MATERIALS PRODUCTION INDUSTRY

The purpose of this project is to help the materials production industries have access to new, low-cost energy and energy efficient processes. Materials production industries (steel, aluminum, foundries, glass and cement) represent the largest sector of power demand in the industrial market. These markets, important to California's future, need to have access to low-cost energy and energy efficient processes to help lower energy-related manufacturing costs and to keep these plants in California. EPRI provides access to new or existing technologies to reduce energy use and energy bills, improve productivity, lower product cost, and improve product quality. Limited resources are available to help individual plants, particularly for evaluating new electrotechnologies. The Commission can use EPRI's resources as a source of information, data, technical expertise, and tools to help California industry thrive.

This project supports the PIER Program objectives of:
• Improving the energy cost/value of California's electricity through technologies that reduce raw material waste, reduce total energy use, increase product output per unit of energy needed, and reduce the total cost of business operations; and
• Improving the environmental and public health costs/risks of California's electricity by applying technologies that reduce combustion processes, thereby lowering overall combustion emissions and reducing California's contribution to global climate change.

Proposed Outcomes:
1. Conduct research to support application of new and existing energy efficient technologies for California's materials production facilities.
2. Provide information and communication tools to increase the potential application of energy efficiency technologies in California's materials production facilities.

Actual Outcomes:
1. Research to support application of new and existing technologies.
• A comparison was conducted of all-electric versus oxy-fuel glass melting to identify the benefits and concerns of conversion to electric glass melting. Findings were published in a report.
• An investigation was undertaken to identify new market niches for a microwave technology developed to separate water-oil emulsions from the metal particulates in steel mill sludge. Findings, published in a report, will assist industries in recycling metalworking fluid and improving waste management practices.
• A software model was developed to compare the costs of electric induction heating versus traditional gas-fired heating systems in the aluminum and steel industries.
• A software model was developed for analyzing electronic arc furnace dust recycling.
• An analysis was conducted and reported on the effect of melting furnace type on the cutting machinability of gray iron.
2. Communication tools.
• A report was produced on power quality problems associated with induction furnaces.
• Information was published on the cost and environmental advantages of electrically powered conveyor systems versus diesel-powered haul trucks for material handling in mining operations.
• Industry segment profiles were published on the powder metal parts and products industry and the fiber-based composite materials industry. Profiles reviewed the industries' characteristics, energy usage, production statistics, and market structure.
• Information was provided on indoor air quality (IAQ) issues for foundries to assist the CEC in better understanding the rules and regulations associated with foundry IAQ.
• Information and guidelines were published on the costs, energy efficiency, emissions, and production advantages of nonferrous metal melting electrotechnology.
• A monthly newsletter was published covering technology developments, applications, and trends in the aluminum industry.
• A monthly newsletter was published updating developments in the steel industry.
• A monthly newsletter was published providing updates and news of EPRI projects related to materials production industries.

Project Status: The Commission's participation in this target ended as of December 31, 2000.