Manufacturing Energy and Greenhouse Gas Emissions Associated with United States Consumption of Organic Petrochemicals
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37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
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Education, Training and Career Pathway Opportunities for Buildings Energy Efficiency Programs Within the Corps Network
The Corps Network (TCN) is a national association that represents more than 150 local organizations around the country that work to provide job training and employment to individuals working on projects that provide community benefits. Through its partnership in the Better Buildings Workforce Accelerator, TCN requested technical assistance from the National Renewable Energy Laboratory (NREL) to support Corps organizations involved in – or interested in developing – programs related to energy efficiency in buildings. The goal of this project is to provide industry-recognized energy efficiency education/training models and resources that can be tailored and replicated by Corps across the country, and which can best prepare Corpsmembers to enter the energy efficiency workforce when they complete their terms of service.
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Use of novel refractory design and installation techniques for improved energy efficiency in iron and steel and other energy intensive industries
This paper describes the planned work to be performed under a United States Department of Energy funded project to bring together the key players necessary to develop and deploy new technology which could increase the thermal efficiency of the steel industry as well as other energy intensive industries. It is hoped that such improvements in energy efficiency will reduce the overall energy and environmental footprint of domestic industry, as well as provide economic benefit to the individual companies. The described project brings together a vertically integrated collaborative team consisting of the end user (U.S. Steel), material producers/suppliers (Allied Mineral Products and Reno Refractories), raw material suppliers (American Metallurgical Services, Minerals Manufacturing), and research organizations (Oak Ridge National Laboratory, National Energy Technology Laboratory and University of Alabama-Birmingham) with the objective of designing and producing new refractory materials based on novel aggregates, improved particle packing, and engineered surface texture. In addition, the recycling and use of spent refractory materials will be investigated and a novel installation technique will be developed taking advantage of new additive manufacturing technology and existing refractory shotcrete technology. It is hoped that the combination of these new technologies will allow for the improvement of the energy, environmental, and economic efficiency of the steel industry while also reducing the environmental footprint of the refractory and steel industries. Additionally, the developed technology is expected to be applicable to other energy intensive industries such as cement, glass, pulp and paper, and non-ferrous metals processing.
Hemrick, James↗
Energy Efficiency as a Foundational Technology Pillar for Industrial Decarbonization
The U.S. government aims to achieve net-zero greenhouse gas emissions by 2050 to reduce the severe impacts of climate change. The U.S. industrial sector will become a focal point for decarbonization since it accounts for 33% of the nation’s primary energy use and 30% of its energy-related CO2 emissions. Industrial emissions are also expected to increase by 15% through 2050, making the industrial sector a logical target for decarbonization efforts. Energy efficiency technology pathways provide low-cost, foundational routes to decarbonization that can be implemented immediately. Energy efficiency technology pathways, such as strategic energy management, system efficiency, smart manufacturing, material efficiency, and combined heat and power, are well established and would immediately reduce energy use and emissions. However, their role in the aggressive net-zero decarbonization pathway for the industrial sector is still unclear. This study aims to address energy efficiency pathways for decarbonization, and reviews studies related to these technologies for industrial decarbonization through 2050. This study identifies different strategies for the industrial sector in general and that are specific to six energy-intensive industries: iron and steel; chemical; food and beverage; petroleum refining; pulp and paper; and cement. Finally, a path toward the successful implementation of energy efficiency technologies is outlined.
Strategic energy management↗
Sustainable Chemistry in RD&D to Transform the Chemicals Sector Roundtable
The U.S. Department of Energy (DOE) Industrial Efficiency and Decarbonization Office and Change Chemistry (formerly the Green Chemistry & Commerce Council, GC3) co-hosted the Sustainable Chemistry in RD&D [research, development, and demonstration] to Transform the Chemicals Sector Roundtable on March 7, 2023. The event brought together about 50 participants—from industry, national laboratories, small businesses, startups, nonprofits, and government—to gather input on how to effectively leverage sustainable chemistry to advance industrial decarbonization, industrial efficiency, and environmental justice goals. This report is a summary of the views expressed by individual participants during the roundtable; it is not intended to represent DOE’s views or programmatic priorities.
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Energy Efficiency's Role in Industrial Decarbonization
Around the world, efforts are increasing to drastically reduce greenhouse gas (GHG) emissions by 2050. The goal of the Paris Agreement is to hold the increase in global average temperature rise to below 2°C as compared with preindustrial levels, specifically aiming to limit it to 1.5°C. As of 2017, the global average temperature rise reached approximately 1°C. It is expected to hit the 1.5°C mark by 2040 if current trends continue. Limiting temperature rise to 2°C will require reaching net zero emissions in the latter half of the 21st century; GHG emissions would need to reach a near-zero value by 2050 to limit the rise to 1.5°C.
Sundaramoorthy, Senthil↗
2023 IEDO Peer Review Report
On behalf of the U.S. Department of Energy (DOE) Industrial Efficiency and Decarbonization Office (IEDO), we are pleased to share the report from our 2023 peer review. Peer review provides us with invaluable insight into our office strategy and program direction from a diverse group of external thought leaders. The findings and actionable recommendations from peer review inform our decision making and help us maintain a constant state of evolution and growth.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Energy Leaders: The Catalyst for Strategic Energy Management
This study investigates the crucial role energy leaders play in driving strategic energy management (SEM) and accelerating cost savings within a manufacturing organization and consequently, the industrial sector. Whereas energy efficiency can be seen as an innovative business practice with irrefutable cost benefits, its effective implementation requires strategic leadership and a structured approach. This research analyzes data collected from 120 participants representing 71 companies attending the Energy Bootcamp events organized by the U.S. Department of Energy’s (DOE) Better Plants program. The collected data focused on the state of SEM implementation, the presence and responsibilities of energy leaders, and the formation and function of energy teams. The findings reveal a significant gap between the perceived importance of SEM and its actual adoption, highlighting the need for strong leadership to drive behavioral changes by championing energy efficiency initiatives. Results indicate that effective energy leaders possess a diverse skill set, including the ability to secure top management buy-in, foster a culture of energy consciousness, and collaborate across departments. This study emphasizes the importance of empowering energy leaders with clearly defined roles and responsibilities as well as the authority to build and lead cross-functional energy teams. Furthermore, integrating energy management into existing organizational structures and leveraging readily available resources are identified as key factors for successful implementation. This research underscores how dedicated leadership and effective SEM practices help achieve industrial energy efficiency goals, providing practical insights for organizations seeking to improve performance and contribute to a resilient future.
energy leader↗
Visualization Within the Department of Energy: NREL IEEE VIS Application Spotlight
This presentation highlights the role of advanced visualization techniques at the National Renewable Energy Laboratory (NREL) in supporting cutting-edge research across diverse energy domains. From immersive analytics and uncertainty visualization to high-resolution and real-time data analysis, NREL's visualization capabilities enable scientists to explore complex datasets more effectively. These tools are critical for advancing research in materials science, renewable energy technologies, biofuels, electric vehicle infrastructure, energy efficiency - from industrial processes to entire communities - and then bringing these innovations to practice through energy systems integration. NREL's visualization tools drive innovation across renewable energy and grid modernization efforts by providing deeper insights and improving decision-making.
grid modernization↗
USE OF NOVEL REFRACTORY DESIGN AND INSTALLATION TECHNIQUES FOR IMPROVED ENERGY EFFICIENCY IN IRON AND STEEL AND OTHER ENERGY INTENSIVE INDUSTRIES
This work describes a US Department of Energy funded program which unites key players to develop and deploy new technologies aimed at increasing energy efficiencies while reducing their overall energy and environmental footprint. The research brings together a vertically integrated collaborative team consisting of the end user (US Steel), material producers/suppliers (Allied Mineral Products and Reno Refractories), raw material suppliers (American Metallurgical Services, Minerals Manufacturing), and research organizations (Oak Ridge National Laboratory, National Energy Technology Laboratory and University of Alabama-Birmingham) with the objective of designing and producing new refractory materials. Design and production criteria are based on novel aggregates, improved particle packing, and engineered surface textures. In addition, the recycling and use of spent refractory materials has been investigated resulting in development of a novel installation technique that utilizes additive manufacturing technology and existing refractory shotcrete technology. The combination of these new technologies will improve the energy, environmental, and economic efficiencies of the steel industry while reducing the environmental footprint. The developed technology is potentially applicable to additional energy intensive industries including cement, glass, pulp and paper, and non-ferrous metals processing.
Hemrick, James↗
Enhancing Operational Performance and Productivity Benefits in Breweries through Smart Manufacturing Technologies
This article uses case studies to demonstrate the potential of smart manufacturing (SM) and Internet of Things (IoT) technologies to enhance operational performance and productivity in industry. The analysis highlights benefits such as cost reduction, production flexibility, shorter product time-to-market, energy/water efficiency and environmental impact reduction, and increased productivity. To illustrate the effectiveness of SM and IoT approaches, the authors sought out manufacturers currently implementing or seeking to implement SM and IoT technologies. The authors identified beer brewing (NAICS Code 312120) as a rapidly expanding industry whose members appear eager to implement SM technologies to optimize production lines by revealing bottlenecks and identifying performance-reducing nodes. This article presents two case studies based on SM and IoT technologies in breweries. It briefly describes a systematic framework introduced elsewhere by the authors and uses it to assess the energy productivity and competitiveness of SM applications in breweries. This article addresses questions concerning the information and communications technology infrastructure needed to build smart breweries and how corporations simplify the installation and deployment of SM and IoT components. This article was originally published in the Proceedings of the 2019 ACEEE Summer Study on Energy Efficiency in Industry.
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Industrial Assessment Center Program (Final Report)
Final technical report for the Nebraska Industrial Assessment Center.
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Industrial Assessment Center for Underserved Delmarva Area
This report summarizes the work done by the Industrial and Training Assessment Center at the University of Delaware under the award number DE-EE0008796. The 38 audits performed during this period (DL0178 – DL0214) happened from October 2019 to October 2022. The facilities audited belong to a total of 27 industry types, according to the Standard Industry Classification (SIC).
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Field Validation of Electrochemical Water Filtration System on Open Loop Cooling Towers at Automotive Plants
Open loop cooling towers play a pivotal role in rejecting heat for chilled water systems serving industrial processes, heating, ventilation, and air conditioning loads. Exposure to outside conditions can present certain operating challenges to system performance including scaling, corrosion, and biological growth. These issues are mitigated through the use of effective cooling tower water filtration and treatment systems to reduce contaminants—along with other total suspended solids (TSS) and total dissolved solids (TDS)—in the system. The U.S. Department of Energy’s Industrial Efficiency and Decarbonization Office is interested in an electrochemical-based filtration system with the ability to remove TSS particulate down to 1 micron. The removal of finer particulates reduces the need for blowdown and, in turn, makeup water use and chemical treatment in the cooling tower. Additionally, the removal process can reduce fouling at the condensers, resulting in better heat exchange and energy savings. Two Industrial Technology Validation program projects validated the electrochemical water filtration system at the Toyota Motor Manufacturing, Mississippi plant in Blue Springs, Mississippi, and the Nissan Canton Vehicle Assembly Plant in Canton, Mississippi. Researchers found that installation of both systems resulted in water and chemical treatment savings with minimal impact on energy use.
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A Modeling Tool to Analyze the Performance of Industrial Cooling Towers
Energy efficiency and energy savings have become an important factor as industries look for ways to save energy and minimize their energy consumption while reducing their carbon footprint. Cooling towers are utilized significantly in industries for either serving chillers or process cooling. Depending on the size of the cooling tower, it can use a surprising amount of energy and water, which is why it is crucial to make sure that the facility has optimized their cooling tower.A modeling tool has been developed to perform a thorough analysis of a cooling tower and its various operations to ensure that the facility has optimized its cooling tower. This model analyzes an annual base case in comparison with the revised case of a cooling tower operation. This modeling tool simulates 8,760 hourly calculations for fan power for various fan controls, water consumption, and pumping energy consumption and demand based on the user’s location and its corresponding Typical Meteorological Year 3 (TMY3) weather data. This model is capable to simulate up to five cooling tower cells as one large tower utilizing one pump or parallel pumping. The successful validated cooling tower model should assist industry to save energy at their facility through their cooling tower, whether they use it for process cooling or heating, ventilation and air conditioning (HVAC) applications. The entering/leaving water temperatures based on a monthly operating schedule or a wet-bulb temperature schedule will be used as inputs, and the model can calculate savings in energy for various conditions including variable-frequency drive (VFD) on the fan/pump, drift eliminators, number of cycles of concentration, reduced water flow rate, etc.
Hooper, Josh↗
Integrating Energy Efficiency into the Permanent Modular Construction Industry [Slides]
This presentation summarizes the project sites for zero-energy homes in multifamily and mixed-used buildings.
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NCSU Industrial Assessment Center
Renewable energy technologies are becoming more attractive and gaining more attention as the world becomes increasingly aware of the negative impacts of global warming and greenhouse gas (GHG) emissions. Two such emerging technologies are geothermal heat pumps (GHP) and solar thermal heating which can be used for heating and cooling of buildings. GHP systems are a well-studied technology that have been proven to be more efficient than traditional air-source heat pumps for space conditioning of buildings. Solar thermal heating has become more common as a way to heat domestic hot water (DHW) in homes, but the two technologies are not often combined. This study presents the findings of combining an open-loop GHP with 100 ft2 of flat plate solar thermal panels and a 5,655-gallon sensible water storage tank for space heating and DHW heating needs of a residential home in Bozeman, MT, USA. The goal of this system was to use energy from the solar panels and storage tank first to decrease pumping energy from the GHP well. The open loop system was designed to be a backup system to the solar thermal panels and sensible storage tank. An actual home was modeled to determine potential energy and cost savings of such a system compared to a traditional propane boiler. Then, a case study was performed on the installed system from January to June 2021. Results obtained from April 2nd to June 5th, 2021 indicated that the combination system supplied all necessary heat, and that heat was supplied from the thermal storage tank 55% of the time. This represents a savings of 330 kWh of energy and $36 compared to operating just the open loop geothermal system. From April 2nd to June 5th the combination system consumed a total of 2,510 kWh of energy and cost $274 to operate. Based on data obtained, there is significant potential for energy savings compared to a propane boiler, however only small potential for cost savings.
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University of Miami Industrial Assessment Center (Final Scientific/Technical Report)
The University of Miami Industrial Assessment Center (MIIAC) is located at the Department of Industrial & Systems Engineering in the College of Engineering at University of Miami. The Center has conducted 402 energy assessments with estimated Total Energy Savings over $\$57.3$ million, Total Non- Energy Cost Savings of $\$23.7$ million, and Total Energy Saving as a 26% of Energy Costs of $\$311$ million. A total of 6.01 TBtu of energy savings were recommended as a result of energy efficiency measures resulting in $\$81$ million in cost savings.
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