Industrial Energy Efficiency

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					           Plant Energy Certification,
               Save Energy Now
              SuperBoiler Update
              American Boiler Manufacturers Association
                      Manufacturers Conference
                           October 2, 2007
Bob Gemmer
Technology Manager
Industrial Technologies Program
Energy Efficiency and Renewable Energy (EERE)
U.S. Department of Energy
ITP is enhancing national energy security,
competitiveness, and environmental quality by
transforming the way U.S. industry uses energy.
                                                        research &

                                                        Delivery of
 Partnerships                                           energy-efficient
                                                        practices and

         Core activities reduce industrial energy intensity through
                  applied R&D and technology delivery.
Industry consumes about one-third of U.S. energy and represents
significant opportunities to save energy.
        2004 Energy Use*
          100.3 Quads
          (Quadrillion Btu)                        U.S. industry represents:
   Transportation               Industry           • 37% of U.S. natural gas
       28%                        33%                demand
                                                   • 29% of U.S. electricity demand
                                                   • 30% of U.S. greenhouse gas
      18%           Residential                    • More energy use than any
                      21%                            other G8 nation

                    *Includes electricity losses

           Industry spent $150 billion in 2003 on purchased energy.
Plant Energy Certification

• Voluntary (ANSI) industry standard

• Not a government regulation
                                  U.S. Industrial Sector
                      Current Situation
• Energy efficiency peripheral to most corporate business strategies
• R&D expenditures minimal for process and energy technologies
• Some US plants are best-in-class; application of state-of-the art
  technology; excellence in energy management
• Combined heat & power applications are common place, but not as
  prolific as in EU and Japan
• Lack of incentives to invest in energy efficiency technologies
• No common standard for managing energy
• Insufficient energy management skills
  in work force
• Limited energy fuel choices
• Volatile US energy prices
• Uncertain future environmental regulations
                                U.S. Industrial Sector
                  Desired Future
• U.S. world leader in manufacturing energy efficiency

• U.S. plants best-in-class for energy-efficient technology

• U.S. plants certified as strong energy managers; continually
  improving across the supply chain

• U.S. is leading exporter of energy efficiency technologies and

• Incentives to stimulate investment in energy efficiency

• Energy management expertise abounds in plants and market

• Energy security with flexible and affordable energy choices
 What would help all U.S. industry capture
 these energy savings?
• Provide industrial plants with easier access
  to information and tools for managing energy
• Provide incentives and recognition for
  effective industrial energy management
  – Integrate energy management into existing
    management systems (treat energy like
    every other resource)
• Develop market value for effective energy
  management and the resulting energy
  savings and carbon reductions
• Meet the R&D and technological support
  needs required to help industry reach an
  annual 2.5% energy intensity reduction goal
  through 2016
         Vision: By 2017

   Goal: US industry improves
energy intensity by 25% from 2007
                                        Vision: By 2017
  Goal: US industry improves energy intensity by 25% from 2007
US Industrial Sector                Leading US Corporations
• A world leader in energy          • Over 100 major corporations
  efficiency                           − Have integrated energy management
• Known for best-in-class plants         into their business strategy
  for energy-efficient technology      − Improved their energy intensity by more
• A leading exporter of energy           than 25% from 2007 to 2017
  efficiency technologies and          − Assist their plants and supply chain in
  solutions                              becoming ANSI certified for energy
• Staffed by and working with            efficiency
  engineers with extensive
  energy management expertise       US Manufacturing Plants
• Driven by the performance of      • 25% of the 200,000 U.S. plants with 10 or
  manufacturing plants                more employees (50,000 plants) have
                                      adopted basic energy management
  − using ANSI-certified energy
    management systems
                                    • 5,000 plants are ANSI certified for energy
  − implementing system
                                      management and committed to continuous
    assessment protocols
                                      improvement in energy efficiency
Plant Energy Certification Partnership Goal
   Reducing U.S. Industry’s Energy Intensity by 25 percent

  • Saves 8.4 quadrillion Btu per year

  • Equal to energy consumption of state of California in one year; every house,
    commercial building, automobile and manufacturing plant
                                                                                         The Process
  Corporate Level

                       Key Elements                  Resources                 Rewards/Recognition
                       • Energy baseline             • Quick Start website     • Enhanced technical
                       • CEO commits to 10 yr        • Tools, training, and      assistance
                         goal to reduce energy         technologies            • Preference in RD&D
                         intensity 25%               • Energy management         solicitations                         25% US industrial
                       • Energy management plan        tools                   • National energy
                       • Technology evaluation/      • Energy assessments        efficiency recognition                 energy intensity
                         best practices adoption                                                                         improvement
                       • Report progress annually                                                                           by 2017

                                       Partner                                                                    Certified
                                       Plant                                                                      Plant
                    Key Elements           Resources               Recognition       Key Elements          Resources               Rewards/Recognition
Plant Level

                    • Energy baseline      • Quick Start website   • Energy          • Energy              • Quick Start website   • Utility incentives
                    • Take steps to save   • System tools &          saving            management          • System tools &        • Tradable
                      energy, including      training                recognition       standards             training                credits/tags
                      creating an energy   • Energy management     • Case study      • System assessment   • Energy                • Market recognition
                      management plan        tools                 • Publicity         protocols             management tools      • Preferred supplier
                    • Report energy        • Energy assessments                      • Independently         & support               status
                      savings annually                                                 certified energy    • Energy                • National energy
                                                                                       savings               assessments             efficiency recognition
What is an ANSI Certified Plant?
• A plant which is continually improving in energy intensity by a
  to-be-defined level and has demonstrated the adoption of
  energy management practices that meets ANSI standards
• The plant‟s energy intensity improvement and compliance with
  standards are validated by a third party
• May use certified practitioners, recognized by third party to
  assist in:
    – Complying with energy management standards
    – Implementing system assessment standards
• Uses measurement and validation experts, recognized by a
  third party, to verify implemented energy savings
• Uses an ANSI-accredited process to achieve third-party
  voluntary plant certification
                                    Key Milestones
•   Nov. „07:    Identify and select ANSI-accredited standards
                 developer for system assessment standards
•   May „08:     Begin field testing of ANSI energy management
                 standard and system assessment standards
•   July „08:    Select third-party certifying organization
•   Sept. „08:   Launch pilot certification program
•   April „09:   Begin field testing of measurement and verification
                 methodology in pilot plants
•   June „09:    Begin training certified practitioners in energy
                 management and system assessments
•   Dec. „09:    First plants are ANSI certified for energy efficiency,
                 based on results from pilot program
•   March „10: National launch of third-party certification program
•   Dec. „11:    Third Party Certifier self-sufficient on fee-based system
Moving U.S. industry to greater
energy efficiency
• Moving the US industrial sector to an energy
  intensity improvement rate of 2.5% per year.
• Certifying plant energy management
  programs; create transparency for continual
  energy efficiency improvement
• Unite US corporate leaders in energy
  efficiency; commit to 25% energy intensity
  improvement over 10 years (through EPACT
  section 106)
• Empowering the supply chain to demand
  energy efficiency
• Enhancing the business case for energy
• Paving the way for U.S. global leadership in
  energy efficiency technologies and practices
                 Asian/Pacific Partnership
          Assist in Improving Energy Efficiency of
                   China’s Top-1000 plants
• Project in the formative stage

• DOE will work with China‟s National Development and Reform Commission
  (NDRC) and other Chinese organizations to assist China on industrial energy
  efficiency to support China‟s 20% goal
       • Develop an Industrial Energy Efficiency Resources/Toolkit
       • Utilize U.S. energy experts to conduct 8-12 pilot assessments
       • Identify needs to expand assessments to larger population of Chinese
            • Training of Chinese Experts
            • Tools
            • Technical Assistance
Where Can ABMA Help and Members

• Plant Certification
   – Provide technical input to development of plant-level
     protocols for steam systems
   – Engage your customers to participate in the Plant Energy
     Certification process
• Asian/Pacific Partnership
   – Participate in US-China partnership to deploy energy
     efficient US technology in Chinese industrial plants
Save Energy Now Status
Save Energy Now Status
• 200 Energy Assessments completed in 2006
   – Over $0.5 Billion in savings identified
   – As of August 31, 2007:
       • 179 plants have reported implementing at least one of the
         recommended energy savings projects
            – Equivalent to $75 million in savings
            – $66 million in additional projects underway
            – Almost $189 million worth of energy savings projects are in
              the planning stage.
• 250 Energy Assessments planned for 2007
   – 152 assessments have been completed
   – 48 are in the process of being scheduled
• Application for 2008 Save Energy Now Assessments is open
Industrial Boilers
   Steam Use
Manufacturing and Mining Energy End Use
               Other      Facilities
      Electro-              8%
Cooling                                         • Steam Use: ~6,200 trillion Btu/yr
  1%                                    Steam   • Steam Onsite Losses: 2,800
           Systems                       35%      Tbtu/yr
                                                    • Generation ~ 1,200 Tbtu/yr

                       Process                      • Distribution ~ 1,000 Tbtu/yr
                       Heating                      • Conversion ~ 600 Tbtu/yr

        Note: Does not include offsite losses
Age of Boilers

 • Total sales of new boilers over the last 40 years
   are smaller than the current boiler inventory. This
   suggests that many boilers used today are more
   than 40 years old
 • Approximately 7% of boiler capacity is less than
   10 years old

   2005 DOE Report: “Characterization of the U.S.
     Industrial Commercial Boiler Population”
Target Opportunity: Steam Generation

                           Big numbers
                           • Boiler population
                           • Energy consumption
                           • Emissions

                         Aging Boiler Fleet Creates
                         Opportunities for New Technology!
SuperBoiler Vision
Target – Steam Generation
       Potential       Increase industrial package        Energy Savings
                        boiler efficiency from 75% to
       Impacts:         95%
                                                           of 1,049 TBtu in
                       Reduce emissions of SOx,
                        NOx, and carbon oxides
 • “Smart” system
   controls                                             Heat Transfer
 • Modeling                                              • Innovative heat
                                                           transfer concepts
                                                         • Modeling and

    System Engineering
       • System integration      Heat Production         Heat Recovery
         approach                                       • Improved materials
                                   • Fundamental R&D
       • Modeling to                                    • Innovative concepts
                                   • CFD Modeling         for heat recovery
         expedite overall
         design                    • “Smart” burners
SuperBoiler?                                          100                                                25

 • Not a bigger boiler but a                              80                                             20
   better boiler!
    – Higher energy efficiency -

                                                                                                              Footprint, sq ft per klb/h
                                                          60                                             15

                                   Energy Efficiency, %
                                         NOx, ppmv
      more than 95% HHV

    – Super-low emissions -                               40                                             10
      down to 2 ppm NOx
      and 5 ppm CO                                        20                                             5
    – Smaller and lighter -
      reduce size and weight by                           0                                              0
      50 percent                                                Typical
                                                                               State of the 2020 Super
                                                                                   art*       Boiler
    – Competitive performance                                    boiler

    – Cost-effective                                              Efficiency    Emissions   Footprint

                                                                    * Not all in the same boiler
First Generation
1st Generation SuperBoiler Concept
• Evaluate four fundamental components in
  modern boilers
   –   Combustion
   –   Heat Transfer
   –   Heat Recovery
   –   Control
• R&D focus
   – Advancements in all 4 boiler components
   – System integration
   – Evaluate a near-term product design that “meet”
     the RFP goals
Potential Benefits of 1st Generation SuperBoiler
     • 499,900,000 MMBtu/year energy
     • $2 billion/year fuel cost savings
     • 18,386,000 ton/year CO2
     • 580,700 ton/year CO
     • 205,600 ton/year NOx
     • Compelling economic benefits to
       accelerate replacement of aging
First Generation SuperBoiler Project
Project Description:
   Gas-fired firetube boiler using innovative
    concepts in burner, heat transfer, heat
    recovery & control
   Develop and test a prototype at industrial
    host site
   Meet aggressive performance targets
   Partnered with Cleaver-Brooks

Technical Objectives
  – 94% efficiency (from 70-83%)
  – <5 ppm NOx (from 30-100 ppm)

  • $2,600,000 -- DOE
  • $3,500,000 – industry cost share
Where are We?
 • Lab testing Complete
    – Optimized combustion performance
    – Validated computer models for scale-up
    – Optimized heat recovery system performance
    – Optimized control strategy
 • Field demonstration
    – First field demonstration at a site in Alabama complete
        • Single stage combustion design with transport membrane
          condenser to recover latent heat
        • Over 6,000 hours of operation with no significant problems
    – Currently installing dual stage combustion design at a fruit
       processing plant in Ontario, California
    – Planning underway to demonstrate retrofit of transport
       membrane condenser
 • Commercialization (Role of Private Sector)
    – Introduce into commercial and light industrial market
Next Steps
SuperBoiler Vision – Next Steps
 • August 2004 Workshop on Ultra-High Efficiency
   Industrial Steam Generation R&D Opportunities
 • FY 2005 Solicitation Objectives:
    • Thermal efficiency greater than 94% (HHV)
    • NOx emissions below 2 vppm
    • CO emissions below 2 vppm
    • VOC emissions below 1 vppm
    • Capable of operating on multiple fuels
    • Capable of producing high temperature/high
      pressure steam (greater than 1500°F/1500 psig)
    • System weight and footprint 50% of currently available
      boilers with comparable performance
SuperBoiler Vision – Next Steps
 • Solicitation for Second Generation Watertube SuperBoiler closed
   April 14, 2005
 • Three proposals selected for funding
    – Babcock and Wilcox
    – Gas Technology Institute
    – Research Engineering Incorporated
 • Research delayed due to elimination of Combustion budget in 2006
 • Two of three projects restarted in 2007
    – Gas Technology Institute
    – Research Engineering Incorporated
 • Two phases:
    – Phase I
       • Up to two years
       • Preliminary design and development
    – Phase II (Following down select)
       • Prototype development and field trial
Resources for Your Plant and Company
  • Energy analysis software tools
  • Case studies and information
  • Energy efficiency training for plant staff
  • Qualified specialists
  • DOE-supported energy assessments

    Call: 877-337-3463

Industrial Energy Savers Website
• 20 Best Ways to Save
  Energy Now
• Learn How Others
  Have Saved
• Develop an Action Plan
• Access the National
  IAC Database

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