U.S. Department of Energy’s Industrial Technology Program and Its Impacts Presented by: Steve Weakley Pacific Northwest National Laboratory

Outline Background, Strategies, and Program Areas of the Industrial Technologies Program (ITP) Technology Tracking Data Gathering Program Results Value of Technology Tracking New Commercial Technologies 2

Background ITP has been working with industry since 1976 to encourage new, energy-efficient technologies to be developed and adopted. Over the past 30 years, ITP has supported more than 600 separate RD&D projects, producing >200 technologies in commercial use. ITP Program Areas: Energy Intensive Industries, Crosscutting Technologies, and Technology Delivery. 3

ITP Strategies Strengthen planning and analysis to identify opportunities with greatest potential. Exploit fuel and feedstock flexibility to give manufacturers options. Investigate cross-cutting R&D to save energy in top energy-consuming processes. Invest in “next-generation” technologies adaptable to processes throughout industry. 4

ITP Strategies (Cont’d) Encourage private investment in energy efficiency through new partnerships and ways to reach industry. Drive ambitious reductions in industrial energy intensity through the Save Energy Now initiative. Promote energy-efficiency improvements throughout the supply chain. Help drive development of energy management standards and a certification program. Emphasize commercialization planning throughout the R&D life cycle. 5

ITP Strategies (Cont’d) Institute rigorous stage-gate project and portfolio management procedures. 6

Program Areas: Energy-Intensive Industries In 1994, ITP implemented an innovative, customer-driven research strategy known as Industries of the Future (IOF). Each industry team develops a vision of its desired future and a “technology roadmap” to guide collaborative partnerships between ITP and industry. Industry teams: AluminumChemicalsForest Products GlassMetal Casting Mining Steel 7

Program Areas: Crosscutting Technologies ITP also funds technology development spanning the seven identified energy-intensive industries. Widespread use of these technologies can mean substantial energy and cost savings. Cross-Cutting Programs: Combustion Distributed Energy/Combined Heat and Power Energy Intensive Processes Fuel & Feedstock Flexibility Industrial Materials for the Future Nanomanufacturing Sensors & Automation. 8

Program Areas: Technology Delivery Program Purpose: To help industry assess and adopt energy-efficient technologies and practices that are currently available on the market to obtain immediate energy savings. Industrial Assessment Centers (IACs) provide free audits to small- and medium-sized manufacturers and recommend techniques to save energy and boost efficiency. The BestPractices Program help industrial firms assess the potential benefits of maximizing efficiency using a systems approach, targeting electric motor, compressed-air, steam, and other plant utility systems. 9

Former Program Areas: Financial Assistance Two programs provided grants to help industry develop and demonstrate energy-efficient, waste-reducing technologies. Inventions and Innovation (I&I) provided up to $200,000 to inventors and small companies with promising ideas/inventions for improving energy efficiency and environmental performance. National Industrial Competitiveness through Energy, Environment, and Economics (NICE 3 ) provided matching funding to state-industry partnerships for projects that developed and demonstrated energy-efficient and pollution-preventing technologies. 10

Technology Tracking Data Gathering PNNL tracks ITP program results and quantifies the technologies’ energy, environmental, and other benefits. PNNL coordinates with program staff to determine commercial successes and emerging technologies from each industry and cross-cutting program. A technology is considered commercial when a full-scale unit becomes operational. After 10 years in operation, the technology is considered historical and is no longer actively tracked. A technology is considered emerging if it is under development and expected to commercialize in 2-3 years. 11

Technology Tracking Data Gathering (Cont’d) Industrial vendors and end users are contacted to obtain the following information: technical description capabilities applications benefits contact information installations and units sold type of fuel saved energy savings and the associated calculation methodology history marketing information. Data are stored in a database and made available to ITP personnel. 12

Technology Tracking Database Information ►Overview: Name of industry partner, year commercialized and number of operating units ►Applications: Industrial areas where technology can be applied ►Description: Summary description of the technology, research development activities, and its benefits ►Benefits: Qualitative description of technology improvements including environmental, quality, productivity, safety, etc. ►Graphic: ►Capabilities: Operational characteristics that display improvement over the baseline technology ►Energy Savings: Btu’s saved in the current year and cumulative since technology inception ►Emissions Reductions: Current year decrease in SOX, NOX, CO2, and particulates ►Contacts: DOE and industry partner name, address, and phone number ►IOF Team: Primary and related industry areas impacted ►Status: Industry supplied update on technology activities ►Installations and Savings: Information on each technologies location and energy savings ►Fuel Types: Type of fuel saved by the technology ►Calculation Methodology: Description of how the energy savings were derived including assumptions ►History: Summary of prior year efforts For each commercial technology, the following information is collected from the industry partner and reported in our database. Technology Title 13

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Technology Tracking Database Information 15

Program Results PNNL engineers work with technology developers to determine a specific energy-savings’ methodology. Annual fuel savings are used to calculate each technology’s current and cumulative energy savings and air pollutant reductions. In 2008, the 104 current commercial industrial technologies saved 75 trillion Btu of energy. Commercial technologies since 1976 cumulatively saved 3.63 quad through

Program Results (Cont’d) IAC Program: Since 1977, cumulatively saved 1.96 quad from energy assessments performed by university engineering students for small- and medium-sized business. BestPractices Program: Since 1998, cumulatively saved 1.14 quad by providing software decision tools, training, and technical assistance to industrial firms. CHP Program: Since 1990, cumulatively saved 2.54 quad from the aggregate reduction in overall fuel consumption based on a percentage of capacity additions since

Program Results (Cont’d) Cumulative Production Cost Savings are based on the Btu of the various industrial fuels saved multiplied by inflation adjusted fuel prices. $21.5 billion through 2008 Cumulative Program Costs are the appropriations for R&D adjusted for inflation. $3.00 billion through 2008 Cumulative Implementation Costs are the capital costs of adopting the new technology (assuming industry requires a two-year payback period on investments so the first two years of energy cost savings are excluded) billion through

Program Results (Cont’d) 19

Program Results (Cont’d) Results are in the ITP Impacts report on the ITP website: /brochures.html. /brochures.html Technology tracking database and hard-copy program files contain the following: 104 commercial industrial and 23 non-industrial technologies 135 emerging industrial and 4 non-industrial technologies 118 historical technologies 260 archived technologies. 20

Value from Tracking Effective management of R&D programs Budget defense Strategic planning Portfolio management Institutional memory. 21

New Commercial Technologies Six technologies added to the Impacts report this year, with the following funding sources: 1 Materials 1 Sensors & Automation 1 Distributed Energy 1 Crosscutting 2 IOF: 1 Chemicals and 1 Forest Products. Types of technologies are as follows: 1 Chemicals: Emission Control 1 Forest Products: Emission Control System 4 Crosscutting: Distributed Power Generation System, Computer Modeling Program, New Material, Advanced Wireless Sensor. 22

Titania-Activated Silica System for Emission Control Developed at the University of Florida. Commercialized and marketed by Sol-gel Solutions, LLC, in Two units operating at a U.S. chlor-alkali facility Reduces the cost per pound of mercury removed compared with activated carbon 23 Eliminates the risk associated with disposing of mercury- laden activated carbon.

Biological Air Emissions Control Developed by BioReaction Industries, LLC, with assistance from Texas A&M. 24 Commercialized by BioReaction Industries with 10 units operating in 2008 Decreases greenhouse gas and ancillary emissions. Saves energy by eliminating use of natural gas in thermal oxidation process. Reduces operating costs by 90% from thermal oxidation.

Advanced Reciprocating Engine Systems (ARES) Developed and being marketed by Caterpillar, Inc., Cummins, Inc., & Dresser Waukesha. 25 Sold >500 engines in U.S. and >1600 internationally. Eliminates transmission costs from utility-provided electricity. Achieves higher power density and improved fuel efficiency. Work continues to improve the efficiency and reduce emissions.

Barracuda ® Computational Particle Fluid Dynamics (CPFD ® ) Software Developed by CPFD Software, LLC ExxonMobil Millennium Inorganic Chemicals, Inc. Sandia National Laboratories. 26 Marketed by CPFD Software. Accurately models complex mixing and chemical reaction processes with liquid-solids or gas-solids. Models biomass and coal gasification systems and the production of white pigment, gasoline, plastics, nylon, and polysilicon. Allows users to design more energy-efficient and environmentally friendly processes.

Ultrananocrystalline Diamond (UNCD) Seal Faces Developed by Argonne National Laboratory with John Crane, Inc., and Advanced Diamond Technologies (ADT). Commercialized in 2008 and sold by ADT. 27 Applies thin UNCD coating to seal face of a silicon carbide ring for industrial pumps and mixers. Reduces seal face temperature and friction between seal faces and improves wear resistance. Increases seal life and energy efficiency; allows sensitive food, biological, and pharmaceutical media to be handled.

Wireless Sensors for Condition Monitoring of Essential Assets Developed by GE Global Research & GE Energy; commercialized in Monitors the condition of motor- driven industrial equipment (e.g., pumps, fans, compressors). 28 Wireless nodes powered by battery or energy harvester technology using the machine’s vibration as the power source. Reduces outage times and occurrences, lowering outage costs. Increases safety by remotely monitoring assets in areas unsafe for humans to enter.