Energy Footprints Target Energy Saving Opportunities
Significant opportunities exist to address energy efficiency in industrial systems, such as heat and power generation, steam distribution, heat exchangers, process heating systems, motor-driven systems, and others. To assist in targeting cost and energy savings opportunities for systems, a series of Energy Footprints was developed to map the flow of energy supply and demand in U.S. manufacturing industries. The Energy Footprints identify the sources and end-uses of energy for individual industries, and pinpoint areas of energy-intensity and loss due to inefficiencies, which can lead to improved efficiency and reduced energy consumption through best energy management practices and new technology. Review the Energy Footprints.
Fan System Assessment Tool (FSAT) Training on September 14!
DOE is launching a new Fan System training program, and will host the first workshop in Arlington Heights, IL on September 14, 2004. This 1-day workshop includes an overview of the new Fan System Assessment Tool (FSAT), a software tool which helps to determine the potential benefit of using a more optimally configured fan system to serve industrial processes. Using FSAT, participants will learn how to calculate the energy a fan system is using, determine how efficiently the system is operating, and quantify savings from system upgrades. Sign up now for the training, and watch for announcement of the FSAT software tool on the BestPractices Web site!
Hot Strip Mill Model Receives First Royalties
The American Iron and Steel Institute (AISI) recently announced the first royalties from sales of the Hot Strip Mill Model (HSMM), developed for commercial use under AISI's Technology Roadmap Program, a collaborative effort between ITP and the steel industry. HSMM is a predictive computer simulation tool that links mechanical properties of hot rolled steel to operating parameters of a conventional hot strip mill, simulating the complete steel hot rolling process for a variety of steel grades and products (PDF 109 KB). This allows the user to optimize the process based on product properties, increasing both efficiency and productivity of hot rolling operations.
ITP-Supported Projects Receive 2004 R&D 100 Awards
The R&D 100 Awards are given annually by R&D Magazine to honor the 100 most scientific and technologically significant new products, processes, materials, and software developed and brought to market during the past year. Awards are based on each achievement's technical significance, uniqueness, and usefulness. For the the past 42 years, DOE has supported the basic research for 633 of these award-winning projects. Review this year's awards to DOE National Laboratories, and read about four ITP-supported technologies which garnered awards this year:
The Advanced Heating System for High-Performance Aluminum Forgings (PDF 804 KB) received an R&D 100 Award for 2004. Developed by ORNL, with ITP sponsorship and support from industry and university partners, the process uses an optimized combination of radiant and convection heat for processing materials. When used to heat aluminum billets, the system reduces heating time and energy consumption and produces high-performance forgings with significantly improved tensile and fatigue properties compared to those heated by conventional techniques
The Glass Furnace Model (GFM), a state-of-the-art computational fluid dynamic (CFD) glass furnace simulation code, was also awarded an R&D 100 Award for 2004. This three-dimensional computer code was developed for the glass industry by Argonne National Laboratory (ANL) and industry partners to evaluate furnace design, performance, and operation. The code generates a computer simulation that conducts experiments that vary operating and design parameters to determine impact on furnace performance, leading to higher efficiency and increased productivity. A free trial license is available for a limited time through ANL's Online Software Shop.
ITP's Mining Industry of the Future (IOF) program has two 2004 R&D 100 Awards in its portfolio. QRDC, Inc. won an award for its SmartScreenSystems Model S3I-102, an innovative screening system that uses a patented energy flow control system to separate particles more efficiently. Unlike conventional equipment, the S3i-102 uses electromagnetic motors to vibrate the screen panel at resonance, reducing energy, equipment maintenance, noise, and vibration. The technology is currently in use at three taconite plants in Minnesota, and may also have application in the aggregates, pharmaceutical, chemical, petroleum, and food processing industries. Another award went to Stolar Research Corporation's Radio Imaging Method System IV (RIM-IV), a radio frequency device that generates high-resolution tomographic images of features below ground. Locating geologic anomalies and hazards ahead of mining operations improves mine planning, lowers operating costs, and reduces the risk of intersecting abandoned, potentially flooded mines. Mining companies, construction firms, and the military have already used the technology worldwide as a safe and effective means of subsurface exploration and extraction.
2003 Chemical Vision2020 Annual Report Available Now!
The U.S. Chemical industry is the second largest consumer of energy in manufacturing, making it a prime target for energy efficiency research and development. ITP's Chemical Industries of the Future (IOF) program teams with the Chemical Industry Vision2020 Technology Partnership to promote energy-efficient, environmentally sound chemical technology. Read the new Chemical Vision2020 Annual Report to review research project highlights of 2003 (PDF 1.58 MB).
Industrial Assessment Centers Benefit Businesses and Students
The Industrial Assessment Centers (IAC) conduct no-cost, comprehensive industrial assessments for eligible small- and medium-sized manufacturers. Engineering faculty and students from 26 U.S. universities perform these assessments and provide recommendations to improve productivity, reduce waste, and save energy. IAC recently published a new case study focusing on an IAC alumnus, which highlights benefits to both businesses and students. Read more about it in the recent case study about Eric Ruffel, available on the IAC Student Forum Careers page, under IAC Alumni Success Stories. To learn more about IAC, view ITP's IAC Web page.
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ITP offers technical publications, software tools, and other resources to help you address your company's industrial energy needs. Here are the latest products from ITP.
Energy Matters Summer 2004 Issue Available Now
Plant-wide assessments are the focus of the latest issue of Energy Matters (PDF 724 KB), winner of the 2004 APEX award for editorial excellence. Learn how effective the plant-wide assessment effort has been at helping industry identify and replicate energy efficiency strategies. Read the comments of plant managers and other industry executives who have seen first-hand the positive effects plant-wide assessments can have on manufacturing operations. And read a detailed case study explaining how Alcoa achieved major energy savings and productivity gains through a plant-wide assessment. Read all this and subscribe to receive Energy Matters electronically.
Plant-Wide Assessment Case Studies
Read these case studies to see how companies have implemented energy and cost savings plans, and how they may be replicated at other facilities.
North Star Steel Company: Iowa Mini-Mill Conducts Plant-Wide Energy Assessment Using a Total Assessment Audit (PDF 608 KB), in Wilton, Iowa. A Total Assessment Audit (TAA) is a synergistic approach used to identify ways to optimize energy use, reduce waste, and improve productivity. If all projects identified at the Wilton plant are implemented, potential annual energy savings would be 140,000 MMBtu in natural gas, and 39 million kWh in electricity, with annual cost savings of over $2.6 million. These assessment techniques and results can also be replicated at other mini-mills.
Rohm and Haas: Chemical Plant Uses Pinch Analysis to Quantify Energy and Cost Savings Opportunities at Deer Park, Texas (PDF 607 KB). This plant-wide assessment included a pinch analysis on four major production areas of the plant: the methyl methacrylate, acid recovery, acrylate monomers, and acetone cyanohydrin plants. The two-phase process identified energy cost reduction potential based on the thermodynamic process, and potential solutions to opportunities identified during the assessment. Several opportunities for energy use reduction were identified, and potential annual savings were predicted to total 2.2 million MMBtu and almost $7.7 million.
Combined Heat and Power Guide Now Available
ITP announces the Guide to Combined Heat and Power Systems for Boiler Owners and Operators, a resource for boiler owners and operators to help evaluate the feasibility of combined heat and power (CHP) systems for new or existing boiler operations. The guide focuses on technical, economic, and regulatory issues that boiler owners and operators should consider during the planning phase of a CHP project, as well as potential benefits and barriers.
Visit the ITP Web site for more BestPractices technical publications, software tools, and case studies to help you improve efficiency, productivity, and the bottom line.
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ITP awards cost-shared funding for R&D and plant assessment projects through a competitive merit review process.
To learn more about project opportunities, visit ITP's solicitation page.
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