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Energy Use Loss and Opportunities Analysis: U.S. Manufacturing & Mining

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Energy Use, Loss and Opportunities Analysis: U.S. Manufacturing & Mining Prepared by Energetics, Incorporated and December 2004 E3M, Incorporated for the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy Industrial Technologies Program Energy Use, Loss and Opportunities Analysis U.S. Manufacturing and Mining December 2004 Prepared by Energetics, Incorporated and E3M, Incorporated For the U.S. Department of Energy Energy Efficiency and Renewable Energy Industrial Technologies Program Preface The U.S. Department of Energy’s Industrial Technologies Program (DOE/ITP) conducts R&D to accelerate the development of energy efficient and environmentally sound industrial technology and manufacturing practices. To help focus its R&D portfolio, the DOE/ITP commissioned this multi-phase study to identify where and how industry is using energy, and to target opportunities for reducing energy consumption. The focus of the study is on energy systems (steam generators, power systems, fired heaters, heat exchangers, compressors, pumps, fans) used across the industrial sector. The results of this study were also used to help develop the Technology Roadmap for Energy Loss Reduction and Recovery (available at www.eere.energy.gov/industry), a joint effort between industry and government. The principal authors of the report are shown below. Questions concerning this report should be directed to the authors. A copy of the report may be obtained on-line at www.eere.energy.gov/industry/energy_systems Energy Use, Loss and Opportunities Analysis Joan L. Pellegrino ([email protected]) Nancy Margolis ([email protected] Mauricio Justiniano ([email protected]) Melanie Miller ([email protected] Energetics, Incorporated 7164 Gateway Drive Columbia, Maryland, 21046 410-290-0370 Opportunities Analysis (petroleum, chemicals, iron and steel) Arvind Thedki ([email protected]) E3M, Incorporated 15216 Gravenstein Way North Potomac, MD 20878 240-715-4333 Table of Contents 1.0 Overview of Energy Use, Loss and Opportunities ............................................................. 1 1.1 Background ........................................................................................................ 1 1.2 Methodology....................................................................................................... 3 1.2.1 Energy Use and Loss Analysis ............................................................ 3 1.2.1.1 General Methodology ............................................................. 3 1.2.1.2 Energy Footprints................................................................... 3 1.2.1.3 Industry Rankings .................................................................. 5 1.2.2 Loss Reduction and Recovery Opportunities Analysis .......................... 6 1.2.3 Definition of Terms ............................................................................ 8 2.0 U.S. Manufacturing and Mining ................................................................................... 10 3.0 Chemicals Industry (NAICS 325).................................................................................. 21 4.0 Petroleum Refining (NACIS 324110)....................................................................................29 5.0 Forest Products (NACIS 321,322) ................................................................................. 36 6.0 Iron and Steel (NAICS 333111) .................................................................................... 43 7.0 Food and Beverage (NAICS 311, 312) .......................................................................... 49 8.0 Mining (NAICS 212).................................................................................................... 55 9.0 Cement (NAICS 327310) ............................................................................................. 59 10.0 Energy Systems 10.1 Fired Systems ................................................................................................. 61 10.2 Steam Systems................................................................................................ 63 10.3 Onsite Power Generation ................................................................................. 65 10.4 Motor Systems ................................................................................................ 67 10.5 Facilities and Other Systems ............................................................................ 69 11.0 Top Twenty Opportunities ........................................................................................... 71 11.1 Opportunity Selection Criteria .......................................................................... 71 11.2 Research, Development and Demonstration Opportunities ................................. 71 11.3 Energy Management and Integration ................................................................ 73 11.4 Cross-Industry Opportunities ........................................................................... 74 References........................................................................................................................... 75 Appendix A Energy Footprints and Sample Calculations ....................................................... 77 Appendix B Opportunity Analysis Data and Assumptions ....................................................121 Appendix C Additional Data for Top Twenty.......................................................................137 Appendix D NAICS Descriptions ...................................................................................... 163 1.0 Overview of Energy Use, Loss and Opportunities 1.1 Background The industrial sector uses about one-third of the total energy consumed annually in the United States (see Figure 1-1), most of it fossil fuels, at a cost of approximately $100 billion. Given that energy resources are limited, and demand for industrial products continues to rise, meeting industrial energy demand and minimizing its economic impact in the future will be a significant challenge. The U.S. manufacturing sector depends heavily on fuels and power for the conversion of raw materials into usable products, Total U.S. Energy Use and also uses energy as a source of raw materials (feedstock 97.3 quads energy). How efficiently energy is used, its cost, and its availability consequently have a substantial impact on the competitiveness and economic health of U.S. manufacturers. Buildings Industry More efficient use of fuels and power lowers production costs, 38.3 32.5 conserves limited energy resources, and increases productivity. quads quads Efficient use of energy also has positive impacts on the environment – reductions in fuel use translate directly into Transport decreased emissions of pollutants such as sulfur oxides, nitrogen 26.5 oxides, particulates, and greenhouse gases (e.g., carbon quads dioxide). Improved efficiency can also reduce the use of feedstock energy through greater yields, which translates to more product Figure 1-1 2002 U.S. Energy Consumption manufactured for the same amount of energy. Reducing the use [Energy Information Administration, Annual of energy feedstocks impacts directly our dependence on Energy Review 2003] imported oil, and alleviates pressure on increasingly scarce and expensive natural gas supplies. Energy efficiency can be defined as the effectiveness with which energy resources are converted into usable work. Thermal efficiency is commonly used to measure the efficiency of energy conversion systems such as process heaters, steam systems, engines, and power generators. Thermal efficiency is essentially the measure of the efficiency and completeness of fuel combustion, or in more technical terms, the ratio of the net work supplied to the heat supplied by the combusted fuel. In a gas-fired heater, for example, thermal efficiency is equal to the total heat absorbed divided by the total heat supplied; in an automotive engine, thermal efficiency is the work done by the gases in the cylinder divided by the heat energy of the fuel supplied. Typical Thermal Efficiencies of Selected Energy efficiency varies dramatically across industries and Energy Systems and Industrial Equipment manufacturing processes, and even between plants manufacturing the same products. Efficiency can be Power Generation 25-44% limited by mechanical, chemical, or other physical Steam Boilers (natural gas) 80% Steam Boilers (coal and oil) 84-85% parameters, or by the age and design of equipment. In some Waste Heat Boilers 60-70% cases, operating and maintenance practices contribute to Thermal Cracking (refineries) 58-61% lower than optimum efficiency. Regardless of the reason, EAF Steelmaking 56% less than optimum energy efficiency implies that not all of Paper Drying 48% Kraft Pulping 60-69% the energy input is being converted to useful work – some is Distillation Column 25-40% released as lost energy. In the manufacturing sector, these Cement Calciner 30-70% energy losses amount to several quadrillion Btus Compressors 10-20% (quadrillion British Thermal Units, or quads) and billions of Pumps and Fans 55-65% Motors 90-95% dollars in lost revenues every year. Given this resource and cost perspective, it is clear that increasing the efficiency of energy use could result in substantial benefits to both industry and the nation. Unfortunately, the sheer complexity of the thousands of processes used in the manufacturing sector makes this a daunting task. A first step in understanding
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    INTERIM GUIDANCE FOR MANUFACTURING ACTIVITIES DURING THE COVID-19 PUBLIC HEALTH EMERGENCY When you have read this document, you can affirm at the bottom. As of June 26, 2020 Purpose This Interim Guidance for Manufacturing Activities during the COVID-19 Public Health Emergency (“Interim COVID-19 Guidance for Manufacturing”) was created to provide owners/operators of manufacturing sites and their employees and contractors with precautions to help protect against the spread of COVID-19 as manufacturing sites reopen. These guidelines are minimum requirements only and any employer is free to provide additional precautions or increased restrictions. These guidelines are based on the best-known public health practices at the time of Phase I of the State’s reopening, and the documentation upon which these guidelines are based can and does change frequently. The Responsible Parties – as defined below – are accountable for adhering to all local, state and federal requirements relative to manufacturing activities. The Responsible Parties are also accountable for staying current with any updates to these requirements, as well as incorporating same into any manufacturing activities and/or Site Safety Plan. Background On March 7, 2020, Governor Andrew M. Cuomo issued Executive Order 202, declaring a state of emergency in response to COVID-19. Community transmission of COVID-19 has occurred throughout New York. To minimize further spread, social distancing of at least six feet must be maintained between individuals, where possible. On March 20, 2020, Governor Cuomo issued Executive Order 202.6, directing all non-essential businesses to close in-office personnel functions. Essential businesses, as defined by Empire State Development Corporation (ESD) guidance, were not subject to the in-person restriction, but were, however, directed to comply with the guidance and directives for maintaining a clean and safe work environment issued by the New York State Department of Health (DOH), and were strongly urged to maintain social distancing measures to the extent possible.
  • Use of Environmental Management Systems and Renewable Energy Sources in Selected Food Processing Enterprises in Poland

    Use of Environmental Management Systems and Renewable Energy Sources in Selected Food Processing Enterprises in Poland

    energies Article Use of Environmental Management Systems and Renewable Energy Sources in Selected Food Processing Enterprises in Poland Stanisław Bielski 1 , Anna Zieli ´nska-Chmielewska 2 and Renata Marks-Bielska 3,* 1 Faculty of Agriculture and Forestry, University of Warmia and Mazury in Olsztyn, M. Oczapowskiego 8, 10-719 Olsztyn, Poland; [email protected] 2 Institute of Economics, Pozna´nUniversity of Economics and Business, Al. Niepodległo´sci10, 61-875 Pozna´n,Poland; [email protected] 3 Faculty of Economic Sciences, University of Warmia and Mazury in Olsztyn, M. Oczapowskiego 4, 10-719 Olsztyn, Poland * Correspondence: [email protected] Abstract: The issue of environmental management systems in food processing companies is gaining importance due to the need to reduce water withdrawal, wastewater, air emissions, and waste generation. New technological solutions and innovations can reduce the negative effects of the enterprises’ production facilities on the environment. In Poland, the phenomenon of increasing use of the amount of renewable energy sources is influenced by, e.g., adopted national and EU legislation, development of new technologies in the field of energy, and increasing awareness of producers and consumers in the field of ecology and environmental protection. It is also important that the state creates favorable conditions for the use of renewable energy in micro-installations. Citation: Bielski, S.; The application goal of the study is to develop a procedure for improvement of the environmental Zieli´nska-Chmielewska,A.; management systems for food processing companies and increase the awareness of potential use and Marks-Bielska, R. Use of implementation of renewable energy sources by food processing entities.
  • Productivity and Costs by Industry: Manufacturing and Mining

    Productivity and Costs by Industry: Manufacturing and Mining

    For release 10:00 a.m. (ET) Thursday, April 29, 2021 USDL-21-0725 Technical information: (202) 691-5606 • [email protected] • www.bls.gov/lpc Media contact: (202) 691-5902 • [email protected] PRODUCTIVITY AND COSTS BY INDUSTRY MANUFACTURING AND MINING INDUSTRIES – 2020 Labor productivity rose in 41 of the 86 NAICS four-digit manufacturing industries in 2020, the U.S. Bureau of Labor Statistics reported today. The footwear industry had the largest productivity gain with an increase of 14.5 percent. (See chart 1.) Three out of the four industries in the mining sector posted productivity declines in 2020, with the greatest decline occurring in the metal ore mining industry with a decrease of 6.7 percent. Although more mining and manufacturing industries recorded productivity gains in 2020 than 2019, declines in both output and hours worked were widespread. Output fell in over 90 percent of detailed industries in 2020 and 87 percent had declines in hours worked. Seventy-two industries had declines in both output and hours worked in 2020. This was the greatest number of such industries since 2009. Within this set of industries, 35 had increasing labor productivity. Chart 1. Manufacturing and mining industries with the largest change in productivity, 2020 (NAICS 4-digit industries) Output Percent Change 15 Note: Bubble size represents industry employment. Value in the bubble Seafood product 10 indicates percent change in labor preparation and productivity. Sawmills and wood packaging preservation 10.7 5 Animal food Footwear 14.5 0 12.2 Computer and peripheral equipment -9.6 9.9 -5 Cut and sew apparel Communications equipment -9.5 12.7 Textile and fabric -10 10.4 finishing mills Turbine and power -11.0 -15 transmission equipment -10.1 -20 -9.9 Rubber products -14.7 -25 Office furniture and Motor vehicle parts fixtures -30 -30 -25 -20 -15 -10 -5 0 5 10 15 Hours Worked Percent Change Change in productivity is approximately equal to the change in output minus the change in hours worked.