Advanced Manufacturing Office IMPACTS Results Summary for CY 2010 March 2013 Table of Contents IMPACTS Table of Contents Executive Summary................................................................. 1 AMO Impacts .......................................................................... 2 Industrial Energy Use Advanced Manufacturing Office Technology Tracking Process Results Appendix A: AMO -Sponsored Technologies Commercially Available .. A-1 Appendix B: AMO Emerging Technologies ............................................. B-1 Appendix C: Historical AMO Technology Successes .............................. C-1 Appendix D: Method of Calculating Results for the IAC Program .......... D-1 Appendix E: Method of Calculating Results for Technology Deployment Program ................................................................................E-1 Appendix F: Method of Calculating Results from DOE’s Combined Heat and Power Activities .............................................................F-1 Appendix G: Methodology for Technology Tracking and Assessment of Benefits ................................................. G-1 ii DOE Advanced Manufacturing Office Executive Summary IMPACTS Manufacturing converts a wide range of raw materials, 713 trillion Btu or $5.12 billion. Cumulatively these net components, and parts into finished goods that meet market benefits correspond to about 10.7 quadrillion Btu or $56.5 expectations. The U.S. Department of Energy’s (DOE’s) billion (in 2010 dollars). Advanced Manufacturing Office (AMO) partners with industry, small business, universities, and other stakeholders This report has seven appendices. Appendix A describes to identify and invest in emerging technologies with the the 98 AMO-supported commercial technologies currently potential to create high-quality domestic manufacturing jobs available, their applications, and benefits. Appendix B lists and enhance the global competitiveness of the United States. the 168 AMO-supported emerging technologies likely to This document offers a 2010 summary of selected impacts be commercialized within two or three years. Appendix C of AMO’s initiatives that are designed to increase energy describes 132 AMO- supported technologies used in past productivity and expand U.S. leadership in clean energy commercial applications. Appendices D and E summarize markets. the benefits of AMO technology deployment activities: the Industrial Assessment Centers and other technology Industry is the largest and most diverse energy-consuming deployment programs. Appendix F summarizes the benefits sector in the U.S. economy. In recent years, the industrial of DOE supported CHP systems. Finally, Appendix G sector used one-third of the energy consumed in the nation, describes the methodology used to assess and track AMO- produced about 1,500 MMT of CO2 per year, contributed supported technologies. 12% to the overall U.S. gross domestic product, and provided nearly 12 million manufacturing jobs. When combined with concerns surrounding energy security, job creation, and global competitiveness, these statistics emphasize the strategic role that improved industrial energy efficiency can have in addressing some of the nation’s most pressing energy, economic, and environmental challenges. Over the past 30 years, AMO has supported more than 600 separate RD&D projects that have produced over 250 commercialized technologies. In 2010 alone, 98 AMO supported commercialized technologies have saved 43.1 trillion Btus. While these energy savings are impressive, industry has reaped even greater benefits from improved productivity, reduced resource consumption, decreased emissions, and enhanced product quality associated with these technological advances. For the period 1992 - 2010, AMO-sponsored projects have resulted in 50 R&D 100 awards and 265 issued patents. Also, many AMO-supported projects have significantly expanded knowledge about complex industrial processes and have laid the foundation for future energy-efficient technologies. Investing in high-risk, high-value RD&D that will reduce industry’s energy requirements while stimulating economic productivity and growth is a primary role for AMO initiatives. Energy is a major input for many key manufacturing industries. In addition to tracking current and cumulative energy savings, AMO monitors other benefits associated with the successfully commercialized technologies resulting from its research partnerships. These benefits include cumulative reductions of various air pollutants including particulates, volatile organic compounds, nitrogen oxides, sulfur oxides, and carbon. In 2010, AMO programs were instrumental in saving industry DOE Advanced Manufacturing Office 1 AMO Impacts IMPACTS Industrial Energy Use The non-energy-intensive industries (3.84 quads) and Industry is the largest and most diverse energy-consuming non-manufacturing industries (agriculture, mining, and sector of the U.S. economy. In recent years, the industrial construction – 3.60 quads combined) accounted for the sector has used one-third of the energy consumed in the remaining energy consumption. Industry used 5.53 quads of the fossil fuels for feedstocks – raw materials for plastics nation, produced about 1,500 MMT of CO2 per year, contributed 12% to the overall U.S. gross domestic product and chemicals – rather than as fuels. Energy expenditures (GDP), and provided nearly 12 million manufacturing jobs. associated with manufacturing account for approximately When combined with concerns surrounding energy security, $230 billion annually. job creation, and global competitiveness, these statistics emphasize the strategic role that improved industrial energy Energy-intensive industries such as forest products, efficiency can play in responding to some of the nation’s most chemicals, petroleum refining, nonmetallic minerals (glass pressing energy, economic, and environmental challenges. and cement, especially), and primary metals account for about 80% of all manufacturing energy use. Many of these In 2010, the industrial sector used 30.14 quads of all types industries are limited in their choice of fuels because the of energy including losses associated with electricity process technologies these industries use require a specific transmission of 6.88 quads (see Figure 1). Petroleum fuel. For example, aluminum production requires large (8.01 quads), natural gas (8.11 quads), and electricity (3.28 amounts of electricity to reduce the alumina to metal. Paper quads delivered) are the three fuels most used by industry, pulping leaves a large amount of residual wood lignin that with coal and renewable energy (predominantly biomass) can be reprocessed for its chemical content and consequently providing another 3.86 quads combined. The industrial supplies the industry with half of its primary energy. This sector consumed a total of 23.26 quads, of which 19.66 quads means that the selection of a number of fuels (and feedstocks) were consumed by manufacturing industries. Of those 19.66 quads, energy-intensive industries consumed 15.82 quads. Electricity Electricity Losses Generation and 6.88 Transmission 10.16 Electricity 3.28 Fuel 3.27 Petroleum 8.01 Feedstocks Manufacturing 4.74 Energy-Intensive 15.82 19.66 Fuel Non-Energy-Intensive Natural 7.70 Gas Fossil Fuels Consumption 3.84 8.11 Feedstocks 17.73 23.26 0.41 Fuel Coal and 1.23 Coke 1.61 Feedstocks 0.38 Non-Manufacturing Renewables 3.60 Renewable 2.25 Source: EIA AER 2010, EIA MECS 2006 Energy 2.25 Figure 1. Industrial Energy Flows (Quads), 2010 2 DOE Advanced Manufacturing Office AMO Impacts IMPACTS used in the industrial sector is a reflection of the specific The energy intensity of the industrial sector has been requirements of the process(es) used to make particular goods declining over the past decade, in part because of investments or commodities. Because of these energy requirements, the in the development of energy-efficient technologies by AMO. industrial sector offers a wide variety of opportunities for Since its peak in 1992, industrial sector energy intensity energy-efficiency improvements that are specific to particular has declined more than 40%, from 15,500 Btu/dollar of real industries. In addition, certain technologies (e.g., boilers and industrial GDP to 8,900 Btu/dollar of real industrial GDP in motors) crosscut many industries. 2010 (see Figure 2). 16 15 14 13 12 11 10 Thousand Btu/$ Btu/$ IndThousand GDP 9 8 1990 1995 2000 2005 2010 Year Sources: EIA Annual Energy Review, 2010, Table 2.1d and BEA, Value Added for Industry, 1990-1997 and 1998-2010, (Constant $2010) Figure 2. Historical Industrial Energy Intensity DOE Advanced Manufacturing Office 3 AMO Impacts IMPACTS The Advanced Manufacturing Office u Next Generation Materials: Innovative materials AMO is the lead government program working to develop can open new design spaces for high-performance and and deploy new, energy-efficient technologies for the U.S. renewable energy technology manufacturing. Projects manufacturing sector. Programs within AMO are tailored focus on three areas with clear energy, carbon, and to address specific barriers faced by technology developers economic benefits. and manufacturers to ensure that cost-effective technologies are effectively transitioned from fundamental to applied AMO R&D investments move emerging technology along research, developed into commercially available products, the innovation pipeline through what is referred to as a and effectively deployed where they are needed throughout technology’s