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