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Slide1: 

Industries of the Future Partnerships for Improving Energy Efficiency, Environmental Performance and Productivity Presented to the NATO/CCMS Pilot Study on Clean Products and Processes Vilnius, Lithuania May 12-16, 2002 by Steven C. Weiner Pacific Northwest National Laboratory Washington, DC, USA

Slide2: 

Inherent Benefits of Energy Efficiency

Industries of the Future Strategy: 

Industries of the Future Strategy Technology for Today Steel Mining Petroleum Aluminum Metalcasting Forest Products Glass Agriculture Chemicals

The IOF Program Continuum: 

The IOF Program Continuum

Industries of the Future Process: 

Industries of the Future Process Industry Today Industry of the Future A Collaborative, Industry-Led Partnership

IOF: Delivering a Plant-wide Portfolio: 

IOF: Delivering a Plant-wide Portfolio

Chemical Industry Vision 2020: 

Chemical Industry Vision 2020 Focus Areas New Chemical Science & Engineering Technology Chemical Science Chemical Synthesis Bioprocesses & Biotechnology Materials Technology Enabling Technologies Process Science & Engineering Technology Chemical Measurements Computational Technologies Information Systems Supply Chain Management Manufacturing and Operations Reference: www.chemicalvision2020.org

Guiding Public R&D Investment: 

OIT Chemical Industry of the Future Guiding Public R&D Investment

Computational Fluid Dynamics: 

Computational Fluid Dynamics CFD Consortium Members Chevron Exxon Dow Chemical Dow Corning DuPont Sandia National Laboratories ORNL Fluent NETL LANL PNNL LBNL Princeton Purdue Illinois Institute of Technology Washington University at St. Louis Clarkson College of Technology Models to predict gas-solid flow properties Applications in the petroleum and petrochemical industries as well as biobased process and chemical engineering Improved overall gas-solid flow operating capacity (60% in some cases versus 95% for all other processes)

Intelligent Extruder: 

Intelligent Extruder Diagnostic and control tools to reduce product variability and increase first-pass yield GE Corporate Research and Development GE Industrial Systems Solutions GE Plastics Corporation Krupp Werner-Pfleiderer Applications in extruded and molded plastics industry Reduced waste and raw material consumption *SBIR Phase II winner

Ultrasonic Tank Cleaning: 

Ultrasonic Tank Cleaning Ultrasonic or high-frequency sound waves to replace harmful chemicals with soap and water in cleaning large industrial storage tanks. Avoids use, treatment, and disposal of hazardous solvents Reduces cleaning time by 86% Safer for personnel and the environment DuPont, Merck

Robotics Inspection System: 

Robotics Inspection System Solex robotic tank inspection system inspects bottoms of aboveground storage tanks containing petroleum and other petrochemical products in service. Reduces inspection costs by $50,000 to $500,000 per tank by eliminating tank draining, cleaning,and downtime Solex Environmental Systems Texas Natural Resource Conservation Commission Benefits: Demonstrated energy savings of more than 95% Reduce CO2 emissions by 8,000 tons by 2010

Supporting a Plant-wide Systems Approach: 

Motor Systems Steam Systems Emerging Process Technologies Boilers/ Burners CHP Systems Predictive Maintenance Compressed Air Systems Corrosion & Wear Supporting a Plant-wide Systems Approach

Slide14: 

Motor Master+ 3.0 Comprehensive motor management software with 25,000 motors in database Repair/replace decision-making Self-training CD ASD Master Screening for Adjustable Speed Drive (ASD) upgrades Energy, non-energy, and economic analysis ASD specification Pump System Assessment Tool (PSAT) Calculation of energy use and efficiency of pumping system Comparisons with optimal system for potential energy and cost savings Energy Management: Software Tools

Slide15: 

Assess and estimate energy and cost savings opportunities in pumping systems Evaluate how well-suited a pump is to a particular service application Generate “What If” assessments, following the pumping system head-capacity curve Examine pumping systems which a prescreening process has identified as worthy of further consideration

PSAT Pumping Efficiency: 

PSAT Pumping Efficiency MCC P P Input = electrical kilowatts Output = Flow rate * head * constant F2

PSAT Main Menu Data Input Screen: 

PSAT Main Menu Data Input Screen Input data Results Measured field data Nameplate type data Duty, cost data

Slide18: 

3E Plus Optimization of the insulation of boiler steam lines Determination of the most economical thickness of insulation materials under varying operating conditions AirMaster+ Compressed air systems assessment and evaluation designed for use with the training program   Steam Scoping Tool Provides steam system profiling while pointing up opportunities for energy savings. Energy Management: Software Tools

Slide19: 

OIT Home Page : www.oit.doe.gov OIT Clearinghouse: 1-800-862-2086