Manufacturing Energy Bandwidth Studies: Chemical, Peroleum Refining, Pulp and Paer, and Iron and Steel Sectors

Energy efficiency underlies American manufacturing competitiveness. Improvements in efficiency yield energy cost savings on site, and can have positive spin-off effects through the supply chain. An evaluation of the technical potential within an industrial subsector requires an understanding of the current average (baseline) energy utilization, the current improvement potential if state-of-the-art technologies are deployed, and future energy savings expected if next generation technologies potentials are realized. These bandwidths between baseline and improved energy efficiency potentials provide a consistent methodology to evaluate, aggregate and communicate energy savings potentials within industry. In this paper, we review bandwidth studies of four of the most energy intensive manufacturing sectors in the United States. The Chemical, Petroleum Refining, Iron and Steel, and Pulp and Paper Energy Bandwidth Studies serve as generalized guides for energy technology advancement opportunities. These studies identify energy intensity and consumption for key manufacturing processes and the sector as a whole. Potential energy savings opportunities are identified by quantifying four measures of energy consumption for each process area: current average (year 2010), state of the art, practical minimum, and thermodynamic minimum. These measures enable prediction of current savings opportunities and future savings opportunities, with supporting detail on opportunity areas. The resulting reports provide useful guides for determining which manufacturing sectors and processes are the most energy-intensive and offer the greatest energy savings opportunities from technology advances