Grand Challenges Portfolio

8/3/2019 Grand Challenges Portfolio

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Contents

Introduction��1

Next-Generation Manuacturing

Concepts ��3

Energy Intensive Processes ��6

Advanced Materials ��10

Industrial Greenhouse Gas EmissionsReduction �� 12



NDUSTRIAL TECHNOLOGIES PROGRAM

The Grand Challenge portolio targets high-risk, high-value research and development ocused on

energy efciency that industry would not typically pursue without ederal leadership and the support

oered by a public-private partnership. Collaborative teams rom industry, academia, and the national

laboratories—nearly 90 partners in total—are sharing the costs and risks o these cutting-edge

research studies.

The Department of Energy’s (DOE’s) Industrial Technologies Program (ITP) has provided $13 million in fundingfor 47 concept denition studies that seek revolutionary solutions to reduce energy use and carbon emissions inmanufacturing. With this portfolio, ITP is pursuing a relatively large number of projects with limited funding($300,000 or less) to focus the best minds in the nation on resolving industry’s challenges. The concept denition

studies will use early-stage research, laboratory-scale experiments, data generation and analysis, and other exploratorymethods to advance new, dramatically different manufacturing concepts and practices.

The portfolio pursues innovation in four topic areas:

• Next-generation manufacturing concepts

• Energy-intensive processes

• Advanced materials

• Industrial greenhouse gas emissions reduction

Each study in the portfolio has a dened goal, provides a solution to a major technical issue, or seeks to overcome the technical barriers in taking a concept tothe next level to achieve a technological breakthrough. The breakthrough mustreduce energy intensity (Btu per unit output) or greenhouse gas emissions by aspecied amount while providing a return on investment compared to today’sindustrial systems.

A list of the 47 concept denition studies by topic area and a descriptionof each study follows.

INTRODUCTION

“Public-private partnerships

with industry are a critical

way to accelerate the

transition to a strong,

competitive, clean energyeconomy in the United

States.”

— Steven Chu,

U.S. Secretary o Energy




List of Grand Portfolio Projects by Topic

Next-Generation Manufacturing Concepts Energy-Intensive Processes

Energy-Saving Glass Lamination via Selective Radio-

Frequency Heating

Friction Stir Processing or Efcient Manuacturing

Dry Krat Pulping at Ambient Pressure or Cost-Eective Energy

Savings and Pollution Deductions

Use o Microwave or Energy-Efcient Heating in

High-Temperature Brazing

Autothermal Styrene Manuacturing Process with Net

Export o Energy

Advanced Production Surace Preparation Technology or Ultra

High-Pressure Diesel Injection

Efcient, One-Step Electrolytic Recycling o Low-Grade and

Post-Consumer Magnesium Scrap

Novel Membranes and Processes or Oxygen Enrichment

Electrical-Assisted Double Side Incremental Forming Process or

Enhanced Sheet Metal Formability and Geometrical Flexibility

Methyl Chloride rom Direct Methane Partial Oxidation:

A High-Temperature Shilov-Like Catalytic System

Direct Solid-State Conversion o Recyclable Metals into

Nanoengineered Bulk Materials

Reduction o Metal Oxide to Metal Using Ionic Liquids

Print-Based Manuacturing or Photovoltaics and

Solid-State Lighting

Membrane Purifcation Cell or Aluminum Recycling

Production o Energy Efcient Preorm Structures

Engineered Osmosis or Energy-Efcient Separations: Optimizing

Waste Heat Utilization

Energy Reductions Using Next-Generation Remanuacturing Techniques

Novel Steels or High-Temperature Carburizing

Microwave Enhanced Direct Cracking o Hydrocarbon Feedstock or

Production o Ethylene and Propylene

Energy-Efcient Microwave Hybrid Processing o Lime or Cement,

Steel, and Glass Industries

Environmentally Friendly Coolant System

Waste Heat Recovery and Recycling in Thermal Separation Processes

Advanced Energy and Water Recovery Technology rom Low-Grade

Waste HeatAdvanced Optical Sensors to Minimize Energy Consumption in

Polymer Extrusion Processes

Near Net-Shaped Fabrication Using Low-Cost Titanium Alloy Powders

Advanced Nanostructured Molecular Sieves or Energy-Efcient

Industrial Separations

New Manuacturing Method or Paper Filler and Fiber Materials

Integrated Ammonia Reactor and Ammonia Pressure Swing

Adsorption Recovery

Ultra-High Efciency and Ultra-Low Emissions Crosscutting

Combustion Technology or Manuacturing Industries

Solid-Fuel Oxygen-Fired Production o Nodular Reduced Iron

Machining Elimination through Application o Thread Forming

Fasteners in Net-Shaped Cast Holes

A New Method or Producing Titanium Dioxide Pigment and

Eliminating CO2

Emissions

Distributive Distillation Enabled by Microchannel Process Technology

Advanced Materials Industrial Greenhouse Gas Emissions Reduction

Aerogel-Based Insulation or High-Temperature Industrial Processes

Ultra-Thin Quantum Well Materials

Thermal and Degradation Resistant Stainless Steel or Industrial Use

Nanostructured Ferritic Alloys: Improving Manuacturing Energy

Efciency and Perormance or High-Temperature Applications

New High-Temperature, Low-Cost Ceramic Media or Natural Gas

Combustion Burners

Ultracoatings: Next-Generation Nanocoatings or High-Contact

Stress Environments

Low-Cost Production o InGaN or Next-Generation

Photovoltaic Devices

Multiphase Nanocomposite Coatings or Energy Optimization

Next-Generation Wireless Instrumentation Integrated with

Mathematical Modeling or Use in Aluminum Production

Removal o Volatile Organic Compounds and Organic Hazardous AirPollutants rom Industrial Waste Streams by Direct Electron Oxidation

Hydrate-Free Concrete: A Low Energy, CO2-Negative Solution

Crude Glycerol as Cost-Eective Fuel or Combined Heat and Power

to Replace Fossil Fuels

New Silica-Alumina-Based Cementitious Material Using Coal Reuse

High Power Industrial Ultraviolet Curing Systems



Energy-Saving Glass Lamination via

Selective Radio-Frequency Heating

The manufacturability of a radio-frequency (RF) heating process will be investigated to reduce glass lamination time andsignicantly lower energy intensity. RF heating saves energy by dissipating RF energy as heat into the vinyl layers withoutheating the glass and has been shown to reduce lamination time

to 1-3 minutes. The manufacturability potential will be evaluated by researching concepts for curvedRF glass lamination, investigatingsafety and regulatory hurdles, anddening energy and environmentalimpacts from widespread use of the RF material. Adoption of this process will also lower the costof laminated products, such asautomotive side windows and solar panels. The project seeks to use RFheating to reduce energy use in glasslamination production by up to 90%.

Friction Stir Processing or Efcient

Manuacturing

Friction Stir Processing (FSP) is an innovative surface hardeningtechnique for metallic materials and components with the potential to replace traditional high-cost, energy-intensive surfacetechnologies. This technology will be evaluated for reducingfriction losses and enhancing wear performance for steel surfacehardening. FSP features a rotating tool that is plunged to a

predetermined depth and manipulated to heat and cause plasticdeformation of the processing area. This process seeks to save timeand energy, versus conventional surface hardening techniques,and eliminate quenchants andother chemicals. The project willdemonstrate a surface hardeningtreatment that has the potential toreduce energy use by 70%compared to conventional thermalheat treatments.

Dry Krat Pulping at Ambient Pressure

or Cost-Eective Energy Savings and

Pollution Deductions

A new dry kraft pulping technology is being investigated toreplace current kraft pulping processes that rely heavily onenergy-intensive black liquor treatments. This dry method is based on the concept of depolymerizing lignin in wood chips atambient pressure without the need for a water medium and will be optimized to overcome the disadvantages of conventionalkraft pulping. This process will save energy by reducing theamount of black liquor treatments, speeding up the pulping production rate, and eliminating high-cost pressurized digester equipment. This process seeks toreduce energy use in the cooking process by 40% and chemical use by 50% due to a reduction in black liquor treatments.

Project Partners

Ceralink, Inc. Rensselaer, NY

Thermex Thermatron Louisville, KY

University of Illinois atUrbana-Champaign Urbana, IL

Pilkington, NSG GroupFlat Glass Business

Northwood, OH

Next-generation manuacturing studies seek new manuacturing concepts that can potentially replace

conventional manuacturing processes and reduce the energy intensity or greenhouse gas emissions oindustrial systems by 25% or more.

NEXT-GENERATION MANUFACTURING CONCEPTS

Project Partners

Friction Stir Link, Inc. Waukesha, WI

Argonne National Laboratory

Argonne, IL

Project Partners

Georgia Institute of Technology

Atlanta, GA




Use o Microwave or Energy-Efcient

Heating in High-Temperature Brazing

A novel microwave brazing technology enables metal castingand fabricated metal producers to effectively apply microwaveenergy—one of the most efcient sources of energy—for joining and repairing metal parts. Bulk metals do not absorbmicrowave energy, but this process forms microwave plasma at

the braze site and produces intense local heating to join metalliccomponents efciently. This process, demonstrated in thelaboratory, will be tested for application in industrial componentsto ensure good melting and braze ow. The project seeks toimprove energy efciency by 50% compared to conventionalvacuum brazing. The results of thisstudy can be used to design acommercial-scale system, which willimpact jet engines and industrial gasturbine production.

Autothermal Styrene Manuacturing

Process with Net Export o Energy

This concept denition study focuses on developing a styrenemonomer (SM) processing technology that reduces lifecycle process energy requirements by 25% compared toconventional technology. Researchers will identify newcatalysts for SM production, develop the conceptual design of a production facility, and formulate a demonstration plan. DOEhas identied SM as the ninth-rankedorganic chemicalon a total production volume basis and having the third-highest potential for process energy savings.

Advanced Production Surace Preparation

Technology or Ultra High-Pressure Diesel

Injection

Ultra high-pressure diesel injection engines—currently targetedfor use in electric power generation and marine power engines— must comply with 2014 Tier 4 emissions standards and provide a projected 2.5% improvement in fuel economy. The project seeksto develop methods to impart more than 700 megapascals (MPa)of compressive residual stress and near-perfect design geometry(within plus or minus 0.5 micrometers) on all surfaces thatcontact the ultra-high injection pressure while using traditionalfuel system engineering materials. This study will also developmethods to prepare key surfaces

of the fuel system for compressiveresidual stress and pulsatingmovements without causingfatigue failure.

Efcient, One-Step Electrolytic Recycling

o Low-Grade and Post-Consumer

Magnesium Scrap

A single-step magnesium scrap recycling process melts low-grade magnesium scrap and renes it to a pure product using

solid oxide membrane (SOM) electrolysis. SOM electrolysiscontinuously feeds magnesium oxide into a molten salt bath where electricity splits it into magnesium metal vapor and oxygen gas in separate chambers. While increasing themagnesium recycling rate, this technology will lower costs,save energy, and reduce carbon emissions in production.Increased use of magnesium in automotive parts will also resultin transportation fuel savings from

lighter vehicles. The project willdesign a small (30 to 60 ton/yr)reactor which demonstrates all of the features of the process and hasthe potential to reduce energycosts by 70% compared to primary production.

Novel Membranes and Processes or

Oxygen Enrichment

This concept denition study focuses on the development of an effective system that produces oxygen-enriched air usingless energy and at one-third the cost of today’s processes.Cheaper oxygen-enriched air will increase the economicattractiveness of converting existing air-fueled furnacesto oxygen-enriched furnaces,which will signicantly improvethe efciency of industrialcombustion processes by 50% to70% while reducing greenhousegas emissions. The newlydiscovered polymers are ten timesmore oxygen-permeable thanconventional membrane materials.

Electrical-Assisted Double Side Incremental

Forming Process or Enhanced Sheet Metal

Formability and Geometrical Flexibility

A new process enhances the formability and fabricationof sheet metals for producing targeted components in theaerospace, automotive, appliance, and medical deviceindustries by combining the double-sided incrementalforming process with the use of pulsed electric current intoone synergistic process. In Electrical-Assisted Double SideIncremental Forming (EADSIF), a forming tool movesalong a pre-dened tool path, while locally deforming aat, peripherally-clamped sheetmetal blank. This process, already

proven to improve formabilityat room temperature, will enablefabricators to create morecomplex parts while reducingenergy requirements andemissions. The project seeksto eliminate 100% of dies andforming presses used in traditionalsheet drawing processes.

Project Partners

GE Global Research Niskayuna, NY

Project Partners

Lummus Technology Bloomfeld, NJ

Project Partners

Membrane Technology andResearch, Inc. Menlo Park, CA

Tetramer Technologies, LLC Pendleton, SC

Gas Technology Institute Des Plaines, IL

Project Partners

Northwestern University Evanston, IL

Ford Motor Company Dearborn, MI

Penn State Erie, The BehrendCollege

Erie, PA

Massachusetts Institute of TechnologyCambridge, MA

Project Partners

Metal Oxygen SeparationTechnologies, Inc.

Natick, MA

Boston University Boston, MA

Project Partners

Caterpillar Inc.Mossville, IL




Methyl Chloride rom Direct Methane Partial

Oxidation: A High-Temperature Shilov-Like

Catalytic System

A single-step, low-temperature (<300°C) partial-oxidation process will convert low-grade natural gas directly to methylchloride—a widely used chemical that can be converted toimportant products or liquid fuels. Using “designer” ionic

liquids and Shilov-like catalysts for partial oxidation, this process could replace multi-step, energy-intensive processesthat involve higher temperature (>500°C) syngas generation,thereby signicantly reducingenergy intensity and greenhousegas emissions by 50% to 60%. This project will develop and optimizethe new methane catalytic system.

Direct Solid-State Conversion o Recyclable

Metals into Nanoengineered Bulk Materials

The feasibility of a direct, solid-state metal conversion (DSSMC) process will be explored for converting aluminum and copper scrap into marketable forms without requiring melting andcasting operations. DSSMC consolidates and converts powders,chips, or other recyclable feedstock metals or scraps directlyinto usable product forms without re-melting the feedstock.The project will also demonstrate the feasibility of utilizingnanoparticle, dispersion-strengthened bulk materials and/or nanocomposite materials for target applications in future electric power generation and deliveryinfrastructure, and in lightweightstructures for automotiveapplications. The project aims toreduce energy use of conventionalmetal casting processes by 80%.

Reduction o Metal Oxide to Metal Using

Ionic Liquids

A transformational low-temperature process will be developedto extract metals from metal oxides, particularly metallic silicon(Si) from silica (SiO

2), using ionic liquids and electrolytic

reduction at low temperatures. Researchers will identify suitableionic liquids to dissolve the metal oxides, characterize the properties of the melts, optimize the electrolysis process, andmake recommendations for process optimization and scale-up.Reducing metal oxides to metals through ionic liquid electrolysiswill enable the domestic metals industry to save energy and

costs by replacing conventional high-temperature chlorinationand carbon-reduction processes.The project aims to improve energyefciency by 36% compared toconventional extraction processes.

Print-Based Manuacturing or

Photovoltaics and Solid-State Lighting

A transformational print-based manufacturing process for fabricating photovoltaics and solid-state lighting couldsignicantly reduce the energy consumption and greenhousegas emissions associated with conventional manufacturingmethods by 50%. This study demonstrates the manufacture of

photovoltaics on barrier plastic substrates using a screen-printing pilot line process. The aim is todene next-generation, print-basedmanufacturing plants to fabricatecommercially-competitive organiclight emitting diodes (OLED) and photovoltaic panels to replaceconventional lighting.

Project Partners

Southwire Company Carrollton, GA

Oak Ridge NationalLaboratory Oak Ridge, TN

Project Partners

The University of Alabama Tuscaloosa, AL

Project Partners

Power Environmental andEnergy Research Institute Covina, CA

Project Partners

University of CaliforniaSanta Cruz, CA

Add-Vision, Inc. Scotts Valley, CA




Membrane Purifcation Cell or Aluminum

Recycling

A membrane purication cell technology will be evaluated toincrease aluminum recycling and enable mixed-alloy streamsto be treated and recycled. A uoride electrolyte systemwill be evaluated to position the membrane puricationtechnology for multi-day operation with stable cell voltage.This technology will improve recyclability by reducing or eliminating the amount of primary aluminum that needs to beadded to the waste stream to offset contamination. Primaryaluminum production requires ten times more energy thanscrap melting processes. The planned membrane cell seeksto reduce energy consumption for producing high-purity aluminum by 75% and the energy content of recycled metal by 70%.

Production o Energy Efcient Preorm

Structures

Ultra net-shape preforms, or shapes close to a nal product’s dimensions, will enable manufacturers of largestructures (e.g., aerospace components) to save energythrough reduced machining and subsequent recycling. These producers must typically remove vast amounts of materialfrom standard mill products, generating large amounts of scrap that must be recycled. A new fabrication methodwill use solid-state joining techniques to produce complexultra net-shape preforms that are closer to a nished part’sdimensions and allow large and bulk product producers tooptimize material use. These techniques do not use high-

energy discharge to melt material, further saving energyand minimizing the need for raw material processing andtransportation. The project seeksto eliminate 90% of materialwaste when manufacturing largeaerospace structures.

Engineered Osmosis or Energy-EfcientSeparations: Optimizing Waste Heat

Utilization

Components of a transformative osmosis-based wastewater treatment technology will be redesigned to prepare thetechnology for full-scale piloting in an industrial facility.The separation process uses low-grade waste heat to produceclean, fresh water from industrial wastewaters, seawater,sewage, and other contaminated waters. The process could beretrotted to existing industrial facilities and could expandinto the desalination market.This technology seeks to reduceseparation electricity usage by87% over market-leading reverseosmosis processes.

Energy Reductions Using Next-Generation

Remanuacturing Techniques

A laser-assisted two-wire arc thermal spraying re-surfacesworn or damaged steel- or aluminum-based parts while providing better metallurgical bonding and durability. This new process ensures a reliable mechanical bond using a hybridapproach of combining a focused laser beam to thermally

Project Partners

Alcoa, Inc. Pittsburgh, PA

Project Partners

The Boeing CompanySeattle, WA

Energy-intensive process studies concentrate on reactions and separations, high-temperature

processing, waste-heat minimization and recovery, sustainable manuacturing, and other technologyareas that can generate large energy-saving benefts in major manuacturing processes across a

variety o industries.

Project Partners

Oasys Water, Inc.Cambridge, MA


ENERGY-INTENSIVE PROCESSES



treat the substrate surface immediately prior to a thermally-sprayed powder treatment. This approach will be optimizedto enable the remanufacturing of components in enginedrive trains and undercarriage systems, which are vital tomachines and engines operated in several industries. Reliableremanufactured parts will extend product life cycle andavoid costly replacements. The project seeks to reduce the energy

required to produce a new part byup to 85%.

Novel Steels or High-Temperature

Carburizing

A generic composition-based practice will be developedto maintain ne austenite grain size in low-alloycarburizing steels. Researchers will determine whether low-alloy steel compositions allow for case carburizing athigher temperatures without adversely affecting product performance. This will lead to the development of a newfamily of commercial carburizing alloys that can nd

application in the petroleum, chemical, forest products,automotive, mining, and industrialequipment industries. Inhibitingundesirable grain modicationswill enable the use of high-temperature carburization, withthe potential to reduce energy use by 55% relative to conventionalcarburization processes.

Microwave Enhanced Direct Cracking o

Hydrocarbon Feedstock or Production o

Ethylene and Propylene

Key technical concepts will be dened to enable directmicrowave treating for hydrocarbon cracking as areplacement for energy-intensive indirect heating methodsin the production of ethylene, one of the largest volumechemicals produced. Hydrocarbon/microwave interactionmechanisms will be modeled and evaluated on precursors and products of ethylene production.This process has the potentialto reduce the energy requiredfor cracking, the most energy-intensive process in the chemicalindustry, by at least 50%. Inaddition, the temperature on

the reactor skin can be reduced,thereby minimizing coke build-up on the reactor wall and prolonging cracker efciencyand operational time.

Project Partners


Advanced Steel Products andProcessing Research Center (Colorado School of Mines) Golden, CO

Energy-Efcient Microwave Hybrid

Processing o Lime or Cement, Steel, and

Glass Industries

A hybrid microwave processingtechnology will reduce the energyrequired for lime and cement production, particularly during

the calcinations of limestone.Microwave Assist Technology(MAT) simultaneously appliesradiant heat and microwave energyin the same kiln, which coulddrastically reduce process time andenergy consumption. Interactions between microwaves and materialswill be studied, modeled, andevaluated for material reactions andenergy use. Early-stage equipmentdesign concepts will be developedand evaluated for possible

retrotting. Use of MAT willenable the limestone calcination process to run at twice the speed, potentially reducing energy use byapproximately 50%.

Environmentally Friendly Coolant System

The Environmentally Friendly Cooling System (EFCS) uses dryice CO

2particles rather than traditional petroleum-based uids

for cooling during machining operations and has the potential toreduce costs in the aluminum, metal casting, and other energy-intensive industries. The EFCS cools surfaces by applyingCO

2particles (and assist gas and bio-oil, if needed) directly

to the cutting zone, and improves cutting speeds by removingmachined particles from the cutting zone. With the potential todisplace petroleum-based machining cooling and lubrication,this technology can nd applications in metal machining,composites drilling, and thermal spraying of molten metals. The project seeks to improve machinethroughput by 30%, replacingconventional machining operationcoolant systems and reducing energyconsumption by 25%.

Waste Heat Recovery and Recycling in

Thermal Separation Processes

Waste-heat powered thermal heat pumps will be evaluated for recovering and recycling at least50% of latent heat from distillation,crystallization, and evaporation processes. Researchers will performa systems analysis to determineoptimum conditions for recovery andrecycling, evaluate a working uid pair for high-temperature pumps,

Project Partners

Ceralink, Inc.Troy, NY

Rennselaer PolytechniqueInstitute

Troy, NY TechnipClaremont, CA

John Balsam Associates, LLC Missoula, MT

Project Partners

Ceralink, Inc.

Troy, NY Worcester PolytechnicInstituteWorcester, MA

Rensselaer PolytechnicInstituteTroy, NY

Mississippi LimeSte. Genevieve, MO

Chemical Lime Company Fort Worth, TX

Harrop Industries, Inc.Columbus, OH

Thermex Thermatron

Louisville, KY Western Lime CorporationWestbend, WI

Project Partners


Project Partners

Cool Clean Technologies Inc. Eagan, MN

Project Partners

FMC Corporation Princeton, NJ

E3Tec Service, LLCClarksville, MD

ChemResearchEngineering, LLC

Bowie, MD




and identify critical needs for improved heat transfer equipment.The results could be used to design and install a pilot plant for further validating the technology.

Advanced Energy and Water Recovery

Technology rom Low-Grade Waste Heat

A nanoporous membrane-based water vapor separation

technology will be developed for recovering energy and high purity water from low-grade, high-moisture industrial wastestreams, which are present in many industrial processes.Conventional technologies often cannot recover heat due to lowheat transfer and moisture-related corrosion issues. The studywill test and prove the nanoporousmembrane-based water vapor separation concept and technologyin the laboratory and evaluateits performance in two differenttypes of industrial environments.The project seeks to improve themembrane’s water and heat recoverycapacity, resulting in 20% to 30%greater energy efciency.

Advanced Optical Sensors to Minimize

Energy Consumption in Polymer Extrusion

Processes

Advanced on-line sensor technology will be developed tomonitor the color and composition of polymer melts to eliminatethe energy, material, and operation costs associated withrecycling off-specication polymer products. Polymer extrusion processes are typically difcult to control, but the developmentof an effective control algorithm would enable rapid correctionsto materials and operating conditions. This information could

be used to identify extruder system issues, diagnose problemsources, and suggest corrective actions in real-time. Applicationof this technology could streamline production of consumer goods, suchas pharmaceuticals, beverages, andcleaning products.

Near Net-Shaped

Fabrication Using Low-Cost Titanium Alloy

Powders

A “meltless” approach to titanium fabrication can signicantlyreduce energy consumption in the aerospace industry by using

low-cost titanium powder to make near-net preforms that can beformed easily into structural components. Airframe structural parts will be assessed to design near-net shape strategies for each part. The technical feasibility of producing these shapeswith small quantities of low-cost titanium powders will also beevaluated, along with quantication of the energy requirementsinvolved. These steps will help to identify the most sustainable

manufacturing approach for reducing scrap formation. The project seeks to establish thetechnical feasibility of processingtitanium powders into fullydense, near-net shaped productsand to reduce machining costs byat least 20%.

Advanced Nanostructured Molecular Sieves

or Energy-Efcient Industrial Separations

This project aims to develop mesoporous zeolite-containingadsorbents in simulated moving bed or pressure swingadsorption processes to replace cost- and energy-intensivedistillation processes in the chemical and petroleum reningindustries. Incorporating mesoporosity into a zeolite adsorbentcan increase diffusivity by about 50% while improving theselectivity and rate of adsorption by about 40%. This studyfocuses on demonstrating the mesoporous zeolite as anadsorbent for the separation of propane from propylene, one of themost energy-intensive, high-volumeindustrial separations.

New Manuacturing Method or Paper Filler

and Fiber Materials

This study seeks to produce paper grades suitable for printingand writing while increasing the ller content of the paper with acomposite produced from kraft and process pulp. Increasing theller content would reduce the pulp requirement and generatecorresponding energy savings for pulp production; however,increased ller content can adversely affect paper quality. Thisstudy will investigate a new ber ller material to resolve

these limitations and improve the efciency of papermaking. If successful, this project couldreduce overall energy use by 20%and life-cycle carbon dioxideemissions in papermakingoperations by at least 5%.

Integrated Ammonia Reactor and Ammonia

Pressure Swing Adsorption Recovery

A new concept increases the yield of ammonia, a widely usedchemical, by integrating an enhanced ammonia reactor with anewly developed recovery system to increase ammonia yield

while lowering energy and cost requirements. This methodintroduces only pure reactants into the synthesis reactor, thenrecovers unused reactants and recycles them back to the reactor free of potential contaminants, such as ammonia and other inertchemicals. Energy savings are derived from recycling withoutthe loss of product or unused reactants and from eliminating theneed to recompress or reheat therecycle stream. This process has the potential to save more than 70%of energy and capital cost for eachammonia plant.

Project Partners

Guided Wave, Inc. Rancho Cordova, CA

PolyOne Corporation Avon Lake, OH

Project Partners

Rive Technology, Inc. Monmouth Junction, NJ

Project Partners

State University of New York,College of EnvironmentalScience and Forestry

Albany, NY

Project Partners

Gas Technology Institute Des Plaines, IL

Oak Ridge NationalLaboratoryOak Ridge, TN

University of Tennessee,Knoxville

Knoxville, TN

Project Partners

The Boeing CompanySaint Louis, MO


Project Partners

SmartKoncept Technology Houston, TX




A New Method or Producing Titanium

Dioxide Pigment and Eliminating CO2

Emissions

The potential for a new methodology for titanium dioxide (TiO2)

pigment production is being demonstrated. The innovativemethod uses chemical sequential treatments and extractionmethodology to produce pure TiO

2with dramatically less CO

2

and environmental waste. The process also eliminates theenergy-consuming step of breaking and reforming the Ti-O bondin the titanium ore–ilmenite rawmaterial. The process is anticipatedto reduce energy use by 40%compared to conventional processes.

Distributive Distillation Enabled by

Microchannel Process Technology

Microchannel process technology can enable distributivedistillation—the use of a larger number of smaller distillationunits in multiple congurations—to greatly improve efciencycompared to a single distillation column. Early experiments haveveried effective, controlled, and highly efcient separationof close boiling mixtures, but the economic viability andmanufacturability of commercial-scale, microchannel distillationunits is yet to be determined.This effort will ascertain theindustrial viability and benets of microchannel distillation, includingthe development of market andeconomic evaluations. This processhas the potential to save up to40% of the energy required byconventional processes.

Ultra-High Efciency and Ultra-Low

Emissions Crosscutting Combustion

Technology or Manuacturing Industries

Radiative Homogenous Combustion (RHC) for high-temperaturefurnaces incorporates intense radiation from the combustionvolume with the newly popular ameless combustion techniqueand seeks to help manufacturers reduce their energy and carbon

intensities. To enable adoption of this technology, researcherswill modify the furnace design to increase radiation and validatecomputational models. Part of the RHC technology will be testedat an aluminum melting furnace. This project seeks to increasefurnace productivity by 50%, reducing energy intensity by 33%,greenhouse gas emissions by 70%,and emissions of nitrogen oxides(NOx) by 5 orders of magnitude.

Solid-Fuel Oxygen-Fired Production o

Nodular Reduced Iron

A nodular reduced iron (NRI) process produces pig iron-quality nodules that can raise electric arc furnace productquality, replacing scrap. As with most other direct-reduced iron processes, the NRI process currently uses natural gas as a fuel.A process is being evaluated that combines the NRI processwith oxygen-red solid-fuel burners and thermally processed biomass. Researchers are assessing potential energy costreductions, improved heat transfer, increased product yield,and reduced greenhouse gas emissions. The use of oxy-biomass combustion has the potential to reduce naturalgas use by up to 75% and NOxemissions by 84% relative toconventionalair combustion.

Machining Elimination through Application

o Thread Forming Fasteners in Net-Shaped

Cast Holes

Thread forming fastener (TFF) technology in aluminumand magnesium castings has the potential to reduce theextensive drilling and tapping operations for threadedfasteners performed at automotiveengine and transmission plants.A series of experiments areinvestigating potential barriersto the implementation of threadforming fasteners in aluminum

and magnesium castings, such asconsistency of clamp load versustorque input and maintainingclamp load as casting dies wear.The project seeks to eliminateapproximately 30% of the machiningin typical automotive engine andtransmission processes by usingthread forming fasteners in as-castholes of aluminum and magnesiumcast components.

Project Partners

The University of UtahSalt Lake City, UT

Project Partners

United States Council for Automotive Research, LLCOakland, MI

Ford Motor Company Dearborn, MI

Acument GlobalTechnologiesTroy, MI

ATF Lincolnwood, IL

REMINCMiddletown, RI

Tech Knowledge Grosse Ile, MI

Project Partners

Velocys, Inc. Franklin, OH

Edison Welding InstituteColumbus, OH

ButylFuel, LLC Gahanna, OH

U.S. Department of Agriculture, Eastern RegionalResearch Center Wyndmoor, PA

Project Partners

University of Minnesota Duluth, MN

Project Partners

University of Michigan Ann Arbor, MI





Aerogel-Based Insulation or High-

Temperature Industrial Processes

Pyrogel HT is an industrial insulation product derived fromnanoporous silica aerogels that has broad application in glassmelting, metal casting, coking, and other energy-intensive processes. The insulation is less costly and 4-5 times morethermally efcient than the current market leaders, mineralwool and calcium silicate. Pyrogel HT achieves low thermal

conductivity at temperatures as high as 1,200°F, addressinga gap in available insulation materials for temperatures between 750°F and 1,200°F. Initialdevelopment focuses on applicationsin the power generation industry;using Pyrogel HT to re-insulatethe piping and equipment in anindustrial facility could reduce piping heat loss by 75%.

Ultra-Thin Quantum Well Materials

Ultra-thin quantum well thermoelectric materials are being fabricated for and evaluated in waste-heat generator

applications in the aluminum, iron, and steel industries. Thin-lm thermoelectrics can provide a large increase in waste heatrecovery from industrial processes and deliver a signicantadvance in cooling efciencies.Thinner lms reduce the timeand costs associated with lmdeposition, while providing highelectrical-thermal performance.The new material has the potentialto achieve 40% heat conversionefciency, in comparison to 10%for current materials.

Thermal and Degradation Resistant

Stainless Steel or Industrial Use

A new class of stainless steel has the potential to achieve atenfold improvement in corrosion performance and signicantlyimprove high-pressure corrosion resistance compared toconventional stainless steel. The new material is being assessed incarburization, suldation, and steamenvironments relevant to chemical

and petrochemical processing andindustrial steam boilers. Improvedcorrosion resistance would increase plant productivity, reduce plantdowntime, and achieve signicantreductions in both energy intensityand greenhouse gas emissions.

Nanostructured Ferritic Alloys: Improving

Manuacturing Energy Efciency and

Perormance or High-Temperature

Applications

Tensile and fatigue crack growth behavior of nanostructured ferriticalloys (NFAs) is being investigated for use in heavy-duty turbinewheels located in hot sections. Current wheel materials limit heavy-duty turbine operating temperatures. Currently, heavy-duty gasturbine wheels experience temperatures of approximately 1,040°Fat the rim. This project seeks to increase this temperature to 1,200°For greater to realize signicant efciency improvements. This newalloy would potentially double the lifetime of the turbine wheels,save energy in the manufacture of wheels, and allow higher-temperatureoperation of turbines with greater energy efciency.

Advanced material studies ocus on industrial materials that can last 10 times longer than current

materials and operate at higher temperatures, or materials that can improve the perormance oenergy production and energy transer equipment by at least 50%.

Project Partners

Aspen Aerogels, Inc. Northborough, MA

American Electric Power Columbus, OH

Project PartnersCarpenter TechnologyCorporation

Northborough, MA


ADVANCED MATERIALS

Project Partners

Hi-Z Technology, Inc. San Diego, CA

Naval Research LaboratoryWashington, DC

State University of New York Albany, NY

University of CaliforniaSan Diego, CA

Project Partners

GE Global Research Niskayuna, NY




New High-Temperature, Low-Cost Ceramic

Media or Natural Gas Combustion Burners

Four different technologies are combined into a singleradiant burner package that functions as both burner mediaand catalyst support for the efcient combustion of naturalgas. This innovative technology seeks to replace inefcientelectric and natural gas radiant heaters used in process

heating throughout manufacturing, signicantly reducingenergy intensity and lowering NOx emissions. The burner has the potential to reduceenergy consumption by 25%for part heating.

Ultracoatings: Next-Generation

Nanocoatings or High-Contact Stress

Environments

Advanced thin-lm coatings are being developed for high-contactstress applications. The new coatingscould exhibit abrasive and erosivewear resistance up to 10 timesgreater than existing materials.Such coatings can enable materialsfor extreme operating conditionsacross a broad range of applications,including coal gasication, high- pressure hydraulic pumps andmotors, transmission gears, andengine timing products.

Low-Cost Production o InGaN or Next-

Generation Photovoltaic DevicesLower-cost and low-energy-use technologies will bedeveloped to produce photovoltaic devices based onInGaN and InAlN materials. These materials can enablethe manufacture of high-efciency photovoltaics and other products, but current processing techniques are expensiveand limit the materials’ commercial production. This projectwill develop a hydride organo-metallic vapor phase epitaxy(HOVPE), a novel deposition technique for InGaN andrelated materials which reduceenergy costs by decreasing thetime required for high-temperature,high-vacuum layer deposition

processes. The HOVPE processhas the potential to reduce thetime required by manufacturingunder high-temperature, high-vacuum processes by a factor of 100, signicantly reducing energyconsumption and costs.

Multiphase Nanocomposite Coatings or

Energy Optimization

A new generation of multi-phased, nanocomposite, ultra-hard,ultra-tough coatings are being developed for use in the drymachining and metal casting industries to reduce energy andmaterial loss. Depending on coating compositions, the ultra-hardcoatings have the potential to achieve hardness values ranging

from 37 to more than 50 gigapascals(Gpa), reducing tool wear by at least50%. The coatings are created usingmagnetron sputtering ion plating(MSIP) and large area ltered arcdeposition (LAFAD) technologies.Processing conditions are optimizedthrough the evaluation of thecoating’s microstructure, thickness,hardness, wear, friction, adhesion,stress level, and toughness.

Project Partners

Structured MaterialsIndustries, Inc.

Piscataway, NJ

Cornell University Ithaca, NY


Goldeneye, Inc.San Diego, CA

Project Partners

Eaton CorporationSouthfeld, MI

Borg-Warner Morse TEC Ithaca, NY

Pratt & Whitney RocketdyneCanoga Park, CA

Ames Laboratory Ames, IA


Project Partners

UES, Inc. Dayton, OH

Argonne National Laboratory Argonne, IL

Triangle PrecisionIndustries, Inc.

Kettering, OH

KAPEX Manufacturing, LLC Troy, MI

Project Partners

3M Company Saint Paul, MN




Next-Generation Wireless Instrumentation

Integrated with Mathematical Modeling or

Use in Aluminum Production

Novel instrumentation is being used to determine the electriccurrent distribution within Hall cells, the large electrolytic cellsused in primary aluminum production, to reduce greenhousegas emissions and improve energy efciency. These sensors usemagnetic eld sensing to measure, in real time, the currents in

cell components, which are then communicated wirelessly. Amathematical model then evaluatesthe benets of current distributionadjustments within the Hall cells.The project seeks to reduce carbondioxide emissions from anodeeffects in Hall cells by 90%.

Removal o Volatile Organic Compounds

and Organic Hazardous Air Pollutants rom

Industrial Waste Streams by Direct Electron

Oxidation

Electron beam technologies can destroy organic pollutants inindustrial waste streams and replace cost-intensive alternatives,such as conventional thermal oxidation processes. This newtechnology also eliminates the CO

2emissions from thermal

oxidation processes, which use large quantities of natural gas toheat pollutant-laden air. This studyinvestigates the appropriate electron beam dose, identies undesirable by- products, and develops a quantitativemodel to calculate energy andgreenhouse gas emission savings.

Hydrate-Free Concrete: A Low Energy,

CO2-Negative Solution

Low-temperature solidication (LTS) technology can producehydrate-free concrete for building facades that does notrequire Portland cement. This technology eliminates energyconsumption and CO

2emissions associated with cement

manufacture. Experiments are being performed to addressuncertainties associated with

the widespread usage of LTStechnology, and design and performance specications are being prepared for prototype facades and blast barriers.

Crude Glycerol as Cost-Eective Fuel or

Combined Heat and Power to Replace

Fossil Fuels

The results of a fundamental characterization of the combustionof a wide range of crude glycerols will ultimately enable biodiesel producers to choose the most cost-effective use of their glycerol

byproduct and expand the availability of the low-cost fossil fuelalternative to the industrial sector. This study will also characterizeemissions and residual ash associatedwith combustion—two areas withlittle or no previous studies—toimprove performance across a rangeof combustion environments and toenable scalability to industrial-scaleapplications. The project seeks toreduce energy consumption in selectedindustrial applications by 25%.

Project Partners

Advanced ElectronBeams, Inc.Wilmington, MA

Industrial greenhouse gas emissions reduction studies advance transormational technologies

that can oer reductions in both carbon intensity and absolute carbon emissions orenergy-intensive industries.

Project Partners

CCS Materials, Inc. New Brunswick, NJ

Rutgers University New Brunswick, NJ

Project Partners

North Carolina StateUniversity

Raleigh, NC

Diversied EnergyGilbert, AZ

Alcoa, Inc. Pittsburgh, PA

INDUSTRIAL GREENHOUSE GAS EMISSIONS REDUCTION

Project Partners

Wireless IndustrialTechnologies, Inc.Oakland, CAJ

AlcoaWenatchee, WA




New Silica-Alumina-Based Cementitious

Material Using Coal ReuseA new silica-alumina-based cementitious material, using coalrefuse as a constituent, could replace the use of Portland cementfor mine backll, mine sealing, and waste disposal stabilization.This study produces the new silica-alumina, based on thesimulation of rock formation, and develops high-performancematerials using the new cementitious

material as binder. A clean, low-temperature process to convert coalrefuse into a desirable constituent isalso being designed.

High Power Industrial Ultraviolet

Curing Systems

This study will demonstrate the potential feasibility of replacing current, inefcient mercury lamps in industrialultraviolet (UV)-curing applications with higher-efciency,low-cost UV LED (light-emitting diode) systems. This studywill produce a compact, modular UV LED system that features

advanced, high-power packing technologies and modular optics that can be scaled up to industrial curing applications.Researchers will determine system requirements and conduct pilot testing of the UV LED curing system. The project seeksto apply technical improvements to demonstrate efciencyimprovements of 30% to 50% abovetoday’s state-of-the-art UV LEDs.The results will enable the adoptionof UV LED curing systems,reducing energy consumption andGHG emissions in applications thatstill use ovens to dry solvent-based paints, inks, and coatings.

Project Partners

University of the PacicStockton, CA

Project Partners

SolidUV, Inc. Chelmsford, MA

Semi Photonics, Inc. (SemiLEDs)

Boise, ID

Armstrong, Inc. Lancaster, PA



Printed with a renewable-source ink on paper containing at least

50% wastepaper, including 10% post-consumer waste.

The Industrial Technologies Program (ITP) is the

lead government program working to increase

the energy efciency o U.S. industry—which

accounts or about one-third o U.S. energy use.

In partnership with industry, ITP helps research,

develop, and deploy innovative technologies

that companies can use to improve their energy

productivity, reduce carbon emissions, and gain

a competitive edge.

DOE/EE-0354

January 2011

Industrial Technologies Program

www.industry.energy.gov

EERE Inormation Center

1-877-EERE-INFO (1-877-337-3463)

www.eere.energy.gov/informationcenter

Grand Challenges Portfolio

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Transcript of Grand Challenges Portfolio