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1. Introduction In 1994 the manufacturing sector consumed 26 EJ of primary energy in the United States, almost one-quarter of all energy consumed that year (U.S. DOE, EIA 1997).1 Within manufacturing, a subset of raw materials transformation industries (primary metals, pulp and paper, cement, chemicals, petroleum refining) require significantly more energy to produce than other manufactured products. In this report we study the energy consumption and intensity in the U.S. chemical industry. The chemical industry is one of the largest energy consuming industrial sub-sectors in the U.S. The chemical industry is complex, encompassing the production of over 50,000 chemical compounds. The industry is also an important part of the global economy, accounting for approximately 7% of global income and 9% of international trade (WEC, 1995). The chemical industry produces many intermediate compounds that are used as the basis for many chemical products. For example, ethylene, one of the most important bulk chemicals from an energy point-of-view, is used to produce products varying from solvents to plastics. Also, many processes in the chemical industry produce different co-products. This makes energy analysis of the chemical industry more complicated compared to other industries. In this report we study the energy consumption of the U.S. chemical industry. We assess current energy consumption and production levels. This information has been used to develop a detailed baseline energy consumption and intensity for three of the most energy intensive and energy consuming chemicals, i.e. ethylene, ammonia and chlorine. We focus on the year 1994, as this is the last year for which the Energy Information Administration has published energy consumption data (the Manufacturing Energy Consumption Survey 1994). No detailed studies on the energy intensity of the U.S. chemical industry have recently been published. The energy intensity baseline will be used for future detailed analyses of the potential of energy efficiency improvement, and carbon dioxide emission reduction in the U.S. chemicals industry. We start with a discussion of the major energy consuming sub-sectors and products in the chemical industry (Chapter 2). This is followed by detailed energy analyses of energy use and energy intensities of three major bulk chemicals, i.e. ethylene (Chapter 3), ammonia and nitrogenous fertilizers (Chapter 4) and chlorine (chapter 5). The reliability and usefulness of the results are discussed in Chapter 6. 2. Energy Use in the Chemical Industry Primary energy use by and associated CO2 emissions from the U.S. chemicals sector (SIC 28) were roughly 20% of total manufacturing primary energy use and CO2 emissions in 1994. The chemical industry produced 11% of total manufacturing value added in the U.S. (see Table 1). Figure 1 depicts carbon dioxide emissions from energy use and value added for SIC 28 between 1985 and 1994.2 Emissions have grown at an annual rate of 2.9% during that period, while value added has increased at a slightly faster rate of 4.6%. 1 In this report we will use SI-units. To convert from GJ to MBtu, multiply by 0.95; to convert from metric tons to short tons, multiply by 1.1; to convert from GJ/metric ton to MBtu/short ton, multiply by 0.86. 2 Carbon emissions estimates include fuels and electricity for energy consumption and feedstocks used for ammonia manufacture less carbon embedded in urea. For other chemical products most of the carbon is not emitted as CO2. Emissions factors are given by EIA (1996). 1 1PDF Image | Energy use and energy intensity
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