DOE Selects 32 New Projects to Improve Energy Efficiency in U.S. Industry

November 12, 2003

WASHINGTON, DC -- Secretary of Energy Spencer Abraham today announced the Department of Energy's (DOE) selection of 32 new projects to improve energy efficiency in U.S. industry. DOE will invest $61 million over the duration of the projects, while industrial partners will put in more than $54 million for a cost-shared investment worth a total of $115 million over the next three years. Two dozen of these projects will pursue collaborative research, development and demonstration (RD&D) of new, energy-efficiency technologies; eight will identify opportunities to boost energy efficiency and productivity in industrial plants using technologies and practices available today.

"These technologies will improve productivity, save energy and reduce environmental impacts in many energy-intensive industries in the nation today," Secretary Abraham said. "The Department of Energy is working closely with industry to help improve energy efficiency leading to America's energy independence."

The projects involve cooperation among more than 150 private companies plus universities, research institutions and Energy Department national laboratories. The department selected all of the projects for negotiation through an open, competitive solicitation process. Seven of the RD&D projects target technologies for the glass or metal casting industries. Seventeen focus on technologies that can be applied throughout industry: advanced industrial materials and sensors and automation.

List of Projects (PDF 76 KB)

Glass R&D

Energy-Efficient Glass Melting: The Next Generation Melter. The Gas Technology Institute will lead a team including six glass companies (Corning Incorporated, PPG Industries, Owens Corning, Schott Glass Technologies, Johns Manville, and CertainTeed) and several suppliers (Fluent Inc., Praxair, A.C. Leadbetter and Son, Eclipse/Combustion Tec) to design and fabricate a pilot-scale submerged combustion glass melter. Once the melter has been fabricated, two series of tests will be performed, and product glass properties will be analyzed. Submerged combustion melting offers the potential to decrease operating and capital costs and significantly lower energy use and emissions, all with a simple design and high reliability. DOE will be providing $3,833,000 of funding for the project, with project participants and the New York State Energy Research and Development Authority providing $2,168,000 in cost-shared funds. David Rue (david.rue@gastechnology.org).

High-Intensity Plasma Glass Melter. Plasmelt Glass Technologies, in collaboration with Johns Manville and Advanced Glassfiber Yarns, will develop a plasma-melting system that is generically suited to melting a large variety of glass compositions. A prototype system will be constructed and tested, and product quality will be evaluated. A modular, high-intensity plasma melter could benefit the U.S. glass industry by significantly reducing energy consumption and reducing emissions while maximizing return on investment. In addition, plasma melting may enable the melting of new glass compositions and products. DOE funding for this project will be $1,076,664, while participants will provide $461,428. Ron Gonterman (Ron@plasmelt.com).

Development/Demonstration of an Advanced Oxy-Fuel Fired Front-End System. Owens Corning will collaborate with Osram-Sylvania, Thomson, BOC Gases, and Eclipse/Combustion Tec to develop a novel, oxy-fuel fired front-end system. After laboratory design testing of burners and system control, the system will be demonstrated in a commercial fiberglass production plant. Oxy-gas-fired front-end technology has the potential to significantly reduce natural gas consumption in the overall glass manufacturing process, as well as lower NOx and CO2 emissions. DOE and project partners will each contribute $900,015 in funding for the project. Christopher Jian (christopher.q.jian@owenscorning.com).

Metal Casting R&D

Energy-Saving Melting and Revert Reduction Technology (Energy SMARRT). The Advanced Technology Institute of Charleston, South Carolina, will lead a research team that includes the University of Alabama, the University of Iowa, University of Missouri (Rolla), CANMET Energy Tech Center of Canada, Case Western Reserve University, Eck Industries (Wisconsin), Worcester Polytechnic Institute, INEEL, Ohio State University, Colorado School of Mines, Iowa State University, Lehigh University, International Lead Zinc Research Organization, and Edison Materials Tech. Center. The project, known as Energy SMARTT, is a balanced portfolio of tasks to make significant improvements in energy efficiency over the next 10 years. This portfolio will improve existing efficiencies dramatically, while developing breakthrough technologies to revolutionize casting production. The team will identify maximum energy savings opportunities for current technologies and processes, and will examine the theoretical minimum energy requirements for existing and new melting technologies. DOE will invest $11,560,492 and over 100 industry partners will provide $11,560,494 in cost share for the project. Mike Gwyn (gwyn@aticorp.org).

In-Situ, Real-Time Monitoring and Control of Mold Making and Filling Processes. Tennessee Technological University will lead ORNL, Walford Technologies, and nine other partners in developing an innovative approach to introduce technologies for real-time characterization of sand molds, lost foam patterns, and monitoring of the mold filling process. The proposed technology will enable better control over the casting process, reducing scrap and improving casting quality. A strong educational component is integrated into the research plan to increase awareness of the industry professional, the potential benefits of the developed technology, and the potential benefits of cross cutting technology. DOE will provide $1,543,000 and the industrial partners will provide $1,698,000 in cost share for the project. Lela Cowan (lmcowan@tntech.edu).

Development of Computational Tools for the Assurance of High-Strength and Fatigue-Resistant Aluminum Castings. General Motors will lead a team consisting of ORNL, the University of Wisconsin, CompuTherm, EKK, and Worcester Polytechnic Institute in a project to develop computational techniques for alloy design, melt treatment, microstructure control, and heat treatment optimization of aluminum castings. With these computational tools, designers of aluminum components and casting engineers can optimize the alloy, as well as the casting and heat treatment processes to achieve strength and fatigue life requirements with minimum lead times and cost. DOE will provide about $2,765,620 in funding with industry providing an equal amount of cost share. Charles Gough (charles.gough@gm.com).

Advanced, Scalable Clean Aluminum Melting Systems. Secat, Inc., will lead a team including ORNL, the DOE Albany Research Center (Oregon), the University of Kentucky, E3M, and nine other partners in a project to develop and integrate the technologies necessary to substitute immersion heating for the conventional radiant burner methods used in reverberatory furnaces. Specifically, the project will couple heater improvements with furnace modeling to enable cost-effective retrofits to a range of existing furnaces, reducing the economic barrier to application and significantly reducing the energy and environmental impacts of melting aluminum. DOE will provide $1,875,000 and the industrial partners will provide $2,175,000 in cost share for the project. Subodh Das, skdas@engr.uky.edu).

Sensors & Automation R&D

Wireless and Sensing Solutions Advancing Industrial Efficiency. Honeywell International is leading a collaborative R&D project involving the University of Illinois at Urbana-Champaign, Caviton, Inc., Axonn, Ember Corporation, EPRI, and iAculum. The partners will create and field test an affordable and easy-to-use wireless network technology for industrial environments and will develop and demonstrate innovative sensor technologies for sampling and analyzing gaseous and liquid process streams. These technologies will reduce process upsets, lower energy consumption, reduce emissions, and enhance competitiveness. DOE and the partnership will each contribute $5,168,713 over the life of the project. Keith Curtner (keith.curtner@honeywell.com).

Distributed Wireless Multi-sensor Technologies. GE Global Research is heading up a project with Rensselaer Polytechnic Institute to develop a novel, low-cost wireless sensor system to measure multiple parameters at multiple locations on or around motors. The innovations will dramatically reduce the cost of owning motor monitoring systems, which should accelerate technology adoption and enable energy savings in motor systems throughout industry. DOE and the partnership will each contribute $2,990,187 in funding for the project. Jay Zhang (zhangj@crd.ge.com).

Eaton Wireless Sensor Network for Advanced Energy Management Solutions. Eaton Corporation is leading a partnership with Red Wing Technologies and Adventium Laboratories to research, test, develop, and deploy a self-configuring wireless sensor network that operates within a range of open wireless protocols and integrates with advanced energy management software. End-user partners BP, International Paper, and Weyerhaeuser will participate in field trials and requirements planning for the network, which is designed for application in a broad range of manufacturing industries. DOE is investing $3,000,000 to the project while the partnership is contributing $3,057,567 in cost-shared funding. Jeff Danowski (jeffrywdanowski@eaton.com).

Boiler and Furnace Efficiency Improvement with Low-Cost CO Sensor and Burner Control System. TIAX LLC is leading a project with the COEN Company to develop an effective, affordable system for reliably reducing excess air usage in industrial boilers and furnaces. The system combines an innovative concept for accurate CO measurement with a neural network burner control system. Potential energy savings from this single, low-cost technology are significant, and the expected simple payback period is less than six months. DOE and the partnership are each contributing $2,868,475 to the project funding. Howard Mason (Mason.howard@tiax.biz).

Surface Quality Assured Steel Bar Project. OG Technologies will develop and demonstrate a prototype system to minimize surface-quality-related rejects currently plaguing the U.S. special quality steel bars and rods industry. By integrating imaging, advanced signal processing, predictive process controls, and a new business protocol, the new system has the potential to reduce annual energy consumption by 6 trillion Btu and annual operating costs by more than $200 million in the special-quality bar rolling and forging industries. DOE is investing $2,500,000 and OG Technologies is supplying $2,537,160 in cost-shared funding for the project Tzyy-Shus Chang (chang@ogtechnologies.com).

Industrial Materials R&D

Materials for Industrial Heat Recovery Systems. Weyerhaeuser Company of King, Washington, will lead an R&D team consisting of Andritz, Inc, Babcock & Wilcox o U.S. and Canada, Domtar, Inc, Eclipse, Inc., Georgia-Pacific, Kvaerner Power, MeadWestvaco, Sandvik Materials Technology, Secat, Inc., Welding Services Inc., Georgia Institute of Technology, University of Kentucky, Paprican, and Oak Ridge National Laboratory. The team will address materials solutions for enhanced heat recovery and reliability in industrial systems. Implementation of materials improvements and associated enhancements in reliability and production capacity are expected to yield significant energy savings. DOE will contribute $3,160,000 of the total project cost of $5,137,000 for the three-year project. Denny Hunter (denny.hunter@weyerhaeuser.com).

Development of Functionally Graded Materials for Manufacturing Tools and Dies and Industrial Processing Equipment o Carpenter Powder Products of Bridgeville, Pennsylvania, in collaboration with Techneglas Corporation, THT Presses Inc., GKN Sinter Metals, Metaldyne Corporation, South Dakota School of Mines and Technology, and Pacific Northwest National Laboratory, will develop functionally graded structures made from ferrous- or nickel-based materials and composites, as well as unique near-net-shape manufacturing processes, to produce tools, dies and equipment for multiple manufacturing industries. These tools and dies are expected to provide significant reductions in energy consumption for various industrial processes by reducing scrap and improving thermal management during manufacturing. DOE will contribute $2,425,000 of the total project cost of $3,850,000 for the three-year project. Louis W. Lherbier (lherbier@cartech.com).

Structurally Integrated Coatings for Wear and Corrosion o Caterpillar Inc. of Peoria, Illinois, working with Deloro Stellite, Select Arc Inc., The University of Illinois, Iowa State University, QuesTek Innovations LLC, Oak Ridge National Laboratory, and Albany Research Center, will develop cost-effective materials and processing solutions to address the wear and corrosion of engineering components. These technologies will lead to significant energy savings in comparison to carburizing and other conventional surface treatment techniques. DOE will contribute $1,828,593 of the total project cost of $3,657,218 for the three-year project. Philip McCluskey (mccluskey_philip_h@cat.com).

Multifunctional Metallic and Refractory Materials for Energy-Efficient Handling of Molten Metals - West Virginia University will lead a team of partners, including Allen Engineering, Metaullics Systems, Sturm Rapid Response Center, Allied Minerals, Monofrax Refractory, Thermal Ceramics, AK Steel, MORCO Refractory, Unifrax, Teckcominco, Pechiney Rolled Products, Vesuvius McDanel, Duraloy Technologies, Weirton Steel, Emhart Glass, Special Metals Magneco/Metrel, Deloro Stellite, Praxair Technologies, Blasch, R.E. Moore and Associates, Energy Industries of Ohio, International Lead Zinc Research Organization, Secat, Inc., West Virginia IOF, West Virginia Steel Futures, Inc., and Oak Ridge National Laboratory. The team will develop multifunctional materials and surface treatments to extend the life of containers and submerged hardware for molten metal production. Improvements in thermal efficiency and enhanced service life of hardware and containers are expected to yield significant energy savings during metals processing. DOE will contribute $2,909,925 of the total project cost of $5,682,788 for the three-year project. Alan B. Martin (Alan.Martin@mail.wvu.edu).

Development of Materials Resistant to Metal Dusting Degradation o Materials Technology Institute of St. Louis, Missouri, working with Air Products and Chemicals, Haldor Topsoe, Special Metals, Haynes International, ConocoPhilips, Rolled Alloys, ThyssenKrupp VDM, Alon Surfaces, ExxonMobil, Sandvik, DuPont, and Argonne National Laboratory, will develop metallic alloys and surface engineering for commercial alloys to improve corrosion resistance and high-temperature mechanical properties in order to mitigate metal dusting degradation during high-temperature manufacturing processes. Considerable energy savings and improvements in process efficiency and product yield are expected as a result of these technologies. DOE will contribute $450,000 of the total project cost of $1,052,500 for the three-year project. James M. Macki (jimmacki@olyten.com).

Development of Bulk, Nanocrystalline Cemented Tungsten Carbide for Industrial Applications o The University of Utah of Salt Lake City, Utah, in collaboration with Kennametal, Inc., Smith International, Inc., and Idaho National Engineering & Environment Laboratory, will employ an innovative powder manufacturing process to develop fully consolidated nanocrystalline cemented tungsten carbide materials for multiple industrial sectors, including metalworking, mining, chemicals, and oil and gas exploration. Energy savings will be realized through more efficient powder processing and consolidation, and through increased tool life and reduced down time. DOE will contribute $1,358,000 of the total project cost of $1,963,000 for the three-year project. Vincent Bogdanski (vincent.bogdanski@osp.utah.edu).

Advanced Integration Of Multi-Scale Mechanics and Welding Process Simulation in Weld Integrity Assessment o Engineering Mechanics Corporation of Columbus (EMC2) of Columbus, Ohio, will lead a team consisting of Shell Oil Company, ChevronTexaco, Southern California Gas Company, Global Industries, US Steel, Duke Energy, Columbia Gas Transmission, Pipeline Research Council International (PRCI), Massachusetts Institute of Technology, Northwestern University, and Oak Ridge National Laboratory. The team will develop an advanced methodology for assessing weld performance and reliability in the chemical, energy, welding, and other manufacturing industries in which performance of welds is a significant safety and economic factor. Significant energy savings are expected as a result of weld process optimization and extended weld lifetimes. DOE will contribute $1,500,000 of the total project cost of $2,250,000 for the three-year project. Yong-Yi Wang (wangemc2@columbus.rr.com).

Development and Implementation of Advanced Wear and Corrosion Resistant Systems through Laser Surface Alloying and Materials Simulation o The Applied Research Laboratory, Pennsylvania State University of State College, Pennsylvania, in collaboration with Spirex Corporation, Praxair Surface Technologies, Inc., Alvord-Polk Corporation, ALSTOM Power, Inc., Synergis Technologies Group, Lumonyx Corporation, and Oak Ridge National Laboratory, will use laser processing techniques to develop and implement ultra-hard coatings through the formation of wear resistant, composite surface structures. Significant improvements in energy efficiency and productivity are expected as a result of enhanced component performance and reduced dependency on the environmentally unfavorable chromium electroplating process. DOE will contribute $255,000 of the total project cost of $465,000 for the three-year project. Pamela R. Righter (prk3@psu.edu).

Prediction of Corrosion of Advanced Materials and Fabricated Components o OLI Systems of Morris Plains, New Jersey, will work with Haynes, ChevronTexaco, Dupont, Shell, Mitsubishi Chemical, Toyo Engineering, and Southwest Research Institute to develop and calibrate comprehensive models for predicting localized corrosion in severe industrial environments and the service life of process equipment. Research is expected to produce substantial improvements in energy and process efficiencies as a result of reduced heat transfer losses and unplanned shutdowns due to corrosion of industrial piping and equipment. DOE will contribute $2,089,747 of the total project cost of $3,204,479 for the three-year project. Marshall Rafal (mrafal@olisystems.com).

Advanced Thermoelectric Materials for Efficient Waste Heat Recovery in Process Industries o PPG Industries, Inc. of Pittsburgh, Pennsylvania, in collaboration with Visteon Automotive Systems, Owens-Illinois, Leadbetter, Michigan Technological University, and Pacific Northwest National Laboratory, will develop high-efficiency thermoelectric energy conversion materials and technology to recover waste energy from exhaust gas and other infrastructure heat losses in industrial processing plants. Significant energy efficiency improvements are expected for process industries through retrofitting of furnaces with thermoelectric generators for recovery and reuse of waste heat from melting. DOE will contribute $1,950,000 of the total project cost of $3,615,000 for the three-year project. Joni Pattock (jpattock@ppg.com).

Low-Temperature Surface Carburizing of Stainless Steels o Swagelok Company of Solon, Ohio, will lead a team of partners including Spirax Sarco Inc, Case Western Reserve University, Energy Industries of Ohio, and Oak Ridge National Laboratory in developing and evaluating low-temperature, colossal supersaturation (LTCSS), a new processing method for improving the surface hardness and degradation resistance of austenitic stainless steels. Substantial energy savings are expected through extended service life and improved efficiency of pumps, pump casings and other stainless steel components used in aqueous environments. DOE will contribute $1,485,000 of the total project cost of $2,544,400 for the three-year project. Dr. Sunniva Collins (sunniva.collins@swagelok.com).

Advanced Research Proposal on Use of High-Strength/High-Alkaline-Resistant Fe-Phosphate (Hhfp) Glass Fibers as Concrete Reinforcement o Mo-Sci Corporation of Rolla, Missouri, will work with University of Missouri-Rolla and industrial partners to evaluate selected glass fiber compositions for use in concrete reinforcement. Energy benefits will be realized through lower fiber processing temperatures, extended furnace lifetimes, and enhanced chemical resistance of the reinforced concrete. DOE will contribute $960,000 of the total project cost of $1,371,000 for the three-year project. Delbert Day (day@umr.edu).

Plant-Wide Assessments

Plant-Wide Energy Assessment for Owens Corning Plant. Owens Corning of Santa Clara, California, will evaluate all major energy-consuming systems required for the glass-melting and fiber-forming processes. The team will focus on efficiency and identify opportunities for state-of-the-art and emerging technologies as part of an overall assessment that will include the adoption of best practices in the design, management, operation, and procurement of systems that support production (i.e., steam, compressed air, etc.). DOE will provide $100,000 and Owens Corning will contribute $371,000 for the assessment. Fred Dannhauser (fred.dannhauser@owenscorning.com).

Norco Chemical Plant Factor 4 Eco-Efficiency Innovation Lab. Shell Chemical of Norco, Louisiana, has hired Rocky Mountain Institute to conduct a study and identify opportunities to improve the eco-efficiency of the chemical plant. Target eco-efficiency improvements include energy conservation, improved product yields, waste reduction, and reduced air emissions. Shell Chemical will provide $220,000 and DOE will