opportunities for improving profitability through

energy efficiency. What are the leading energy-

wasting culprits? Industrial processes driven by

motors, steam, compressed air, and heating sys-

tems are just some examples. Because costs

associated with these systems are many times

not attached to a particular process or product,

they are often treated as fixed costs of produc-

tion and remain largely uncontrolled in many

operations.

The good news is that practical, affordable, and proven improvements

to these systems can yield immediate energy and materials savings —

freeing up dollars that flow directly to the bottom line. These same

improvements often reduce air emissions and other waste streams

associated with energy and materials use. And in the process of

making their operations more energy-efficient and materials-efficient,

manufacturers often realize productivity and reliability increases as well.

The place to start

Focusing on overlooked energy-saving and cost-saving opportunities

is the purpose of the portfolio of Technical Assistance resources under

the Office of Industrial Technologies (OIT). Technical Assistance provides

the tools and assistance to help manufacturers identify their best energy-

efficient, pollution-preventing options, from a systems and life-cycle cost

approach.

Technical Assistance can provide the latest information on both emerging

and widely commercialized technologies. Technical Assistance seeks to

accelerate the application of practical, proven energy-saving approaches

in U.S. industrial facilities, particularly the most energy-intensive

industries represented by OIT’s Industries of the Future initiative.

Technical Assistance provides a continuum of services — from

conducting energy assessments and evaluations, to helping operators

implement technologies in plant sites, to providing the tools and

resources for measuring the effectiveness of new technologies.

Technical Assistance focuses on five key opportunities for energy efficiency

and waste reduction: electric motors, steam, compressed air, combined

heat and power, and the Industrial Assessment Centers (IACs). By the year

2000, these programs will reach an estimated 6,555 manufacturing plants

and will achieve $390 million in savings as a result of Technical Assistance.

Plant-wide energy assessments for small

and medium-sized plants

Small and medium-sized plants stand to benefit greatly from energy-

saving investments. In fact, depending on the industry, energy bills can

account for 10 percent or more of their total operating costs. Yet many

small and medium-sized facilities lack the resources and in-house

expertise to systematically assess and identify the best approaches on

their own.

OIT’s Technical Assistance can help. Through no-charge audits conducted

by the Industrial Assessment Centers, small and medium-sized manufac-

turers gain the assistance they need to implement cost-effective technolo-

gies that minimize energy and materials use, reduce pollution, boost pro-

ductivity, and often improve product quality.

IAC analyses are performed by teams of engineering faculty and students

drawn from 30 participating universities nationwide. In a typical analysis,

a locally-based team conducts a one-day site visit, taking process mea-

surements and evaluating equipment as a basis for engineering recom-

mendations. Within 60 days, the team delivers a report to the client that

details the analysis, findings, and recommendations; and in six to nine

months the team performs a follow-up with the plant manager.

On average, a typical assessment identifies nearly $55,000 in potential

annual savings: more than $20,000 in energy savings and the balance in

waste-related and productivity savings.

Slashing electricity bills through

motor system improvements

Working through OIT Technical Assistance, industry can gain new strate-

gies for improving motor system efficiency. Motor system optimization

can typically achieve 10 to 20 percent in energy savings over conven-

tional systems, and often as much as 50 percent. Such improvements

can translate into huge potential dollar savings in the U.S., where more

than 20 million motor systems are currently in use in industrial locations.

Motor-driven equipment accounts for 64 percent of electricity consumed

by U.S. industry. Energy bills attributable to motor-driven equipment total

six times the equipment’s initial purchase price each year.

Industry has proven that using a systems approach can improve not only

motor system efficiency, but also plant productivity and reliability. Factors

contributing to motor system efficiency include the efficiency of individual

components, but also and more important, how these components are

integrated into a complete system.

Working with OIT, industry partners gain new strategies for improving

motor system efficiency. They learn from other motor system users and

get unbiased information and advice. By optimizing motor-driven technol-

ogy and systems, participants in the program have racked up cumulative

energy savings of $50 million since 1994.

3

Reducing fuel use in steam systems

Over 33,000 large boilers are used by U.S. industry to produce steam.

Steam production accounts for approximately two-thirds of all fuel

burned by industrial plants, with an associated fuel cost of $21 billion.

Steam production has significant environmental implications, releasing

196 million metric tons of carbon equivalent each year, or 40 percent of

total U.S. industrial emissions.

Optimizing operation, maintenance, and use of industrial steam systems

represents one of the largest energy-saving and emissions-reduction

opportunities in U.S. industry. Efficiency improvements of 30 to 40 per-

cent are readily achievable through best-practice approaches and can

result in large aggregate annual savings: decreasing industrial energy

consumption by 2 quads, reducing energy costs by $4.2 billion, and pre-

venting 43 million metric tons of emissions.

OIT, the Alliance to Save Energy, and U.S. industry have partnered to

provide plant operators with the tools and technical assistance they need

to improve the efficiency of their steam systems. By lowering production

costs and enhancing productivity, these improvements help plants gain a

more solid competitive footing.

Optimizing compressed air systems

to save electricity

Nearly every industrial plant has some type of compressed air system

that is vital to its operations. In many plants, the compressed air system

consumes more electricity than any other type of equipment. Across the

U.S., these systems annually account for $4.5 billion in industrial energy

costs and one and a half percent of industrial air emissions.

Energy-saving opportunities in compressed air systems are frequently

overlooked, even though many companies could potentially save thou-

sands of dollars annually. Optimization of these systems can easily

reduce energy consumption and costs by 20 to 50 percent while main-

taining or even improving system performance and reliability.

Lack of information has been cited as a key reason why industry has not

adopted energy-efficient measures for compressed air systems. Industry

can gain the essential education and technical training needed to imple-

ment improvements.

A window of opportunity for combined

heat and power

Within the next decade, a large proportion of industrial boilers will need

to be replaced, opening an opportunity to upgrade this equipment with

clean and efficient combined heat and power (also known as cogenera-

tion) systems. These systems provide steam for industrial processes, just

as conventional boilers do. But in addition, they generate electric power,

and they also recover steam that would otherwise be lost, applying it to

heating and cooling.

Combined heat and power systems capture a very large percentage of the

energy value of the fuels they consume. In contrast, when electric power

and thermal energy are generated separately by centralized plants and

then transported to the factory through power and steam lines, the major-

ity of the fuel’s energy value is actually lost.

Because of their high efficiency, combined heat and power systems often

provide a good energy value for industrial facilities. Per unit of energy

produced, they also emit lower levels of air pollutants than conventional

centralized power plants and thermal energy plants that are operated

separately.

Restructuring of the electric power industry and new environmental regu-

lations are key factors driving interest in combined heat and power as an

efficient and cost-effective energy strategy. The combined heat and power

program is creating a national dialog on this technology to raise aware-

ness of its benefits and to promote innovative efforts to accelerate its use.

The program brings together policymakers and industry representatives

to promote collaboration, and leverages activities of other government

and industry programs.

PORTFOLIO HIGHLIGHTS

4

Partnering for clean and competitive

Industries of the Future

Our Nation’s strength is based in large part on our access to afford-

able and reliable energy. As we move into the new millennium, our

mission is to develop and deploy new ways to meet our energy

needs and improve our environmental quality through use of renew-

able energy and increased energy efficiency.

Through Industries of the Future, the Office of Energy Efficiency and

Renewable Energy is actively engaged with U.S. industry to capture

energy and natural resource savings by developing and displaying

clean and energy-efficient technologies and practices. Working with

the Nation’s most energy-intensive industries, we are mapping a

vision of the energy future of American industry and developing the

technology needed to implement that vision. This profile describes

a few of the many ways that the DOE-industry alliance is working

toward a more competitive future for U.S. industry and our Nation.

Dan W. Reicher

Assistant Secretary

Energy Efficiency and Renewable Energy

A continuum of technical assistance

Technical Assistance’s resources — information, tools, training, and

direct plant-level assistance — can be accessed directly by working with

a representative, calling the Information Clearinghouse or the OIT

Resource Room, or accessing OIT’s home page.

Direct plant-level assistance

• Energy, waste, and productivity assessments

• Showcase demonstration projects

• Plant energy profiles

• Technology sur veys

• Plant benchmarking and energy performance comparisons

Tools

• Motor Master+3.0 software

• ASDMaster adjustable speed-drive evaluation methodology

and application software

• 3E Plus software (steam program)

• The IAC database

Information

• Improving Compressed Air System Performance: A Sourcebook

for Industry

• Energy Efficient Electric Motor Selection Handbook

• Fact sheets and case studies

• Steam Energy Efficiency Handbook

• The IAC Self-Assessment Workbook

• Market assessment studies

• Energy Matters newsletter

• Information Clearinghouse

• Industrial Projects Locator (IPLocator)

• OIT’s Resource Catalog

Training

• Motor, steam, and compressed air systems training sessions

Industry defines its vision and R&D priorities

OIT’s centerpiece strategy is the Industries of the Future, a partnership

process that engages each participating industry in developing its vision

of a more resource-productive, energy-efficient future, and in defining

technology developments critical to realizing this vision.

Nine major industries — agriculture, aluminum, chemicals, forest prod-

ucts, glass, metalcasting, mining, petroleum, and steel — are participants

in the Industries of the Future initiative. These energy-intensive industries

account for over 75 percent of the energy consumed by U.S. industry and

face significant environmental challenges.

OIT is working closely with the nine Industries of the Future to help them

define their sustainable futures and prioritize their technology needs over

the next two decades. This industry-driven strategy is central to helping

align Federal R&D and other resources with industry priorities and

improving access to a wide array of technical expertise and facilities.

As part of the Industries of the Future process in developing the visions

and technology roadmaps, industry identified a need to address specific

technology and materials requirements common to all of the vision indus-

tries. The goal of Technical Assistance is to work with industry partners to

conduct cost-shared R&D which has application across all of the vision

industries, as well as to provide the tools and technical assistance needed

to speed the implementation of energy-efficient, clean manufacturing

technologies.

Through the support of OIT’s Technical Assistance, many technologies

and processes are now part of the Industries of the Future R&D portfolio.

Technical Assistance projects have supported many crosscutting tech-

nologies that have application across most energy-intensive industries.

5

Technical Assistance helps Industries of the Future

make a difference today

Agriculture—Process integration study results in savings at corn

milling plant

OIT sponsored a process integration study with American Fructose, Inc.’s,

wet corn milling plant in Decatur, Alabama. The plant installed a waste

steam recovery heat pump recommended by the study. The new system

is saving the company $300,000 per year in energy costs with a one-year

payback. The new system has also allowed increased production of prod-

uct. Efficiency and productivity improvements such as these contribute to

the overall health of the agricultural industry.

Aluminum—Fan systems analysis optimizes aluminum potline

Alumax Inc., explored ways to improve the energy efficiency of potline

dust collection fan systems at its Mount Holly, South Carolina, aluminum

refining plant. Alumax measured fan speed, air temperature, air flow,

static pressure, and fan motor power consumption under three scenarios.

This plant found that shutting off one of four fans in each potline fume-

collection system netted an annual energy savings of more than

$103,000. The aluminum industr y’s Partnerships for the Future points to

these types of energy conservation efforts as critical to meeting perfor-

mance targets.

Chemicals—Motor systems optimization brings energy and cost savings

3M Corporation in Maplewood, Minnesota, successfully conducted an in-

house performance optimization project that evaluated electric motor sys-

tems in 26 of its buildings. 3M applied a systems approach to optimize the

performance of electric motor systems at all facilities on the corporate head-

quarters campus and achieved annual energy savings of 10.8 million kWh.

When these electricity savings are combined with maintenance savings and

reduced steam and chilled water, the annual cost savings amount to

$823,000. Upgrades included installing energy-efficient motors, variable

speed drives, and a digital control system. This project is just one example

of how Technical Assistance programs support the primary targets of the

chemical industry’s Vision 2020.

Forest Products—Steam-line insulation improves wood drying

operations

The Georgia-Pacific plywood plant in Madison, Georgia, used the steam

3E PLUS software tool to determine the best insulation thickness for sev-

eral steam lines leading to dryers. The computer analysis motivated the

company to insulate 1,500 feet of steam lines, reducing fuel costs by

$50,000 and carbon emissions by 200 tons per year, as well as improving

the efficiency of the drying process. The plant cut steam usage by

approximately 6,000 lbs/hour and eliminated all natural gas purchases.

Capital effectiveness and pollution prevention efforts such as these align

with the goals and objectives of Agenda 2020, the forest products

industry vision.

Metalcasting—Energy assessment improves efficiency at

metalcasting plant

Amcast Precision Products manufactures aircraft parts for commercial

and military use. Metal parts are cast in the plants’ foundry using molds

created on-site. The San Diego State University Industrial Assessment

Center provided a no-cost energy audit in 1996. Implemented recommen-

dations included modifications to the lighting system, worth $17,400

annually in electricity savings, and changes in operating practices to

reduce drag-out losses from process tanks, worth $26,300 annually.

Energy efficiencies such as these are in concert with the profitability and

industry health goals outlined in the metalcasting industry vision,

Beyond 2000.

Mining—Pump system enhances coal washing process

Peabody Holding, a large coal producer, upgraded six 100-horsepower

cyclone pumps at its Randolph Coal Preparation Center. By optimizing the

pump systems, Peabody reduced the operating cost of each pumping

system by $5,000 per year. Energy efficiencies gained through mechani-

cal improvements such as those achieved at Peabody support the mining

industry’s goal of maintaining its competitive position, as outlined in its

vision, The Future Begins with Mining.

Petroleum—Refinery cuts energy costs 30 percent through diesel

hydro-treater pump system upgrade

Chevron’s Richmond refinery typically processes 240,000 barrels of crude

oil per day, with annual electricity costs exceeding $25 million. Pump sys-

tem efficiency upgrades on the refinery’s diesel hydro treater (DHT) unit

has reduced energy consumption by 1 million kWh per month, resulting

in $700,000 cost savings per year. In addition, mechanical reliability and

process control have improved because efficient motor/pump systems

have decreased the vibration levels, reducing the failure rates of seals and

bearings. Currently under development, the petroleum refining industry’s

vision of the future will encompass efforts like these, which contribute to

competitiveness and domestic energy security.

Steel—Motor systems modifications optimize hot strip mill process

at steel works

LTV Steel Company has conserved water and energy, increased capacity,

and improved operating efficiency through upgrades to the hot strip mill

(HSM) process contact water system. Variable speed high-efficiency

pump systems were installed, increasing HSM capacity without expand-

ing the waste water treatment plant. Pump subsystems were tuned so

they can be adjusted to efficiently match a new range of expected operat-

ing points. LTV is saving $440,000 a year and contributing to improved

production efficiency, a critical area outlined in the industry vision,

Steel: A National Resource for the Future.

RESEARCH, SERVICES,

AND RESOURCES

DOE programs encourage

innovation in the most

energy-intensive industries

O

IT’s Technical Assistance programs are a

complementary portfolio of resources to promote

the development and use of energy-efficient,

pollution-preventing technologies.

To help industry access and ensure timely implementation of its technolo-

gies and capabilities, OIT is developing an integrated delivery approach

for products, services, and emerging technologies. Through this process,

companies are made aware of OIT’s full portfolio of energy, environmen-

tal, and productivity enhancement technologies, matching the right

resources to meet the customer’s needs.

Enabling Technologies

AIM (Advanced Industrial Materials) develops and commercializes new

and improved materials to increase energy efficiency, improve productivity,

and enhance material longevity and product quality.

The Combustion program increases productivity, improves energy effi-

ciency, reduces emissions, and enhances fuel flexibility by developing

cost-effective and energy-efficient technologies that are necessary for

global competitiveness.

Continuous Fiber Ceramic Composite Materials pursues ceramic com-

posite technologies that improve productivity by utilizing higher process

temperatures, extending component and system lifetimes, and reducing

downtime.

Sensors and Controls develops and deploys integrated measurement sys-

tems for operator-independent control of the manufacturing process.

Priority goals are improving technology both in sensors embedded in

high-temperature and harsh environmental applications, and in informa-

tion processing to detect and remedy malfunctions.

Bethlehem Steel—an industry model for energy-efficient operations

Through the long-standing OIT and Bethlehem Steel partnership, an

industry model of efficient plant design and operation has been created

at the company’s flagship facility in Burns Harbor, Indiana. The facility,

which produces hot- and cold-rolled sheet and plate for the automotive,

machinery, and appliance markets, has implemented over a dozen OIT-

supported technologies and processes to help control energy costs

and optimize productivity. Many of these technologies were developed

jointly between the steel industry and OIT through the Industries of the

Future initiative.

In 1987, Bethlehem Steel contracted with General Conservation

Corporation to improve the energy efficiency of the basic oxygen fur-

nace #3. By installing a variable frequency drive and modifying associ-

ated equipment to the induced draft gas removal fans, the fans’ speeds

were better matched to the furnace’s varying requirements. Electrical

usage dropped nearly 50 percent to 15,500 MWh, resulting in annual

savings of $620,100. Meade Industrial Services, Inc., performed the

electrical installation on the project.

A concurrent Burns Harbor project focused on improving the perfor-

mance of a steam turbine generator. The turbine was redesigned to use

warm condenser cooling water for boiler feedwater instead of cool lake

water. This project resulted in an annual savings of 40,000 MWh of elec-

tricity and 85,000 million Btu of natural gas, adding up to $3.3 million in

energy cost savings per year. Emissions also declined, with lower-tem-

perature water discharges and decreased coke oven and blast furnace

gas emissions.

These and other technologies and programs were showcased when the

Burns Harbor facility hosted over 300 individuals and organizations

interested in learning more about one of the world’s most efficient steel

mills. The event highlighted the technologies and programs being used

or field-tested at the facility, as well as featuring demonstrations, tours,

and seminars.

Case Study

6

HOW TO GET INVOLVED

Distributed Generation Technologies

Cogeneration improves the efficiency of fuel use and reduces overall

emissions. This program supports extensive research, development, and

demonstration to meet the technical and market challenges associated

with enhancing industrial cogeneration and moderate-size independent

power production opportunities.

Financial Assistance

NICE

3

(National Industrial Competitiveness Through Energy,

Environment, Economics) is an innovative cost-sharing program that pro-

motes energy efficiency, clean production, and economic competitiveness

in industry by providing funding to State and industry partnerships for

technology demonstration projects.

The Inventions and Innovation program provides financial assistance for

establishing technical performance and conducting early development of

innovative ideas and inventions. Ideas with potential for significant energy

savings and commercial use are chosen for financial support through a

competitive solicitation process. Technical guidance and commercializa-

tion support are offered to successful applicants.

Information Resources

Two resources that provide information on all of OIT’s products are the

IPLocator and the Resource Catalog.

IPLocator (www.oit.gov/locator) provides access to information on federally

sponsored R&D projects that are ongoing or recently completed, optimizing

the complementary research and development strengths of industry, univer-

sities, National Laboratories, and government.

OIT’s Resource Catalog, available by calling 202-585-2090, describes

over 400 publications and other information products of interest to our

customers.

A network of

technical support

T

echnical Assistance facilitates partnerships

and alliances between industry and organiza-

tions to help increase energy efficiency and

reduce emissions. By promoting the use of

available technologies, Technical Assistance

helps industry immediately impact its bottom-

line performance and build its position in

global markets.

There are many ways to get information and participate in any of the

Technical Assistance resources.

• Contact the Information Clearinghouse at 1-800-862-2086 for access

to all products and services.

• Receive additional materials by calling OIT’s Resource Room

at 202-586-2090.

• Browse the OIT home page at www.oit.doe.gov and directly connect

to information about any of the industry areas and technical

assistance programs.

7

U.S. Department of Energy

Office of Energy Efficiency

and Renewable Energy

Office of Industrial Technologies

February 1999

DOE/GO-10099-692

For more information on

Technical Assistance, contact:

Charles Glaser

Industrial Assessment Centers

202-586-1298

chuck.glaser@ee.doe.gov

Paul Scheihing

Motor, Compressed Air, and

Steam Technology

202-586-7234

paul.scheihing@ee.doe.gov

Fred Hart

Steam Technology

202-586-1496

fred.hart@ee.doe.gov

Patricia Hoffman

Combined Heat and Power

202-586-6074

patricia.hoffman @ee.doe.gov

U.S. Department of Energy

Office of Industrial Technologies

1000 Independence Avenue, SW

EE-20 Room #5G067

Washington, DC 20585-0121

Visit the OIT Web site at

www.oit.doe.gov

Contact the Information

Clearinghouse at 1-800-862-2086

or OIT’s Resource Room at

202-586-2090