Energy Intensive Processes Industry Profile
The U.S. manufacturing sector ranks first in the world based on economic output. To produce millions of different products, U.S. industry consumed 32.4 quadrillion British Thermal Units (Btu) of energy in 2006, approximately one-third of the total energy consumption in the United States. Industrial productivity is essential to the nation's economic health, and that's why the Energy Intensive Processes (EIP) works with industrial partners to transform the way that they use energy to improve national energy security, the climate and environment, and economic competitiveness.
The four technology platforms and their relationship with all industrial sectors (ranked by fuel and electricity use)
The Industrial Technology Program's (ITP) R&D approach focuses on four technology-based platforms that address the top energy-consuming industrial activities. Each technology platform encompasses three or four technological focus areas that support a core manufacturing process. Deployment of the resulting technologies will contribute ITP's goal to reduce industrial energy use by 25% while also reducing subsequent carbon emissions.
Industrial Reactions and Separations – targets the development of advanced technologies to reduce energy consumption in reactions and separations. Focus areas include advanced water removal, gas separations, hybrid distillation, and energy-intensive conversions.
High-Temperature Processing – focuses on the development of new materials, material processing, and process monitoring technologies that increase energy efficiency during high-temperature processing.
Waste Heat Minimization and Recovery – reduces fuel demands of steam boilers and furnaces by utilizing waste heat recovery. Focus areas include developing the Super Boiler for highly efficient steam generation; an ultra-high efficiency furnace for aluminum and steel applications; and waste heat recovery systems for process energy and electricity generation.
Sustainable Manufacturing – advances materials and technologies to improve yields per unit energy cost for multiple elements of the manufacturing chain. Focus areas include: net and near-net design; engineered functional materials and coats; advanced forming, joining, and assembly; and integrated, predictive manufacturing and plant options.