Check out the expanded OIT Times-on-the-Web at www.oit.doe.gov/oittimes fied in their industry’s roadmaps. Harvey Wong, OIT’s Metalcasting Team Leader, refers to these consensus documents as a “blueprint.” “Our roadmap, created in tandem by all sectors of the highly diverse metalcasting industry, guided us throughout the process—from the solicitation, to the projects suggested by industry, to the final selection,” Wong said. “We were very pleased with the excellent proposals we received, and with the quality of projects selected. We are cost-sharing 17 of them, and some of the projects have as many as 30 partners. So I think our work is gaining very broad interest and support.” OIT and industry partners launch more than 130 new RD&D projects in ‘99 Through OIT’s customer-driven “Industries of the Future” strategy, industry representa- tives work together to identify their priority pre-competitive technology investments— technologies that will best help their indus- tries save energy, boost productivity and reduce waste. In 1999, with OIT’s help, over 130 of these technologies came on a faster track to development and commercial deployment. This special “new projects issue” of The OIT Times lists our new start- up projects during 1999. “Many valuable technologies are too costly for a single organization to develop alone,” explained Denise Swink, DOE’s Deputy Assistant Secretary for Industrial Technolo- gies. “Our role is to get the competing players to identify the technologies that will make their industries more competitive and energy-efficient. We support R&D projects that can best help meet these goals by sharing the funding of those efforts. As valuable as this work is, much of it would probably not move forward without this kind of support.” The aluminum industry, for example, is excited about its newly revitalized focus on developing inert anodes, a roadmap technology that could revolutionize its energy usage and emissions profiles. And, indeed, OIT’s Aluminum Team “Class of ’99" includes a project investigating an innovative anode technology. “Non- consumable anodes were given very high priority by the industry in our roadmapping efforts,” said Sara Dillich, OIT’s Aluminum Team Leader. “We’re pleased to be co-funding an R&D effort that is taking a promising new approach to the challenge.” All of OIT’s Industry Teams solicit R&D proposals that address priority needs identi- INSIDE 6 OIT Times-on-the-web expanded on trial basis 7 OIT solicitation schedule for FY2000 announced 10 Secretary Richardson helps launch OIT-supported cogeneration system 14 Ohio diecasting showcase a success Vol. 3, No. 1 OFFICE OF INDUSTRIAL TECHNOLOGIES • www.oit.doe.gov/oittimes ENERGY EFFICIENCY AND RENEWABLE ENERGY • U.S. DEPARTMENT OF ENERGY THE OIT TIMES “Turning Industry Visions into Reality” WINTER 2000 To maximize the leverage of its efforts, OIT engages as many partners from as many levels as possible. In one new approach, OIT’s “BestPractices” is helping plants benefit from new technologies and well-proven cost saving opportunities in motor, steam and other plant-wide systems. “We believe that if you take a plant-wide systems approach—looking at all the opportunities in total—you can often reduce energy use by up to 30% in 3 to 10 years,” explained OIT BestPractices Lead Paul Scheihing. “Through BestPractices, we can share a wide range of near - and long-term technology solutions for specific processes and plant-wide operations.” In 1999, BestPractices started its first cost- shared, plant-wide energy efficiency assess- ments by partnering with seven plants in four industries. BestPractices is now looking for new partners to work with in 2000. A com- plete schedule of current and planned OIT solicitations appears on page 7. NEW PROJECTS ISSUE
Transcript
Check out the expandedOIT Times-on-the-Web atwww.oit.doe.gov/oittimes
fied in their industry’s roadmaps. HarveyWong, OIT’s Metalcasting Team Leader,refers to these consensus documents as a“blueprint.” “Our roadmap, created intandem by all sectors of the highly diversemetalcasting industry, guided us throughoutthe process—from the solicitation, to theprojects suggested by industry, to the finalselection,” Wong said. “We were verypleased with the excellent proposals wereceived, and with the quality of projectsselected. We are cost-sharing 17 of them, andsome of the projects have as many as 30partners. So I think our work is gaining verybroad interest and support.”
OIT and industry partners launch morethan 130 new RD&D projects in ‘99
Through OIT’s customer-driven “Industriesof the Future” strategy, industry representa-tives work together to identify their prioritypre-competitive technology investments—technologies that will best help their indus-tries save energy, boost productivity andreduce waste. In 1999, with OIT’s help, over130 of these technologies came on a fastertrack to development and commercialdeployment. This special “new projectsissue” of The OIT Times lists our new start-up projects during 1999.
“Many valuable technologies are too costlyfor a single organization to develop alone,”explained Denise Swink, DOE’s DeputyAssistant Secretary for Industrial Technolo-gies. “Our role is to get the competingplayers to identify the technologies that willmake their industries more competitive andenergy-efficient. We support R&D projectsthat can best help meet these goals bysharing the funding of those efforts. Asvaluable as this work is, much of it wouldprobably not move forward without this kindof support.”
The aluminum industry, for example, isexcited about its newly revitalized focus on
developing inert anodes, a roadmaptechnology that could revolutionizeits energy usage and emissionsprofiles. And, indeed, OIT’sAluminum Team “Class of ’99"includes a project investigating aninnovative anode technology. “Non-consumable anodes were given veryhigh priority by the industry in our
roadmapping efforts,” said SaraDillich, OIT’s Aluminum Team Leader.
“We’re pleased to be co-funding an R&Deffort that is taking a promising new
approach to the challenge.”
All of OIT’s Industry Teams solicit R&Dproposals that address priority needs identi-
INSIDE
6OIT Times-on-the-web expandedon trial basis
7OIT solicitation schedule for FY2000announced
10Secretary Richardson helps launchOIT-supported cogeneration system
14Ohio diecasting showcase asuccess
Vol. 3, No. 1
OFFICE OF INDUSTRIAL TECHNOLOGIES • www.oit.doe.gov/oittimesENERGY EFFICIENCY AND RENEWABLE ENERGY • U.S. DEPARTMENT OF ENERGY
THE OIT TIMES“Turning Industry Visions into Reality”
WINTER 2000
To maximize the leverage of its efforts, OITengages as many partners from as many levelsas possible. In one new approach, OIT’s“BestPractices” is helping plants benefitfrom new technologies and well-proven costsaving opportunities in motor, steam and otherplant-wide systems. “We believe that if youtake a plant-wide systems approach—lookingat all the opportunities in total—you can oftenreduce energy use by up to 30% in 3 to 10years,” explained OIT BestPractices LeadPaul Scheihing. “Through BestPractices, wecan share a wide range of near - and long-termtechnology solutions for specific processesand plant-wide operations.”
In 1999, BestPractices started its first cost-shared, plant-wide energy efficiency assess-ments by partnering with seven plants in fourindustries. BestPractices is now looking fornew partners to work with in 2000. A com-plete schedule of current and planned OITsolicitations appears on page 7.
NEWPRO
JECTS
ISSUE
2
Forest Products
Quarterly Highlights
Title: Accelerated Stem Growth Rates andImproved Fiber Properties of Loblolly PinePartners: Institute for Paper Science andTechnology (IPST)
Title: Quality Trait Loci and Candidate Genes for GrowthTraits in Pinus Taeda L.Partners: Texas A&M Univ., The Timber Co., Union CampCorp., International Paper Co., Weyerhaeuser Co., Perkin-Elmer AgGen, Western Gulf Forest Tree ImprovementProgram, Texas Agricultural Experiment Station
Title: Use of Residual Solids from Pulp andPaper Mills for Enhancing Strength andDurability of Ready-Mixed ConcretePartners: Univ. of Wisconsin-Milwau-kee, Advance Cast Stone Co., FoxRiver Fiber, Weyerhaeuser Co.
Title: Environmental Assessmentof Low Temperature PlasmaTechnologies for Treating VOC’sfrom Pulp Mills and Wood ProductsPlantsPartners: Univ. of Illinois, Pacific NorthwestNational Lab, Georgia-Pacific, Current EnvironmentalSolutions, Ecos, Ltd., American International Technologies,ANL
Title: Control of Emissions from Wood Waste Burners andWood DryersPartner: Univ. of Washington
Title: High Selectivity Oxygen DelignificationPartners: IPST, North Carolina State Univ.
Title: Non-process Element Removal Using FunctionalizedMonolayers on Mesoporous SupportsPartners: Pacific Northwest National Lab, WeyerhaeuserCo.
Title: Bubble Size Control to Improve Oxygen-BasedBleachingPartners: IPST, Air Products and Chemicals Inc., Consoli-dated Papers Inc., Wisconsin Tissue
Title: Increasing Yield and Quality of Low Temperature,Low Alkali Kraft Cooks with Microwave Pretreatment
Partners: Oak Ridge National Lab, Bechtel Technology andConsulting, Beloit Corporation R&D Center, Communicationsand Power Industries, Consolidated Papers Inc., North CarolinaState Univ., Potlatch Research and Development Center,Weyerhaeuser Technology Center
Title: Application of a Device for Uniform Web Drying andPreheating Using Microwave EnergyPartners: IPST, Industrial Microwave Systems
Title: Intermediate-Sized, Entrained Particles: Characterization,Foundation, and Control
Partners: Sandia National Lab, IPST,McDermott Technology Inc., University of
Toronto
Title: Selection and Development ofMetallic and Refractory StructuralMaterials for Black Liquor andBiomass GasificationPartners: Oak Ridge National Lab,IPST, Univ. of Missouri-Rolla,National Renewable Energy Lab,Air Products and Chemicals Inc.,
Georgia-Pacific Corp., Harbison-WalkerRefractories Co., Monofrax Inc.
Title: 3D Characterization of the Structure of Paper and PaperBoardPartners: Univ. of Minnesota, State Univ. of New York,Hercules Inc.
Title: Stability and Regenerability of Catalysts for the Destruc-tion of Tars from Biomass and Black Liquor GasificationPartners: Georgia Tech Univ., IPST
Title: Acoustic Separation TechnologyPartners: IPST, Beloit Corp., Southeast Paper ManufacturingCo., State of Georgia
Title: Development of Screenable Pressure Sensitive AdhesivesPartners: Univ. of Minnesota, IPST, H.B. Fuller Co.
Title: Surfactant Spray: A Novel Technology to ImproveFlotation De-inking PerformancePartners: IPST, Voith Sulzer
THE OIT TIMES/WINTER 2000
Title: Thermostable EnzymaticTransformationsPartners: Altus Biologics Inc.,Genencor, Oak Ridge National Lab,Cargill
Title: Utilization of Corn-based PolymersPartners: Cargill Dow Polymers Inc., National Renew-able Energy Lab, Colorado School of Mines
Title: Catalytic Upgrading of GlucosePartners: National Corn Growers Assoc., PacificNorthwest National Lab, Michigan State Univ.
Title: Products from Wheat MillingPartners: Pendleton Flour Mill Inc., Mennel Milling Co.,Pacific Northwest National Lab
Title: Soy-based 2-cycle Engine OilsPartners: Terresolve Technologies Ltd., United SoybeanBoard, Smith Bucklin & Associates, Omni Tech Interna-tional.
Title: Chemicals from LignocellulosePartners: Univ. of California-Davis, Argonne NationalLab, BC International, NTEC-Versol
Title: Energy Efficient IrrigationPartner: Northwest Precision Ag Inc. (I&I)
Contact: Doug Faulkner, 202-586-2119
Agriculture
3
Title: Preventing Strength Loss of Unbleached Kraft FiberPartners: North Carolina State Univ., Hercules Inc., Interna-tional Paper Co.
Title: Mechatronic Design and Control of a Waste Paper SortingSystem for Efficient RecyclingPartners: North Carolina State Univ., SCA Packaging Research,Lions Adhesives
Title: Linear CorrugatingPartner: Mr. Lloyd Chapman (Inventions and Innovation)
Title: Guided Acoustic Wave Monitoring of Corrosion andErosion in Recovery Boiler TubingPartners: Lawrence Livermore National Lab, Weyerhaeuser Co.
Title: Laser Sensors for On-Line Monitoring of Carryover inRecovery BoilersPartners: Sandia National Lab, Weyerhaeuser Co., Georgia-Pacific Corp., McDermott Technology Inc.
Title: Development of a Field Mobile Near Infrared Sensor forMeasurement of Chemical Composition and MechanicalProperties of Standing WoodPartners: National Renewable Energy Lab, Weyerhaeuser Co.,Georgia-Pacific Corp., Boise-Cascade, U.S. Forest ServiceSouthern Research Station
Title: Evaluation and Development of a Prototype ElectrokineticSonic Amplitude SystemPartners: Pacific Northwest National Lab, Miami Univ.,Colloidal Dynamics, Weyerhaeuser Co., IPST
Title: Model-based Approach to Soft Sensing and Diagnosis forControl of a Continuous DigesterPartners: Univ. of Delaware, Weyerhaeuser Co., Westvaco,IETek
Title: BestPractices Plant-wide Energy EfficiencyAssessmentsPartner: Boise Cascade, Caraustar Industries, Inc.,GeorgiaPacific Corp., Inland Paperboard and Packaging Inc.
Title: Energy and Environmental Innovations for Chemically-Preserved Wood WastesPartner: Georgia Tech Applied Research Corp. (Inventions andInnovation)
Contact: Valri Robinson, 202-586-0937
Coming Soon! Petroleum to become9th “Industry of the Future”
The petroleum refining industry will soon join eightother energy-intensive industries when it establishes aformal “Industry of the Future” partnership with DOE.A compact signing ceremony featuring senior execu-tives from the petroleum industry, the AmericanPetroleum Institute, the National Petrochemical andRefiners Assoc. and DOE is planned. OIT’s PetroleumTeam also recently opened its first solicitation (seepage 7). (Contact: Gideon Varga, 202-586-0082)
Title: Energy Consumption of Die Casting OperationsPartners: Ohio State Univ., Premier Tool & Die Cast Corpora-tion, GM Powertrain
Title: The Effects of Externally Solidified Product on WaveCelerity and Quality of Die Cast ProductsPartners: Ohio State Univ., Briggs & Stratton Corp., Heick DieCasting Corp., Walkington Engineering
Title: Computer Modeling of Shot SleevesPartners: Ohio State Univ.,Walkington Engineering, Briggs &
Title: Effects of Die Design and Dimensional Features onThermal Fatigue Cracking of Die Casting DiesPartners: Case Western Reserve Univ., DCD Tech-nologies, General Die Casters, Procast,Lester, Thyssen, Latrobe SteelCompany, FPM HeatTreatment, A. Finkl &Sons, CSM Industries,Brush Wellman, AlloyTool Steel, Hayes-TechCenter, Chem-Trend,Badger Metal Technology
Title: Development of FatigueProperties Database for Use withModern Design MethodsPartners: Climax Research Services,Applied Process Technologies,Intermet, Caterpillar, Hayes LemmerzInternational, Lucas Varity, Wheland Foundry
Title: Optimization of Composition and Heat Treating ofDie Steels for Extended LifetimePartners: Case Western Reserve Univ., Latrobe SteelCompany, FPM Heat Treatment, Alloy Tool Steel,Hayes/CMI Tech, DCD Technology, Chem-Trend, Badger MetalTechnology
Title: Understanding the Relationship Between FillingPattern and Part Quality in Die CastingPartners: Ohio State Univ., General Die Casters,Walkington Engineering, GM Bedford, Lester Precision DieCasting
Title: Clean Cast Steel TechnologyPartner: Univ. of Alabama, American Steel Foundries,Atchison Casting Corp., Dominion Castings Ltd., FalkCorporation, Flow Technology, Harrison Steel CastingsCompany, National Castings, Inc., Pelton Casteel, Inc., The
Mining
THE OIT TIMES/WINTER 2000
5
Title: Selective Flocculation of Fine MineralParticlesPartners: Albany Research Center, JR Simplot,Peabody Group, Florida Institute of PhosphateResearch, Univ. of Kentucky, Pennsylvania StateUniv., Univ. of Idaho
Title: Robotics Technology for Improving Mining ProductivityPartners: Idaho National Engineering and Environmental Lab,Carnegie Mellon Univ., Joy Mining Machines, CONSOL Inc.
Title: Development of a Mine Compatible LIBS Instrument forOre GradingPartners: Idaho National Engineering and Environmental Lab,Advanced Power Technology Inc., JR Simplot, Baker HughesProcess, Univ. of Idaho
Title: Development of a 3-Dimensional Version of the MillsoftSimulation SoftwarePartners: Idaho National Engineering and Environmental Lab,Univ. of Utah, Process Engineering Resources Inc., BarrickGoldstrike Mines, Kennecott Utah Copper
Title: Drilling and Blasting Optimization Using Seismic Analysisand X-Ray Fluorescence SpectroscopyPartners: Lawrence Berkeley National Lab, Univ. of Arizona,Phelps Dodge Mining Inc., Thunderbird Pacific Corp.
Title: The Application of High Temperature Superconductors toUnderground CommunicationsPartners: Los Alamos National Lab, Hecla Co., CONSOL Inc.,Cyprus, Asarco, Phelps Dodge Mining Inc., Raton TechnologyResearch, WIPP, Harris Communications, Colorado School ofMines
Title: Mineral Byproduct RecoveryPartners: Oak Ridge National Lab, SepraDyne Corp., ColoradoSchool of Mines, Univ. of Arizona
Title: Development and Deployment of On-Board Lubrication Oiland Hydraulic Fluid Analysis SystemsPartners: Caterpillar Inc., Additional mining partners to be namedlater
Title: Crosswell System for Imaging Ahead of MiningPartners: Sandia National Lab, West Virginia Univ., StolarHorizon Inc., CONSOL Inc., Kennecott Utah Copper
Title: Safe and Low Cost Hydrogen Storage for Fuel Cell MiningVehiclesPartners: Savannah River Technology Center, Fuelcell PropulsionInstitute, Hydro Quebec, Univ. of South Carolina
Note: Additional mining projects to be announced soon, and willbe posted on OIT Times-on-the-web.
Contact: Toni Grobstein Marechaux, 202-586-8501
Title: Sensors for Die CastingPartners: Hayes Lemmerz Inc., Oak Ridge Natl. Lab,Briggs & Stratton, Chem-Trend, Littler Diecast Corp.,Kennedy Die-Casting, Inc., The Newten B New Haven Co.,Prince Machine Corp.
Title: The Development of Surface Engineered Coatings forDie Casting DiesPartners: Colorado School of Mines, SPX Contech, BlueRidge Pressure Castings, Hard Chrome, ISM, HayesLemmerz
Title: Age Strengthening of Gray Cast Iron, Phase IIIPartners: Tri-State Univ., LECO, Dalton Kendallville,Dalton Warsaw, Auburn Foundry, Bremen Castings, ACMColdwater, Dock Foundry
Title: Creep Resistant Zinc Alloy DevelopmentPartners: International. Lead-Zinc Research Organization,Inc., Die Makers, Eastern Alloys
Title: BestPractices Plant-wide Energy Efficiency Assess-mentPartner: AMCAST Industrial Corp.
Title: Increasing Productivity and Reducing EmissionsThrough the Enhanced Application Control of Die CastingDie LubricantsPartners: North American Die Casting Association, IllinoisDepartment of Commerce and Community Affairs (NICE3)
Title: Cryogenic Separation of Foundry Sands and Reuse ofReclaimed Streams.Partners: Air Products and Chemicals Inc., Ohio Depart-ment of Development’s Office of Energy Efficiency(NICE3)
Contact: Harvey Wong, 202-586-9235
OIT receives Special RecognitionAward from Diecasting Industry
The North American Die Casting Association presented aSpecial Recognition Award to OIT and DOE. The awardsaid that, “By considering the many points of view of thisdiverse industry, (OIT’s) Industry of the Future approach isimproving the exchange of information and helping toidentify and overcome major barriers. Coordinatedplanning also helps eliminate duplication and gaps in R&Dactivities. As a result, cycle time from technologicalconcept to application in the foundry is being reduced—insome cases to as little as 18 months.”
6
Quarterly Highlights
Inventions & InnovationTitle: Industrial Fuel Cell Micro-GeneratorPartner: Fuel Cell Technologies Inc.Title: Membrane Technology to RemoveEntrapped Air from Ammonia Refrigera-tion SystemsPartner: Enerfex Inc.
Title: A DSP-Based Power Electronics Interface forAlternate/Renewable Energy SystemsPartner: University of Houston
Title: Multielement Selective Emitter: A New HighEfficiency Incandescent Light SourcePartner: Sonsight Projects Inc.
Title: Novel 4-Way Refrigerant Reversing Valve for HeatPumpsPartner: University of Arkansas
Title: Innovative Energy-Efficient DryerPartner: Research Triangle Institute
Title: High Temperature Refractory CeramicPartner: Trilliam Thermo Technologies Inc.
Title: Electrocaloric Materials for Room TemperatureRefrigerationPartner: CeramPhysics, Inc.
Title: High Efficiency, High Capacity Cooling andRefrigerationPartner: Environmental Technology and Education Center
Title: Increasing Efficiency in Permanent Magnet DCMotors through Magnetic Pseudo Liquid-Filled Air GapsPartner: Bodine Electric Company
Title: Development of a Composite Reinforced AluminumConductorPartner: W. Brandt Goldsworthy & Associates Inc.
Title: In-Situ, Real Time Measurement of Melt Constitu-ents in the Aluminum, Glass, and Steel IndustriesPartner: Energy Research Company
Title: High Speed, Permanent Magnet Motor Testing forthe AC MarketPartner: SatCon Technology Corporation
Title: Rotary BurnerPartner: Calcpos Engineering
Title: Fault Warning Device Using Fiber-Optic PartialDischarge Sensor for Prevention of Destructive Arc Faultsin Metal-Clad Electrical Switchgear and BusPartner: Forsyth Electro-Optics Inc.
Title: Miniature, Inexpensive, Amperometric OxygenSensorPartner: CeramPhysics, Inc.
Note: Additional I&I projects are listed with the relevantIndustries of the Future.
Contact: Sandy Glatt, 202-586-3897
The OIT Times-on-the-web expanded on atrial basis
Unfortunately, listing all our new projects in the current issueof The OIT Times precluded us from providing our readerswith other continuing news about our many Industry of theFuture teams and program areas. So, on a trial basis,we’ve expanded the HTML version of The OIT Times-on-the-web to include the regular news features that our readers areaccustomed to. You can view, download or print the Winterissue of The OIT Times-on-the-web at www.oit.doe.gov/oittimes.
OIT’s NICE 3, Inventions programs accept-ing pre-proposals for 2000 solicitations
The NICE3 and Inventions and Innovation (I&I) programsare now accepting two-page pre-proposals for their FY2000solicitations through March 17, 2000. Although pre-proposalsare optional, potential applicants are highly encouraged tosubmit a desciption of their project in the format designatedby each program.
The NICE3 program funds up to $525,000 (50% cost sharingrequired) for the first commercial demonstration of industrialtechnologies that reduce energy consumption, waste produc-tion and operating costs. I&I provides financial assistance attwo levels: up to $40,000 or up to $200,000 depending on thestage of development for establishing technical performanceand conducting early development of inventions that have asignificant energy savings impact and commercial marketpotential. In addition to financial assistance, I&I offerstechnical guidance and commercialization support to success-ful applicants.
In December, Inventions and Innovation and NICE3 areexpected to concurrently announce additional new projectsthat will be listed in the Winter, 2000 issue of The OIT Times-on-the-web soon after they are selected.
For more information on pre-proposal requirements, visitwww.oit.doe.gov/nice3 and www.oit.doe.gov/inventions.
OIT’s 3rd Customer Day to help keep us“customer-focused”
OIT’s 3rd biennial “Customer Day” is planned for February16 in Washington, DC. About 200 of our customers will hearabout current OIT initiatives and provide their valuablefeedback in what promises to be a very interesting program.At a Customer Day awards ceremony OIT plans to recognizeits first annual “Technology of the Year” and “Partner of theYear.” A reception the evening before Customer Day is alsoplanned. This is a key event on our calendar and helps insureOIT remains a strongly customer-focused organization. Lookfor the Spring issue of The OIT Times for all the news about“Customer Day.”
7
THE OIT TIMES/WINTER 2000
Current OIT Solicitation Schedule*
Industry/Program RFP Proposals Due Selections Funding (approx) URL (www.):
Agriculture 12/99 2/00 4/00 $3 mil TBD
Aluminum (‘00/‘01) Past Past 1/00 $6 mil oit.doe.gov/aluminum/alsolict.html
Chemicals 3/00 6/00 9/00 $4 mil oit.doe.gov/chemical
Forest Products Past Past 4/00 $3 mil oit.doe.gov/forest
Forest Products - Biomass & Now Open 1/00 3/00 $9 mil oit.doe.gov/forest
Black Liquor Gasification
Glass 1/00 3/00 6/00 $3 mil TBD
Metalcasting 11/99 2/00 7/00 $1-2 mil TBD
Mining - Industry Past Past 12/99 $1-3 mil fetc.doe.gov/business/solicit.html
Petroleum (‘00) Now Open 3/00 4/00 $900K TBD
Steel - American Iron and 3/00 5/00 8/00 $1-2 mil steel.org/mt
Steel Institute
Steel - Industry Now Open 12/99 1/00 $5-6 mil id.doe.gov/doeid/psd/solicit.html
Inventions & Innovation (‘00) Past Past 12/99 $2.3 mil ——
Inventions & Innovation (now 5/00 7/00 12/00 $2.3 mil oit.doe.gov/inventions
accepting two page-pre-proposals)
NICE3 (‘00) Past Past 12/99 $4 mil ——
NICE3 (now accepting two page- 5/00 7/00 12/00 $4 mil oit.doe.gov/nice3/grants/grants.htmlpre-proposals)
Industrial Power - Low Emissions Now Open 1/00 3/00 $2 mil ch.doe.gov/business/acq.htm
Industrial Power - Advanced 12/18/99 2/00 4/00 $3 mil ch.doe.gov/business/acq.htm
Materials for Turbines
Industrial Power - Reciprocating 12/30/99 2/00 5/00 $2 mil ch.doe.gov/business/acq.htm
Engine
Industrial Power - Microturbine 12/30/99 2/00 4/00 $3 mil ch.doe.gov/business/acq.htm
Engine
Industrial Distributed Generation TBD TBD TBD $2 mil TBD
States IOF (tentative) Now Open 2/00 4/00 $2.8 mil oit.doe.gov/states/#solicitationPlant-Wide Energy Efficiency Now Open 1/00 2/00 $500K-700k E-mail: [email protected]
Assessments (‘00)
* As of 12/15/99. FY01 funds, unless indicated. Information in this table is periodically updated.For latest data, visit: www.oit.doe.gov/new/solicitations.shtml
8
Chemicals
Sensors & Controls
Quarterly Highlights
Title: Tunable Diode Lasers Sensors forMonitoring and Control of Harsh Combus-tion EnvironmentsPartners: American Air Liquide, Inc.,Physical Sciences, Inc.
Title: Solid-State Chemical Sensors for Monitoring Hydro-gen in IOF Process StreamsPartners: Pennsylvania State University, Air Products andChemicals, Sandia National Laboratory, DCH Technologies
Title: Diagnostics and Control of Natural Gas Fired Furnacesvia Flame Image Analysis Using Machine Vision andArtificial Intelligence TechniquesPartner: University of Missouri-Rolla
Title: Remote Automatic Material On-line SensorPartner: Quantum Magnetics, Inc.
Title: Corrosion Monitoring SystemPartners: Honeywell, Eastman Chemical Co., Oak RidgeNational Lab, Materials Technology Institute
Title: Advanced Intermetallic and Alloy for EthyleneReactors
Partners: Exxon Chemical Co., Equistar Chemi-cals—LP, Shell Chemical Co., BP Amoco, AirProducts and Chemicals, Inc., Akzo NobelChemicals, Inc., Sandvik Steel Co., Inco Alloys,Inc., Nooter Fabricators, Inc., Duraloy Technolo-gies, Inc., Oak Ridge National Lab
Title: Study of Metal Dusting Phenomenon andDevelopment of Materials Resistant to MetalDustingPartners: Argonne National Lab, Air Productsand Chemicals, Inc., DuPont Chemical Co.,Exxon Chemical Co., AlliedSignal, HaynesInternational, Avesta Sheffield, Sandvik SteelCo., Duraloy Technologies, Inc., Special Metals
Title: Separation of Aromatic IsomersPartner: Gallatin Research (Inventions and
Innovation)
Title: Plastic Manufactured from Recovered Post-ConsumerDurable GoodsPartners: MBA Polymers Inc., California Energy Commis-sion (NICE3)
Title: Low-Frequency Sonic Mixing TechnologyPartner: Montec Associates, Inc. (Inventions and Innova-tion)
Contact: Hank Kenchington, 202-586-1878
Title: Prediction of Corrosion of Alloys inMixed Solvent EnvironmentsPartners: OLI Systems, Inc., DowChemical Co., DuPont Chemical Co.,Westvaco: Membrane Technology Insti-tute, Oak Ridge National Lab
Title: Enhancement and Commercialization of the AlloySelection System for Elevated TemperaturesPartners: Shell Oil Co., Oak Ridge NationalLab, Humberside Solutions, Ltd., Materi-als Technology Institute, Texaco, Shell,Foster Wheeler Development Corp.,Caterpillar, Inco Alloys International,Haynes International, KEMA (Nether-lands), The Royal Military College ofCanada, Ecole de Polytechnique de Montreal
Title: Development of New PSA Technology toRecover Products for Waste StreamsPartners: Air Products and Chemicals, Inc.,Phillips Petroleum Co., Univ. of Kentucky
Title: Development of Integrated Workbench forGas-phase Thermodynamics, Kinetics, andReaction ModelingPartners: Colorado School of Mines, National RenewableEnergy Lab, Exxon Research & Engineering Co., MCResearch and Innovation Center, Lorentzian, Inc., ReactionDesign, Inc., Univ. of Delaware, Wesleyan Univ., NationalInstitute of Standards and Technology, Gaussian, Inc.
Title: Advanced Catalytic Hydrogenation Retrofit ReactorPartners: Air Products and Chemicals, Inc., JohnsonMatthey
Title: New Optical Coupling of Infrared Analyzers toIndustrial Processes*Partner: Advanced Fuel Research, Inc.
Title: Fiber Optic Sensor for Industrial Process Measurementand Control*Partner: Metrolaser, Inc.
Title: Real-Time Gas Composition Analyzers for On-LineProcess Control*Partner: Nanomaterials Research Corporation
Title: High-Temperature Micromachined Sensor for IndustrialGas Streams*Partner: Nanomaterials Research Corporation
* = S&C Small Business Technology Transfer Award
Contact: Eric Lightner, 202-586-8130
9
THE OIT TIMES/WINTER 2000
Industries of the Future--StatesTitle: Northeast Regional Industries of the FuturePartners: New York State Energy Research and Develop-ment Authority, New Hampshire Governor’s Office ofEnergy and Community Services, Connecticut Office ofPolicy Management, University of Massachusetts, RhodeIsland State Energy Office, Vermont Department of PublicService, Alfred University, Hofstra University, State Univer-sity of New York, Maine Department of Economic Develop-ment, University of Maine, Massachusetts Division ofEnergy
Title: Vision 2020 for the Alabama Chemical Industry:Development of a Research/ Implementation Agenda forAlternative Reaction MediaPartners: University of Alabama Huntsville, IndustrialEnergy Advisory Service, Alabama Power, Alabama Centerfor Green Manufacturing
Title: Building Capability for Industry PartnershipsPartners: Arkansas Energy Office, Arkansas Department ofEconomic Development
Title: Municipal Case Studies for Distributed Energy Re-sourcesPartners: California Energy Commission, California Alliancefor Distributed Energy Resources (CADER), City of Irvine,Association of Bay Area Governments
Title: Development of an Industries of the Future Action Planand Information Dissemination for the Colorado ForestProducts IndustryPartners: Colorado Office of Energy Conservation, McNeilTechnologies, Inc., Colorado State Forest Service, ColoradoTimber Industry
Title: Illinois Industrial Energy Technical AssessmentPartners: King Technology, Illinois Department of Com-merce and Community Affairs, Capital Surini Group Interna-tional, Inc.
Title: Kentucky Aluminum Technology RoadmapPartners: Kentucky Division of Energy, Southeast Center forAluminum Technology
Title: Action Plans for Maine’s Forest Products IndustryPartners: Maine Department of Economic and CommunityDevelopment, Maine Manufacturing Extension Partnership,Maine Chamber and Business Alliance, University of Maine,Maine State Planning Office, Central Maine Power Company
Title: Montana’s Implementation of the Forest and WoodProducts Industry Technology RoadmapPartners: TechLink, Montana Department of EnvironmentalQuality, Montana State University
Title: Ohio’s Industries of the Future Showcase Demonstra-tion Project
Partners: Ohio Department of Development, Ohio Office ofEnergy Efficiency, American Municipal Power - Ohio
Title: Oregon Industries of the FuturePartners: Oregon Office of Energy Efficiency, Oregon StateUniversity Industrial Assessment Center
Title: Implementation of the Industries of the Future in the Stateof PennsylvaniaPartners: Concurrent Technology Corporation, PennsylvaniaDepartment of Environmental Protection
Title: Industrial Technologies Benefiting Industries of the FuturePartners: South Carolina Manufacturing Extension Partnership,South Carolina Energy Office
Title: State of Utah Industries of the Future InitiativePartners: ETC. Group, Inc., Utah State Office of Energy Ser-vices, Utah Technology Finance Corporation, Utah Manufactur-ing Extension, Utah Engineering Experiment Station
Title: The Virginia Mining Industry: Making the TechnologicalTransition to the 21st CenturyPartners: Virginia Department of Mines, Minerals, and Energy,Virginia Polytechnic Institute and State University, VirginiaCenter for Coal and Energy Research, Powell River Project,Virginia Aggregates Association, Virginia Coal Association, WeirInternational Mining Consultants
Title: Guidebook for the Development of CHP at IOF IndustrialSitesPartners: Washington State University Cooperative ExtensionEnergy Program, Washington Department of Community, Trade& Economic Development Energy Division, International DistrictEnergy Association
Title: Industries of the Future - West VirginiaPartners: West Virginia University, West Virginia DevelopmentOffice
Title: Wisconsin Metal Casting Industries of the FuturePartners: Wisconsin Energy Bureau, Energy Center of Wiscon-sin, University of Wisconsin - Milwaukee
Title: Combined Heat and Power Proposal for the State of IndianaPartners: Caterpillar Gas Engines, Indiana Department ofCommerce - Energy Division
Title: Louisiana Industries of the FuturePartners: Louisiana State University, Louisiana Department ofNatural Resources
Title: Industrial TechnologiesPartners: Mississippi Department of Economic and CommunityDevelopment - Energy Division
Contact: Sandy Glatt, 202-586-3897
Quarterly Highlights
10
Combustion
A festive mood prevailed as Secretary of Energy BillRichardson visited Malden Mills on November 8 todedicate the plant’s new, advanced cogenerationsystem. The Secretary was joined by Malden MillsCEO Aaron Feuerstein, Congressman Marty Meehan(D-MA), and Max Kennedy (representing his uncle,Senator Ted Kennedy) in dedicating the system that issaving energy, cutting costs, and sharply reducingemissions at the Lawrence, MA, textile mill. The state-of-the art system, featuring continuous-fiber ceramiccomposite (CFCC) components, was developed bySolar Turbines in partnership with OIT’s IndustrialPower Generation and CFCC programs.
Calling the event “a wonderful celebration of what isgood in this country,” Secretary Richardson praised thecooperative efforts by national, state, and localofficials to make the technology demonstration projecta reality. The cogeneration system saves energy bysimultaneously generating electricity and thermalenergy for the mill, achieving an overall efficiency of73%–more than twice the efficiency of the averageU.S. power plant. The highly efficient and clean-burning system uses two innovative Solar Centaur 50gas turbine engines with CFCC liners to cut carbonemissions by 41%, reduce NOx by 58%, and virtuallyeliminate SO
2 emissions. At full production, the
project will save Malden Mills $1 million annually.
DOE Secretary Richardson helps launch high-efficiencycogeneration system at Massachusetts textile mill
The advanced cogeneration system is symbolic of thecompany’s rebirth after a devastating fire in 1995. At thattime, the mill’s charismatic, 70-year-old CEO made nationalnews by pledging to keep all employees on the payroll whilerebuilding the mill–which is a mainstay of the localeconomy. The rebuilding process, completed earlier this year,preserved the company’s old clock tower and skilled workforce, while introducing more modern design and technologyto enhance environmental performance and promote sus-tained success. Since the fire, company sales have increased40%.
The Secretary presented Feuerstein with a Certificate ofPartnership to recognize his outstanding leadership andcommitment to excellence. William Demmons, director ofengineering at Malden, was awarded a similar certificate toacknowledge the instrumental role he played in the project.
After a brief tour of the new system, Demmons was askedabout the risk involved in committing his company to acutting-edge technology. He replied that the in-houseengineering staff had worked closely with DOE and SolarTurbines in examining system capabilities, and felt totallyconfident in the technology’s ability to deliver–a confidenceborne out by the system’s performance to date. The permit-ting process presented by far the biggest hurdle to theproject. The removal of such hurdles is a key objective ofOIT’s new Combined Heat and Power Initiative.
Title: Packed Media/Transport MembraneBoiler Development and DemonstrationPartners: Gas Research Institute, Institute ofGas Technology, Donlee Technologies
Title: High-Efficiency, Low Emission Integrated ProcessHeater SystemPartners: Arthur D. Little, Inc., Exxon Research andEngineering Co., Callidus Technologies, Inc.
Contact: Gideon Varga, 202-586-0082
Aluminum
NICE 3
11
THE OIT TIMES/WINTER 2000
Title: Development of a Novel Non-Consum-able Anode for Electrowinning PrimaryAluminumPartners: Ohio State Univ. Research Founda-tion, Kaiser Aluminum Co., Siemens-
Westinghouse, Gas Research Institute
Title: Integrated Numerical Methods and Design Provisionsfor Aluminum StructuresPartners: Cornell Univ., The Aluminum Assoc.
Title: Intelligent Potroom OperationPartners: Applied Industrial Solutions LLC, West VirginiaUniv., Century Aluminum, Gensym Corp.
Title: Spray Rolling Aluminum StripPartners: Univ. of California, Colorado School of Mines,Idaho National Energy Engineering Lab, Aluminum compa-nies pending
Title: BestPractices Plant-wide Energy Efficiency Assess-mentPartner: Alcoa
Title: Brazing and Spot Welding Innovations for JoiningAluminum Alloys in Vehicle ManufacturingPartner: Innovative Technology Inc. (Inventions andInnovation)
Title: Demonstration of a High Temperature, CorrosiveResistant Recuperator for the Metals IndustryPartners: Alcoa, Indiana Department of Commerce, EnergyPolicy Division (NICE3)
Contact: Sara Dillich, 202-586-7925
SteelTitle: Controlled Thermo-MechanicalProcessing of Tubes and Pipes forEnhanced Manufacturing and Perfor-mancePartners: The Timken Co.,DaimlerChrysler Corp., Ford Motor Co.,
Friedrich Kocks Gmbh & Co., Idaho Nat=l EnergyEngineering Lab, National Research Council Canada,Oak Ridge National Lab, Univ. of British Columbia,U.S. Steel Group
Title: Research Related to the Development of theAutomated Steel Cleanliness ToolPartners: R.J. LeeGroup Inc., R.J. LeeInstruments,Ltd., R.J.FruehanConsulting,Oak RidgeNational Lab,U.S. Steel, CSC,Ltd., LTV Steel Co.,MacSteel, Inc.
Title: Development and Demonstration of Novel Low-NO
x Burners for Boilers in the Steel Industry
Partners: Institute of Gas Technology, Covol Technolo-gies, Detroit Stoker Co.,Univ. of Utah
Title: BestPractices Plant-wide Energy EfficiencyAssessmentPartner: Crucible Specialty Metals
Title: Clean Production of Coke from Waste Carbon-aceous FinesPartner: Combustion Resources (Inventions andInnovation)
Title: Hot Mill Transfer Bar Rapidfire Edge Heat ProjectPartners: Weirton Steel Corporation, West VirginiaEnergy Efficiency Program (NICE3)
Title: Method of Making Steel Strapping & StripPartner: Robert Reilly & Associates (Inventions andInnovation)
Title: Portable Parallel Beam X-Ray Diffraction Systemfor In-Line Process Control in the Steel IndustryPartner: X-Ray Optical Systems, Inc. (Sensors &Controls)
Note: Additional steel projects to be announced soon,and will be posted on OIT Times-on-the-web.
Contact: Scott Richlen, 202-586-7925
Title: A Device for Efficiently and UniformlyDrying Nonwoven Materials Using Micro-wave TechnologyPartners: Industrial Microwave Systems Inc.,North Carolina Department of Environmentand Natural Resource
Note: Additional NICE3 projects are listed with the relevantIndustries of the Future.
Contact: Lisa Barnett, 202-586-2212
12
Information Corner
To request copies, call 1-800-862-2086.
IPLocator 3.0 scheduled for release
Identifying R&D opportunities within the Federal government can be adaunting task. OIT’s Industrial Projects Locator (IPLocator) addressesthat challenge and helps leverage Federal and private R&D resourcesby providing industry customers with an accessible, centralized sourceof R&D and contact information. The IPLocator is a user-friendlydatabase of over 10,000 industrial-related R&D projects that aresupported by the Federal government.
The IPLocator is both comprehensive and easy to use. Users can searchfor opportunities by key word, agency, funding amount, industry, orproject start date. Search results provide the project title, performingorganization and other participants, sponsoring agency, points ofcontact, a project abstract, funding amounts and vehicles, beginningand ending dates, and other relevant data.
With the continued cooperation of other Federal agencies, OITperiodically updates the IPLocator to include the most current ongoingand recently completed R&D projects. The latest version of theIPLocator, Version 3.0, is scheduled for CD-ROM distribution inFebruary, 2000. Improvements to Version 3 will allow faster searchingand sorting.
The IPLocator is available at no charge on CD-ROM; over 2,000 CDshave been distributed to date. Toll-free telephone and email support arealso available for user questions and comments. Users can also accessthe most up-to-date data in the on-line version of the IPLocator at http://www.oit.doe.gov/iplocator.shtml. (Contact: Jim Quinn, 202-586-5725)
Engineering Ceramics & Structures Conference,Port Canaveral, FL, Jan 23-28, 2000
Pump Systems/PSAT Workshop, Novi, MI, Jan27, 2000, contact Anna Maksimova at 360-754-1096, ext. 100
Pump Systems/PSAT Workshop, Vancouver,WA, Jan 27, 2000, contact Anna Maksimova at360-754-1096, ext. 100
Paper Week International 2000, MontrealQuebec, CAN, Jan 31-Feb 4, 2000
Combined Heat and Power: Energy Solutions forthe 21st Century, Washington, DC, Feb 1-2, 2000
Society for Mining, Metallurgy, and Exploration(SME) Annual Meeting and Exhibition, SaltLake City, NV, Feb 28-Mar 1, 2000
“Commodity Classic” Trade Show andExposition, Mar 5-7, Orlando, FL
A Celebration of Steel: The Pittsburgh RegionalSteel Showcase, Pittsburgh, PA, May 4-5, 2000
IGTI, ASME Turbo Expo, Munich, GER, May 8-11, 2000
Calendar
NEW PUBLICATIONS
OIT Information Resources Catalog, 2000
1999 State Fact Book
Continous Fiber Ceramic Composite Program PlanUpdate—Accomplishments and Program CompletionRoadmaps
Combined Heat and Power: A Vision for the Future
Combined Heat and Power in the State of California
Conservation in Combustion, also available on-line atwww.oit.doe.gov/combustion
IPLocator Version 3.0
Inventions to Innovation (revised)
Title
EDITORIAL
Industry Trends
13
Now open! “One-stopshop” for questions aboutOIT products, servicesBy Lou SousaManaging Editor, The OIT Times
• An R&D manager in the forest productsindustry wanted to know about potentialGovernment cost-sharing opportunities.
• A refinery facility manager needed helpjustifying a preventative maintenanceprogram for his steam system.
• An aluminum industry supplier heardabout the industry’s vision and roadmapsand wanted to know how to get copies.
• A foundry with 8000 hp of air compres-sors had a moisture carry-over problem.
• A glass firm was looking for funding tohelp demonstrate an innovative meltingtechnology.
• A chemical manufacturer heard that OIThelps plants assess their energy con-sumption and opportunities for im-proved performance.
What do these people have in common?They all called OIT’s new InformationClearinghouse for help!
These questions—and many more—make upa typical day for the engineers and staff atour new Clearinghouse. They are gettinghundreds of calls monthly from all over thecountry with pressing questions about how tomake industrial plants more competitive andenergy efficient, businesses more profitable,processes more reliable.
You, too, are invited to call them about anyof the products and services that OIToffers—including technical assistance foryour motor, steam, compressed air andcombined heat and power systems. Staytuned to future issues of The OIT Times andour web site for more details about our newClearinghouse.
As OIT partners with U.S. industry todevelop and deliver technologies and bestpractices that improve efficiency and profitsand reduce waste, our Clearinghouse can beyour first stop on the way to solutions.They’re open 9 am to 8 pm EST. Call them at1-800-862-2086!
THE OIT TIMES/WINTER 2000
Projected Cost Savings fromE-Commerce on the Internet, 2002
Manufacturing
Metals/Natural
Resources
0
$10
$20
$30
$40
$50
$60
Chemicals
Energy
Bill
ions Total Projected
Cost Savings
Source: Giga Information Groupand Manufacturing News
Metals/Natural
Resources
As Percentof TotalRevenues
0%
1%
2%
3%
4%
5%
6%
Chemicals
Energy
Manufacturing
THE OIT TIMES/WINTER 2000
Office of Industrial Technologies, EE-20Energy Efficiency and Renewable EnergyU.S. Department of EnergyWashington, DC 20585www.oit.doe.gov
Content reprintable without permission.Correspondence, including requests foradditional copies, or to be added to ordeleted from the mailing list, may bedirected to:
THE OIT T IMES“Turning Industry Visions into Reality”
On November 4, 1999, OIT, the North American DieCasters Association (NADCA), and Lester Precision DieCasting hosted a technology showcase to demonstrateenergy efficiency and productivity advancements inLester’s Twinsburg, OH, facility. Over 300 guests fromthe die casting industry, academia, and governmentattended the event, which featured facility tours, as wellas “Tech Talks” by some of the nation’s leading diecasting researchers.
The showcase highlighted technologies developedthrough OIT’s Metalcasting Industry of the Future(IOF) program. IOF program participants, includingDOE, NADCA and hundreds of partners from themetalcasting industry and academia, perform cost-sharedR&D to address both DOE’s national energy efficiencygoals and industry goals outlined in the Metal CastingIndustry Technology Roadmap. This research has resultedin numerous technology advances that have beenimplemented at plants like Lester’s Twinsburg facility.
The facility tour featured technologies like visualizationtools and advanced computer modeling programs. Lesteralso demonstrated how OIT-supported R&D is enhancing thequality of die-cast products. For example, high magnesium-content castings enable lighter weight automotive castingsthat can meet stringent load and strength requirements. A“crosscutting” technology highlighted on the tour was aninnovative membrane system designed to treat Lester’swastewater that was developed in partnership with DOE’sIdaho National Engineering Lab.
The tour also focused on Lester’s use of OIT BestPracticesresources—products and services that help industry becomemore energy efficient today. For example, Lester highlightedenergy-saving technologies and processes implemented as aresult of an OIT-sponsored energy audit, one of OIT’s manyBestPractice resources.
Diecaster teams with OIT in hosting technology showcase
