their local economies and environment. TheTeam brings right to the doorstep of thesegroups the benefits of energy-saving tech-nologies, and waste- and pollution-reducingmethodologies, while helping to foster localindustry and create jobs. The Team helps OITspread the word and get a higher level ofinvolvement with products and services thathave a proven record of helping industry bemore competitive. It’s a win for all con-cerned.”

States Team grantsUnlike OIT’s nine industry teams, the StatesTeam does not specifically fund R&Dprojects. Rather, it provides grant funding(through DOE’s State Energy Program) tointrastate or regional groups working to bringtogether representatives of a particular IOFindustry or industries in their areas. DOE’sRegional Offices bring news about theproducts, services, new technologies andpartnership opportunities available throughOIT.

One excellent example of a States Teamongoing success story is its first participant,the State of West Virginia. Local IOF coordi-nator, Carl Irwin, a Director of ProgramDevelopment at West Virginia University’sCoal and Energy Research Center, describesthe genesis of OIT’s States Team.

“Our carbon products group was partneringwith OIT on an Advanced IndustrialMaterials project,” he explained. “(DOE’sDeputy Assistant Secretary for IndustrialTechnologies) Denise Swink was visiting thefacility and I mentioned that the IOF indus-tries were prominent in WV. She saw theopportunity right away, and said ‘sounds likewe need a States IOF.’ The idea really clickedwith everyone in the room.”

OIT’s “States Team” extends“Industry of the Future” philosophyand resources to local levels

As many of our partners around the countrycan tell you, OIT’s States Team operates alittle differently from its nine industry teams.For example, OIT’s industry teams—Agriculture, Chemicals, Forest Products,Aluminum, Metalcasting, Steel, Glass,Mining and Petroleum Refining—all have anational focus. Often, they partner withcompanies in their respective industriesthrough national trade associations. TheStates Team, on the other hand, organizes itsefforts by geography first. It forms industrycoalitions in states or geographic regions, andhelps states take advantage of industryvisions, roadmaps, activities, investments,partnerships, and programs at the nationallevel.

“The States Team simply takes a different‘cut’ on the universe of American manufac-turing companies,” explained Doug Kaempf,Director of OIT’s Office of Industrial ProcessSystems. “By looking at our potentialcustomers geographically, from a state orregional perspective, we can involve manyadditional organizations—those that mightnot want to send people across the country tomeetings, or those represented locally onlyon a plant level, or those that simply mightnot have heard about national OIT programs.The States Team complements, supports andextends the IOF philosophy by informingmore people about their industry’s vision,roadmap and newly commercialized tech-nologies, and greatly expands our partnership

opportunities.”

“By reaching industry people in theirroles as ‘state corporate citizens,’ we’reproviding a different type of incentive andcoming at it from a different angle,” addedOIT States Team Leader Jim Quinn. “Partici-pants are not only assisting their owncompanies and their own industries, but also

INSIDE

2Four OIT projects receive R&D 100,President’s “Green Chemistry”awards

2-7Several IOF teams, programslaunching new R&D projects

3OIT’s new strategic plan published

12Agriculture and forest productsteams participate in President’sBioenergy Initiative

Vol. 2, No. 5

OFFICE OF INDUSTRIAL TECHNOLOGIES • www.oit.doe.gov/oittimesENERGY EFFICIENCY AND RENEWABLE ENERGY • U.S. DEPARTMENT OF ENERGY

THE OIT TIMES“Turning Industry Visions into Reality”

FALL 1999

(continued on page 8)

The Agriculture Team selected itsfirst round of Renewable Re-sources 2020 projects. AltusBiologics, Cambridge, MA, willlead development of an improvedcatalytic process to convert corn to

chemicals. In Minnetonka, MN, Cargill DowPolymers will work with NREL and ColoradoSchool of Mines to explore using corn-derivedpolylactic acid to make a new class ofbiodegradable plastic material. TheNational Corn Growers Assoc., St.Louis, MO, will lead the develop-ment of new processes for turningcorn into value-added chemicals.Pendleton Flour Mills inPendleton, OR, will exploreusing mill feed starch fromwheat flour milling to makeselected consumer goods. Aseries of biodegradable, low-toxicity soybean-based engine oilsfor recreational marine use will beexamined by Terresolve Technologies inEastlake, OH. The Univ. of California at Daviswill develop technology and data to support acommercial bioprocess using wood waste, ricestraw, or waste sugar to make commodity chemi-cals and other products.... DOE’s Office of EnergyEfficiency and Renewable Energy selected theTeam’s topic on “BioEnergy for the 21st Century”for the next SBIR program solicitation. TheBioEnergy topic will cover renewable resource-based chemicals, fuels and power. (Contact: DougFaulkner, 202-586-2119)

A Chemicals Team project onlevulinic acid received the Presiden-tial Green Chemistry Award at theNational Academy of Science in June.Started in 1994 and managed by

OIT’s Merrill Smith and Gloria Kulesa, the projectsought ways to convert paper sludge into an inexpen-sive, intermediate chemical that could in turn be

processed into new materials, herbicidesand fuel extenders. Project partners

receiving the award includedBiofine, National Renewable

Energy Lab, Pacific North-west National Lab, the NewYork State Energy R&DAuthority, Merichem andPencor.... Team memberscontinue a hectic pace of sitevisits and workshops. ACS’

Office of Industry Relationswill be sponsoring a site visit to

Bishop, TX to learn about BASF’snew process for making ibuprofen.

The visit will also kick-off ACS’ “Alter-natives” Roadmap. ACS and the Supply ChainCouncil are moving ahead with panels and work-shops on supply chain issues for the chemicalindustry. Also, the Materials Technology Institutewill complete its roadmapping efforts with a finalworkshop in September. Team partners–CeraMemCorp. and Membrane Technology and Research, Inc.–received SBIR Phase II awards. (Contact: HankKenchington, 202-586-1878)

An ingenious new manufacturingprocess, supported by the Inven-tions & Innovation program, hasbeen selected to receive a 1999R&D Magazine R&D 100 Award.

The process, developed by William Kemp ofHouston, is called the Mechanical FluidizedVacuum (MFV) system, an innovative method fortreating metal and ceramic powders that reducesenergy consumption by some 70%. A fact sheet onthe technology is available at www.oit.doe.gov/inventions.... Proposals received in response to the

Three OIT-sponsoredtechnologies will receive1999 R&D MagazineR&D 100 awards. Theseinclude:• A submergible roboticsystem, called Maverick,developed by SolexRobotics and IdahoNational Engineeringand Enviromental Labunder support fromNICE3.• An innovative methodfor treating metal andceramic powders, theMechanical FluidizedVacuum (MFV) system,developed by WilliamKemp of Houston andsponsored by theInventions & Innova-tion program.• A Galvanneal Tempera-ture MeasurementSystem supported byOIT’s Steel Team anddeveloped by Oak RidgeNational Lab, theAmerican Iron and SteelInstitute, Bailey Engi-neers and National SteelTechnical Center

Cummins Engine Co.,U.S. Electrical Motorsand McBroom ElectricCo. were recognized byMotor Challenge forjoint participation in amotor system efficiencyproject. The effortresulted in annual energycost savings of $207,000for Cummins’ Colum-bus, IN, plant.

Dr. F. William Kirschwas recognized at theIndustrial AssessmentCenter Annual DirectorsMeeting for his 20-yearcontribution to the IACprogram.

ChemicalsTeam project wins President’sGreen Chemistry Award

2

Quarterly Highlights

Renewable BioproductsSix new projectsunderway

Awards

program’s FY00 solicitation are currently in MeritReview. Selection of 25-30 new projects is antici-pated later this year.... The I&I program is holding aseries of conferences to help familiarize inventorsand small businesses with the technology needsidentified in IOF industry roadmaps. The events willbe held through December in Tacoma, WA, India-napolis, Houston, San Diego, Boise, ID, Anchorage,Seattle, Tulsa, and Salt Lake City. Additionalinformation on these and previously sponsored I&Iconferences can be found at www.oit.doe.gov/inventions. (Contact: Sandy Glatt, 202-586-3897)

3

THE OIT TIMES/FALL 1999

The Forest Products Team has selected 24new R&D projects for FY00 funding. Thenew project partners, which include universi-ties, trade associations, National Labs andprivate firms, are sharing on average about

30% of project costs. The projects were chosen fromamong five key Agenda 2020 technology areas: 2 inSustainable Forestry, 6 in Environmental, 6 in Energy, 5 inRecycling and 5 in Sensors and Controls.... With itsInstitute of Paper Science & Technology partner, the Teamproudly sponsored Energy Challenge ’99, held this year atGeorgia’s Sweetwater Creek State Park. This innovativecontest challenges college-level students to solve anengineering problem using only paper products. Thisyear’s event demanded the design and construction of afloatable nine-foot long kayak constructed solely frompaper products. The Univ. of Maine, with Senior JaimeMorin at the helm, won the competition, paddling its paperkayak 300 meters in just over three minutes. Thecompetition correlates with Agenda 2020,fostering education and awareness ofdesign efficiency, packaging technology,waste minimization and paper industrialprocesses. .... The Team recentlyannounced that its FY2001 solicitationfor new R&D proposals is nowopen, and will be so untilNovember 1. Additionalinformation on the newsolicitation is availableat www.oit.doe.gov/forest/. (Contact:Valri Robinson,202-586-0937)

This year’s NICE 3 solicitation includedseveral new features that distinguish itfrom those held in the past. The NICE3

solicitation was run concurrently with thatof the Inventions & Innovation program

in order that proposers could benefit from opportunitiesavailable through both programs. Also, NICE3 workedclosely with colleagues from OIT’s many industry teamsin order to get word about the solicitation out to innovators

Forest ProductsTwo dozen new projectsunderway

New OIT Strategic Plan helps chartorganization’s future courseOIT’s new strategic plan should help our customers gaininsight into the challenges and opportunities facing theorganization and how it intends to respond. The planprovides an analysis of the state of energy-intensive U.S.industries, and explains why joint public-private sectortechnology partnerships are a necessary strategy forcoping with the complex environmental, technological andglobal competitiveness challenges facing industry today.By identifying OIT’s vision, mission, and goals, the Officeof Industrial Technologies’ Strategic Plan sets the futurecourse for the organization.

The Strategic Plan also describes key elements of OIT’sstrategy, e.g., to:

• Focus on energy-intensive and environmentally-sensitive industries

• Establish partnerships with industry• Facilitiate the State IOF process• Apply the IOF strategy to align industry and

government resources

The plan details the factors that drive these elements andhow OIT plans to determine that its efforts are achievingtheir intended results.

Finally, the Strategic Plan discusses program implementa-tion. The publication states that, “To ensure success, OITmust implement its programs effectively, employing soundFederal research management strategies.”

The OIT Strategic Plan will be available October, 1999, atno cost to OIT customers. To obtain a copy, contact OIT’sResource Room at (202) 586-2090

in these industries. In addition, a new Merit Review Commit-tee—comprised of OIT staff and experts from academia,industry and DOE National Labs—will evaluate NICE3 propos-als with an eye on potential synergies with proposals submittedto the I&I program. Awardees for both programs are scheduledto be announced in December. (Contact: Lisa Barnett, 202-586-2212)

4

The Aluminum Teamannounced that a newsolicitation for R&D propos-als will be open until Novem-ber 4. The new solicitationsupports the Aluminum

Industry Roadmap and the Inert AnodeRoadmap. Solicitation information can befound at www.id.doe.gov/doeid/PSD/proc-div.html.... For advanced cell R&D, addi-tional background information is provided in

the Report of the American Society ofMechanical Engineer’s Technical

Working Group on Inert AnodeTechnologies, published in

July 1999. The reportassesses the technical,economic and environ-mental barriers ofadvanced reductionsystems, and themerits of variousapproaches to devel-oping these systems. It

also summarizes past andcurrent R&D efforts in

advanced cell technology, andsuggests possible directions for

future R&D in the area. Prepared at therequest of OIT, the report was written by apanel of experts in aluminum productiontechnology, and coordinated by ASME’sCenter for Research and Technology Devel-opment. Copies are available from the OITResource Room at 202-586-2090. (Contact:Sara Dillich, 202-586-7925)

The Steel Team has selectedthree new R&D projects basedon industry-identified priorities.“Controlled Thermo-MechanicalProcessing of Tubes and Pipesfor Enhanced Manufacturing and

Performance” will develop a simulation modelof the tube making process with componentmodels of heat transfer, deformation, andmetallurgical responses. “Research Related tothe Development of the Automated SteelCleanliness Tool” will develop a practicalelectron microscopy technique fordetermining the composition, size,shape and distribution of inclu-sions in steel during process-ing. “Novel Low-NOxBurners for Boilers in theSteel Industry” will developa gas-fired burner that canmaintain less than 15 ppmNOx emissions in steelindustry boilers usingavailable combinations ofblast furnace, coke oven, andnatural gas.... The Team iscreating a number of studies to helpinform steelmakers about the green-house gas emissions of various processes,and effective and practical reduction opportu-nities. One study is looking at the “theoreticalminimum” CO

2 emission levels of each

process, a second study is quantifying “reason-ably achievable” levels using “best practices,”and a third study provides details on the latesttechnologies and procedures to reduce steelmill CO

2 emissions. (Contact: Scott Richlen,

202-586-2078)

AluminumNew solicitationannounced

Quarterly Highlights

SteelThree new projectsselected

Initial “plant-wide”energy efficiencyassessments coming

OIT will soon select the initialsix participants for its new“plant-wide” energy efficiencyassessments. At a plant sitefor each of the participants,the assessments will evaluate avariety of energy efficiencyopportunities in steamsystems, electric-motorsystems, compressed airsystems, heat exchangenetworks, combined heat andpower systems and so on. Theassessments will evaluateenergy efficiency opportuni-ties using process engineeringand best practice analysistechniques. OIT and theparticipants will share the costof the assessments (estimatedat about $150,000 per plant)on a “50-50” basis.

Plants will be selected basedon proposals received inresponse to a solicitation thatOIT ran earlier this year. Eachproposer is being evaluated ondemonstrated technicalproficiency and core compe-tency in the implementation ofa comprehensive plant-widesystems approach to increaseenergy efficiency and reduceenvironmental emissions.

OIT hopes that the resultsfrom these assessments willencourage other energy-intensive U.S. companies toreplicate this approach toimproving energy efficiency.Hence, OIT will publish andwidely distribute the com-pleted assessments in order tohelp inform industry about the

benefits of using a plant-wide approach toenergy efficiency and how to do this.

Another OIT “plant-wide” assessmentsolicitation is imminent. Proposals will likelybe due in January, 2000. For additionalinformation, go to www.oit.doe.gov/news/solicitations.shtml.

Get back issues of The OIT Timeson the web

Just a reminder that this issue and allback issues of The OIT Times areavailable at www.oit.doe.gov/oittimes.All issues are available in both HTMLand PDF formats for easy viewing,downloading and copying. You canalso sign up to get on The OIT Timesmailing list.

5

In partnership with the North American DieCasting Association, the Team will sponsorDiecasting Showcase ‘99 on November 4 atLester Precision Die Casting, Inc. inTwinsburg, OH (near Cleveland). The event

will demonstrate various energy-efficient diecasting tech-nologies and “best practices” that have been supported byOIT. The Lester plant, which opened in 1992, is astate-of-the-art die casting facility and one of the most highlyautomated such plants in North America.... OIT’s compre-hensive new Energy and Environmental Profile of the U.S.Metalcasting Industry establishes a baseline for assessing theindustry’s future technology advancements and progresstoward energy and environmental goals. For each majormetalcasting process, the report provides a descriptiveoverview, estimates energy requirements by fuel type, andcharacterizes the emissions, effluents, byproducts, andhazardous wastes. Existingtreatment and controltechnologies are alsodiscussed. The 106-page report isavailablethrough OIT’sResourceRoom at 202-586-2090.(Contact:Harvey Wong,202-586-9235)

THE OIT TIMES/FALL 1999

The Industrial Assessment Center programhas started an alumni newsletter for programgraduates. The latest issue featured threealumni who credit the IAC program withhelping them excel in their careers. Phylissa

Miller and Michael Rogers, who joined the program at theUniv. of Tennessee and San Diego State Univ. respectively,now hold management positions at energy consulting firms.The third, Adam Boese, is owner of his own energy consult-ing firm. Says Boese: “The IAC program provided a jump

MetalcastingDiecasting Showcase ‘99coming in November

States Corner

OIT’s States Team, in conjunction with the State Energy

Program Special Projects for Industry effort, recently

awarded FY99 grants totaling $3.5 million to 27 groups

in 26 states (see map on p.8). The grants will enable

states and regional groups to bring together energy-

intensive industries in their areas to benefit from OIT

Best Practices programs and IOF R&D efforts as well as

potentially become involved in national R&D projects.

State grant recipients include: KY where ARCO Alumi-

num is helping to champion the effort; OR which is

starting up a variety of marketing analyses, workshops

and showcases for energy-intensive industries in the

state; and PA which will start four industry-specific

roadmaps (steel, metal casting, mining and glass), and

form alliances to implement R&D action plans of the

state’s agriculture and chemical industries.... The Team

is working with WV’s IOF organization on the latter’s

3rd Annual Symposium later this Fall. The Symposium

brings together representatives from industries through-

out WV to discuss their IOF work and look for addi-

tional opportunities to work cross-industry and boost

competitiveness and energy efficiency in the state.

Several OIT staff and partners are planning to attend.

(Contact: Jim Quinn, 202-586-5725)

start to my career in energy efficiency.” In addition, Boesesees the energy efficiency industry as one offering greatpotential for graduating engineers, noting that “There is agreat need for their clear minds and innovation.” Copies ofthe newsletter are available at oipea-www.rutgers.edu/iac/iac_f.html.... The IAC program held its annual Directors’Meeting in August. Over two dozen IAC Directors fromacross the country attended to discuss a recent assessment ofthe program and hear about numerous current topical areas inOIT. (Contact: Chuck Glaser, 202-586-1298)

6

Quarterly Highlights

The Petroleum Refining Teamrecently met with officials fromthe National Petrochemical andRefiners Assoc. who presentedan overview of the industry, fromthe chemistry and science of therefining process to national

industry statistics.... The Team’s well-receivedreport “Energy and Environmental Profile ofthe U.S. Petroleum Refining Industry” is now

available for down-load in a pdf file atwww.oit.doe.gov/petroleum/....Although theindustry’s Visionand TechnologyRoadmap are stillbeing finalized,petroleumrefiners shouldkeep abreast ofthe long list ofindustry-relevant

technologies being developed with supportfrom other OIT programs. Work of interest tothe Petroleum Refining industry is currentlybeing sponsored by the Chemicals Team, aswell as the Advanced Industrial Materials,CFCC, Distributed Generation, Sensors &Controls, Combustion, and NICE3 pro-grams. (Contact: Gideon Varga, 202-586-0082)

The Mining Team’s firstsolicitation has resulted inten new cost-shared R&Dprojects. The new projectselections were based onrecommendations from the

National Mining Assoc., and address suchareas as improved rock blasting and crushing,modeling of mining processes, ore imagingand analysis technologies, improved under-ground communication, and advanced vehiclesystems. This first batch of new projects are allNational Lab-led enabling the miningindustry to benefit fromexpertise of the DOE labsin such areas as fuel cells,computer modeling,high-temperaturesuperconductors,advanced materials, androbotics. More than 20private firms and 8universities across 21states are partneringwith DOE labs in these projects.... Asecond Mining Team solicitation, invitingproposals directly from industry and universitypartners, closed in August. Awardees will beannounced soon at www.oit.doe.gov/mining....Federal coordination efforts included a visit tothe Army Research Lab in Aberdeen, MD toevaluate military technologies for possible useby the mining industry. (Contact: ToniGrobstein Marechaux, 202-586-8501)

Petroleum RefiningTeam meets withNPRA

MiningFirst solicitation leadsto ten new projects

The Advanced Industrial

Materials (AIM) Program

held its Annual Review

Meeting in CA in June.

Industrial partners who made

presentations included Dow

Chemical, FMC, Stone and

Webster, Greenleaf, National

Refractories, Weyerhaeuser,

BP Amoco, Accutru Interna-

tional, Ford, and Delphi

Automotive Systems. Partici-

pants also visited the Com-

bustion Research Facility at

Sandia National Laboratories

in Livermore, where they

viewed the construction of a

one-third scale glass melting

furnace to be used by the

glass industry for combustion

and melting investigations....

A recent issue of Dateline:

Los Alamos featured an article

on advanced ultracapacitors,

powerful and long-lived

battery-like devices that cut

energy use and emissions

across many industrial

sectors. These devices were

developed with long-term

assistance from the AIM

Program. (Contact: Charlie

Sorrell, 202-586-1514)

The Distributed Generation program launched an 8000-hour demonstration of itsCFCC liners at Malden Mills in MA. Developed with Solar Turbines, the liners willoperate in the textile mill’s gas turbine.... To broaden the scope of its AdvancedTurbine Systems R&D effort, the program is planning several solicitations address-ing reciprocating engines, microturbines and other high efficiency technologies,

possibly starting by late 1999.... The program sponsored a workshop to facilitate an industry-ledadvanced materials technology roadmap for gas turbines. Workshop proceedings are available atwww.oit.doe.gov/cogen/. (Contact: Pat Hoffman, 202-586-6074)

7

THE OIT TIMES/FALL 1999

The Glass Team signed a cooperativeagreement with the Glass ManufacturersIndustry Council, the first organization torepresent the entire multi-faceted glassindustry. GMIC will help facilitate the Team’s

relationship with the industry in line with its strategic visionand roadmap goals. Says Michael Greenman, GMIC ActingExecutive Director, “The agreement formalizes our relation-ship and helps assure this will be a long-term partnership thatwill benefit all sectors of the American glass industry. Thecloser relationship between OIT and GMIC will also make iteasier for the glass industry to benefit from other valuableOIT programs, such as Motor Challenge and NICE 3”.... TheTeam is working with GMIC on its R&D solicitation forFY01, which is scheduled to open this Fall. The solicitationis expected to seek the development of high priority tech-nologies including: advanced sensor technologies andmeasurement techniques; intelligent controls for productionand fabrication processes; improved combustion efficiencyor heat recovery; accurate, validated melter models; identifi-cation of emission mechanisms from glass and raw materi-als; and predictiveemissionmodeling tools,as well as thedevelopmentof innovativeuses of glass.(Contact: TheoJohnson, 202-586-6937)

GlassPartnership with GMICformalized

As part of the Continuous Fiber CeramicComposite (CFCC) program, EngineeredComposites Inc. has been evaluating the use ofthe advanced material for gas circulation fans inheat treating furnaces. Replacement of theincumbent steel fans with lighter CFCC fans is

expected to result in reduced power usage, improved efficiency,greater durability, and reduced maintenance costs. The materialis fabricated using a versatile polymer impregnation andpyrolysis process, and has survived five months of continuousexposure in a 1600˚F carburizing environment. A full-sizedfurnace fan has been fabricated for evaluation by SurfaceCombustion, and a full scale test is planned for later in 1999.(Contact: Debbie Haught, 202-586-2211)

The Combustion Program will soon select newR&D projects from its FY99 solicitation. Thesolicitation targeted needs identified in the combus-tion industry-led vision and roadmap. Selectionswill be based on recommendations from industry

reviewers, and will focus on improving the efficiency andemission performance of integrated boiler systems and integratedprocess heater systems. Selections will be posted atwww.oit.doe.gov/combustion.... Two demonstration projects arecurrently underway. One, a FIR burner operating at a manufac-turing facility in CA, is expected to demonstrate NOx perfor-mance of 9 ppm or less. The other project, focusing on diluteoxygen combustion technology, is operating at Auburn Steel inNY. The technology is expected to significantly reduce NOx andincrease productivity in the 2000˚F+ environment of a steelreheat furnace. Next, Praxair will redesign a furnace to fullyrealize the benefits of dilute oxygen combustion. (Contact:Gideon Varga, 202-586-0082)

The recent Sensors and Controls (S&C)program solicitation–which focused on sensorsand measurement technologies, data processingand transformation, and sensor and controlintegration–expects to announce its new project

selections soon. Awards will be posted at www.oit.doe.gov/sens_cont. Additional S&C topics may be included in theDOE/EE SBIR/STTR FY00 solicitations.... Awards selectedfrom the SBIR FY99 topic area on “Advanced Measurementand Control Technologies for Industrial ManufacturingApplication” are scheduled to be announced soon.... Theprogram is organizing a session on “Sensors and IndustrialProcess Control” for the PittCon 2000 Symposium in NewOrleans March 12-17, 2000. Topics to be addressed includeon-line measurements of physical properties; chemicalcomposition of industrial processes; integrated, intelligentsensing devices such as wireless sensors; and chemistry-laboratory-on-a-chip. Session proceedings will be availablethrough the OIT Resource Room after the event. Visit thePittCon 2000 website (www.pittcon.org) for a full conferenceagenda. (Contact: Eric Lightner, 202-586-8130)

Industrial partners of the Combined Heat& Power (CHP) Challenge program havecompleted a technology vision. To view acopy, go to www.oit.doe.gov/chpchallenge.... This Fall, the program will

be sponsoring workshops to bring together public utilitycommissions, suppliers, end-users and other interested partiesto address the barriers to installing, permitting and siting CHPunits. Workshops will be held in New York on Oct. 6, and inChicago on Nov. 10. An international workshop is planned forFebruary, 2000.... The program recently redesigned its websiteat www.oit.doe.gov/chpchallenge. New features include factsheets, case studies, and meeting schedules. (Contact: PatHoffman, 202-586-6074)

8

Quarterly Highlights

(continued from page 1)

The West Virginia exampleAs the first participant in the effort, Irwin and his WVUcolleagues had their work cut out for them. “We calledseveral meetings, and, frankly, wondered if the conceptwould catch on. But the response was outstanding,” Irwinrecalled. “And once industry people started talking andbrainstorming, things really took off. Most of the industrygroups in West Virginia did not have a history of gettingtogether to discuss R&D needs but this meeting created alot of synergies. Once you sit around a table with eightlocal colleagues saying similar things, it really focuseseveryone’s attention and leads to a strong call for action.”

A seasoned participant in the overall IOF program, Irwinsees the States Team as filling a niche. “I think in someways it’s very natural for people to identify themselves asa member of a state industry as opposed to industryoverall. People are generally enthusiastic about bolsteringtheir own state’s industry and economy,” he said. “For us,the local flavor certainly helped build camaraderie.”

Irwin proudly listed a few of the many successes that theWest Virginia IOF groups have achieved in less than twoyears.

• A WV glass firm won funding from OIT’s GlassTeam for an R&D project of special local interest• Several WV metalcasters have banded together todiscuss innovative uses for spent foundry sand• An intrastate team proposed and won a NICE 3

grant of interest to the steel industry• And many companies, made aware of OITresources by the efforts of the WV-IOF, are takingadvantage of resources available through OIT’sMotor Challenge, Steam Challenge and otherprograms, as well as OIT’s extensive collection ofuseful technical resources such as software,databases and fact sheets.

In addition, OIT is supporting WV’s IOF effort instaging its 3rd Annual Symposium, which bringstogether representatives from all the state’s energy-intensive industries to discuss common opportunities.

“OIT has been very helpful and cooperative,” said Irwin.“Denise, Doug, Jim and the IOF team leaders have beenvery accessible to us.”

“Carl is an excellent example of an ‘industry champion’on the local level, someone who sees the benefits of thenational IOF and can explain first-hand the benefits ofparticipation to local organizations,” observed Kaempf.

Regional variations foster diverse approachesWest Virginia has since been joined by several dozenother states and regions as States Team partners. Forexample, in Kentucky, the Univ. of KY has created theSoutheast Center for Aluminum Technology. The Centersponsored an aluminum industry roadmap workshop thatseveral industry representatives attended. The roadmap,which will help focus dialogue on the regional aluminumindustry’s R&D needs, should be published soon.

“There is no single best approach to implementingIndustries of Future at the state level,” noted StatesTeam Leader Quinn. “The Team is very flexible,dedicated to working with industries and governmentswithin a particular state or region to bring in the rightkind of OIT resources to help them meet our commonenergy-saving and waste- and emission-reduction goals.We invite more states and regions to work with OIT formutual benefit.”

States receivingOIT grants in 1999*

*Complete listing of new state projects, partners available at www.oit.doe.gov/states.

Now Available! OIT StateFact Book for 1999

OIT has just published its 1999State Fact Book which lists all ourpartners–including manufacturers,universities, National labs,suppliers and so on–on a state-by-state basis. The useful report alsoprovides state-level data onemployment, wages and shipmentsfor the nine Industries of theFuture. To get a copy, call OIT’sResource Room at 202-586-2090.

9

Improving steam systems efficiency: The Mobil Corp. experienceIf you’re trying to improve your organization’s steamsystems efficiency, check out a series of steam-relatedcase studies developed for OIT by Mobil Corp. Thecompany is documenting with OIT several steam systemsimprovements. According to OIT Best Practices SteamProgram Manager Fred Hart, “Mobil’s experience canreally benefit other industrial steam users. Mobil takes thekind of systematic approach to plant energy efficiencythat Best Practices promotes.”

Mobil’s approach involves a three-person Energy Man-agement Team that oversees a 140-person network (seefigure below). The network is composed of energy sitespecialists from divisions around the world. One of thekey activities of the network is the coordination of on-siteenergy surveys. Members of the network ask the EnergyManagement Team to perform energy surveys in theirplants. These surveys identify potential cost reductions inenergy intensive areas including steam, compressed air,cooling systems, HVAC, lighting and motors. The resultsof each survey are written up, reviewed and approved bythe site and then sent to the entire network. After receiv-ing the survey report, the site that was surveyed imple-ments the changes. So far, 39 surveys have been per-formed. Since 1994, network facilities have realized over

THE OIT TIMES/FALL 1999

Results

Surveys

Network

Energy ManagementTeam Management

Economic

Environmental

Best Practices

TechnologyTransfer

Implementation JointlyOwned by Site and EM Team

Generate

Sponsors

• Promote

• Encourage

• FacilitateMonitorsImplementation

Reports to Management Awards and Recognition

Mobil’s EnergyManagement Process

$103 million of savings through energy initiatives—a realsuccess story for Mobil.

One member of Mobil’s Energy Management Team, FredSchoeneborn, describes the company’s initiative as “keyto Mobil’s energy management efforts.” According toSchoeneborn, “The Energy Management Team consists ofindividuals who ‘own’ energy consumption in Mobilplants around the world. That’s why their voluntaryparticipation is so important. Their dedication to theprogram has been an important factor in our success.” Headds that Mobil’s recognition of staff contributions alsoplays a part in the program’s success. Mobil’s Excellencein Energy Efficiency Award recognizes staff that contrib-ute to a 5% reduction in energy consumption or $1million in savings in a year at their sites.

Copies of OIT’s Mobil steam system efficiency casestudies will be available soon from OIT’s Resource Roomat (202) 586-2090. Case study topics include improvedprocess heating, reducing losses in steam distribution, andcombined heat & power. For more information on OIT’sBest Practices steam program, contact Fred Hart at (202)586-1496 or visit www.oit.doe.gov/steam.

IEA Annex Meeting on Cogeneration, Sep 27-28,San Diego, CA

AISE’s Iron and Steel Show, Sep 27-30, Cleveland,OH

Association of Small Business Development CentersFall Conference, Oct 2-5, San Diego, CA

CHP Meeting, Oct 6, NY, exact location TBD

National Mining Assoc.’s Convention ‘99, Oct 10-13,St. Louis, MO

Copper ‘99, Oct 10-13, Phoenix, AZ

Glass Problems Conference, Oct 18-20, Champaign-Urbana, IL

Alaska Complete Facilities Management Trade Show& Conference, Oct 28-29, Anchorage, AK

ASM Materials Conference, Nov 1-4, Cincinnati, OH

National Assoc. of Management and TechnicalAssistance Centers Fall Conference, Nov 7-9, Seattle,WA

National Assoc. of State Universities, Commission onFood, Environment, and Renewable Resources, Nov.8-9, San Francisco, CA

ATS Annual Program Review, Nov 8-10, Pittsburgh,PA

ACerS Refractory Ceramics Division Joint Meeting,Nov 14-16, Pittsburgh, PA

West Virginia Industries of the Future Symposium,Nov 18, Flatwoods, WV

** Numerous OIT “best practice” motor, pump, andwater workshops are planned; visit www.oit.doe.gov/news/calendar for dates and locations.

10

Information Corner

Calendar**

Coming Soon

The 2000 edition of OIT’s Information ResourcesCatalog will be available Fall, 1999. OIT custom-ers will find useful information on more than 400OIT-sponsored products that can help increaseindustrial energy efficiency and productivity, andreduce pollution and waste. Products includetechnical reports, brochures, databases, videos andsoftware among numerous other useful items.

The catalog and most OIT products described in itare available at no cost. To sign up for a copy of thecatalog, contact OIT’s Resource Room at (202)586-2090.

New study shows DOE Labs contributionsto industrial technology development

According to a report by the Laboratory Coordinating Council (LCC),DOE’s National Labs have made significant contributions to the develop-ment of OIT-sponsored technologies. The LCC’s study looked at technolo-gies identified in a January, 1999, OIT report, Impacts, which describessome of the benefits OIT investments have had on the U.S. economy andenvironment (see p. 1 of the Summer, 1999 issue of The OIT Times).

The results indicate that 14 of the 34 (over 40%) commercially-availabletechnologies involved one or more national laboratories at some stage inthe technology development cycle. In all, the 14 projects involved sevendifferent laboratories. The laboratories were primarily involved withprojects related to the aluminum, chemicals, steel and crosscutting sectors.

The results also indicate that 31 of 60 (52%) emerging technologiesinvolved one or more national laboratories at some stage in the technologydevelopment cycle. Nine differentlaboratories were involved with develop-ment of emerging technologies. Thelaboratories heavily contributed to projectsin the petroleum, aluminum, chemicals,metalcasting, steel, forest products, andcrosscutting sectors.

For a copy of the report, titled NationalLaboratory Technology ContributionsImpact the Economy and Environment,call Steve Weiner, Chair of the LCC, at202-646-7870 or visit the LCC’s websiteat www.oit.doe.gov/LCC/.

Call 202-586-2090 to order copies.

NEW PUBLICATIONS

Project Summaries and SignificantAccomplishments, FY 1998

Advanced IndustrialMaterials

AreaTitle

Advanced IndustrialMaterials

Combustion

Combustion

Glass

I&I

Aluminum

Metalcasting

Annual Progress Report, FY 1998

Energy & Environmental Profile of the U.S.Metalcasting Industry

Report of Technical Working Group on InertAnode Technologies

From Invention to Innovation, 1999

Oxyfuel II Workshop Proceedings

Combustion Industry Roadmap

Combustion Industry Vision

PNNL’s Steve Weiner,Chair of the LCC

Unlocking the Savings inSteam System Efficiency

by Fred HartOIT Steam “Best Practices” ProgramManager

Because steam production and use annuallyaccount for over 7 quadrillion Btu’s and 30%of carbon emissions in U.S. Industry, bettermanagement of a plant’s total steam systemcan unlock substantial savings. We believethat investment in improved steam efficiencycombined with other energy efficiency bestpractices can reduce plant energy use by 10%to 30%.

To help industry and the nation realize suchsavings, we have formed a Steering Commit-tee that is fully committed to designing andcarrying out the steam initiative. TheAlliance to Save Energy is partnering withOIT to facilitate the many activities of theCommittee. Steam users, steam systemequipment suppliers, steam-related tradeassociations, and state energy organizationsare also represented on the Committee whichis guiding the program’s activities andproducts.

Highlights of the Steering Committee’saccomplishments include:

• an energy efficiency handbook developedby the Council of Industrial BoilerOwners,

• insulation software developed by the Na-tional Association of Insulation Manufac-turers,

• an active website,• a listing of steam system-related specifi-

cations and guidelines, and• a listing of training resources.

In progress are steam system best practices,training guidelines, and case studies. Formore information visit our web site atwww.oit.doe.gov/steam or call the OITClearinghouse at 1-800-862-2086.

GUESTEDITORIAL

Industry Trends

11

THE OIT TIMES/FALL 1999

Doug Faulknerphoto

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....and doubling its contribution to GDP growth

President’s Bioenergy Initiative launched; OIT’s Ag and Forest Productsteams participate

Office of Industrial Technologies, EE-20Energy Efficiency and Renewable EnergyU.S. Department of EnergyWashington, DC 20585www.oit.doe.gov

Deputy Assistant Secretary forIndustrial Technologies,Denise Swink

Managing Editor,Lou Sousa

Assistant Editor,Jill Fisher

ReporterGregg Siegel

Industry Trends,Keith Jamison

Designer,Allen Austin

Content reprintable without permission.Correspondence, including requests foradditional copies, or to be added to ordeleted from the mailing list, may bedirected to:

Lou SousaFax: (202) 586-9234E-mail: lou.sousa@ee.doe.gov

THE OIT T IMES“Turning Industry Visions into Reality”

THE OIT TIMES/FALL 1999

President Clinton recently signed a new Executive Orderthat promotes use of crops, trees and wastes to maketransportation fuels, electricity, chemicals and otherindustrial products. He set a goal of tripling the use ofbioenergy and bioproducts by 2010. The Order alsodirects the formation of several new organizations, led bythe Secretaries of Energy and Agriculture, to focus federalefforts in developing 21st century, biobased technologiesthat can help the economy, enhance U.S. energy security,and meet environmental challenges like global warming.

Notables attending the event included Senator RichardLugar (R-IN), author of “The National Sustainable Fuelsand Chemicals Act,” Dr. Bruce Dale, from Michigan StateUniv., who helped to lead the National Research Council’srecent report Biobased Industrial Products: Priorities forResearch and Commercialization, and Amal Mansour fromManufacturing and Technology Conversion Internationalwho is developing a steam reforming technology togenerate energy from biomass.

DOE Secretary Bill Richardson announced the award ofmore than $13 million in financial assistance to promote thegrowth of the biomass industry and support the President’sExecutive Order. Many of these new R&D projects comefrom OIT’s Forest Products and Agriculture Teams’ recentsolicitations.

DOE Assistant Secretary Dan W. Reicher’s BioEnergyInitiative, started last fall, also directly supports thePresident’s action. The BioEnergy Initiative has broughttogether public and private sector leaders to begin integrat-ing and building this new industry. As part of that effort, astrategic vision is almost complete and discussions areunderway about developing technology roadmaps. OIT andother offices under Reicher have been working as a team onthat vision and are helping to plan implementation of theExecutive Order.