R&D Portfolio

Fatigue Resistant Energy Efficient (FREE) Welding
This project aims to achieve the capability to weld in multiple orientations with high fatigue strengths. Successful development of this technology could reduce total energy requirements by 35%; improve fabrication weld cycle time by up to 30%; and reduce distortion of fabricated structures by 20%. (PDF 746 KB). Download Adobe Reader.

The Industrial Energy Systems program provides cost-shared funding for R&D projects that address industry-wide priorities in the most energy intensive industrial systems. Priorities are set based on national goals for energy and the environment. Funded projects focus on potentially high-payoff technologies and resources that are too risky or costly to attract adequate private funding.

Active and Completed R&D

The Industrial Energy Systems Subprogram has both active and completed R&D projects that are carried out by the:

Chemical Industry Challenge

Chemical Industry Innovative Energy Systems Challenge is an R&D initiative to significantly improve energy systems that are integrated with chemical processing and energy supply systems within chemical plants. By 2020, innovations in these systems could result in savings of more than 700 million Btu and $2-3 billion dollars per year. For more information, read the project overview (PDF 63 KB) Download Adobe Reader.

The Innovative Energy Systems Challenge is supporting technology development to reduce energy losses in the U.S. chemicals industry.

Illustration of how Industrial Energy Systems lead to Chemical Industry Energy Opportunities. Power and Steam Generation (Power Cogeneration, Renewable Energy Systems, and Fuel Flexible Systems) lead to 1,251 trillion Btu (TBtu), Offsite Electricity Losses, 328 TBtu Onsite Boiler Losses, and 54 TBtu Onsite Power Losses in Chemical Industry Energy Opportunities. Heat Integration and Energy Management (Tools and Controls, Energy Transmission and Distribution, and Energy Storage) lead to 985 TBtu Heat Losses and 3,499 TBtu Wasted Heat. Heat Transfer and Energy Recovery (Heating System Upgrades, Advanced Heat Transfer Systems, Corrosive Steam Handling, and Waste Heat and Byproducts Recovery) lead to -2,000 TBtu Waste Heat and Millions of Pounds of Chemical Releases.