Energy and Utilities


Energy and Utilities Workshop - Roadmap to the Energy Efficient, Sustainable and Decarbonized Steel Industry

14–17 March 2022Oak Ridge National Laboratory and Embassy Suites by Hilton Knoxville West • Oak Ridge, TN, USA

►Download Schedule (PDF)

Monday, 14 March 2022

2–4 p.m.

Registration

4 p.m.

Introductions and Opening Remarks
Larry Fabina, Cleveland-Cliffs Burns Harbor, and Xin Sun, Oak Ridge National Laboratory

4:30 p.m.

Industrial Energy Management — Better Plants and ENERGY STAR Resources and Tools
John O’Neill, U.S. Department of Energy (DOE), and Elizabeth Dutrow, U.S. Environmental Protection Agency (EPA)
This presentation showcases the DOE's tools and resources, and the Better Plants program. A decarbonized steel industry will require a variety of approaches. Energy efficiency is a key action. ENERGY STAR tools and resources can assist steel producers to advance energy efficiency and enhance savings

5:30–6:30 p.m.

Welcome Reception 

Tuesday, 15 March 2022

7:45 a.m.

Bus Departs for Oak Ridge National Laboratory 

8:15 a.m.

Registration at Oak Ridge National Laboratory 

8:45 a.m.

Introductions and Opening Remarks

9 a.m.  

Energy Management Systems, Industrial Energy Efficiency Standards ISO 50001 and DOE’s 50001 Ready Navigator Tool
Thomas Wenning, Oak Ridge National Laboratory

9:45 a.m.

The MEASUR Tools Suite — DOE’s Manufacturing Energy Assessment Software for Utility Reduction
Kristina Armstrong, Oak Ridge National Laboratory
The MEASUR tool suite helps to evaluate the current energy use and potential energy savings opportunities of industrial energy systems based on field measured data. MEASUR includes modules for pumps, fans, process heating, steam, compressed air, motors and energy treasure hunts. There are also more than 65 stand-alone calculators. The tool is open-source, free to download and available online.

10:30 a.m.

Break

10:45 a.m.

Industrial Steam Systems
Thomas Wenning, Oak Ridge National Laboratory

11:30 a.m.

Working Lunch and Understanding Electricity and Natural Gas Bills
Senthil Kumar Sundaramoorthy and Christopher Price, Oak Ridge National Laboratory
The topic will help audience to understand the various charges of their natural gas bills. In addition, strategies to save on utility costs will also be presented, as well as an overview of the fundamentals of utility billing. For the electricity portion, the presentation will focus on common billing topics including demand charges, power factor correction and rate structures.

12:30 p.m.

Industrial Process Heating – Energy Efficiency Opportunities and DOE’s Process Heating Assessment Tools
Sachin Nimbalkar, Oak Ridge National Laboratory and Bethany Worl, Cleveland-Cliff Burns Harbor
Process heating accounts for about 70% of all process energy (energy applied to convert material into manufactured products) used in the U.S. manufacturing sector. During this session, the audience will learn practical tips on process heating maintenance, how to improve the energy efficiency of furnaces and how to use DOE’s MEASUR tool (Process Heating Assessment module). MEASUR helps survey furnaces and heaters, identify major energy-using equipment, prioritize improvement opportunities, and assess available methods to improve thermal efficiency in industrial plants.

1:15 p.m.

Lighting Energy Savings and Challenges Within the Iron and Steel Industry
Larry Fabina, Cleveland-Cliffs Burns Harbor
Lighting systems are one of the major energy end users for manufacturing facilities. This session covers various lighting technologies (CFL, HID, LED, etc.), lighting system control strategies (occupancy censors, light level sensors, etc.) and energy savings opportunities. In particular, it will include discussion on installing LED fixtures in challenging steel mill environments to save energy, reduce maintenance and improve safety. Examples of completed lighting projects will be presented

1:30 p.m.

Smart Manufacturing and Internet of Things for the Iron and Steel Industry
Christopher Price, Oak Ridge National Laboratory and Chenn Zhou, CIVS, Purdue University Northwest
U.S. manufacturing is beginning its digital transformation as part of the fourth industrial revolution. Connected devices and the industrial internet of things are allowing new sensors and controls technologies to make manufacturing smarter and more energy efficient. These technologies can be used to create cutting-edge physics-based and data-driven tools for real-time decision making to address critical issues related to energy efficiency, carbon-footprint and other pollutant emissions, productivity, quality, operation efficiency, maintenance, and more. This presentation gives an overview of smart manufacturing opportunities in the iron and steel sector and presents results from case studies analyzing the feasibility of smart projects from an energy standpoint.

2:30 p.m.    

Break

2:45 p.m.

Motors and Motor-Driven Systems — DOE’s Software Tools for Estimating Energy Efficiency
Daryl Cox, Oak Ridge National Laboratory
This presentation will cover energy optimization considerations and how to apply the MEASUR software tool to quantify potential savings associated with implementing energy saving opportunities.

3:30 p.m.

Compressed Air Systems — DOE’s MEASUR Software
Alex Botts, Oak Ridge National Laboratory, and Wendy DiMino, Universal Compressed Air
The presentation will give an overview of compressed air systems and the key components that drive their energy usage. In addition to a topical overview, the common energy efficiency opportunities implemented will be discussed. Finally, a brief demonstration of DOE resources will be given to show how to analyze compressed air systems and estimate possible savings

4:15 p.m.

Energy System Demonstrations
Alex Botts, Kiran Thirumaran and Thomas Wenning, Oak Ridge National Laboratory
The session will review the principle and demonstrate via tabletop units the workings of auxiliary energy systems in the iron and steel industry, compressed air, pump and fan systems, and steam system. Common energy efficiency opportunities associated with these systems will also be discussed

5 p.m.

Depart From Oak Ridge National Laboratory

Wednesday, 16 March 2022

7:45 a.m.

Bus Departs for Oak Ridge National Laboratory           

8 a.m.

Developing Road Maps for Sustainability and Decarbonization
Sachin Nimbalkar and Thomas Wenning, Oak Ridge National Laboratory
This session will provide an overview on decarbonization technology pillars such as electrification, low-carbon electricity and fuels, and carbon capture utilization and storage.

9 a.m.

Decarbonizing the Steel Industry – Approaches, Technologies and Economics
Abhijit Sarar, Dastur and Larry Fabina, Cleveland Cliffs-Burns Harbor
With 1.86 tons of CO2 emitted for every ton of steel produced in 2020, decarbonizing industrial activity and specifically the steel industry, which accounts for 7–9% of the global greenhouse gas emissions (according to the World Steel Association), is a priority for steelmakers, governments and the informed public. This presentation will survey the approaches taken and how they compare in terms of abatement, implementation cost and time, and operating impact. Discussion will focus on capture technologies, the role of hydrogen as a clean reductant and carbon disposition alternatives available to steelmakers. 

9:45 a.m.

Electrification Opportunities in the Iron and Steel Industry and the Demand for Low-Carbon Electricity
Kiran Thirumaran, Oak Ridge National Laboratory
The session will discuss opportunities to electrify existing fuel-fired thermal systems in the iron and steel industry. The advantages, barriers and state of adoption will be explored with examples.

10:30 a.m.

Break

10:45 a.m.

Use of Hydrogen in Steelmaking
Anup Sane, Air Products
This presentation will discuss the use of hydrogen in steelmaking for decarbonization.

11:30 a.m.

A Bio-Gas CCUS Option for Steelmakers
Tom Dower, LanzaTech
Discussion of industry-leading microbial gas fermentation, providing an innovative, commercial-scale carbon reduction option for iron- and steelmaking. This biology-based carbon capture and utilization technology can put emissions to productive and efficient use, creating sustainable fuels, chemicals and products in the circular economy

Noon

Working Lunch

1 p.m.

Energy Efficiency Primer on Water/Wastewater Treatment Operations
Kiran Thirumaran, Oak Ridge National Laboratory
The session will review energy efficiency opportunities associated with wastewater treatment in the iron and steel industry. Common treatment processes and suitable technologies will be discussed with examples.

2 p.m.

Alternative Reductants for the Ironmaking Process
Mitren Sukhram, Hatch
This presentation will discuss the use of alternative reductants for ironmaking processes.

2:30 p.m.

Break

2:45 p.m.

Introduction to the Molten Oxide Electrolysis (MOE) Technology for GHG-Free Production of Iron and Steel
Stephan Broek, Boston Metal
Electrification is a key tool to decarbonize production processes, including iron- and steelmaking. Presented is an MIT discovery that is currently being commercialized to employ an electrolysis process to produce iron from iron ore in one step using only electricity. Combining this with inert anodes made from high-temperature alloys, a breakthrough technology is created that not only eliminates Scope 1 GHG emissions, but also eliminates Scope 2 emissions if renewable electricity is used. The result is a truly GHG-free iron product. The presentation discusses the principles of the process, its flexibility regarding iron ore grades, the quality of the iron product, and ways the technology platform can be deployed by companies to help decarbonize the iron and steel industry.

3:15 p.m.

Roundtable Decarbonization Discussion
Producer panel discussion will dive into the decarbonization movement.

  • Ms. Traci Forrester, Cleveland-Cliffs Inc.

  • Mr. David Miracle, Nucor Corporation

  • Mr. Craig A. Blue, Ph.D, Fellow SME & ASM, Oak Ridge National Laboratory

5 p.m.  

Depart Oak Ridge National Laboratory

Thursday, 17 March 2022

7:30 a.m.

Bus Departs for Oak Ridge Manufacturing Demonstration Facility

8:15 a.m.

 Tour of Oak Ridge Manufacturing Demonstration Facility

9 a.m.

Transfer to Main Oak Ridge National Laboratory Campus

9:30 a.m.

Tour of Manhattan Project Nuclear Reactor Museum  

10 a.m.

Bus Transfer to Supercomputer Overlook

10:15 a.m.

Tour of Supercomputers

10:45 a.m.

Break

11 a.m.

Transfer to Oak Ridge Advanced Material Characterization Facility and Tour Spallation Neutron Source Facility
Research into new material properties using a neutron source accelerator.

12:15 p.m.

Return to Hotel

12:30 p.m.

Conference Adjourn