Steam systems are a part of almost every major industrial process today. Thirty-seven percent of the fossil fuel burned in US industry is burned to produce steam. In this paper we will establish baseline energy consumption for steam systems. Based on a detailed analysis of boiler energy use we estimate current energy use in boilers in U.S. industry at 6.1 Quads (6.4 EJ), emitting almost 66 MtC in CO2 emissions. We will discuss fuels used and boiler size distribution. We also describe potential savings measures, and estimate the economic energy savings potential in U.S. industry (i.e. having payback period of 3 years or less). We estimate the nationwide economic potential, based on the evaluation of 16 individual measures in steam generation and distribution. The analysis excludes the efficient use of steam and increased heat recovery. Based on the analysis we estimate the economic potential at 18-20 percent of total boiler energy use, resulting in energy savings approximately 1120-1190 TBtu (1180-1260 PJ). This results in a reduction of CO2 emissions equivalent to 12-13 MtC.

The U.S. chemical industry is the largest in the world, and responsible for about 11 percent of the U.S. industrial production measured as value added. It consumes approximately 20 percent of total industrial energy consumption in the U.S. (1994), and contributes in similar proportions to U.S. greenhouse gas emissions. Surprisingly, there is not much information on energy use and energy intensity in the chemical industry available in the public domain. This report provides detailed information on energy use and energy intensity for the major groups of energy-intensive chemical products. Ethylene production is the major product in terms of production volume of the petrochemical industry. The petrochemical industry (SIC 2869) produces a wide variety of products. However, most energy is used for a small number of intermediate compounds, of which ethylene is the most important one. Based on a detailed assessment we estimate fuel use for ethylene manufacture at 520 PJ (LHV), excluding feedstock use. Energy intensity is estimated at 26 GJ/tonne ethylene (LHV), excluding feedstocks.The nitrogenous fertilizer production is a very energy intensive industry, producing a variety of fertilizers and other nitrogen-compounds. Ammonia is the most important intermediate chemical compound, used as basis for almost all products. Fuel use is estimated at 268 PJ (excluding feedstocks) while 368 PJ natural gas is used as feedstock. Electricity consumption is estimated at 14 PJ. We estimate the energy intensity of ammonia manufacture at 39.3 GJ/tonne (including feedstocks, HHV) and 140 kWh/tonne, resulting in a specific primary energy consumption of 40.9 GJ/tonne (HHV), equivalent to 37.1 GJ/tonne (LHV). Excluding natural gas use for feedstocks the primary energy consumption is estimated at 16.7 GJ/tonne (LHV). The third most important product from an energy perspective is the production of chlorine and caustic soda. Chlorine is produced through electrolysis of a salt-solution. Chlorine production is the main electricity consuming process in the chemical industry, next to oxygen and nitrogen production. We estimate final electricity use at 173 PJ (48 TWh) and fuel use of 38 PJ. Total primary energy consumption is estimated at 526 PJ (including credits for hydrogen export). The energy intensity is estimated at an electricity consumption of 4380 kWh/tonne chlorine and fuel consumption of 3.45 GJ/tonne chlorine, where all energy use is allocated to chlorine production. Assuming an average power generation efficiency of 33 percent the primary energy consumption is estimated at 47.8 GJ/tonne chlorine (allocating all energy use to chlorine).

This paper analyzes the energy efficiency and carbon dioxide emissions reductions potential of the U.S. pulp and paper industry, one of the largest energy users in the U.S. manufacturing sector. We examined over 45 commercially available state-of-the-art technologies and measures. The measures were characterized, and then ordered on the basis of cost-effectiveness. The report indicates that there still exists significant potential for energy savings and carbon dioxide emissions reduction in this industry. The cost-effective potential for energy efficiency improvement is defined as having a simple pay-back period of three years or less. Not including increased recycling the study identifies a cost-effective savings potential of 16 percent of the primary energy use in 1994. Including increased recycling leads to a higher potential for energy savings, i.e. a range of cost-effective savings between 16 percent and 24 percent of primary energy use. Future work is needed to further elaborate on key energy efficiency measures identified in the report including barriers and opportunities for increased recycling of waste paper.