2008 R&D 100 Awards Honor Two ITP-Supported Technologies
The annual R&D 100 Awards mark the 100 most technologically significant new products and processes of the year. For 45 years, the awards, known as "The Oscars of Invention," have been helping companies provide the important initial push a new product needs to compete successfully in the marketplace. R&D 100 awards are selected based on the technical significance, uniqueness, and usefulness of projects and technologies from across industry, government, and academia. ITP-sponsored technologies have garnered numerous awards in the past, and this year is no exception. The 2008 winners are:
- Ultrananocrystalline Diamond Mechanical Seals—Ultrananocrystalline Diamond (UNCD®) (PDF 1.07 MB) offers a unique diamond thin-film microstructure that provides superior low-friction, corrosion- and wear-resistance when used in mechanical seal applications. UNCD can help prevent fluids from escaping into the environment while reducing pump shaft frictional torque by as much as 75%. The ITP-sponsored project was developed in partnership with Argonne National Laboratory, Advanced Diamond Technologies, Inc., and John Crane, Inc.
- Velocys-FT: Fischer-Tropsch Fuels Using Velocys Microchannel Technology—The size and cost of second-generation biofuel facilities can be greatly reduced by microchannel reactor technology (PDF 1.08 MB). Primary benefits include favorable economics at smaller scales, more easily deployed and modular units, and improved heat transfer. Successful commercialization of the technology has the potential to save 13 trillion Btu per year by 2020 in ethylene production alone. This ITP-supported technology was developed in partnership with Pacific Northwest National Laboratory, Velocys, Inc., and Battelle.
See the DOE press release for the full list of DOE-funded research projects receiving awards.
New Case Studies Reveal How Three Companies Improved Energy Efficiency and Saved More Than $1.5 Million
After participating in a Save Energy Now energy assessment, J.R. Simplot, Kaiser Aluminum, and Shaw Industries have saved a combined $1.5 million. The companies have also reaped other benefits such as natural gas and No. 6 fuel oil savings, improved energy efficiency, and knowledge of analysis software tools that can be used to assess systems company-wide. Read the following case studies to see how these facilities reduced their energy use:
- J.R. Simplot Company steam assessment, Pocatello, Idaho (PDF 525 KB)
- Kaiser Aluminum process heating assessment, Sherman, Texas (PDF 637 KB)
- Shaw Industries steam assessment, Dalton, Georgia (PDF 532 KB).
See more Save Energy Now case studies.
Save Energy Now Assessments Offered at No Cost—Apply Today!
There's still time to apply for a 2008 Save Energy Now energy assessment of your facility to discover new and cost-effective ways to save energy. To date, U.S. manufacturing facilities have identified energy cost savings of more than $807 million through Save Energy Now. Typically, large plants must consume at least 0.3 trillion (300 billion) Btu per year to qualify for an assessment. However, ITP is now reviewing applications on a case-by-case basis. Read the requirements for participation. A DOE Energy Expert who is trained in the use of DOE's software tools will work with representatives from your company to analyze your most energy-intensive manufacturing process systems. It is recommended that your staff attend DOE training on the system to be analyzed prior to the assessment. Companies are also asked to use the Quick Plant Energy Profiler (Quick PEP) tool to evaluate the overall energy use in your plant and obtain a preliminary estimate of potential energy and cost savings. Apply for an assessment today.
ITP is partnering with utilities to improve U.S. industrial energy efficiency.
Webinar to Highlight Save Energy Now Resources for Utilities
Utilities know that large industrial facilities are not only important loads, but also valuable assets to the entire community, and that keeping those customers economically healthy is a top priority. What many power providers may not know is that ITP offers no- and low-cost resources to help them reduce their industrial customers' costly energy bills. On August 20, 2008, a Webinar entitled "Exploring Options for Keeping Industrial Customers Competitive" will take place from 12:00 p.m. to 1:30 p.m. MDT. This is the first in a series of energy management Webinars sponsored by ITP, Western Area Power Administration, and American Public Power Association.
Participants will learn about ITP's Save Energy Now initiative and how utilities can leverage resources such as energy assessments, software tools, training, and recognition programs to benefit their industrial customers. According to Medeiros McEnroe of Silicon Valley Power, a presenter at the Webinar, there is plenty of positive motivation for utilities to offer their industrial customers ITP services. "The [Save Energy Now] assessment provides contact with the customer, and that opens the door to communication on many issues." Utilities are invited to register for this no-cost Webinar. For more on ITP's partnership with utilities, see the Utilities Working with Industry: An Action Plan (PDF 2.1 MB).
Data Center Efficiency Strategy Workshop Attracts More Than 150 Participants
The DOE-sponsored National Data Center Energy Efficiency Strategy Workshop held on July 8, 2008, and hosted at Microsoft Corporation, was attended by more than 150 industry and government leaders. During the workshop participants reviewed recent progress made to improve data center energy efficiency, described successes in accelerating the adoption of data center energy management best practices, and identified approaches for joint government/industry cooperation to further increase data center efficiency. Data centers now use about 1.5% of all electricity generated in the U.S. and unless efficiency measures are adopted, their electricity use is expected to increase by 12% per year. A summary report of the workshop is being produced and will be posted on ITP's Web site when it becomes available. Learn more about this effort and sign up to partner with DOE on reducing data center energy use.
IEA Report Outlines Global Impact and Benefits of Combined Heat and Power
ITP data was used in part to generate the International Energy Agency's (IEA) report on the benefits of a global investment in combined heat and power (CHP). The report outlines the role that CHP can play in reducing carbon dioxide emissions and estimates a potential global cost-reduction due to CHP use of approximately $800 billion over the next 20 years. The IEA report emphasizes the need for improved documentation of CHP benefits, as well as a better understanding of those benefits by energy, environmental, economic, and regulatory organizations. In addition, increased communication between governments and industry audiences about CHP is also recommended, including a greater awareness of the potential of CHP in economies such as Brazil, China, India, Mexico, and South Africa. Read the report (PDF 751 KB). Learn more about ITP's CHP activities.
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ITP-sponsored technologies help U.S. industry save energy, boost productivity, and reduce emissions. Below you will find new technologies to help increase energy efficiency at your company.
The energy-efficient Ice Bear system is compatible with new or existing air conditioning units.
Ice Bear® Energy Storage Technology Operates Successfully in Manufacturing Environment
FiberLok, Inc., located in Fort Collins, Colorado, produces Lextra® Fiber Graphics such as heat transfers, appliqués (patches), stickers, and mouse pads. To manufacture a consistent product, the processing area must be kept at 62°F with 65% relative humidity (RH) and 100% make-up air. Initially the area was cooled with 24 tons of conventional cooling equipment, but when outside air temperatures approached more than 95°F the process area temperature would exceed tolerance. This resulted in lost production time of as much as two weeks during the summer—FiberLok's busiest time of year. In an effort to combat the problem, the company installed two Ice Bear® systems, and cooling coils in existing duct work down stream of the conventional air conditioning (AC). Ice Bear is an energy storage technology that was developed as part of DOE's Inventions and Innovation program by Powell Energy Products and commercialized by Ice Energy®.
The technology works by shifting AC energy use from peak to off-peak periods and storing the energy as ice. During peak daytime cooling, the unit functions as a condenser to provide cooling using a 300 watt refrigerant pump to circulate ice-condensed refrigerant to the evaporator coil. Benefits of the Ice Bear technology include:
- Shifts 95% of AC load from peak to off-peak periods, saving energy consumption and lowering utility bills
- Reduces energy requirements by 5% to 25%, depending on climate zone and application
- Reduces air emissions from 23% to 40%.
Since the Ice Bear systems were installed at FiberLok, the company has successfully shifted 10 tons of cooling while increasing productivity. The Ice Bear unit is compatible with new or existing AC equipment and can be used in conjunction with 3.5- to 20-ton AC units and offers energy storage capacity of 45-ton hours, yielding up to 7.5 tons of cooling for six hours. To learn more about this industrial application visit the Ice Energy Web site and see page 29 of the ITP publication Energy Technology Solutions: Public-Private Partnerships Transforming Industry (PDF 3.7 MB). To find out whether or not your utility sponsors a load shifting program, consult with your local utility representative or visit ITP's States Incentives and Resources Database.
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Attend these key events to learn about the latest energy-efficient technologies and practices, and network with industry peers.
The Utility Integrated Resource Planning Conference will be held September 8-10, 2008, in Atlanta, Georgia. Attendees can discuss options for determining the best combination of resources to serve customer needs with a focus on the importance of adopting energy efficiency programs. Jon Wellinghoff, Commissioner of the Federal Energy Regulatory Commission, will be a keynote speaker.
More than 1,500 exhibitors will occupy 1.2 million square feet at the International Manufacturing Technology Show, September 8-13, 2008, in Chicago, Illinois. Attendees can view more than 15,000 new machine tools, computers, software, controls, components, systems, and processes that can improve efficiency. The show is divided into eight product pavilions, including Metal Cutting and Metal Forming and Fabricating/Laser.
The Predictive Maintenance Technology Conference and Expo will be held September 15-18, 2008, in Omaha, Nebraska. It will provide leading techniques and case studies for vibration analysis, airborne ultrasound, infrared thermal imaging, motor testing, and other condition monitoring technologies. Equipment engineers, maintenance managers, and anyone else involved in the planning, implementation, and use of condition-based maintenance programs or predictive maintenance programs are invited to attend.
Nine industry-related shows will take place under one roof during National Manufacturing Week September 22-25, 2008, in Chicago, Illinois. The event features products and services for design engineering, plant engineering and maintenance, industrial automation, sustainable manufacturing, and more. Industry leaders will provide the latest technical training designed for immediate application.
The 31st World Energy Engineering Congress is returning to Washington, DC, October 1-3, 2008. End users and energy professionals in all areas of the energy field can attend the multi-track conference to learn more about the technologies and services available to them, including energy efficiency and energy management, combined heat and power/cogeneration/distributed energy, integrated building automation, boilers and combustion controls, and more.
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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.
A sound reliability-centered motor maintenance program can help manufacturers achieve significant energy and cost savings.
Shape Up Your Motor Systems: Read the Summer 2008 Issue of Energy Matters to Find Out How
Read the new issue of Energy Matters, ITP's quarterly e-magazine, for information on improving energy efficiency and reliability in industrial motors and motor-driven systems, including:
- A proactive approach to implementing a successful motor system management plan at your manufacturing facility
- How CEMEX, a major cement manufacturer, is reinforcing its commitment to sustainable business practice with help from DOE's MotorMaster+ software tool and Save Energy Now energy assessments
- The Ask an Energy Expert column, which answers questions about how to identify inefficient fans and determine operating costs of your fan system
- Two new motor technologies that are now commercially available and offer energy savings, improved reliability, and reduced operational costs.
New Motor Tip Sheets Offer Technical Advice to Improve Efficiency
In addition to the extensive information featured in Energy Matters to help facilities improve their motor efficiency, seven new motor tip sheets are now available on ITP's Web site. Quick and to the point, these 2-page documents serve as a handy technical reference for plant personnel. The following new additions complete a set of previously published tip sheets, for a total of 15.
- Improve Motor Operation at Off-Design Voltages (PDF 224 KB)
- Turn Motors Off When Not in Use (PDF 237 KB)
- Adjustable Speed Drive Part-Load Efficiency (PDF 250 KB)
- Is it Cost-Effective to Replace Old Eddy-Current Drives? (PDF 258 KB)
- Magnetically Coupled Adjustable Speed Motor Drives (PDF 254 KB)
- When Should Inverter-Duty Motors be Specified? (PDF 213 KB)
- Minimize Adverse Motor and Adjustable Speed Drive Interactions (PDF 227 KB)
AIRMaster+ and Steam System Assessment Tool Software Updated
Be sure to download the updated versions of AIRMaster+ and the Steam System Assessment Tool (SSAT) software, which allow measurement inputs in either English or metric units. AIRMaster+ Version 1.2.2 replaces earlier versions of the software and corrects unit labeling errors in some screens of the English version. The SSAT Version 3 corrects all known problems with Version 2 and is compatible with Microsoft Vista and Microsoft Excel 2007. Learn more about DOE's other software tools and how you can use them in your plant to assess and identify system-specific opportunities for increased energy efficiency.
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.
Financial Opportunity Resources for Industry
ITP provides approximately $50 million annually in cost-shared funding for R&D. Funding is awarded through an open, competitive solicitation process designed to meet the top technology needs identified in industry's roadmaps. This is just one financial resource offered by the government that can help a company or research institution move a cutting edge, energy-saving technology from RD&D into the commercial market. Read the Financial Opportunities Help Advance New Technologies article in the latest issue of Energy Matters to learn about other organizations that offer funding opportunities.
American Public Power Association DEED Applications Due August 15, 2008
The American Public Power Association's Demonstration of Energy-Efficient Developments (DEED) Program is the only research and development program funded by and for public power utilities. A utility must first be a member of DEED to apply for funding through a DEED grant (up to $75,000), which can be used to improve utilities by increasing efficiency, reducing costs, investigating new technologies, offering new services, and improving processes and practices to better serve customers. Grants can support pilot projects, new technology demonstrations, early commercialization projects, and the development of best practices. Any issue encountered by members—reliability, safety, security, energy efficiency, telecommunications, and the environment—is an appropriate topic for a grant. See a list of current projects (PDF 156 KB). Applications are accepted two times per year: August 15 and February 15.
To learn more about project opportunities, visit ITP's solicitation page.
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