Next Generation Manufacturing Processes
New process technologies can rejuvenate U.S. manufacturing. Novel processing concepts can open pathways to double net energy productivity, enabling rapid manufacture of energy-efficient, high-quality products at competitive cost.
Four process technology areas are expected to generate large energy, carbon, and economic benefits across the manufacturing sector. Click the areas below to view our current projects in each.
Reactions and Separations: New technologies that provide high energy efficiency and process intensification can yield dramatic energy and cost savings in a range of industries, including oil refining, food processing, and chemical production. Example technologies include separation processes that rely on high-performance membranes and catalysts.
- Advanced Nanostructured Molecular Sieves for Energy-Efficient Industrial Separations (pg. 8)
- Advanced Water Removal via Membrane Solvent-Extraction Technology
- Distributive Distillation Enabled by Microchannel Process Technology (pg. 9)
- Engineered Osmosis for Energy-Efficient Separations: Optimizing Waste Heat Utilization (pg.6)
- Launching A New Route To Styrene Monomer - SBIR Phase III Xlerator Program (pg.3)
- New Design Methods and Algorithms for Multi-component Distillation Processes
- A New Method for Producing Titanium Dioxide Pigment and Eliminating CO2 Emissions (pg. 9)
- Process Intensification with Integrated Water-Gas-Shift Membrane Reactor
- Real-Time Remote Detection of HR-VOC Content in Flares - SBIR Phase II Recovery Act
- Reduction of Distillation Usage in the Manufacture of Ethanol By Reactive Water Separation - SBIR Phase III Xlerator Program (pg. 3)
- Reduction of Metal Oxide to Metal Using Ionic Liquids (pg. 5)
- Ultra-High-Efficiency Aluminum Production Cells
High-Temperature Processing: Non-thermal or lower-energy alternatives to conventional, high-temperature processing technologies will enable more efficient production or recovery of critical materials (metallic and non-metallic). Such technologies could enable or enhance water-based, selective extraction of critical materials from low-grade ores; recovery of high-value materials in obsolete electronic equipment and waste; and low-temperature, high-efficiency chemical or electrochemical processes.
- Advanced Laser-Based Sensors for Industrial Process Control
- Energy Efficient Melting and Direct Delivery of High Quality Molten Aluminum
- Fuel-Flexible Combustion System for Refinery and Chemical Plant Process Heaters
- Fuel-Flexible, Low Emissions Catalytic Combustor for Opportunity Fuels
- Improved Heat Recovery in Biomass-Fired Boilers
- Low-Emissions Burner Technology using Biomass-Derived Liquid Fuels
- Minimization of Blast Furnace Fuel Rate by Optimizing Burden and Gas Distribution
- Novel Steels for High-Temperature Carburizing (pg. 7)
- Paired Straight Hearth Furnace
- Rapid Conditioning for Next-Generation Melting (pg. 9)
Waste Heat Minimization and Recovery: Technology advances in ultra-efficient steam production, high-performance furnaces, and innovative waste-heat recovery will help to improve sustainability, reduce water usage, and decrease the energy footprint of U.S. manufacturing.
Sustainable Manufacturing: New manufacturing technologies that reduce process steps, materials usage, or part counts will reduce the energy embedded in the manufacturing value chain and decrease the use of raw materials in multiple markets. The same is true of technologies that enable the manufacture of materials or components that increase recycling and recyclability. Upon initial product conceptualization, new design and process tools could enable selection of a manufacturing process to meet specific cost, time, energy intensity, and life-cycle energy consumption requirements.
- Dry Kraft Pulping at Ambient Pressure for Cost-Effective Energy Savings and Pollution Deductions (pg. 3)
- Electrohydraulic Forming of Near-Net Shape Automotive Panels
- Energy Saving Melting and Revert Reduction Technology (E-SMARRT)
- Flexible Hybrid Friction Stir Joining Technology
- Hot Rolling Scrap Reduction through Edge Cracking and Surface Defects Control
- New Manufacturing Method for Paper Filler and Fiber Materials (pg. 8)
- Ultra-Efficient and Power-Dense Motors
Projects are also continuing under the former AMO R&D area: Combined Heat and Power.