Engineering topics

Botts, Alex

Publications and source records attributed to Botts, Alex.

9 records

DOE OSTI2024

Unlocking Manufacturing Sustainability: Energy Efficiency Opportunities through the US Department of Energy’s Better Plants Program Energy Treasure Hunts (2023–2024)

The US manufacturing sector faces critical challenges: improving sustainability, reducing energy consumption, and reducing greenhouse gas emissions. Energy Treasure Hunt (ETH) training, a service provided by the US Department of Energy’s Better Plants program, offers a compelling solution. Although ETHs have traditionally focused on energy and cost savings, data indicate that ETHs can be used to identify opportunities to reduce emissions and water use and to support a sustainable and circular operation. These 3-day on-site events engage employees in a collaborative search for operational and maintenance efficiency improvement opportunities. The success of ETHs lies in a comprehensive methodology. Each phase in an ETH uses various tools and resources to empower employees to identify practical solutions. This study presents data from 13 ETHs conducted between 2023 and 2024 across diverse manufacturing subsectors in the United States and demonstrates that the events can help create a pragmatic decarbonization pathway. Through the events, a total of 234 energy and emissions reduction opportunities were identified, and the potential impact is significant. Implementing the recommendations could translate to annual savings of 497,299 MMBtu of energy, 64,374 kgal of water, and 4.85 million tCO 2 e of emissions. The fiscal savings from the proposed recommendations translate into nearly $\$$5 million annually. This study identifies the opportunities by energy system type and by the specific actions recommended, while also analyzing the identified opportunities, presenting the most established sustainability recommendations. Case studies from participating partners are presented to further demonstrate that ETHs provide a practical and impactful approach to reducing energy consumption, emissions, and operating costs and promote a more sustainable future for the industrial sector.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Identifying Energy Inefficiencies in Compressed Air Systems: A Systematic Approach with the Compressed Air Scoping Tool

This paper highlights the importance of improving compressed air systems, outlines the tool’s development and features, and underscores its value as a nonbiased resource for system evaluation and optimization. Additionally, the paper presents a case study based on a food manufacturing facility to demonstrate the practical application of the tool. Furthermore, the paper discusses potential future opportunities for enhancing the CA Scoping Tool.

compressed air benchmarking↗

DOE OSTI2024

Challenges in Tracking Waste Reduction Performance Improvement in Manufacturing Plants

The recently released Circularity Gap Report 2023 by Circle Economy Foundation found that the circularity score for the global economy is declining. This indicates that material extraction from virgin sources is climbing over earlier years. As per data released by US Geological Survey, material use in the US economy has increased exponentially with the expanding US economy over last century. EPA tracked municipal solid waste from 1960 to 2018 and found that 50% of the waste is destined for landfills. EPA estimates that US industry is responsible for 2.7 billion ton of solid non-hazardous waste annually in our mostly linear economy model. The circular economy framework aims at decoupling economic value generation from virgin materials extraction from nature. The linear model of material extraction and disposal at end of life is highly unsustainable. Manufacturing companies have realized this and in their commitments to sustainability are adopting ambitious waste reduction targets. Through Better Plants program US Department of Energy has established Waste Reduction Network where it is offering technical assistance to partners to achieve these ambitious waste reduction goals. Basic requirements of establishing a target include identifying a baseline, quantifying waste performance, and measuring progress over time. One problem faced by industry is the unstandardized metrics to quantify waste performance that may not be well suited to demonstrate progress. In this paper, we research methods traditionally used to measure waste performance and highlight advantages, gaps and limitations of each method. Suitability of the methods applicable to different manufacturing circumstances are also examined. Finally, we present a case study of a large manufacturer that faced inconsistencies in their tracked measurement metric. A solution was proposed to alter the methodology to enable more accurate waste performance tracking against a baseline.

Chaudhari, Subodh↗

DOE OSTI2024

US Department of Energy Federal Energy Management Program Energy Treasure Hunt Toolkit

The US Department of Energy’s Federal Energy Management Program (FEMP) aims to assist federal agencies and their stakeholders with their energy-focused goals, opportunities, and barriers. The program offers various technical trainings and resources to its stakeholders. One of these resources is an energy treasure hunt program. This report presents the FEMP energy treasure hunt toolkit, a technical resource designed for systematic application for federal facilities seeking to optimize their energy and carbon usage. The toolkit was designed to help facilitate energy-focused kaizen events, identify energy-saving recommendations, analyze identified opportunities, and provide the tools needed to detect actionable projects to advance federal facilities. Through a collaboration with the Oak Ridge National Laboratory team that executed the industrial-focused Better Plants energy treasure hunt program, a similar treasure hunt toolkit was designed for FEMP. The purpose of this report is to provide an overview of the treasure hunt process and FEMP toolkit capabilities.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

MEASUR Up: Identifying opportunities in a facility

The commercial and industrial sectors account for nearly half of the total U.S. energy consumption. To help these sectors reduce their energy intensity, the U.S. Department of Energy (DOE) designed the Better Buildings, Better Plants Initiative. Through this initiative, more than 900 industrial, commercial, public and residential organizations commit to long-term sustainability goals and share their proven energy efficiency strategies, which inspire others to tap into the continued potential for energy efficiency. Collectively, these organizations have saved 2.5 quadrillion BTUs of energy, equivalent to US$15.3 billion, and 155 million metric tons of carbon dioxide. Within the initiative, the Better Plants side of the program focuses specifically on the industrial sector. More than 270 industrial partners have taken advantage of the unique selection of resources offered including workforce development programs, information sharing, peer-to-peer networking, diagnostic tool loans and software tools. One of the most powerful tools off ered is a revitalization of the legacy DOE software tools used by industry for decades. These have been transformed into a new, free, opensource software tool suite: MEASUR (Manufacturing Energy Assessment Software for Utility Reduction)

Armstrong, Kristina↗

DOE OSTI2022

Demand Response in Industrial Facilities: Peak Electric Demand

The US Department of Energy’s (DOE’s) Better Buildings, Better Plants Program (Better Plants) is a voluntary energy efficiency leadership initiative for US manufacturers and water/wastewater entities. The program encourages organizations to commit to reducing the energy intensity of their US operations over a 10-year period, typically by 25%. Companies joining Better Plants are recognized by DOE for their leadership in implementing energy efficiency practices and for reducing their energy intensity. Better Plants Partners are assigned to a Technical Account Manager, who can help companies establish energy intensity baselines, develop energy management plans, and identify key resources and incentives from DOE, other federal agencies, states, utilities, and other organizations that can enable them to reach their goals. Better Plants Partners are expected to report their progress to DOE once a year. This involves establishing an energy intensity baseline upon joining the program and then tracking their progress over time. Demand Response in Industrial Facilities: Peak Electrical Demand is intended to help companies understand peak demand response programs offering by their local utility. Manufacturing industries can learn about time-varying rates and smart technologies they can use to help them reduce their energy bills. This guidance document is applicable to companies participating at either the program or challenge level. Although this guide is intended primarily to assist companies participating in Better Plants, the methodologies and guidance within the document are applicable to any organization interested in understanding peak demand response programs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Understanding Your Utility Bills: Electricity

Electricity bills can often be difficult to decipher. Depending in the electricity provider, bills can be very long and detailed or extremely short, with only a few totals listed. Different charges can appear each month with no apparent explanation of how or why they are calculated. Learning how to read electricity bills and understand why different charges are assessed is key to maximizing cost savings through energy efficiency. This document provides guidance on the basics of understanding electricity bills and covers electricity generation, rate structures, usage trends, and savings opportunities. The information in this guide can be used to help companies collect and report their energy efficiency improvements to the DOE Better Plants Program.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Understanding Your Utility Bills: Natural Gas

As a fossil fuel NG is a colorless and odorless gas in its natural state and is one of the cleanest burning hydrocarbons. The factors that contribute to the popularity of natural gas in the US manufacturing sector include ease of availability, clean burning properties, market deregulation, and increased domestic production. Analyzing natural gas (NG) bills can sometimes pose unique problems. Learning to read your utility bills and understand why your utility charges different fees is critical in maximizing your cost savings through energy efficiency. A key to creating a baseline is collecting and analyzing natural gas utility data. Historical data from NG bills can identify trends and help to find the baseline usage for a manufacturing operation. This guide intends to help Better Plant Program partners in understanding natural gas bills and analyzing usage to reduce costs. The guide focuses on natural gas production and transportation, understanding key charges on bills, different rate structures, and saving opportunities. A fictitious worked out example in the final section demonstrates how readers could go about analyzing natural gas bills.

03 NATURAL GAS↗

DOE OSTI2021

Understanding Your Utility Bills: Water

Better Plants partners join the program by setting energy intensity goals over a 10-year period. Over the same period partners have the option to set water and waste goals. "Understanding Your Utility Bills: Water" is intended to help companies comprehend their bills and assist with analysis for annual reporting.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗