Publication: THE SUNDAY
GAZETTE-MAIL
Published: 07/27/2003
Page: 3C
Headline:
STATE INDUSTRIES NEED IOF SAVINGS TO
CONTINUE
Byline: KAREN PRICE
WEST VIRGINIA manufacturers have benefited greatly from IOF.
We're talking about the U.S. Department of Energy's Industries of
the Future Program, which was conceived under the administration of
President George H.W. Bush, took root under President Clinton, and has
really bloomed under President George W. Bush.
Under this program, through competitive grants, co-funded by
industry, organized in partnerships between government, industry and
university researchers, the cost of energy in our basic industries
has been reduced by $15 billion nationally, and that improvement continues
every year. IOF is a tool that the manufacturing industry cannot
afford to lose.
But there is now a proposal in Congress reducing the budget for
IOF. There are ongoing programs in more than 33 states that have
established state-level programs. The program is just now hitting
its stride and if the funding that facilitates the industry, university
and government partnerships is removed, these projects will be at the
least disrupted and possibly dismantled.
By any criteria, it is not a good time to jeopardize a program that
produces billion-dollar results on million-dollar budgets. The best
resolution would be to restore the IOF budget to its 2002 level, or
at the least leave it at the budget level for fiscal year 2003.
In 1997, West Virginia was the first state that put together
a state-level program. In the words of two successive West Virginia
governors, "This is a program that works."
In West Virginia, co-directors for IOF-WV are John Herholdt,
the West Virginia Development Office's energy efficiency manager, and Carl
Irwin of West Virginia University. Through their efforts in partnership
with West Virginia's basic industries and the Department of Energy,
the energy cost reduction in West Virginia is nearing $1 billion. Here's
an example:
Weirtec, the research and development arm of Weirton Steel, had 70
researchers at work five years ago. Today, it has four. This depletion of
industry researchers is being replicated nationwide in all basic
industries, as is the growing cost of energy. As Weirton Steel
struggled to survive, it turned to IOF-WV for research help.
The thrust of the IOF-WV program is to secure seed-money
grants to reduce energy costs through new technology and new
energy-efficient processes that are environmentally friendly. One of many
IOF-WV and Weirton Steel partnership projects was to assess the
benefits of utilities automation. The project was a success, reducing
steel production costs by $8 a ton, which on 2.3 million tons a year,
amounts to $18 million annually.
Weirton Steel is now the lead partner in another IOF-WV
project that is far more significant - new pot hardware that will reduce
line downtime and save Weirton close to $50 million annually in lost
production time and energy costs. Practically the entire national steel
industry making galvanized products has joined in the partnership and the
impact nationwide will amount to hundreds of millions a year. The industry
has provided co-funding on this nearly $3 million research project, and if
the federal IOF budget is reduced, the project is in danger of
losing momentum in this economically troubled industry.
Let's look at a few other examples, the Bayer Chemicals plant in
New Martinsville. An IOF-WV plantwide energy assessment project
turned up potential energy savings of $1.4 million annually. The
cost of realizing these savings can be recovered in less than a
year and Bayer is in the midst of implementing the necessary changes as
fast as its budget allows.
Century Aluminum of America at Ravenswood is in the midst of
another IOF-WV partnership project dealing with smelting
operations, which also effects the glass industry. The targeted energy
savings for Century Aluminum is $15 million a year. For the U.S.
aluminum industry nationwide, there are potential savings of 500
million kilowatt hours per year and the project is adaptable to any
existing smelting operations. Like other IOF-WV projects, it is
co-funded by participating industry members, but without continued support
of the national IOF program, progress might be disrupted or really
strung out. The proposed budget cut makes the prognosis gloomy.
DynaTech Adhesives is another ongoing project that could be in
peril. It involves polymers in pressure sensitive adhesives, such as those
on postage stamps. The adhesives currently being used are most efficiently
produced using solvents that harm the environment. This project will
produce a more environmentally friendly, energy efficient, water-based
adhesive.
To date, it has received $1.4 million in federal research funds,
with co-funding in the amount of $1.3 million. Progress has been
significant and the program is nearing completion - but could be derailed
if the proposed IOF budget is cut.
As West Virginia struggles to maintain a vibrant manufacturing
industry providing good paying jobs and benefits, we need
Industries of the Future to help us become more competitive in the
global marketplace.
Price is president of the West Virginia Manufacturers Association.