Energy Analysis

The Industrial Technologies Program (ITP) regularly conducts analytic studies to identify energy-saving opportunities. The following publications are energy analyses for materials, used to help ITP focus R&D and help companies identify the best opportunities for savings. Also, browse our tools and publications, as well as project summaries, presentations and posters from the ITP Materials Project and Portfolio Review Meeting.

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Engineering Scoping Study of Thermoelectric Generator Systems for Industrial Waste Heat Recovery

This report examines the performance and engineering requirements of using recently discovered thermoelectric materials in waste heat applications. These new materials (nanostructures, thin-film super lattice, quantum wells...) have been characterized with thermal to electric energy conversion efficiencies of 12-25+%. These advances allow the manufacture of small-area, high-energy-flux (350 W/cm² input) thermoelectric generating (TEG) devices that operate at high temperatures (~750^oC). TEG technology offers the potential for large-scale economic conversion of waste heat. The report identifies manufacturing operations (e.g., Hall-Heroult cells and aluminum, magnesium, metal and glass melting furnaces) where there is little need or opportunity to use current heat recovery technologies. These applications are suitable for advanced TEG technology. This report provides an analysis of the potential energy recovery and of the engineering issues that are expected when integrating TEG devices into existing manufacturing processes. The report brings to light the need for new hot-side heat exchange materials, designs and systems with performance characteristic that significantly exceed current technology. Development of these new heat exchangers is required to gain the full advantage of the new thermoelectric materials. (PDF 2.4 MB)

Opportunity Analysis for Recovering Energy from Industrial Waste Heat and Emissions

U.S. industry yields waste products directly through its manufacturing processes and indirectly through its energy consumption. These waste products come in two forms, chemical and thermal. Both forms of waste have residual energy values that are not routinely recovered. Recovering and reusing these waste products may represent a significant opportunity to improve the energy efficiency of the U.S. industrial complex. This report analyzes the opportunity to recover chemical emissions and thermal emissions from U.S. industry. It also analyzes the barriers and pathways to more effectively capitalize on these opportunities. (PDF 5.9 MB)

Materials for Separation Technologies: Energy and Emission Reduction Opportunities

Separation processes are among the most energy intensive operations in industry, accounting for more than a third of the energy used in manufacturing. This study addresses opportunities for materials innovations for industrial separations. New materials with improved selectivity, stability, morphology, and ability to regenerate will be needed for continued development and implementation of low-temperature, low-energy, separation technologies. Successful development of these technologies could lower separations energy consumption by 40 to 80 percent while reducing capital costs. (PDF 2.0 MB)

Refractories for Industrial Processing: Opportunities for Improved Energy Efficiency

Refractory materials with properties suitable for high-temperature applications are used throughout U.S. industry as insulation and/or containment vessel linings in high-temperature and corrosive environments. Indeed, it would be difficult to identify an industrial process that does not use refractory materials in one aspect or another. These materials must not only be capable of performing these tasks at elevated temperatures, but may also be called upon to bear mechanical loads and transfer heat. Refractories are characterized by two aspects that qualify them as enabling materials in support of U.S. industry: (1) their ability to contain heat, chemicals, and melts; and (2) the crosscutting nature of their utility. This report describes the current furnace technologies used by U.S. industries with analysis focused on four furnace types (kilns/calciners, reverberatory furnaces, boilers and reactor systems, and gasifiers) which are common to multiple industries and are representative of areas where significant energy improvement could be made through future refractory improvement. (PDF 3.0 MB)

New Materials and Technologies Available for Use in Industrial Infrastructure

Industrial infrastructure materials and the technologies used to apply them are major determinants of manufacturing capacity and efficiency. The many different choices and applications of infrastructure materials have a significant environmental and economic impact on U.S. manufacturing. This paper provides an overview of different types of new industrial infrastructure materials and technologies that are available. It is intended to promote a dialogue concerning where infrastructure material research and development has been focused in the past, where R&D efforts may shift in the future, and the obstacles to innovation that exist. (PDF 107 KB)

Energy and Emission Reduction Opportunities for the Cement Industry

This report describes the cement industry and its technology. It provides background information necessary to develop realistic work plans to reduce energy usage and to lower CO2 emissions. (PDF 1.3 MB)