Energy Efficiency in Illinois, Indiana, Michigan, Ohio, and Wisconsin's Industrial Fan Systems

East North Central fan sys EE cost curve-Final.png
East North Central fan sys EE cost curve-Final.png

Energy Efficiency in Illinois, Indiana, Michigan, Ohio, and Wisconsin's Industrial Fan Systems

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This report analyzes energy efficiency and GHG reduction potentials and their cost-effectiveness in industrial fan systems in Illinois, Indiana, Michigan, Ohio, and Wisconsin, separately.

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Pages: 73    |     Figures: 31    |       Tables: 23

File format: PDF

Publication date: September 2017

Research Director: Ali Hasanbeigi, Ph.D.

Global Efficiency Intelligence, LLC.

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Industrial electric motors account for over 70% of electricity consumption in manufacturing in the U.S. Motors are used to drive pumps, fans, compressed air systems, material handling, processing systems and more. Industrial motor systems represent a largely untapped cost-effective source for energy savings that could be realized with existing commercialized technologies. Fan systems are widely used throughout manufacturing industries. In many industrial facilities, fans are among the highest electricity consuming equipment. Inefficiencies in fan systems are common.

One of the major barriers to effective policy making and increased action by states and utilities to improve energy efficiency in industrial fan systems is the lack of information and data on the magnitude and cost-effectiveness of the energy savings potential in industrial fan systems in each state. This lack of information creates an obstacle to developing a comprehensive and effective strategy, roadmap, and programs for improving fan systems efficiency cost-effectively. It is far easier to quantify the incremental energy savings of substituting an energy-efficient motor for a standard motor than it is to quantify the energy conservation of applying other energy efficiency and system optimization practices to an existing fan system. 

Global Efficiency Intelligence, LLC. conducted a large initiative to study industrial motor systems in 30 states from different U.S. regions. This includes the top 20 U.S. states in terms of industrial energy consumption. We focused on industrial pumps, fans, and compressed-air systems which together account for over 70% of electricity use in U.S. industrial motor systems.

This report by Global Efficiency Intelligence, LLC. focuses on analyzing energy use, energy efficiency, and CO2 emissions-reduction potential in industrial fan systems in selected East North Central U.S. states of Illinois, Indiana, Michigan, Ohio, and Wisconsin. We have also published similar reports for industrial pump systems and compressed air systems for these states.

Now that states have different programs to set targets, including passing legislation to enact formal energy efficiency resource standards, setting long-term energy savings targets through utility commissions tailored to each utility, or incorporating energy efficiency as an eligible resource in renewable portfolio standards (RPS), investment in energy efficiency in industrial fan systems to tap into the huge saving potentials quantified in this report can help utilities to meet their targets, reduce their greenhouse gas emissions, and thereby help with climate change mitigation.

In addition, energy efficiency in industrial motor systems stimulates economic growth and creates jobs in a variety of ways (direct, indirect, and induced jobs creation). Investment in energy efficiency creates more jobs per dollar invested than traditional energy supply investments. Energy efficiency in industrial motor systems also creates more jobs in the local economy, whereas energy supply jobs and investment dollars often flow outside the state.

Key analyses and results included:

  • Electricity use by manufacturing subsector (NAICS code 31-33) in each state studied
  • Electricity use for motor systems and fan systems by manufacturing subsector (NAICS code 31-33) in each state studied
  • Electricity use by industrial fan systems by size in each state studied
  • Market barriers to energy efficiency in industrial motor and fan systems
  • Energy Efficiency Cost Curves for industrial fan systems for each state using eight major energy efficiency measures
  • Energy saving potential and cost of conserved energy (US$/MWh-saved) for each efficiency measures in each state studied
  • The cost-effective and total technical energy efficiency potential in industrial fan systems in each state studied
  • Energy saving potential for each energy efficiency measure by system size
  • GHG emissions reduction potential for each efficiency measure in each state
  • Sensitivity of the results with respect to changes in electricity prices and discount rates
  • Implications for markets, utilities, and policy makers

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Who should read this report?

  • Utilities
  • Government energy and environmental agencies
  • State regulators and policy makers
  • Energy Service Companies (ESCOs)
  • Demand Response (DR) service and technology providers
  • Energy management service and technology providers
  • Motor, fans, and fan systems service and technology providers
  • Energy efficiency equipment vendors
  • Climate and environmental NGOs and think tanks
  • Investor community

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Table of Contents

Executive Summary  

1. Introduction

2. Market Barriers to Energy Efficiency in Motor and Fan Systems     

3. Energy Use in Industrial Motor and Fan Systems in each State, by Manufacturing Subsector       

3.1. Industrial Electricity Use in each State by Manufacturing Subsector    

3.2. Industrial Motor Systems Electricity Use in each State by Manufacturing Subsectors 

3.3. Electricity Use in Industrial Fan Systems in each State by Manufacturing Subsectors    

3.4. Electricity Use in Fan Systems in each State by System Size  

4. Energy Efficiency Potential and Cost in Industrial Fan Systems in each State        

4.1. Energy-Efficiency Cost Curve for Industrial Fan Systems in Illinois       

4.2. Energy-Efficiency Cost Curve for Industrial Fan Systems in Indiana    

4.3. Energy-Efficiency Cost Curve for Industrial Fan Systems in Michigan     

4.4. Energy-Efficiency Cost Curve for Industrial Fan Systems in Ohio

4.5. Energy-Efficiency Cost Curve for Industrial Fan Systems in Wisconsin

4.6. Sensitivity Analyses        

5. Summary and Implications for Markets, Utilities, and Policy Makers       

5.1. Summary

5.2. Implications for Markets, Utilities, and Policy Makers    

Appendices    

Appendix 1. List of acronyms

Appendix 2. List of Figures and Tables         

Appendix 3. Methodology and Scope of the Study    

Appendix 4. Bibliography and References    

Appendix 5. Related Reports from Global Efficiency Intelligence, LLC.        

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List of Figures

Figure 1. Global total final electricity use by end use in 2014

Figure 2. Electric motor systems energy use profile

Figure 3. Final electricity consumption in motor-driven systems in the IEA’s New Policies and 450 Scenarios      

Figure 4. Illustration of two industrial electric motor-driven systems: (a) normal and (b) efficient   

Figure 5. A typical fan system           

Figure 6. Industrial electricity use by manufacturing subsector (NAICS code 31-33) in Illinois in 2015      

Figure 7. Industrial electricity use by manufacturing subsector (NAICS code 31-33) in Indiana in 2015    

Figure 8. Industrial electricity use by manufacturing subsectors (NAICS code 31-33) in Michigan in 2015

Figure 9. Industrial electricity use by manufacturing subsector (NAICS code 31-33) in Ohio in 2015        

Figure 10. Industrial electricity use by manufacturing subsector (NAICS 31-33) in Wisconsin in 2015      

Figure 11. Share of motor systems from total electricity use in manufacturing in Illinois, Indiana, Michigan, Ohio, and Wisconsin in 2015

Figure 12. Estimated industrial fan systems electricity use by manufacturing subsectors (NAICS code 31-33) In Illinois in 2015

Figure 13. Estimated industrial fan systems electricity use by manufacturing subsectors (NAICS code 31-33) In Indiana in 2015          

Figure 14. Estimated industrial fan systems electricity use by manufacturing subsectors (NAICS code 31-33) In Michigan in 2015        

Figure 15. Estimated industrial fan systems electricity use by manufacturing subsectors (NAICS code 31-33) In Ohio in 2015  

Figure 16. Estimated industrial fan systems electricity use by manufacturing subsectors (NAICS code 31-33) In Wisconsin in 2015     

Figure 17. Estimated industrial fan systems electricity use by system size in Illinois in 2015         

Figure 18. Estimated industrial fan systems electricity use by system size in Indiana in 2015       

Figure 19. Estimated industrial fan systems electricity use by system size in Michigan in 2015     

Figure 20. Estimated industrial fan systems electricity use by system size in Ohio in 2015

Figure 21. Estimated industrial fan systems electricity use by system size in Wisconsin in 2015  

Figure 22. Energy Efficiency Cost Curve for industrial fan systems in Illinois          

Figure 23. Comparison of energy saving potential (GWh/yr) for each efficiency measure in Illinois when each measure is implemented in isolation or is implemented along with other measures           

Figure 24. Energy Efficiency Cost Curve for industrial fan systems in Indiana        

Figure 25. Comparison of energy saving potential (GWh/yr) for each efficiency measure in Indiana when each measure is implemented in isolation or is implemented along with other measures           

Figure 26. Energy Efficiency Cost Curve for industrial fan systems in Michigan     

Figure 27. Comparison of energy saving potential (GWh/yr) for each efficiency measure in Michigan when each measure is implemented in isolation or is implemented along with other measures         

Figure 28. Energy Efficiency Cost Curve for industrial fan systems in Ohio

Figure 29. Comparison of energy saving potential (GWh/yr) for each efficiency measure in Ohio when each measure is implemented in isolation or is implemented along with other measures   

Figure 30. Energy Efficiency Cost Curve for industrial fan systems in Wisconsin   

Figure 31. Comparison of energy saving potential (GWh/yr) for each efficiency measure in Wisconsin when each measure is implemented in isolation or is implemented along with other measures                  

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List of Tables

Table 1. Industrial fan system electricity-savings potential in five East North Central U.S. states in 2015  

Table 2. Share of motor systems and fan systems electricity use in each U.S. manufacturing subsector 

Table 3. Industrial motor systems electricity use by manufacturing subsectors (NAICS code 31-33) for each state studied in 2015       

Table 4. Share of fan systems from total electricity use in manufacturing and from industrial motor systems electricity use in each state in 2015           

Table 5. Cumulative annual electricity saving and CO2 emission reduction potential for efficiency measures in industrial fan systems in Illinois ranked by final CCE   

Table 6. Total annual cost-effective and technical energy saving and CO2 emissions reduction potential in industrial fan systems in Illinois      

Table 7. Cumulative annual electricity saving potential for efficiency measures in industrial fan systems in Illinois by system size (GWh/yr)      

Table 8. Cumulative annual electricity saving and CO2 emission reduction potential for efficiency measures in industrial fan systems in Indiana ranked by final CCE    31

Table 9. Total annual cost-effective and technical energy saving and CO2 emissions reduction potential in industrial fan systems in Indiana    

Table 10. Cumulative annual electricity saving potential for efficiency measures in industrial fan systems in Indiana by system size (GWh/yr)  

Table 11. Cumulative annual electricity saving and CO2 emission reduction potential for efficiency measures in industrial fan systems in Michigan ranked by their final CCE       

Table 12. Total annual cost-effective and technical energy saving and CO2 emissions reduction potential in industrial fan systems in Michigan

Table 13. Cumulative annual electricity saving potential for efficiency measures in industrial fan systems in Michigan by system size (GWh/yr)           

Table 14. Cumulative annual electricity saving and CO2 emission reduction potential for efficiency measures in industrial fan systems in Ohio ranked by their final CCE       

Table 15. Total annual cost-effective and technical energy saving and CO2 emissions reduction potential in industrial fan systems in Ohio      

Table 16. Cumulative annual electricity saving potential for efficiency measures in industrial fan systems in Ohio by system size (GWh/yr)      

Table 17. Cumulative annual electricity saving and CO2 emission reduction potential for efficiency measures in industrial fan systems in Wisconsin ranked by their final CCE       

Table 18. Total annual cost-effective and technical energy saving and CO2 emissions reduction potential in industrial fan systems in Wisconsin           

Table 19. Cumulative annual electricity saving potential for efficiency measures in industrial fan systems in Wisconsin by system size (GWh/yr)           

Table 20. Sensitivity analyses for the cost-effective electricity saving potentials in the industrial fan systems with different discount rates         

Table 21. Sensitivity analyses for the cost-effective electricity saving potentials in the industrial fan system with different electricity price          

Table 22. Total annual technical energy saving and CO2 emissions reduction potential in industrial fan systems in the studied states   

Table 23. Policies driving customer-funded energy-efficiency programs  

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