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DOE OSTI2012

United States Industrial Sector Energy End Use Analysis

The United States Department of Energy’s (DOE) Energy Information Administration (EIA) conducts the Manufacturing Energy Consumption Survey (MECS) to provide detailed data on energy consumption in the manufacturing sector. The survey is a sample of approximately 15,000 manufacturing establishments selected from the Economic Census - Manufacturing Sector. MECS provides statistics on the consumption of energy by end uses (e.g., boilers, process, electric drives, etc.) disaggregated by North American Industry Classification System (NAICS) categories. The manufacturing sector (NAICS Sector 31-33) consists of all manufacturing establishments in the 50 States and the District of Columbia. According to the NAICS, the manufacturing sector comprises establishments engaged in the mechanical, physical, or chemical transformation of materials, substances, or components into new products. The establishments are physical facilities such as plants, factories, or mills. For many of the sectors in the MECS datasets, information is missing because the reported energy use is less than 0.5 units or BTUs, or is withheld to avoid disclosing data for individual establishments, or is withheld because the standard error is greater than 50%. We infer what the missing information likely are using several approximations techniques. First, much of the missing data can be easily calculated by adding or subtracting other values reported by MECS. If this is not possible (e.g. two data are missing), we look at historic MECS reports to help identify the breakdown of energy use in the past and assume it remained the same for the current MECS. Lastly, if historic data is also missing, we assume that 3 digit NAICS classifications predict energy use in their 4, 5, or 6 digit NAICS sub-classifications, or vice versa. Along with addressing data gaps, end use energy is disaggregated beyond the specified MECS allocations using additional industry specific energy consumption data. The result is a completed table of energy end use by sector with mechanical drives broken down by pumps, fans, compressed air, and drives.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2014

Industrial Waste Heat Recovery - Potential Applications, Available Technologies and Crosscutting R&D Opportunities

The purpose of this report was to explore key areas and characteristics of industrial waste heat and its generation, barriers to waste heat recovery and use, and potential research and development (R&D) opportunities. The report also provides an overview of technologies and systems currently available for waste heat recovery and discusses the issues or barriers for each. Also included is information on emerging technologies under development or at various stages of demonstrations, and R&D opportunities cross-walked by various temperature ranges, technology areas, and energy-intensive process industries.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2015

Renewable Electricity Use by the U.S. Information and Communication Technology (ICT) Industry

The information and communication technology (ICT) sector continues to witness rapid growth and uptake of ICT equipment and services at both the national and global levels. The electricity consumption associated with this expansion is substantial, although recent adoptions of cloudcomputing services, co-location data centers, and other less energy-intensive equipment and operations have likely reduced the rate of growth in this sector. This paper is intended to aggregate existing ICT industry data and research to provide an initial look at electricity use, current and future renewable electricity acquisition, as well as serve as a benchmark for future growth and trends in ICT industry renewable electricity consumption.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2015

Opportunities and Challenges for Water and Wastewater Industries to Provide Exchangeable Services

Water and wastewater treatment plants and distribution systems use significant amounts of energy, around 2 - 4% of the total electricity used in the US, and their energy use is projected to increase as populations increase and regulations become more stringent. Water and wastewater systems have largely been disconnected from the electric utilities' efforts to improve energy efficiency and provide energy efficiency and provide grid services, likely because their core mission is to provide clean water and treated wastewater. Energy efficiency has slowly crept into the water and wastewater industry as the economic benefit has become more apparent, but there is still potential for significant improvement. Some of the larger, more progressive water utilities are starting to consider providing grid services; however, it remains a foreign concept to many. This report explores intrinsic mechanisms by which the water and wastewater industries can provide exchangeable services, the benefit to the parties involved, and the barriers to implementation. It also highlights relevant case studies and next steps. Although opportunities for increasing process efficiencies are certainly available, this report focuses on the exchangeable services that water and wastewater loads can provide to help maintain grid reliability, keep overall costs down, and increase the penetration of distributed renewables on the electric grid. These services have potential to provide water utilities additional value streams, using existing equipment with modest or negligible upgrade cost.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2015

Electric Industry Structure and Regulatory Responses in a High Distributed Energy Resources Future

The emergence of distributed energy resources (DERs) that can generate, manage and store energy on the customer side of the electric meter is widely recognized as a transformative force in the power sector. This report focuses on two key aspects of that transformation: structural changes in the electric industry and related changes in business organization and regulation that are likely to result from them. Both industry structure and regulation are inextricably linked. History shows that the regulation of the power sector has responded primarily to innovation in technologies and business models that created significant structural changes in the sector’s cost and organizational structure.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2015

Progress for the Industry Application External Hazard Analyses Early Demonstration

This report describes the current progress and status related to the Industry Application #2 focusing on External Hazards. For this industry application within the Light Water Reactor Sustainability (LWRS) Program Risk-Informed Safety Margin Characterization (RISMC) R&D Pathway, we will create the Risk-Informed Margin Management (RIMM) approach to represent meaningful (i.e., realistic facility representation) event scenarios and consequences by using an advanced 3D facility representation that will evaluate external hazards such as flooding and earthquakes in order to identify, model and analyze the appropriate physics that needs to be included to determine plant vulnerabilities related to external events; manage the communication and interactions between different physics modeling and analysis technologies; and develop the computational infrastructure through tools related to plant representation, scenario depiction, and physics prediction. One of the unique aspects of the RISMC approach is how it couples probabilistic approaches (the scenario) with mechanistic phenomena representation (the physics) through simulation. This simulation-based modeling allows decision makers to focus on a variety of safety, performance, or economic metrics. In this report, we describe the evaluation of various physics toolkits related to flooding representation. Ultimately, we will be coupling the flooding representation with other events such as earthquakes in order to provide coupled physics analysis for scenarios where interactions exist.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2013

Industry Research and Recommendations for Small Buildings and Small Portfolios

Small buildings have been left behind in the energy efficiency marketplace because financial and technical resources have flowed to larger commercial buildings. DOE's Building Technologies Office works with the commercial building industry to accelerate the uptake of energy efficiency technologies and techniques in existing and new commercial buildings (DOE 2013). BTO recognizes the SBSP sector'spotential for significant energy savings and the need for investments in resources that are tailored to this sector's unique needs. The industry research and recommendations described in this report identify potential approaches and strategic priorities that BTO could explore over the next 3-5 years that will support the implementation of high-potential energy efficiency opportunities for thisimportant sector. DOE is uniquely positioned to provide national leadership, objective information, and innovative tools, technologies, and services to support cost-effective energy savings in the fragmented and complex SBSP sector. Properly deployed, the DOE effort could enhance and complement current energy efficiency approaches. Small portfolios are loosely and qualitatively defined asportfolios of buildings that include only a small number of small buildings. This distinction is important because the report targets portfolio owners and managers who generally do not have staff and other resources to track energy use and pursue energy efficiency solutions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2016

Oil & Natural Gas Technology A new approach to understanding the occurrence and volume of natural gas hydrate in the northern Gulf of Mexico using petroleum industry well logs

The northern Gulf of Mexico has been the target for the petroleum industry for exploration of conventional energy resource for decades. We have used the rich existing petroleum industry well logs to find the occurrences of natural gas hydrate in the northern Gulf of Mexico. We have identified 798 wells with well log data within the gas hydrate stability zone. Out of those 798 wells, we have found evidence of gas hydrate in well logs in 124 wells (15% of wells). We have built a dataset of gas hydrate providing information such as location, interval of hydrate occurrence (if any) and the overall quality of probable gas hydrate. Our dataset provides a wide, new perspective on the overall distribution of gas hydrate in the northern Gulf of Mexico and will be the key to future gas hydrate research and prospecting in the area.

03 NATURAL GAS↗

DOE OSTI2016

Assisting the Tooling and Machining Industry to Become Energy Efficient

The Arizona Commerce Authority (ACA) conducted an Innovation in Advanced Manufacturing Grant Competition to support and grow southern and central Arizona’s Aerospace and Defense (A&D) industry and its supply chain. The problem statement for this grant challenge was that many A&D machining processes utilize older generation CNC machine tool technologies that can result an inefficient use of resources – energy, time and materials – compared to the latest state-of-the-art CNC machines. Competitive awards funded projects to develop innovative new tools and technologies that reduce energy consumption for older generation machine tools and foster working relationships between industry small to medium-sized manufacturing enterprises and third-party solution providers. During the 42-month term of this grant, 12 competitive awards were made. Final reports have been included with this submission.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2016

What China can learn from international policy experiences to improve industrial energy efficiency and reduce CO 2 emissions?

China’s industrial sector dominates the country’s total energy consumption and energy efficiency in the industry sector is crucial to help China reach its energy and CO 2 emissions reduction goals. There are many energy efficiency policies in China, but the motivation and willingness of enterprises to improve energy efficiency has weakened. This report first identifies barriers that enterprises face to be self-motivated to implement energy efficiency measures. Then, this report reviews international policies and programs to improve energy efficiency and evaluates how these policies helped to address the identified barriers. Lastly, this report draws conclusions and provides recommendations to China in developing policies and programs to motivate enterprises to improve energy efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2016

Lifecycle Industry GreenHouse gas, Technology and Energy through the Use Phase (LIGHTEnUP) – Analysis Tool User’s Guide

The LIGHTEnUP Analysis Tool (Lifecycle Industry GreenHouse gas, Technology and Energy through the Use Phase) has been developed for The United States Department of Energy’s (U.S. DOE) Advanced Manufacturing Office (AMO) to forecast both the manufacturing sector and product life-cycle energy consumption implications of manufactured products across the U.S. economy. The tool architecture incorporates publicly available historic and projection datasets of U.S. economy-wide energy use including manufacturing, buildings operations, electricity generation and transportation. The tool requires minimal inputs to define alternate scenarios to business-as-usual projection data. The tool is not an optimization or equilibrium model and therefore does not select technologies or deployment scenarios endogenously. Instead, inputs are developed exogenous to the tool by the user to reflect detailed engineering calculations, future targets and goals, or creative insights. The tool projects the scenario’s energy, CO 2 emissions, and energy expenditure (i.e., economic spending to purchase energy) implications and provides documentation to communicate results. The tool provides a transparent and uniform system of comparing manufacturing and use-phase impacts of technologies. The tool allows the user to create multiple scenarios that can reflect a range of possible future outcomes. However, reasonable scenarios require careful attention to assumptions and details about the future. This tool is part of an emerging set of AMO’s life cycle analysis (LCA) tool such as the Material Flows the Industry (MFI) tool, and the Additive Manufacturing LCA tool.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2017

Industrial Assessment Center (IAC) Operations Manual

IAC Operations Manual describes organizational model and operations of the Industrial Assessment Center (IAC), Center management activities, typical process of energy assessment, and energy assessment data for specific industry sectors.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2015

Risk-Informed Margin Management (RIMM) Industry Applications IA1 - Integrated Cladding ECCS/LOCA Performance Analysis - Problem Statement

The U. S. NRC is currently proposing rulemaking designated as “10 CFR 50.46c” to revise the LOCA/ECCS acceptance criteria to include the effects of higher burnup on cladding performance as well as to address some other issues. The NRC is also currently resolving the public comments with the final rule expected to be issued in the summer of 2016. The impact of the final 50.46c rule on the industry will involve updating of fuel vendor LOCA evaluation models, NRC review and approval, and licensee submittal of new LOCA evaluations or reanalyses and associated technical specification revisions for NRC review and approval. The rule implementation process, both industry and NRC activities, is expected to take 5-10 years following the rule effective date. The need to use advanced cladding designs is expected. A loss of operational margin will result due to the more restrictive cladding embrittlement criteria. Initial and future compliance with the rule may significantly increase vendor workload and licensee cost as a spectrum of fuel rod initial burnup states may need to be analyzed to demonstrate compliance. Consequently there will be an increased focus on licensee decision making related to LOCA analysis to minimize cost and impact, and to manage margin.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

Chapter 3: Commercial and Industrial Lighting Controls Evaluation Protocol. The Uniform Methods Project: Methods for Determining Energy Efficiency Savings for Specific Measures

This Commercial and Industrial Lighting Controls Evaluation Protocol (the protocol) describes methods to account for energy savings resulting from programmatic installation of lighting control equipment in large populations of commercial, industrial, government, institutional, and other nonresidential facilities. This protocol does not address savings resulting from changes in codes and standards, or from education and training activities. When lighting controls are installed in conjunction with a lighting retrofit project, the lighting control savings must be calculated parametrically with the lighting retrofit project so savings are not double counted.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Q2/Q3 2017 Solar Industry Update

This technical presentation provides an update on the major trends that occurred in the solar industry in Q2 and Q3 of 2017. Major topics of focus include global and U.S. supply and demand, module and system price, investment trends and business models, and updates on U.S. government programs supporting the solar industry.

14 SOLAR ENERGY↗

DOE OSTI2018

Q3/Q4 2017 Solar Industry Update

This technical presentation provides an update on the major trends that occurred in the solar industry in the Q3 and Q4 of 2017. Major topics of focus include global and U.S. supply and demand, module and system price, investment trends and business models, and updates on U.S. government programs supporting the solar industry.

14 SOLAR ENERGY↗

DOE OSTI2018

Training and Certification Programs on Industrial Energy Systems in the United States

The major industrial energy systems commonly found in manufacturing facilities are compressed air, ammonia refrigeration, chilled water, steam, process heating, combined heat and power, pumps, and fans. The efficiency of these systems contributes significantly to the whole-facility energy performance. On the national and even the international level, well-structured training and highly recognized certification programs help develop a highly skilled and qualified workforce to maintain and improve facilities' energy performance, particularly as technologies within these systems become more and more advanced. The purpose of this paper is to review currently available vendor-agnostic training and certification programs focusing on these systems and to identify the gap between market needs and currently available programs. Its three major conclusions are (1) most training programs focus on operations, maintenance, safety, and design although some briefly touch on energy performance aspects. (2) The Certified Refrigeration Energy Specialist certification by RETA the and Pump System Assessment Professional certification by HI were the only certifications found to be tool-agnostics and emphasize knowledge and skills for improving and maintaining systems energy performance. (3) Developing energy efficiency focused training and ANSI accredited certification programs for industrial energy systems will fill the gap between market needs and currently available programs.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

DOE OSTI2018

Silver-free Metallization Technology for Producing High Efficiency, Industrial Silicon Solar Cells

The goal of this project is to provide a commercially viable Ag-free metallization technology that will both reduce cost and increase efficiency of standard silicon solar cells. By removing silver from the front grid metallization and replacing it with lower cost nickel, copper, and tin metal, the front grid direct materials costs will decrease. This reduction in material costs should provide a path to meeting the Sunshot 2020 goal of 1 dollar / W DC . As of today, plated contacts are not widely implemented in large scale manufacturing. For organizations that wish to implement pilot scale manufacturing, only two equipment choices exist. These equipment manufacturers do not supply plating chemistry. The main goal of this project is to provide a chemistry and equipment solution to the industry that enables reliable manufacturing of plated contacts marked by passing reliability results and higher efficiencies than silver paste front grid contacts. To date, there have been several key findings that point to plated contacts performing equal to or better than the current state of the art silver paste contacts. Poor adhesion and reliability concerns are a few of the hurdles for plated contacts, specifically plated nickel directly on silicon. A key finding of the Phase 1 budget period is that the plated contacts have the same adhesion as the silver paste controls. This is a huge win for plated contacts. With very little optimization work, state of the art electrical results for plated contacts on laser ablated lines have been demonstrated with efficiencies up to 19.1% and fill factors ~80% on grid lines 40-50 um wide. The silver paste controls with similar line widths demonstrate similar electrical results. By optimizing the emitter and grid design for the plated contacts, it is expected that the electrical performance will exceed the silver paste controls. In addition, cells plated using Technic chemistry and equipment pass reliability testing; i.e. 1000 hours damp heat and 200 thermal cycles, with results similar to silver paste control cells. 100 cells have been processed through Technic’s novel demo plating tool built and installed during budget period 2. This plating tool performed consistently from cell to cell, providing gentle handling for the solar cells. An agreement has been signed with a cell manufacturer to process their cells through our plating chemistry and equipment. Their main focus for plated contacts is to reduce the direct materials cost by utilizing nickel, copper, and tin in place of silver paste. Based on current market conditions and cost model calculations, the overall savings offered by plated contacts is only 3.5% dollar/W versus silver paste contacts; however, the direct materials savings depend on the silver market. If silver prices increase, plated contacts may find a wider adoption in the solar industry in order to keep the direct materials costs down for front grid contacts.

14 SOLAR ENERGY↗