1 | Energy Efficiency and Renewable Energy eere.energy.gov
Leveraging Information Technology for Manufacturing Innovation at the U.S. Department of Energy
FOCAPO / CPC 2017Tucson, AZ
January 9th, 2017
Mark Johnson
Director
Advanced Manufacturing Office
www.manufacturing.energy.gov
2
A little history: The Start of a pair of Revolutions
Lexington & Concord
1775
Watt, Boulton & Co.1775
(intelligence: steam regulation
for external combustion engines)
3
“… the encouragement of manufactures is the
interest of all parts of the Union.”
“Not only the wealth; but the independence and
security of a country, appear to be materially
connected with the prosperity of manufactures.“
“… it is the interest of a community with a view to
eventual and permanent economy, to encourage
the growth of manufactures.”
- Alexander Hamilton
US Treasury Secretary (1789-1795)
Reports to Congress
First Report on the Public Credit - 1790
Second Report on Public Credit - 1791
Report on the Subject of Manufactures - 1791
US Manufacturing Strategy for First Industrial Revolution
4
Second Industrial Revolution
ElectrificationProcess Scaling
Energy & Materials
Standardization &
Assembly Line
5
Energy Intensive Industries -Today
Primary Metals
1608 TBTU
Petroleum Refining
6137 TBTU
Chemicals
4995 TBTU
Wood Pulp & Paper
2109 TBTU
Glass & Cement
716 TBTU
Food Processing
1162 TBTU
Other Manufacturing
~1600 TBTU
6
How will Manufacturing, Economy and Security of the Nation depend on
Information, Actuation and Communication Technology in the 21st Century?
Third Industrial Revolution - Now
Scaled-out
Intensified
Generalized
Microprocessor
Integrated
Centralized
7
• Overview of DOE Advanced Manufacturing Office
• Technology Assistance Programs
• Research and Development Projects
• Research and Development Consortia
8
Focus on:• Technology Innovation impacting Manufacturing and Energy
(Energy Efficiency and Life-Cycle Energy Costs)
• Technology RD&D + Talent (People)
Advanced Manufacturing
and Energy Technology
Environment
Security
• Competitiveness in
energy products
• Domestic jobs
• Clean Air
• Clean Water
• Energy independence
• Stable, diverse energy
supply
Economy
Energy and Manufacturing: Nexus of Opportunities
9
Advanced Manufacturing – Strategic Framing
Advanced Manufacturing
Partnership (AMP2.0)
Strategic Plans
(DOE 2014 & EERE 2016)
Quadrennial Technology Review
(DOE / Science and Technology 2015)
1) Broadly Applicable EnergyEfficiency Technologies for Energy Intensive and Energy Dependent Manufacturing
2) Platform Materials, Process and Information Technologiesfor Manufacturing with Sustainable Life-Cycle Impact
Authorizations
EPAct2005 and EISA2007
10
More Advanced Manufacturing Issues
Quadrennial Energy Review (QER): 2015
- Manufacturing for Infrastructure and the Grid
Water-Energy Nexus: 2014
- Water for Energy & Energy for Water
Energy Productivity 2030: 2015
- Double GDP/kJ Economy from Energy
Innovation Strategy: 2015
- Technology, Workforce & Capabilities
Job Training and Apprenticeship: 2015- Advanced Manufacturing Skills and Opportunities
Revolution Now: 2015
- Cost Effective New Technologies
4) Partnerships for Energy Technology and Practices Dissemination in Manufacturing
5) Tools, Training & Human Capital Development
3) Responsible & Effective Integration of US Manufacturing to our Diverse & Abundant Energy Resources
11
Energy Use in the US Economy
12
ChemicalsPetroleum Refining
Forest ProductsFood & Beverage
Iron & Steel
Other Manufacturing
0.0 MMT
50.0 MMT
100.0 MMT
150.0 MMT
200.0 MMT
250.0 MMT
300.0 MMT
0 TBtu 500 TBtu 1,000 TBtu 1,500 TBtu 2,000 TBtu 2,500 TBtu 3,000 TBtu 3,500 TBtu 4,000 TBtu 4,500 TBtu 5,000 TBtu
20
10
MEC
S To
tal E
mis
sio
ns
(On
site
+ O
ffsi
te)
2010 MECS Onsite Energy Consumption
Plastics and Rubber
ProductsTransportation Equipment
Electronics
AluminumCement
GlassMachinery
Textiles
Foundries
5.0 MMT
10.0 MMT
15.0 MMT
20.0 MMT
25.0 MMT
30.0 MMT
35.0 MMT
40.0 MMT
100 TBtu 200 TBtu 300 TBtu 400 TBtu 500 TBtu 600 TBtu 700 TBtu
Primary Energy & energy-related Emission by Sector
13
Processes for Clean Energy Materials & TechnologiesEnergy Dependence: Energy Cost Considered in Competitive Manufacturing
Solar PV Cell
Carbon Fibers
Light Emitting Diodes
Electro-Chromic Coatings
Membranes
EV Batteries
Multi-Material Joining
Water Desalination
14
Manufacturing Bandwidth Studies: Energy Savings Potential
Current opportunities represent energy savings that could be achieved by deploying the most energy-efficient commercial technologies available worldwide. R&D opportunities represent potential savings that could be attained through successful deployment of applied R&D technologies under development worldwide
15
Deeper Look at Energy in Manufacturing
16
Quadrennial Technology Review: Manufacturing
Materials DevelopmentAdvanced Manufacturing Processes
Energy & Resource Management
Flow of Material thru Industry
(Sustainable Manufacturing)
Critical Materials
Direct Energy Conversion Materials(Magnetocaloric, Thermoelectric, etc)
Wide Bandgap Power Electronics
Materials for Harsh Service Conditions
Advanced Materials & their Manufacture
Additive Manufacturing
Composite Materials
Roll-to-RollProcessing
Process Intensification
Process Heating
Advanced Sensors, Controls, Modeling
& Platforms
Waste Heat Recovery
Combined Heat and Power
EfficiencyTechnologies
Enabling PlatformTechnologies
Information Processes Materials
17
Advanced Manufacturing Office Multiyear Program Plan (draft) Areas
18
Impact Areas of Cross-Cutting Efficiency Technology for Energy Intensive Industry Sectors
Chemicals & Bio-chemicals
PetroleumRefining
PrimaryMetals
Forest &Food Products
Clean Water
SMART Manufacturing
Process Intensification
CHP & Grid Integration
Sustainable Manufacturing
Sector Specific Roadmaps
Developed with Industrial Sector Partnerships
19
• Overview of DOE Advanced Manufacturing Office
• Technology Assistance Programs
• Research and Development Projects
• Research and Development Consortia
20
Technical Assistance: Better Plants Program
• Key component of Better Buildings Initiative to improve energy efficiency of commercial and industrial buildings by 20% by 2020.
• Voluntary pledge by manufacturers and industrial-scale energy users to reduce energy intensity
• DOE provides technical assistance to meet goals and firms report progress
• To date, Better Plants Partners have reported
(more than 0.45 Quads of energy)
21
ISO 50001–Energy Management Systems (EnMS)
International standard that draws from best practices around the world.
Developed with input from 56 countries, many countries now adopting it as
a national standard.
ISO 50001 specifies
requirements for establishing,
implementing, maintaining
and improving an EnMS.
Light blue text represents new data-driven sections in
ISO 50001 that are not in ISO 9001 & ISO 14001
It does not prescribe
specific energy performance
improvement criteria.
22
ISO 50001
Components in place:
• Top Management
• Energy Team
• Policy
• Planning
• Baseline
• Performance Metrics
Superior Energy Performance
Single facility ISO
50001
conformance with
verified energy
performance
improvement
ISO 50001ISO 50001 is a
foundational tool
that any
organization can
use to manage
energy
Superior Energy Performance™
• SEP is a certification program that
helps facilities meet the ISO 50001
energy management standard and
verify the savings they achieve
• 28 plants have been certified so far.
Nine improved energy performance
by an average of 10% and saved
over $500,000 per year
23
Technical Assistance: Industrial Assessment Centers
Energy Assessments & Student Training
University-based Industrial Assessment Centers
Support for small/medium sized manufacturing
Energy.gov/IAC
24
• Overview of DOE Advanced Manufacturing Office
• Technology Assistance Programs
• Research and Development Projects
• Research and Development Consortia
25
R&D Projects: Manufacturing Materials, Processes & Information Tools
Ultrafast, femtosecond pulse lasers
(right) will eliminate machining defects
in fuel injectors. Image courtesy of Raydiance.
Energy-efficient large thin-walled
magnesium die casting, for 60%
lighter car doors.
Graphic image provided by General Motors.
Protective coating materials for
high-performance membranes,
for pulp and paper industry.
Image courtesy of Teledyne
A water-stable
protected lithium
electrode. Courtesy of PolyPlus
26
R&D Projects: Combined Heat & Power (CHP) & Grid Integration of Manufacturing
Capstone photos source: capstoneturbines.com
Advanced MicroTurbine System (AMTS) R&D Program
Advanced Reciprocating Engine Systems (ARES) R&D Program
C200 MicroTurbine Engine
QSK60G engine
27
R&D: Next Generation Electric Machines (NGEM)
• Focus on developing energy efficient, high power density, integrated medium voltage drive systems.
Current efforts:
• Manufacturing of high performance thermal and electrical conductors
• Manufacturing of low-loss silicon steel
• High temperature superconducting wire manufacturing
• Manufacturing of other enabling technologies to increase performance.
Potential to save 1.6% of
28
Goal is to accelerate the manufacturing capability of
a multitude of AM technologies utilizing various
materials from metals to polymers to composites.
Arcam electron beam
processing AM equipment
Microstructure Control
During Metal Additive
Deposition
Manufacturing Demonstration Facility
Spallation Neutron Source
Supercomputing Capabilities
29 29
Additive – Rapidly Developing Technology –Big-Area Additive Manufacturing (BAAM)
Developed Unique 3D Printing Tool
(with Cincinnati Inc.)
Developed blended polymer / fiber
(with Sabic & Techmer Inc.)
Developed Surface Process
(with Tru-Design Inc.)
Designed & Printed Car Prototype
(with Shelby Inc.)
Printed Cobra Project: Design to Prototype
Six (6) people in six (6) weeks.
Crowdsource Design &
Build EV
(with Local Motors
30
Partnerships with Vehicles and Buildings R&D
3D Printing of Large Area
Structures
Partnership with Designers,
Manufacturers, Universities,
Laboratories and Suppliers
31
MDF: 3D Printing Wind Blade Molds
Bringing Manufacturing Innovation to the Renewable Energy Space
• Enable innovative blade designs
• Achieve lower overall costs and higher efficiencies
• Collaboration with Oak Ridge, Sandia, and TPI Composites
• Potential copper metal casting projects
32
HPC for Manufacturing
• Program teams manufacturers with DOE’s network of National Labs
• Applying High Performance Computing to face critical manufacturing challenges
33
High Performance Computing for Manufacturing
Apply modeling and simulation capabilities to manufacturing challenges
• Industry defined challenges
• Businesses Partner with National labs
• Business-friendly terms and streamlined partnering process
A computer simulation of the
virtual blast furnace. Image
courtesy of Purdue University –
Calumet/Northwest.
34
MGI - Framework
New Material Innovations for Clean Energy 2X Faster and 2X Cheaper
Predictive Simulation
Across Scales
Synthesis & Characterization
Rapid Screening
End Use Performance
Process Scalability
Process Control
Real-time Characterization
Reliability Validation
Data Management & Informatics
Coordinated resource network with a suite
of capabilities for advanced materials R&D
Applied R&D for Materials Genome Initiative (MGI)
35
Cyclotron Rd and Lab Embedded Entrepreneurial Partnership
Lab Embedded Accelerator Model:Let the nation’s energy innovators “spin in” to national labs
35
Recruit the world’s
best energy
technology
innovators
Leverage
experts and
facilities at a
world-class
R&D institute
Deploy people,
IP, and
technology
to the
marketplace
① ② ③
Licensing
Corp.
M&A
VC
http://www.cyclotronroad.org/
…First pilot phase spurred $10 million in follow-on funding and launched privately-funded startups
FY17: extend to more labs & projects
36
• Overview of DOE Advanced Manufacturing Office
• Technology Assistance Programs
• Research and Development Projects
• Research and Development Consortia
37
Address market disaggregation challenge to the industrial commons
How could we get innovation into manufacturing today?- RD&D Consortia- Workforce Development and Education- Public-private Partnership to Scale
R&D Facilities & Consortia
Ford River Rouge Complex, 1920sPhoto: Library of Congress, Prints & Photographs Division, Detroit Publishing Company Collection, det 4a25915.
Then Now
OEM
Tier 1
Tier 2
Tier 3
Tier 2
Tier 3
Tier 1
Tier 2
Tier 3
38
Manufacturing Technology Maturation
TRL 6/7: System Testing in Production Relevant EnvironmentMRL 6/7: System Components made in Pilot Environment
TRL 5/6: Hardware-in-Loop System Testing in LaboratoryMRL 5/6: Investigate Pilot Environment to Make Systems
TRL 4/5: System Technology Tested in Laboratory MRL 4/5: Investigate Pilot Environment to Make Components
TRL 3/4: Enabling Technology Tested in Laboratory MRL 3/4: Enabling Components Made in Laboratory
Foundational
Science
Dep
loym
ent
Dem
on
stra
tio
nD
evel
op
men
tA
pp
lied
Res
earc
h
Bas
ic
Res
earc
h
TRL 1-3:MRL 1-3:
End-Use Adoption
Tech
no
logy
Ne
eds
and
Re
qu
ire
me
nts
Tech
no
log
y C
apab
iliti
es a
nd
Op
po
rtu
nit
ies
Industry
Partnerships
Lab
Facilities
39
13 Manufacturing Innovation Institutes launched to date
39
America MakesAdditive Mfg.
Youngstown, OH
Power AmericaPower Electronics
Raleigh, NC
LIFTLight/Modern Metals
Detroit, MI
IACMIAdv. Composites
Knoxville, TN
DMDIIDigital Mfg.Chicago, IL
• Over $500 million federal funding catalyzed over $1.2 billion from consortia
• Institutes have attracted hundreds of companies and universities as active partners from across the country
NextFlexFlex. Electronics
San Jose, CA AFFOAAdv. Textiles
AIM PhotonicsPhotonics
Rochester, NY
Smart Mfg.
REMADESustainable Materials
Rochester, NY
Process IntensificationRAPID Institute
40
40
Institute has:
1) Clear, unique institute
focus
2) Clear industry value
proposition
3) Strong partnerships
4) Ability to address critical
challenges
5) A balanced portfolio
of projects
Industry-Academia-Government Partnership
Consortia are open—new members able to join
41
• Launched in January 2015
• 17 industry members, 7 universities and 3 national labs (ANL, NRL, NREL)
• $70 million Federal support matched by $70 million non-Federal
• Dramatically reduce costs of wide bandgap materials and devices
• Will enable higher temps, voltages, frequency, and power loads
DOE Institute #1: PowerAmerica (Raleigh, NC)
42
PowerAmerica: Develop advanced manufacturing processes that will enable large-scale production of wide bandgap semiconductors.
DOE Institute #1: PowerAmerica (Raleigh, NC)
43 Read More at: https://www.whitehouse.gov/blog/2016/04/04/depth-look-how-manufacturing-hubs-helped-business-innovate
Highlights: X-Fab Texas launches SiC Merchant Foundry
X-Fab Texas
• Using existing Si fab line, launched first available “merchant” SiC line
• Will dramatically reduce cost of SiC wafers for global power electronics market
• Supports 400 jobs in Lubbock, TX and will produce first device fall 2016
44
DOE Institute #2 – Carbon Fiber Composites (Oak Ridge, TN)
Institute for Advanced Composite Material Manufacturing (IACMI): Develop and demonstrate technologies to produce carbon fiber composites at 50% the cost and 75% less energy.
• Launched in January 2015
• $70 million Federal support matched by $180 million non-Federal
• 94 Total members including 72 industry members, 14 universities, and 2 national labs
• 46 Small and medium-sized industry partners
45
50% Lower Cost
Using 75% Less Energy
And reuse or recycle >95%
of the material
ObjectiveDevelop and demonstrate innovative technologies that will, within 10 years, make advanced fiber-reinforced polymer composites at…
Institute for Advanced Composite Materials Innovation (IACMI)
46
DOE NNMI Institute #2 – Carbon Fiber Composites (Oak Ridge, TN)
• Established regional centers of excellence across a number of fiber composite applications
47
Focus on Real-Time
For Energy Management Institute Goals
• >50% improvement in energy productivity
• >50% reduction in installation cost of Smart Manufacturing hardware and software
• 15% Improvement in Energy Efficiency at systems level
• Increase productivity and competitiveness across all manufacturing sectors
• Advanced sensors and controls for real-time process management
Institute #3 – Smart Manufacturing (SMLC/UCLA) – CESMI Institute
48
Energy Use in the Manufacturing Sector
Opportunity for Efficiency Through
How Manufacturing Systems are
Operated
Requires Improved Situational
Awareness and Decision Support
in Manufacturing Systems:
Intelligence in Manufacturing
49
Dep
loym
en
t C
ost
for
En
erg
y
Pro
du
cti
vit
y I
mp
rovem
en
t
NRE Costs: First of Kind
Deployment
NRE Costs: Nth of Kind Deployment
Cost of Deploying Manufacturing IT
Today Future
Hardware & Installation
O&M Costs
Energy Cost
ParityCost Parity For
Investment Recovery
($/MBTU, ¢/kWh)
2x–5x
Above
Parity
Platform Costs: Zeroth of Kind Deployment
50
SMART Systems - Significant Technical Challenges
PlatformChallenges
1st of Kind Demonstration
Nth of Kind Demonstration
Hardware &Deployment
O&M
High Fidelity Modelling X X X
Data Architecture & Platforms
X X X
Sensor Development & Qualification
X X X X
Algorithms, Controls and Data
X X X X X
DemonstrationTestbeds (1st of Kind)
X X X
51
RAPID (Rapid Advancement in Process Intensification Deploment) Institute - Modular Chemical Process Intensification
Process Intensification has significant potential to improves costs, increase scalability, improve safety and enhance technology for variety of energy intensive, energy related and clean energy manufacturing applications
• Applied research and development into the Equipment, Methods and Technologies: Catalysis, Reactions, Separation, Mixing, Hybrid or Integrated Processes, Heating/Cooling, Thermal Recovery, etc.
• Test-bed demonstration of PI in first-of kind applications
• Develop technologies for manufacturing of process intensified modules.
• Dissemination of knowledge, pre-competitive testing of standards and practices, and education of workforce
• Potential Impact on several key sectors:
Chemicals, Refining, Fiber (Pulp/Paper), Fuel Cells, Natural Gas, Environmental Management, Bio-Mass Processing, etc.
Example Possible Application: Gas to Liquids
December 2016: RAPID/American Institute of Chemical Engineers (AICHE)
New York, NY (Lead Organization)
52
REMADE Institute – Reducing EMbodied-energy And Decreasing Emissions in materials manufacturing
E-WasteMetals
Rapid Gathering, Identification and Sorting
Removal of Trace Contaminants
Separating Mixed Materials
Information Collection, Standardization & Design Tools for Material Utilization
Robust & Cost Effective Reprocessing & Disposal Methods
• Open Data on Materials Flow across Firms & Industries• Tools for Lifecycle Analysis of Embodied Energy in
Waste• Model Based Design Tools for Recovery of Embodied
Energy in Manufactured Products• High Speed Robotic and Vision Systems • Real-time in-situ Tools to Identify Composition• Rapid Particle Size / Morphology Detection
• Highly Throughput Chemical Selective Separation• Advanced Physical/Mechanical Selective Separation• Recovery of High-Value Components• Advanced Melting, Distillation and Crystallization
• Selective Elimination of Trace Metals and Compounds• Removal of Organic and Inorganic Residues• Advanced Membranes for Liquid Waste Separation
• Lower Energy Thermal Processes• Adaptive Processes for Multiple Feedstocks• Low Material and Energy Loss Processing
FibersPolymers
Mat
eri
al P
roce
ss F
low
s
Enab
ling
Tech
no
logy
Ne
ed
s
Applied Sciences: Separation Chemistry, Data Analytics, Visualization & Decision Science, Multi-Spectral Sensing, Robotics & Automation, Materials Processing, Bio-Chemistry, Membrane and Fiber Science, Resource Economics
Fou
nd
atio
nal
Kn
ow
led
ge N
ee
ds
January 2017: Sustainable Materials Innovation Alliance
Rochester, NY (Lead Organization)
53
Selected Goals
• Materials supply chains assured for clean energy
manufacturing in the US
• Commercialize at least one technology in each of
its three technical focus areas
• Develop updated criticality assessments to
ensure relevance of CMI research and identify
potential critical materials for clean energy
Eliminate materials criticality as an impediment to the commercialization of clean energy technologies for today and tomorrow.
Initial Support
• $120M for R&D June 2013-June 2018
54
54
…including intake, pumps, separations, and effluent
management
Water
SourcesOutput• Seawater
• Surface
• Lake
• Brackish
• Processes
• Produced
• Municipal
• Industrial
• Agricultural
From Pretreatment through Reverse Osmosis…
Energy Inputs
Electricity, Waste Heat, Pressure
• Address manufacturing barriers to producing low-energy, cost-competitive clean water
• Technology priorities arise from facility-level systems relevant challenges
• Leverage existing federal resources (e.g. DOI/Bureau of Reclamation testbeds)
Goals: Pipe Parity
Primary Energy, Cost and Carbon Neutral
Clean Water Hub: Water-Energy Technology Innovation
55
• Addressing Global Energy Challenges means Addressing the Energy
Challenges in Manufacturing
– Use of Energy in Sector & Embodied Energy in Products Used in All Sectors
• Manufacturing Energy Efficiency is Foundation for Economic
Competitiveness
• Technology Innovation Enables Both Economic and Energy Benefits
– Science and Technology Research Issues to Achieving these Energy Benefits
– Connect Science and Technology Advanced to Human Capital Development
• Tremendous Opportunity to Leverage Information Technology
Advances With Impact Across the Economy
– Cost Parity a Must
Summary
56
What does Success Look Like?
…And Competitively Made Here!
Energy Products Invented Here…
57
Thank You
Questions?
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