Energy Intensive Processes (EIP)

Zhili Feng, fengz@ornl.gov, (865) 576-3797

Background: Friction Stir Welding (FSW) is a novel solid-state joining process which can reduce the energy used in welding by 60-80% while producing higher quality welds. FSW is now a very successful "specialty" welding process used for aluminum and other low melting materials. Current gantry systems for FSW are limited to in-house fabrication of simple geometry and thin sectioned structures. FSW has captured only a small fraction of overall welding market due to its limitations in steel, complex structures, thick-sections, and the lack of on-site construction capability.

Goal: The goal of this project is to transform friction stir welding into a mainstream materials joining technology by enabling on-site construction of large, complex and typically thick-sectioned structures of high-performance and high-temperature materials. The project will develop new materials for FSW tools, develop hybrid FSW with auxiliary heating to reduce forge load, and develop multi-pass multilayer technology for very thick-sections. The partners will then develop portable a field-deployable FSW system to provide flexibility and affordability for on-site construction. The initial application of this technology will be for large oil and gas pipelines.

Partners: ExxonMobil Corporation, ESAB Group, Inc, MegaStir Technologies, Edison Welding Institute

Gail Mackiewicz Ludtka, ludtkagm@ornl.gov, 865-576-4652

Background: High Magnetic Field Processing (HMFP) is a transformational materials processing technology that adds a new dimension to materials processing. Magnetic fields can enhance reaction kinetics and shift the phase boundaries targeted by heat treatment to enhance material performance and eliminate heat treatment steps. Huge energy savings are possible through the elimination of heat treatment steps and the use of superconducting magnets.

Goal: The goal of this project is to develop magnetic processing for industrial steels for use during continuous cooling operations through eliminating/optimizing high temperature processing treatments and eliminating: cryogenic processing. The project will also develop higher field (>9T), larger-bore-size (>6-inch) magnet technology designs for the next generation magnet system which will enable treatment of larger scale industrial components. ORNL will work with project partners to eliminate a processing step while improving performance of a steel alloy of interest to each partner.

Partners: American Magnetics Inc., AjaxTOCCO, American Safety Razor, Carpenter Technologies, Caterpillar Inc.

Jim Keiser, keiserjr@ornl.gov, (865) 574-4453

Background: Greater utilization of biomass fuels offers a means to reduce U.S. dependence on imported fossil fuels. The efficiency of boilers in recovering heat is generally controlled by the maximum operating temperature. The maximum operating temperature in turn is frequently limited by the corrosion rate of the superheater tubes which is strongly dependent on the melting point of the deposits that accumulate on the tubes. Improved heat recovery can be accomplished by raising superheater temperatures, which requires decreasing the corrosion rate of the superheater tubes.

Goal: This project will identify the mechanisms responsible for rapid degradation of superheater tubes operated above the melting point of the inorganic deposits. Once these mechanisms are understood, the team will identify alloys and/or coatings that give improved resistance to superheater tube degradation and/or work with manufacturers to find improved superheater designs to minimize degradation. To accelerate deployment of this technology the group will develop software that will help determine the energy benefits from the use of superheater alternatives.

Partners: FPInnovations, SharpConsultants, University of Tennessee-Knoxville, Alstom Power, Andritz Oy, Babcock & Wilcox, Domtar Corporation, FM Global, Haynes International, International Paper, MeadWestvaco, OutoKumpu, Rolled Alloys, Special Metals , ThyssenKrupp VDM, Weyerhaeuser Company, Chalmers University, SKYREC

Bill Peter, peterwh@ornl.gov, (865) 241-8113

Background: Titanium offers superior strength, corrosion, and high temperature properties for industrial applications across broad range of markets, but is currently too expensive for widespread use. Titanium is now produced primarily by the Kroll process, which is expensive, energy intensive, and yields very high rates of scrap production. The recent development of low cost titanium powders offers a new lower cost route to titanium metal production that can be employed in a continuous process with the ability to fabricate prealloyed powders at competitive cost.

Goal: The goal of this project is the consolidation of new Armstrong titanium and titanium alloy powders into low cost net shape components for energy systems such as aerospace components and heat exchangers. The project team will explore consolidation via press and sinter, pneumatic isostatic forging (PIF), hot isostatic pressing (HIP), and adiabatic compaction.

Partners: Ohio State University, LMC, Inc., Ametek, Inc., Lockheed Martin, Aqua Chem

Read about this R&D 100 Award winning technology in Materials World

Nanomanufacturing

Bill Peter, peterwh@ornl.gov, (865) 241-8113

Background: Researchers at ORNL have developed scaled melting, powder fabrication, and laser processing techniques that fuse and devitrify amorphous iron-based powders into ultra-hard nano-composite coatings which are 1.3 to 7 times harder than conventional steel tools. Nanocrystalline metals are harder than conventional metals and can help reduce the estimated $65B/yr cost of wear to the U.S. economy. In a previous project laboratory tests performed at ORNL showed that uncoated disc cutters for tunnel boring machines exhibited 3.5 times higher wear rates than disc cutter material coated with the wear resistant coatings. Subsequent field trials demonstrated a 20% improvement in wear resistance for disc cutters.

Goal: The new iron-based amorphous alloy powder precursors fused and devitrified with high heating/cooling rate furnace technologies at ORNL enable the determination of microstructures, the production of nano-structured coatings metallurgically bonded to substrate, and the fabrication of bulk nanocrystalline components. Carbon and boron supersaturated steels can be made which avoid segregation and develop nano-sized ceramic precipitates. This project will develop low-cost, scalable processes for incorporating nano-sized boron/carbide particles into metal matrix coatings and components for wide range of wear-resistant applications.

Partners: Carpenter Powder Products

For a Poster on the Project

Lonnie Love, lovelj@ornl.gov , (865) 576-4630

Background: Oak Ridge National Laboratory has developed methods to control the properties of particles produced by particular strains of thermophilic anaerobic bacteria. Using a natural, fermentation process ONRL can control the size and shape of nanoscale magnetite produced in industrial size fermentors at low temperature. The ability to integrate a surfacant into the production enables a nanoproduct that is easily dispersed. This process is low cost, low temperature and easily scalable, and was awarded an R&D 100 award.

Goal: This is a Concept Definition Project. The goal is to apply this technology to the production of quantum dots for potential applications in energy efficient photovoltaics, such as CdS, CIGS, and CIGSe. The bacterial strains utilized by ORNL can facilitate production of other materials including compounds in quantum dots. This project will identify quality and scaling laws for bacterially synthesized CdS and CIGS quantum dots

Fact Sheet (PDF 169 KB)

W. L. Griffith, griffithwl@ornl.gov , (865) 574-4970

Background: This is a Concept Definition Study of microwave activation of nanostructured metal oxide catalysts. Microwave activation is expected to lower process energy by selective heating and activation of catalyst surface sites. Selective activation is expected to lower bulk process temperature required and increase product yield by minimizing back reactions. Refining of heavy crude oil was selected for initial evaluation because the tremendous opportunities for energy savings. The three most energy intensive refining catalytic processes, catalytic cracking, reforming, and hydrotreating, are all used to convert heavy crude oils to consumer fuels, and these processes are also bottlenecks in many refineries.

Goal: Preliminary results from a previous ITP MPLUS study showed that heavy oils are microwave transparent in industrially permitted frequencies (915 MHz and 2.45GHz) which couple with refinery catalysts. A bench scale evaluation will delineate process conditions under which microwave activation of nanostructured catalysts enhances catalyst performance on compounds which model heavy crude oil. The research will to develop data about process specifications; technology options; performance; markets; risks; and customers for this technology. Microwave activation of nanocatalysts also has the potential to decarboxylate biomaterials at lower temperatures. Decarboxylation at lower temperatures via microwave activation could provide a direct route to petroleum-like streams which can be processed using petrochemical technologies.

Partners: Mach I Inc. and the Materials Technology Institute.

James Hemrick, hemrickjg@ornl.gov, (865) 776-0758

Background: Nano-scale Interpenetrating Phase Composites (IPC’s) have been demonstrated to show improved mechanical, electrical, and thermal properties over traditional refractory materials that are subject to corrosion and mechanical degradation, which limit their use at high temperature. Nano-scale IPC’s have previously been demonstrated at the lab scale, but have been limited to thin films. IPC components of useable size have not been possible with current processes due to difficulties infiltrating preforms (low wetting) and closing pores within the preform.

Goal: This is a Concept Definition Project. The project will explore the technical and economic feasibility of producing nano-scale IPC components of a useable size for testing/implementation in real applications. The work will investigate methods to improve and scale up the current common low temperature IPC processing techniques, and evaluate the technical feasibility of modifying an alternative high temperature TCON process to produce nano-scale IPC components.

Partners: Fireline, TCON, Inc.

Chaitanya Narula, narulack@ornl.gov, 865- 574-8445

Background: Diesel engines offer 30% better fuel economy than gasoline engines, but their use is limited by the ability to meet emission regulations. Emission requirements for on-road applications are becoming more stringent, and off-road engines are also coming under regulation. Urea-Selective Catalytic Reduction (SCR) of NOx is the leading approach for emission treatment, but the effectiveness of this treatment is limited by catalyst performance.

Goal: This project will develop durable zeolite nanocatalysts with broader temperature operating windows to treat diesel engine emissions. Zeolites are ultimate nano-catalysts where catalyst centers are isolated at atomic level. ORNL will analyze failure modes of zeolite catalysts under SCR operating conditions, then use this information to synthesize new nano-structure modified, hydrothermally stable, zeolite catalysts. The new catalysts will be evaluated under laboratory conditions then undergo Dynamometer testing. The goal of the project is to improve hydrothermal durability by 50ºC, and to improve the operating temperature window (NOx conversion at 150ºC).

Partners: John Deere Power Systems

John Simpson, simpsonjt@ornl.gov, (865) 574-5565

Background: Superhydrophobic (water-repelling) materials have the potential for tremendous energy savings because of the ability to reduce friction and to reduce corrosion in a wide variety of applications. ORNL has developed oxide-based superhydrophobic powders which have nanoscale features precisely repeated and of highly uniform dimensions on the surface of each particle. These features are coated with a monolayer of a fluorinated compound treatment.

Goal: The project will work to produce commercially available powder based coatings with extreme water repellent properties. The team will optimize powder properties and binders to produce more uniform and durable coatings for use on a variety of substrates. The coatings will be optimized for drag reduction and corrosion resistance.

Partners: Ross Technology Corp. and Stevens Institute of Technology

Fact Sheet (PDF )

David DePaoli, depaolidw@ornl.gov, 865-574-6817

Background: Energy storage devices are critical enabling technologies for a variety of renewable energy, transportation, and electrical grid, technologies. However, current electrodes for supercapacitors have cost, energy density, and performance issues. ORNL has developed a capability to synthesize novel carbon materials with tailored energy-storage performance to serve as electrodes in electrochemical capacitors (supercapacitors). Carbon materials with controllable, nanoscale pore size can now be produced by self-assembly using conventional manufacturing processes.

Goal: The new ORNL materials have competitive energy and power densities relative to commercial activated carbon materials. This project will optimize the materials for energy storage and water treatment applications, improve the economics of the materials, scale up manufacturing processes, and test the materials in prototypes.

Partners: Honeywell Specialty Materials and Campbell Applied Physics

Poster highlight

Adrian Sabau, sabaua@ornl.gov, (865) 241-5145

Background: ORNL has developed a unique high-density plasma arc-based pulse thermal processing technology for rapid thermal annealing of thin-film light-emitting diodes and thin-film and nano-particle photovoltaic (PV) materials. This process has the potential to significantly increase PV collection efficiency and LED electrical properties, while increasing production rates and decreasing production costs. ORNL is working with a multitude of companies that are on the leading edge of their respective technologies.

Goal: This is a Concept Definition project. High-Density Infrared (HDI) plasma arc-based technology is an enabling tool for broad-area nanoscale processing. However, currently Individual nanostructures are rarely initially synthesized with appropriate phase and/or morphology. This project will use an experimental and computational approach to address critical additional steps of as-synthesized nanostructured materials, such as annealing, phase transformation, or activation of dopants over large areas. The project will develop a computer model based on first principles, and validate the process models based on comparison between measured and computed data for ZnO as a solid state lighting application.

Poster

Materials

Jim Keiser, keiserjr@ornl.gov, (865) 574-4453

Background: A prototype transport membrane condenser (TMC) system has been successfully demonstrated for the separation of water vapor and recovery of heat from a clean, controlled gas stream. This prototype membrane system employed a porous ceramic membrane on a porous ceramic tube to condense the water vapor in order to recover the heat. In order to utilize this novel system in a variety of industrial gas streams, new materials, particularly the substrate, must be identified that have sufficient corrosion resistance, strength, and toughness for the intended application.

Goal: Recovery of energy from relatively low-temperature waste streams has been a goal that has not been achieved on any large scale, but TMCs offer a means to achieve that goal. In this project, the goal is to identify materials that have improved thermal conductivity and robustness as well as sufficient corrosion resistance to serve in the anticipated industrial waste and process streams.

Partners: Gas Technology Institute, Media & Process Technology, Cleaver Brooks, and University of Tennessee-Knoxville.

Fact Sheet (PDF 1.2 MB)

Stephen Nunn, nunnsd@ornl.gov, (865) 576-1668

Background: AlMgB₁₄-based composites are a new class of super-hard materials that were developed at Ames Laboratory. Initial studies of AlMgB₁₄ composites demonstrated the potential for obtaining a high-wear-resistance material through powder metallurgy processing, however, the approach employed to prepare these composite samples was based on research-scale mechanical alloying and hot pressing. To be used commercially, the composites will need to be produced in larger quantities and in a more cost efficient manner.

Goal: The goal of this project is to increase operating efficiency and operating lifetime of industrial pumping systems and other wear-intensive industrial components by developing and commercializing a family of ceramic-based composites that have shown outstanding wear resistance in laboratory tests. A major objective of the proposed effort is to develop a cost-effective, industrial-scale processing and synthesis method for making AlMgB₁₄ composites that is capable of producing bulk materials possessing comparable or even improved wear-resistance properties compared to the research-scale compacts. Optimization of composition and processing on the laboratory scale will serve as an initial milestone, providing industrial processing partners with a "template" for developing their industrial-scale procedures. Emphasis will be placed on examining alternate powder processing techniques and powder blending and densification methods to eliminate porosity and achieve products exhibiting a maximum combination of hardness and toughness. Successful development of these new wear-resistant composites is expected to result in U.S. energy savings of 31 trillion BTU/year by 2030.

Partners: This project is led by Ames National Laboratory. Other project partners include Carpenter Powder Products, IMI Vision / CCI Valve, University of Missouri, Rolla, and University of Alberta.

Fact Sheet (PDF 1.2 MB)

Peter Blau, blaupj@ornl.gov, (865) 574-5377

Background: The development of high-hardness nano-coatings by Ames Laboratory (AL) presents an exceptional opportunity to increase durability and lower the friction in a range of industrial systems. Successful implementation will contribute to reduced material wastage and enhanced energy-efficiency. A joint industry-national laboratory project team reviewed the potential for energy savings and selected the two key technologies on which to demonstrate the benefits of novel nano-coatings: (I) Hydraulic system components: A typical industrial hydraulic system contains a pump, valve, actuator, and sump along with a controller. Eaton's vane pump, spool valve, and gerotor motor actuators were selected as the best test-beds for the study. (II) Tooling: Currently Greenleaf uses WC-6%Co and TiAlN-coated WC-6%Co for low-speed machining of Ti alloys such as Ti-6Al-4V. These coatings will serve as baselines against which to compare the new nano-coatings.

Goal: The project goal is to develop and commercialize degradation-resistance materials-nano-coatings of AlMgB₁₄ and AlMgB₁₄-TiB₂ - applicable to both industrial hydraulic and tooling systems, that result in surface hardness exceeding 30GPa. The project targets for the new Al nano-coatings are: i) sliding friction reduction of 50%; ii) torque-to-turn reduction of 50%; iii) volumetric loss reduction over simulated lifetime of 50% (resulting in pumping efficiency improvement of 3 to 5%); and iv) start-up torque reduction of 75%. For cutting tools these coatings are also targeted at increasing useful life by a factor of two. The technology advanced by this project is expected to result in U.S. energy saving of 31 trillion BTU/year by 2030, with associated energy cost savings of $179M/year. ORNL's role is to develop and apply test methods to investigate and establish the friction, wear, and durability the nano-coatings related to the stated applications.

Partners: This project is led by Eaton Corporation. Other project partners include GreenLeaf Corporation and Ames National Laboratory.

Fact Sheet (PDF 1.1 MB)

Highlight (PDF 13 KB)

James Hemrick, hemrickjg@ornl.gov, (865) 776-0758

Background: Currently available refractory materials are limited in their application by many factors including chemical reactions between the service environment and the refractory material, mechanical degradation of the refractory material by the service environment, temperature limitations on the use of a particular refractory material, and the inability to install or repair the refractory material in a cost effective manner or while the vessel is in service.

Goal: The objective of this project is to address the need for new innovative refractory compositions by developing a family of novel Mg-Al₂O₃, MgAl₂O₄, or other similar magnesia/alumina containing unshaped refractory compositions (castables, gunnables, shotcretes, etc) utilizing new aggregate materials, bond systems, protective coatings, and phase formation techniques. The newly developed materials are expected to offer alternative material choices for high-temperature, high-alkali environments that may be capable of operating at higher temperatures (goal of increasing operating temperature by 100-200°C depending on process) or for longer periods of time (goal of twice the life span of current materials). This will lead to less process down time, greater energy efficiency for associated manufacturing processes (more heat kept in process), and materials that can be installed/repaired in a more efficient manner. The overall project goal is a 5% improvement in energy efficiency resulting in a savings of 3.7 TBtu/yr (7.2 billion ft³ natural gas). Additionally, new application techniques and systems will be developed as part of this project to optimize the installation of this new family of refractory materials to maximize the properties of installed linings and to facilitate nuances such as hot installation and repair.

Partners: MINTEQ International, Inc., Aleris International, Eastman Chemical, PPG Industries and Weyerhaeuser Company.

Fact Sheet (PDF 1.1 MB)

Other Projects

Wayne Manges, mangesww@ornl.gov, (865) 574-8529

Background: The National Research Council has declared robust wireless telemetry as a critical cross-cutting technology for the Industrial Technologies Program. This research has been ongoing for about six years.

Goal: Development of robust wireless technology that provides building blocks and technology underpinnings for the deployment of intelligent industrial process control systems, promoting the long-term goal of increased energy efficiency in the industrial sector. A wireless technology architecture (integrating principle) and components will be developed to address the following needs:

Technology that cross-cut the needs of the high-energy-consuming industries through:

1. reliable (deterministic) communications and networks,
2. environmentally robust systems packaging,
3. an easily deployable and cost-effective infrastructure, and
4. standardized communication protocols and data structures.

Additionally, this activity will address the critical needs of industry by integrating sensor and control suppliers as early as possible into the development and commercialization process.

Partners: Eaton Corporation, Honeywell and General Electric

Fact Sheet (PDF 1.1 MB)

For Information about the Extreme Measurement Communications Center (EMC2) (PDF 519 KB)

For a story tip on wireless sensors (PDF 14 KB)

Jim Keiser, keiserjr@ornl.gov, (865) 574-4453

Background: Transportation of large quantities of ethanol from biorefineries to markets is likely to be most cost effective by pipeline. However, no ethanol pipeline infrastructure currently exists. Therefore, ethanol must be piped in existing lines or a new network must be built. Pipeline operators typically do not now transport ethanol in petroleum pipelines. In addition to concerns about corrosion, ethanol is an effective solvent for the impurities that precipitate from petroleum during transport. Ethanol also could be adversely affected by water that typically accumulates in pipelines. New pipelines to deliver ethanol must be both durable and cost effective. Limited cases of stress corrosion cracking (SCC) of a steel tank containing ethanol are known, however, critical variables (such as composition, thermo-mechanical history, microstructure, ethanol compositions) for steel compatibility with ethanol are uncertain. Because of this knowledge gap, stainless steel is currently the material of choice for new pipelines. However, stainless steel is up to ten times as expensive as mild steels, and is already in short supply. The opportunity exists to identify lower cost and more readily available materials to better enable the US biofuels industry.

Goal: The scope of this project is to perform a literature study and benchmarking analysis to identify corrosion issues in existing ethanol plants and petroleum pipelines. The project will compare performance boundaries for materials (mild and stainless steels) as a function of ethanol production and handling variables in an attempt to determine if less expensive mild steels can be used in place of baseline stainless steels for ethanol storage and transport.

Partners: Project partners include the Materials Technology Institute and BCS, Incorporated.

For the results of the literature search from this project (PDF 0.5 MB)

Jim Keiser, keiserjr@ornl.gov, (865) 574-4453

Background: The Gas Technology Institute was awarded a project addressing the topic of "Ultra-High Efficiency Industrial Steam Generation". The first phase of the project will involve research into methods to achieve ultra-high efficiency for industrial water-tube and/or fire-tube package boilers. Oak Ridge National Laboratory will provide technical support to the Gas Technology Institute in the selection of tube materials for the superheaters.

Goal: ORNL will help in the identification of an alloy that has the high temperature strength and corrosion resistance to satisfy the requirements of a superheater operating at 816°C (1500°F) and a pressure of ~102 atm. (1500 psig). ORNL will identify potential candidate materials, conduct corrosion tests in simulated environments, then characterize these exposed samples. Based on results of these tests, ORNL will help in the acquisition and instrumentation of tubular samples, exposure of these samples and characterization of the exposed samples.

Partners: This project is led by the Gas Technology Institute. Other partners include Cleaver-Brooks, Alstom Power, Georgia Institute of Technology, and Pacific Northwest National Laboratory.

Fact Sheet (PDF 1.1 MB)

For More Information on the Superboiler Project

Patti Garland, garlandpw@ornl.gov, (202) 586-3753

Background: The Industrial Technologies Program (ITP) is committed to researching and developing technologies that will improve national energy security, climate and environment, and economic competitiveness. The Industrial DE program seeks to lead technology innovation and spur the widespread commercial deployment of combined heat and power (CHP) solutions and achieve significant energy intensity and greenhouse gas emissions reductions.

Goal: Partnering with private industry and states, the Industrial DE Program targets the acceleration and deployment of distributed energy and combined heat and power (CHP) systems and applications. CHP is a real, near-term solution for energy consumption issues and carbon constraints, in the U.S. However, CHP has not been fully deployed because of a number of market and technical issues. ITP activities help eliminate regulatory and institutional barriers to widespread commercialization, and increase market awareness of industrial distributed energy technologies. ITP also promotes education, technical assistance, and assessments through the CHP Application Centers.

Partners: UTRC, IBM and Frito Lay

For More information: See Combined Heat and Power: Effective Energy Solutions for a Sustainable Future (PDF 2.5 MB)