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OfficeofEnergyEfficiency&RenewableEnergyAdvancedManufacturingOffice

QuadrennialTechnologyReview(QTR):TechnologyAssessment-SustainableManufacturing/[email protected]

SustainableManufacturingWorkshopPortland,ORJanuary6,2016

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QuadrennialTechnologyReview-2015hOp://www.energy.gov/quadrennial-technology-review-2015

TheQTRisacomprehensiveassessmentofscienceandenergytechnologyR&DopportuniHestoaddressournaHon'senergy-linkedeconomic,environmental,andsecuritychallenges.

•  TheClimateAcHonPlan(June2013):–  CutcarbonemissionsintheUnitedStates–  PreparetheUnitedStatesfortheimpactsofclimatechange–  LeadinternaYonaleffortstoaddressglobalclimatechange

•  QuadrennialEnergyReview(QER):Analyzegovernment-wideenergy

policy,parYcularlyfocusedonenergyinfrastructure.

•  QuadrennialTechnologyReview(QTR):AnalysisofthemostpromisingR&DopportuniYesacrossenergytechnologiesleadingtowardsacleanenergyeconomy.

TheresulHnganalysisandrecommendaHonsoftheQTR2015willinformthenaHonalenergyenterpriseandwillguidetheDepartmentofEnergy’sprogramsandcapabiliHes,budgetaryprioriHes,industryinteracHons,andnaHonallaboratoryacHviHes.

AdministraHonprioriHes

ExpandedScopeofQTR2015

TheQTRevaluatesmajorchangessincethefirstvolumeoftheQTRwaspublishedin2011andprovidesforwardleaninganalysistoinformDOE’sstrategicplanninganddecisionmaking,via:

•  SystemsAnalyses–toevaluatethepower,buildings,industry,andtransportaYonsectors,enablingasetofopYonsgoingforward.

•  TechnologyAssessments–Examinesindetail,thetechnicalpotenYalandenablingscienceofkeytechnologiesoutto2030.

•  RoadMaps–UsestheseanalysesandassessmentstoextendR&DRoadmapsandframetheR&Dpathforward.

QTR2015

hOp://energy.gov/quadrennial-technology-review-2015

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SustainableManufacturingTechnologyAssessmentApproach–OutlineaframeworktobeOercaptureeconomy-wideaffectenergyandGHGemissions,andtohelpcharacterizeimprovementopportuniYes,including:•  Changesinmaterialsandindustrial/manufacturingprocesses•  Materialflowsandmanufacturedproducts•  Cross-sectoralandlifecycleimpacts•  EmbodiedEnergy&GHGs

•  EnergyreducYons•  EmissionsreducYons

•  Useandre-useenergy/emissionsreducYons•  Increasedvalue-added•  Improvedquality/Improvedservice

Materials Manufacture Transport DisposalEndUse/Re-use

IntermediateUse

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SustainableManufacturingTechnologyAssessmentApproach–OutlineaframeworktobeOercaptureeconomy-wideaffectenergyandGHGemissions,andtohelpcharacterizeimprovementopportuniYes,including:•  Changesinmaterialsandindustrial/manufacturingprocesses•  Materialflowsandmanufacturedproducts•  Cross-sectoralandlifecycleimpacts•  EmbodiedEnergy&GHGs

•  EnergyreducYons•  EmissionsreducYons

•  Useandre-useenergy/emissionsreducYons•  Increasedvalue-added•  Improvedquality/Improvedservice

Materials Manufacture Transport DisposalEndUse/Re-use

IntermediateUse

TargetTechnologies

•  TransformaHve:Resultsinsignificantchangeinthelife-cycle

impact(energeYcoreconomic)ofmanufacturedproducts

•  Pervasive:CreatesvalueinmulYplesupplychains,diversifiestheenduse/markets,appliestomanyindustrial/usedomainsinbothexisYngandnewproductsandmarkets

•  GloballyCompeHHve:RepresentsacompeYYve/strategiccapabilityfortheUnitedStates

•  SignificantinCleanEnergyIndustry:HasaquanYfiableenergeYc,environmentaloreconomicvalue.

TargetedtechnologiesareimpacWul,forexample:

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U.S.Economy:95Quads

U.S.Economy-WideEnergyDemand

Source:EIAMonthlyEnergyReview,Aug2014;AEO2014

2012Data

IndustryandManufacturingEnergyUse

U.S.Economy:95QuadsIndustry:31Quads


Fuelmixshowsdiversenatureofindustry

energyuse

2012Data *Renewablesconsistprimarilyofbiomassenergy(2.2Quads),withtheremainderfromonsitehydroelectric,geothermal,windandsolarenergy. 10

IndustryandManufacturingEnergyUse


2012Data

U.S.Economy:95Quads

2012Data *Renewablesconsistprimarilyofbiomassenergy(2.238Quads),withtheremainderfromonsitehydroelectric,geothermal,windandsolarenergy.

Manufacturing:24.4Quads

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Minusfeedstocks=19.2Quads

2012Data *Renewablesconsistprimarilyofbiomassenergy(2.238Quads),withtheremainderfromonsitehydroelectric,geothermal,windandsolarenergy.

U.S.Economy:95Quads


12



2012Data


*Renewablesconsistprimarilyofbiomassenergy(2.238Quads),withtheremainderfromonsitehydroelectric,geothermal,windandsolarenergy.

U.S.Economy:95Quads

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2012Data


*Renewablesconsistprimarilyofbiomassenergy(2.238Quads),withtheremainderfromonsitehydroelectric,geothermal,windandsolarenergy.

U.S.Economy:95Quads

Ofthe24.4Quadsof

manufacturingenergy

demandà6.9Quadsareapplied.

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Systemsapproachtoindustrial&manufacturinganalysis

SystemBounds:ImpactedbyManufacturing

Note:1quad=1,000TBtu

U.S.EnergyEconomy95quads*

TransportaHonSector

27quads

ResidenHalSector

20quads

CommercialSector

17quads

IndustrialSector31quads

Supply-ChainSystems

ProducHon/FacilitySystems

ManufacturingSystems/UnitOperaHons

IndustrialSystems31quads

Equipmentusedformanufacturingprocessandnonprocessunitopera3ons

Networkoffacili3esandopera3onsinvolvedinmovingmaterialsthroughindustry,fromextrac3onofrawmaterialstotheproduc3onoffinishedgoods.

Equipment,processflow,andenergystrategiesthatcompriseagoods-producingfacility

•  Technologiesforclean&efficientmanufacturing•  Technologiestoimproveenergyuseintransporta3on•  Technologiestoimproveenergyuseinbuildings•  Technologiestoimproveenergyproduc3onanddelivery

EnergyProducHon

EnergyDelivery

Manufacturing,facility,andsupply-chainimprovementsreducethe12quadslostwithintheindustrialsector

Energy-efficienttechnologiesreducethe58quadslostthroughoutthe

U.S.EnergyEconomy

PetroleumRefinery

FacilitySteam

~26TBtu

~5TBtu

RefiningIndustry~4quads

Example:PetroleumRefining

AtmosphericDisHllaHonUnit

Hydro-cracker

CatalyHcReformer

~4TBtu ~2TBtu ~3TBtu

16*2012,EIA

DriverstoReduceEnergy&EmissionsthroughtheProductLifeCycle

EnergyIntensitye.g.:ProcessefficiencyProcessintegraYonWasteheatrecovery

CarbonIntensity,e.g.:Processefficiency

FeedstocksubsYtuYonGreenchemistry

Biomass-basedfuelsRenewables

UseIntensitye.g.:

RecyclingReuseandremanufacturing

MaterialefficiencyandsubsYtuYonBy-products

Product-Service-Systems17

EnergyIntensityImprovements




Biomass-basedfuelsProcesschangesRenewables

UseIntensitye.g.:

RecyclingReuseandremanufacturingMaterialefficiencyand

subsYtuYonBy-products

Product-Service-Systems

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TechnicalEnergySavingsOpportuniHes:

Source:DOE/AMO,EnergyBandwidthStudies(2015)Note:1quad=1000TBtu

CarbonIntensityImprovements

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Directemissionswithefficiencyimprovementsonly…

…andwithfuelswitchingandmaterialsubsYtuYon

ExampleanalysisusingtheBuildings,Industry,Transport,ElectricityScenario(BITES)tool

CarboncaptureandsequestraYon(CCS)technologiesofferaddiYonalopportuniYes

Agriculture,mining,construcYon:OpportuniYesforadvancedengines,biofuels,etc.





UseIntensitye.g.:




UseIntensityImprovements

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ExpandedTechnologyOpportunitySpace:• MaterialsShin–Toenableincreaseofsecondaryaluminumbymanufacturing• End-of-lifeshin–Toenablegreatercaptureanduseoflandfill+scrapexport• Systems-wide–Materials&productdesign,manufacturing,useandre-use.





UseIntensitye.g.:




SystemsapproachintheQTRIndustry&Manufacturingchapter:

SystemLevel AsdefinedintheQTRManufacturingSystems/UnitOperaHons

TechnologyandequipmentusedformanufacturingprocessandnonprocessunitoperaAons


Equipment,processflow,andenergystrategiesthatcompriseagoods-producingfacility

Supply-ChainSystems FaciliAesandoperaAonsinvolvedinmovingmaterialsthroughanindustry,fromtheextracAonofrawmaterialstotheproducAonoffinishedgoods.

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TechnologyopportuniHesexistateachsystemslevel

SystemLevel Examples R&DOpportunityExamplesManufacturingSystems/UnitOperaHons

•  Composites/curingsystem•  ChemicalsseparaYonsystem•  Lowthermal-budgetprocess

heaYng

•  TransiYonfromautoclavetoout-of-theautoclavetechnology

•  TransiYonfromdisYllaYontomembranes

•  Smartmanufacturingequipment


•  Petroleumrefinery•  Vehicleassemblyplant•  Facilitysteamsystems•  Enterprisecomputer/control

systems

•  ProcessintensificaYon•  Smartenterprisesystems•  AdvancedCHPsystems•  Grid-friendlyequipment

Supply-ChainSystems •  Steelindustry•  TransportaYonequipment

industry•  Distributedmanufacturing

•  Recyclability/designforre-use•  AlternaYvematerials

development•  Useoflow-carbonfuelsand

feedstocks•  TechnologyopportuniYesto

transformmarkets

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AdvancedMaterialsManufacturing

ManufacturingSystems–UnitOperaHons

ProducHon/FacilitySystems–EnergyandResourceUHlizaHon

SustainableManufacturing/FlowofMaterialsthroughIndustry

CriHcalMaterials

DirectThermalEnergyConversionMaterials,DevicesandSystems

WideBandgapSemiconductorsforPowerElectronics

MaterialsforHarshServiceCondiHons

AddiHveManufacturing

CompositeMaterials

Roll-to-RollProcessing

ProcessIntensificaHon

ProcessHeaHng

AdvancedSensors,Controls,PlaWormsandModelingfor

Manufacturing

WasteHeatRecoverySystems

CombinedHeatandPowerSystems

BeyondthePlantBoundaries–SupplyChainandLifeCycle

Secondaryimpactsassessed

Manufacturingsystemslevelinchapter

Legend

23

QTRIndustry&ManufacturingTechnologyAssessments

TechnologyAssessmentsattheirprincipalmanufacturingsystemslevel:

SystemLevel QTRManufacturingTechnologyAssessmentsManufacturingSystems/UnitOperaHons

ExisAngProcesses;NewApproaches

•  ProcessHeaAng•  ProcessIntensificaAon•  Roll-to-RollProcessing•  AddiAveManufacturing


FuelFlexibilityandWasteEnergy;DataandAutomaAon

•  CombinedHeatandPowerSystems•  WasteHeatRecoverySystems•  Adv.Sensors,Controls,PlaQormsandModelingforMfg.

Supply-ChainSystems

IncreasingSustainability;ManufacturingEnergy-EfficientProducts

•  AdvancedMaterialsManufacturing•  CriAcalMaterials•  SustainableManufacturing•  DirectThermalEnergyConv.Materials,Devices&Systems•  MaterialsforHarshServiceCondiAons•  WideBandgapSemiconductorsforPowerElectronics•  CompositeMaterials

24

Energy,CarbonandUseIntensityImprovements

25





UseIntensitye.g.:




��


26





UseIntensitye.g.:




��


27

��


ManufacturingSystems–UnitOperaHons

ProducHon/FacilitySystems–EnergyandResourceUHlizaHon


CriHcalMaterials





CompositeMaterials



ProcessHeaHng


Manufacturing



BeyondthePlantBoundaries–SupplyChainandLifeCycle

Secondaryimpactsassessed

Manufacturingsystemslevelinchapter

Legend

TechnologyAssessments-Currenttechnologystatus,R&Dneeds,andpotenHalimpacts.

28

SustainableManufacturing–FlowofMaterialsthroughIndustry



MaterialsforHarshServiceCondiEons


AddiEveManufacturing

CompositeMaterialsManufacturing


ProcessIntensificaEon

ProcessHeaEng


CombinedHeatandPower

CriEcalMaterials

AdvancedSensors,Controls,PlaJormsandModelingfor

Manufacturing

Buildings TransportaEonGrid Fuels

ConnecEonstootherQTRChaptersandTechnologyAssessments

ElectricPower

SustainableManufacturingTechnologyAssessment–Scope:

•  Supplychainissues,fromresourceextracYontoendoflife(LifeCycleAnalysis)•  Flowdiagramstodemonstratesupplychainissues•  Materialefficiency:mechanismsforreducingdemandformaterials(e.g.,lightweighYng,

scrapreducYon,increasedmateriallongevity)•  DesignforRe-use/Recycling










ProcessHeaEng



CriEcalMaterials


Manufacturing



ElectricPower

Cross-EnergyConnecHons•  ElectricPower:managementofwater&energyresources•  Buildings:recyclingandmaterialssubsAtuAon/minimizaAon

SustainableManufacturingTechnologyAssessment-ConnecHons

Intra-ManufacturingConnecHons

•  CriHcalMaterials:materialssubsAtuAon

•  ProcessHeaHng:sharedownershipofequipmenttomaximizeproducAonintensity

•  MaterialsforHarshServiceCondiHons/AdvancedMaterialsManufacturing:materialstoincreasedurabilityorfacilitatere-use

•  CombinedHeatandPower/ProcessIntensificaHon:modularequipmentdesignforeasierreconfiguraAon,upgradeandrepair

•  AddiHveManufacturing:distributedmanufacturing;rawmaterialminimizaAon

•  CompositeMaterials:Lightweightmaterialsmanufacturingforlife-cycleenergysavings

•  AdvancedSensors,Controls,PlaWorms,andModelingforManufacturing:smarttechnologiestoenabletrack&traceofmaterialsthroughthelifecycle

•  WasteHeatRecovery:opAmizaAonofheatflowstomaximizeproducAonintensityandminimizewasteheatlosses










ProcessHeaEng



CriEcalMaterials


Manufacturing



ElectricPower

Cross-EnergyConnecHons•  ElectricPower:managementofwater&energyresources•  Buildings:recyclingandmaterialssubsAtuAon/minimizaAon

SustainableManufacturingTechnologyAssessment-ConnecHons

TechnologyHighlights–UseIntensityImprovements

33

1.09kg

•  65%weightreducHon•  81%reducHoninbuy-to-flyraHo•  66%energysavings•  Mostsavingsoccurinusephase

0.38kg

CaseStudy:OpHmizedAircralBracket

Source:MFIandLIGHTEnUPAnalysisNote:1quad=1×109MMBtu

•  LightweightcomponentsforthetransportaYonsector

•  Advancedtoolingformanufacturing

•  Customproductsandsmall-batchproducYon

•  Accelerateddesigncyclesforrapidproductdevelopment

ApplicaHonsinMulHpleSectors

•  FabricaYonoflargeproducts•  Distributedmanufacturing•  Time-qualityopYmizaYon•  Materialsefficiency

R&DChallenges

Energy,cost,andenvironmentalimpacts(throughoutlifecycle)areapplicaYondependent.


Life-CycleEnergySavingsforAddiHveManufacturedAircralBracket

TechnologyHighlights–UseIntensityImprovements

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ImpactsfromAircralFleet-WideAdopHonofAddiHveManufacturing

•  LightweightcomponentsforthetransportaYonsector

•  Advancedtoolingformanufacturing

•  Customproductsandsmall-batchproducYon

•  Accelerateddesigncyclesforrapidproductdevelopment

ApplicaHonsinMulHpleSectors

•  FabricaYonoflargeproducts•  Distributedmanufacturing•  Time-qualityopYmizaYon•  Materialsefficiency

R&DChallenges

Energy,cost,andenvironmentalimpacts(throughoutlifecycle)areapplicaYondependent.


ScenarioSlowAdopHonnewaircranonly

Mid-RangeAdopHonnewaircranandnewparts

RapidAdopHonnewaircran,newparts,andacceleratedreplacement

AnnualEnergySavingsforFleet-WideAdopHonofAddiHveManufacturedComponentsinAircral

EnergySavingsBreakdown:Over95%ofsavingsoccurinusephase

Source:R.Huang,etal.,“TheEnergyandEmissionsSavingPotenYalofAddiYveManufacturing:TheCaseofLightweightAircranComponents.”(AnalysisInProgress). Note:1quad=1,000TBtu

SlowAdopYon Mid-RangeAdopYon RapidAdopYon

•  CarbonFiber(CF)iscurrently~5xmoreenergyintensivethansteel:•  ImprovedCFis~½energyintensitythanPAN:•  Significantlyimprovedmaterialsandmanufacturingenergyimprovesnetenergyfootprint

TechnologyAssessment–LifeCycleEnergySavingsfromLight-weighHngCarbonFiberReinforcedPlasHcsvs.Steel

Theimportanceofimprovingmaterialsandmanufacturingenergyuse

Theimportanceofusephaseenergysavings

ORNL/DOEanalysis–preliminaryresults

35

36

TheCircularEconomy

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CircularEconomy–InDecember2015,theEuropeanCommission2030targetsforrecyclingmunicipalwaste(65%)andpackagingwaste(75%).

1.   ProducHon1.1.Productdesign1.2.ProducYonprocesses

2.ConsumpHon3.Wastemanagement4.Fromwastetoresources:boosHngthemarketforsecondaryrawmaterialsandwaterreuse5.Priorityareas

5.1.PlasYcs5.2.Foodwaste5.3.CriYcalrawmaterials5.4.ConstrucYonanddemoliYon5.5.Biomassandbio-basedproducts

6.InnovaHon,investment,andotherhorizontalmeasures7.Monitoringprogresstowardsacirculareconomy

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“TheEuropeanCommission’sclearandconsistentrecyclingdefiniAonsareveryencouraging.Theproposaltomovethepointofmeasurementofrecyclingtoa]erthesorAngphaseratherthanatthecollecAonphasewillensurethatMemberStatesreportonrealrecyclingresults.”“Aboutonemilliontonnesofaluminiumscrapwasexportedin2014,thisisaneconomicwastemakingEuropeevenmorereliantonimports.ThiscouldbeavoidedthroughgreaterinvestmentinEuropeancollecAonandsorAnginfrastructure.ExporAngscrapislikeexporAngtheenergyembeddedinthemetal.IfwerecycledthisquanAtyhereinEuropewewouldsavetheequivalentoftheannualenergyconsumpAonofcountriessuchasLatviaorLuxembourg.”hOp://www.euracYv.com/secYons/sustainable-dev/europe-should-conYnue-strive-ideal-circular-economy-320140

ConsideraHonsaswestartthisworkshop….

•  Whatsustainablemanufacturingtechnologiesandsystemimprovements*couldyieldthegreatesteconomy-wideimpacts?

•  HowcanwesustainablyleveragedomesYcenergyresources(e.g.,NG)?

•  WhatYmelyinvestmentscouldpotenYallyenableU.S.leadershipandopenmarkets?

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*forexample:•  DevelopingandUsingAlternaYve/SustainableFeedstocks•  ReducYonofWasteinManufacturingProcesses•  End-of-LifeManagement•  Materials,WaterandEnergyManagement•  SustainableDesignandDecision-Making

Back-UpSlides

41

42

CriHcalMaterials

Cross-EnergyConnecHons•  ElectricPower:permanentmagnetsforwind

turbines•  Buildings:phosphorsforLEDlighAng•  TransportaHon:dysprosiumandotherrare

earthsformotors;plaAnumforfuelcellcatalysts

Intra-ManufacturingConnecHons•  SustainableManufacturing:materials

subsAtuAon•  AdvancedSensors,Controls,PlaWorms,and

ModelingforManufacturing:modelstominimizecriAcalmaterialsuse

•  AdvancedMaterialsManufacturing:computaAonaltechniquestodevelopcriAcalmaterialalternaAves










ProcessHeaHng



CriHcalMaterials


Manufacturing

Buildings TransportaHonGrid Fuels

ConnecHonstootherQTRChaptersandTechnologyAssessments

ElectricPower

Scope•  DynamicnatureofcriYcality•  Permanentmagnetsforwindturbinesandelectricvehicles•  PhosphorsforenergyefficientlighYng•  SupplydiversityandglobalmaterialcriYcality

43


Cross-EnergyConnecHons•  ElectricPower:waterwithdrawalforpower

plantcooling;wasteheatrecoveryinpowerplants

•  Buildings:thermoelectricheatpumpsforHVAC•  TransportaHon:directthermalenergy

conversionforinternalcombusAonengines

Intra-ManufacturingConnecHons•  MaterialsforHarshServiceCondiHons:thermal

conversionmaterialsanddevicesforhigh-temperatureorcorrosiveenvironments

•  Roll-to-Roll:thermoelectricdevicefabricaAonviaroll-to-roll

•  Wasteheatrecovery:novelenergyconversionmaterials,devicesandsystemsforwasteheattopower

•  AddiHveManufacturing:addiAvemanufacturingofthermoelectricmodules

•  AdvancedSensors,Controls,PlaWormsandModelingforManufacturing:thermalcontrolsystems;powerforwirelesssensornetworksWideBandgapSemiconductors

forPowerElectronics







ProcessHeaHng




Manufacturing




ElectricPower

CriHcalMaterials


Scope•  Thermoelectricmaterials(includingnewprovenmaterialssuchasSkuOeruditesandHalf-Heusleralloys)•  Newmanufacturingprocessessuchaswafer-basemanufacturingtoreplacepick-and-place•  Wasteheatrecoveryequipment•  ThermoelectricgeneraYonofelectricity(costtarget:$1/WaO)

44


Cross-EnergyConnecHons•  Grid:solidstatetransformersforpowerflow

control;invertersforrenewableenergy•  Buildings:variablespeeddrivesforHVAC

systems;AC-to-DCandDC-to-ACadapters•  TransportaHon:Powerelectronicsforelectric

vehicles

Intra-ManufacturingConnecHons•  SustainableManufacturing:smaller-footprint

electronicswithreducedcoolingrequirements•  AdvancedSensors,Controls,PlaWormsand

ModelingforManufacturing:variablefrequencydrivesandmotorspeedcontrol

•  AdvancedMaterialsManufacturing:low-cost,commercial-scaleproducAonmethodsforwidebandgapdevices








ProcessHeaHng




Manufacturing


CriHcalMaterials



ElectricPower


Scope•  OpportuniYesforsiliconcarbide(SiC)andgalliumnitride(GaN)toreplacesilicon(Si)inpowerelectronics•  ApplicaYonsincludeACadapters,datacenters,andinvertersforrenewableenergygeneraYon

45


Cross-EnergyConnecHons•  Fuels:corrosioninoffshoredrillingequipment;

ashfoulinginbiomassconversionequipment;hydrogenembrielementinH2pipelines

•  ElectricPower:radiaAon-resistantfuelcladding;high-temperaturealloysfornuclearreactorsandgasandsteamturbines

•  TransportaHon:corrosion-resistantlightweightmaterials

Intra-ManufacturingConnecHons•  SustainableManufacturing/Advanced

MaterialsManufacturing:materialstoincreasedurabilityorfacilitatere-use;materialsgenometechniquesfornewmaterialsdevelopment

•  CompositeMaterials:lightweight,durablestructuralcomponentsforautomobiles;erosion-resistantcompositesforwindturbinebladesandturbomachinery

•  DirectThermalEnergyConversion:thermalconversionmaterialsanddevicesforhigh-temperatureorcorrosiveenvironments

•  AdvancedSensors,Controls,PlaWormsandModelingforManufacturing:computaAonalmodelingtosupportadvancedmaterialsdevelopment;MaterialsforHarsh

ServiceCondiHons






ProcessHeaHng




Manufacturing





ElectricPower

CriHcalMaterials


Scope•  Materialsforextremeenvironmentsincludinghightemperatures,highpressures,corrosivechemicals,heavy

mechanicalwear,nuclearradiaYon,andhydrogenexposure

46


Cross-EnergyConnecHons•  ElectricPower:Materialsgenometechniquesto

screenmaterialsforuseincarboncaptureandstorage(CCS)applicaAons

•  Buildings:Advancedbuildingenvelopematerials•  TransportaHon:PredicAvedesign,modeling,and

simulaAonforvehicleproductdevelopment

Intra-ManufacturingConnecHons•  AddiHveManufacturing:materialformulaAons

foraddiAvetechniques•  Roll-to-Roll:thin-andthick-filmsubstrate

producAon;mulAlayeralignment•  SustainableManufacturing/Materialsfor

HarshServiceCondiHons:materialstoincreasedurabilityorfacilitatere-use;materialsgenometechniquesfornewmaterialsdevelopment

•  AdvancedSensors,Controls,PlaWormsandModelingforManufacturing:computaAonalmodelingtosupportadvancedmaterialsdevelopment;controlsandsensorstosupportadvancedmanufacturingtechniques

•  WideBandgapSemiconductors:low-cost,commercial-scaleproducAonmethodsforwidebandgapdevices







ProcessHeaHng




Manufacturing



CriHcalMaterials



ElectricPower


Scope•  Broad-brushdiscussionofnextgeneraYonmaterials,technicalbarriers,andopportuniYes•  EmergingprocessesforadvancedmaterialsproducYon•  MaterialsGenomeandcomputaYonalmanufacturingasrelatedtoCleanEnergyManufacturing

47


Cross-EnergyConnecHons•  Fuels:fuelcells•  ElectricPower:customelectricalcomponentsin

substaAons;complexpartsforpowerplants;toolingforlargecasAngsforpowerplants

•  Buildings:heatexchangersforHVACsystems;windowframes

•  TransportaHon:PrototypingandtoolinginautomoAveapplicaAons;fuelcells

Intra-ManufacturingConnecHons•  AdvancedSensors,Controls,PlaWormsand

ModelingforManufacturing:metrologyandcontrolsystemsforimprovedquality,defectdetecAon,andthroughput

•  ProcessIntensificaHon:microchannelreactorfabricaAon

•  Roll-to-RollManufacturing:commontechnologyneedsforaddiAve2-D(roll-to-roll)and3-D(addiAvemanufacturing)prinAngtechnologies

•  CompositeMaterials:3-DprinAngofreinforcedpolymersandothercomposites

•  AdvancedMaterialsManufacturing:materialformulaAonsforaddiAvetechniques

•  DirectThermalEnergyConversion:addiAvemanufacturingofthermoelectricmodulesMaterialsforHarsh

ServiceCondiHons






ProcessHeaHng



CriHcalMaterials


Manufacturing





ElectricPower


Scope•  StructuralcompositematerialsforlightweighYng,includingautomoYve,wind,andgasstorageapplicaYons•  Formingandcuringtechnologiesforthermose{ngandthermoplasYcpolymercomposites

48

CompositeMaterials

Cross-EnergyConnecHons•  Fuels:hydrogenfuelstorage•  ElectricPower:lightweightwindturbineblades•  TransportaHon:compressedgasstoragefor

mobileapplicaAons;automoAvelightweighAng

Intra-ManufacturingConnecHons•  AddiHveManufacturing:3-DprinAngof

reinforcedpolymersandothercomposites•  MaterialsforHarshServiceCondiHons:

lightweight,durablestructuralcomponentsforautomobiles;erosion-resistantcompositesforwindturbinebladesandturbomachinery

•  AdvancedSensors,Controls,PlaWormsandModelingforManufacturing:inspecAontechniquesforqualitycontrol;automatedtapelayingandautomatedtapeplacement

•  SustainableManufacturing:Lightweightmaterialsmanufacturingforlife-cycleenergysavings







ProcessHeaHng




Manufacturing



CriHcalMaterials



ElectricPower


Scope•  StructuralcompositematerialsforlightweighYng,includingautomoYve,wind,andgasstorageapplicaYons•  Formingandcuringtechnologiesforthermose{ngandthermoplasYcpolymercomposites

49


Cross-EnergyConnecHons•  ElectricPower:flexiblesolarpanels•  Buildings:windowinsulaAonfilms•  TransportaHon:baeeryelectrodes

Intra-ManufacturingConnecHons•  AdvancedSensors,Controls,PlaWormsand

ModelingforManufacturing:metrologyandcontrolsystemsforimprovedquality,defectdetecAon,andthroughput

•  ProcessIntensificaHon:roll-to-rollforproducAonofseparaAonmembranes

•  AddiHveManufacturing:commontechnologyneedsforaddiAve2-D(roll-to-roll)and3-D(addiAvemanufacturing)prinAngtechnologies

•  DirectThermalEnergyConversion:thermoelectricdevicefabricaAonviaroll-to-roll

•  AdvancedMaterialsManufacturing:thin-andthick-filmsubstrateproducAon;mulAlayeralignment








ProcessHeaHng




Manufacturing


CriHcalMaterials



ElectricPower


Scope•  Roll-to-roll(R2R)applicaYonssuchasflexiblesolarpanels,printedelectronics,thinfilmbaOeries,andmembranes•  DeposiYonprocessessuchasevaporaYon,spuOering,chemicalvapordeposiYon,andatomiclayerdeposiYon•  MetrologyforinspecYonandqualitycontrol

50


Cross-EnergyConnecHons•  Fuels:naturalgasandmodularproducAon•  ElectricPower:chemicalconversionof

biofeedstocks;separaAonsforCCS•  Buildings:membranesfordehumidificaAon•  TransportaHon:adsorbentsystemsfor

compressedgasstorage

Intra-ManufacturingConnecHons•  ProcessHeaHng/WasteHeatRecovery:

integratedcontrolsystems;replacementofbatchoperaAonswithconAnuousones;facilityintegraAontoenablere-useofexhaustgasesinlower-temperatureprocesses

•  CombinedHeatandPower/SustainableManufacturing:modularequipmentdesignforeasierreconfiguraAon,upgradeandrepair

•  Roll-to-RollProcessing:roll-to-rollforproducAonofseparaAonmembranes

•  AddiHveManufacturing:microchannelreactorfabricaAon

•  AdvancedSensors,Controls,PlaWorms,andModelingforManufacturing:on-linedataacquisiAonandmodelingforprocesscontrol;enterprise-wideoperaAonsopAmizaAon








ProcessHeaHng



Manufacturing


CriHcalMaterials





ElectricPower

Scope•  ProcessintensificaYonequipmentandmethods•  SeparaYonstechnologies•  Feedstockuseandfeedstockconversiontechnologies•  Focusontheenergy-intensivechemicalsector

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ProcessHeaHngSystems

Cross-EnergyConnecHonsNone,asthisisamanufacturing-specifictechnology

Intra-ManufacturingConnecHons•  CHP:integraAonofCHPwithprocessheaAng

equipment•  SustainableManufacturing:sharedownership

ofequipmenttomaximizeproducAonintensity•  WasteHeatRecovery:wasteheatrecoveryfrom

processheaAngequipment;facilityintegraAontoenablere-useofexhaustgasesinlower-temperatureprocesses

•  ProcessIntensificaHon:integratedcontrolsystems;replacementofbatchoperaAonswithconAnuousonesSustainableManufacturing–

FlowofMaterialsthroughIndustryDirectThermalEnergyConversionMaterials,DevicesandSystems








ProcessHeaHng



CriHcalMaterials


Manufacturing



ElectricPower

Scope•  Lowthermalbudgettechnologies•  SensorsandprocesscontrolsforprocessheaYngequipment•  ProcessheaYngenergysavingopportuniYes,e.g.wasteheatrecovery,non-thermaldrying,andlow-energyprocessing•  Fuel,electricity,steam,andhybridsystems

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AdvancedSensors,Controls,PlaWorms,andModelingforManufacturing

Cross-EnergyConnecHons•  Grid:advancedmetering;sensorsforpowerflow•  ElectricPower:gridintegraAon•  Buildings:advancedsensorsforlighAngand

HVAC•  TransportaHon:vehiclesenginecontrolsystems

Intra-ManufacturingConnecHonsConnecHonsspanningallmanufacturingtechnologies,including:integratedsensorsandcontrolsforincreasedmanufacturingthroughput,efficiency,andqualitycontrol;computaAonalmodelsforsimulaAonsandacceleratedmaterialsdevelopment








ProcessHeaHng


Manufacturing

CriHcalMaterials DirectThermalEnergyConversion

Materials,DevicesandSystems



ElectricPower




Scope•  Smartsystemsandadvancedcontrols•  Advancedsensorsandmetrology,includingpower/costsensorsandcomponenttrackingacrossthesupplychain•  Distributedmanufacturing•  PredicYvemaintenance•  ProductcustomizaYon•  HPC,cloudcompuYngandopYmizaYonalgorithms


Cross-EnergyConnecHons•  ElectricPower:wasteheatrecovery

opportuniAesinelectricgeneraAon•  Buildings:heatexchangersinHVACsystems•  TransportaHon:wasteheatrecoveryfrom

internalcombusAonengines

Intra-ManufacturingConnecHons•  CHP:heatrecoveryinCHPsystems•  SustainableManufacturing:opAmizaAonof

heatflowstomaximizeproducAonintensityandminimizewasteheatlosses

•  DirectThermalEnergyConversion:novelenergyconversionmaterials,devicesandsystemsforwasteheattopower

•  AdvancedSensors,Controls,PlaWormsandModelingforManufacturing:sensorstomonitortemperature,humidity,andlowerexplosionlimitstoenableincreasedexhaustgasrecycling;predicAvemodelsforcombusAon

•  ProcessIntensificaHon:integratedcontrolsystems;replacementofbatchoperaAonswithconAnuousones

•  ProcessHeaHng:wasteheatrecoveryfromprocessheaAngequipment;facilityintegraAontoenablere-useofexhaustgasesinlower-temperatureprocesses









ProcessHeaHng




Manufacturing

CriHcalMaterials



ElectricPower


Scope•  Wasteheatrecoverytechnologies,includingrecuperators,recuperaYveburners,staYonaryandrotaryregenerators,

andshell-and-tubeheatexchangers•  Majorwasteheatsourcessuchasblastfurnaces,electricarcfurnaces,melYngfurnaces,andkilns•  OpportuniYesforlow,medium,andhigh-temperaturewasteheatrecovery

53

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Cross-EnergyConnecHons•  Grid:CHPfordistributedgeneraAon•  ElectricPower:CHPfordistributedgeneraAon

Intra-ManufacturingConnecHons•  SustainableManufacturing/Process

IntensificaHon:modulardesignforeasierreconfiguraAon,upgradeandrepair

•  WasteHeatRecovery:heatrecoveryinCHPsystems

•  AdvancedSensors,Controls,PlaWorms,andModelingforManufacturing:modelstosupportdevelopmentofhigh-efficiencyCHPconfiguraAons;improvedcontrolsforgridintegraAon

•  ProcessHeaHng:integraAonofCHPwithmanufacturingequipment









ProcessHeaHng




Manufacturing

CriHcalMaterials

TransportaHonGrid Fuels


ElectricPower Buildings


Scope•  Supplychainissues,fromresourceextracYontoendoflife(LifeCycleAnalysis)•  FlowdiagramstodemonstratesupplychainissuesMaterialefficiency:mechanismsforreducingdemandformaterials

(e.g.,lightweighYng,scrapreducYon,increasedmateriallongevity)•  DesignforRe-use/Recycling

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Cross-EnergyConnecHons•  ElectricPower:managementofwater&energy

resources•  Buildings:recyclingandmaterialssubsAtuAon/

minimizaAon

Intra-ManufacturingConnecHons•  CriHcalMaterials:materialssubsAtuAon•  ProcessHeaHng:sharedownershipof

equipmenttomaximizeproducAonintensity•  MaterialsforHarshServiceCondiHons/

AdvancedMaterialsManufacturing:materialstoincreasedurabilityorfacilitatere-use

•  CombinedHeatandPower/ProcessIntensificaHon:modularequipmentdesignforeasierreconfiguraAon,upgradeandrepair

•  AddiHveManufacturing:distributedmanufacturing;rawmaterialminimizaAon

•  CompositeMaterials:Lightweightmaterialsmanufacturingforlife-cycleenergysavings

•  AdvancedSensors,Controls,PlaWorms,andModelingforManufacturing:smarttechnologiestoenabletrack&traceofmaterialsthroughthelifecycle

•  WasteHeatRecovery:opAmizaAonofheatflowstomaximizeproducAonintensityandminimizewasteheatlosses










ProcessHeaHng



CriHcalMaterials


Manufacturing



ElectricPower

Scope•  Supplychainissues,fromresourceextracYontoendoflife(LifeCycleAnalysis)•  FlowdiagramstodemonstratesupplychainissuesMaterialefficiency:mechanismsforreducingdemandformaterials

(e.g.,lightweighYng,scrapreducYon,increasedmateriallongevity)•  DesignforRe-use/Recycling

IntroducHon-FlowofEnergythroughtheU.S.Economy

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IntroducHon–FlowofEnergyThroughManufacturing

Note:1quad=1,000TBtu57

Driver–EnergyIntensityImprovementsTechnicalEnergySavingsOpportuniHes:Iron&SteelIndustry2015BandwidthStudy–potenHalbymajorprocessarea

Source:DOE/AMO,Iron&SteelIndustryEnergyBandwidthStudy(2014) Note:1quad=1000TBtu58

FinalProcessing

SecondaryProcessing(8.72kg)

KeyassumpHons:•  Ingotembodied(source)energy918MJ/kg(255kWh/kg)[5]•  Forging1.446kWh/kg[5],AtomizaYon1.343kWh/kg[6,7,8],Machining9.9kWh/kgremoved[9],SLM29kWh/kg[10,11],EBM17kWh/kg[10]•  11MJprimaryenergyperkWhelectricity• Machiningpathwaybuy-to-fly33:1[15],supplychainbuypoint=forgedproduct(billet,slab,etc.)•  AMpathwaybuy-to-fly1.5:1,supplychainbuypoint=atomizedpowder•  ArgonusedinatomizaYonandSLMincludedinrecipesbutnotfactoredintoenergysavingsinthispresentaYon

Powder ElectronBeamMelYng(EBM)

Addi3veManufacturing-Buy-to-FlyRa3o1.5:1

FinishedPart

Source:MFIandLIGHTEnUPAnalysis

PrimaryProcessing(15.9MJ/kg)

FinishedPartMillProduct(slab,billet,

etc.)

MachinedProduct

Conven3onalMachining-Buy-to-FlyRa3o8:1

AtomizaHon(14.8MJ/kg)

(0.57kg)

FinalProcessing(0.38kg)

1.09kg

0.38kg

*“Average”convenYonalbracket1.09kg,“average”AMbracket0.38kg

Ingot(918MJ/kgembodiedenergy)

TechnologyAssessment–AddiHveManufacturingExample:OpHmizedAircralBracket

59

Driver–CarbonIntensity

60

Directemissionswithefficiencyimprovements,…

…andwithfuelswitchingandmaterialsubsYtuYon

ExampleanalysisusingtheBuildings,Industry,Transport,ElectricityScenario(BITES)tool

CarboncaptureandsequestraYon(CCS)technologiesofferaddiYonalopportuniYes

Agriculture,mining,construcYon:OpportuniYesforadvancedengines,biofuels,etc.

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Driver–UseIntensity:AluminumExample

MaterialsShin–ToenableincreaseofsecondaryaluminumEnd-of-lifeshin–Toenablegreatercaptureanduseoflandfill+scrapexportSystems-wide–Materials&productdesign,manufacturing,useandre-use.

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oﬃce of energy eﬃciency & renewable energy advanced ... · program name or ancillary text...

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