DOE Announces $26M to Develop Energy Efficient Processes for U.S. Industry
September 2, 2008 // Published as a news service by IHS
These projects support the Energy Policy Act of 2005 goal of reducing the energy intensity of U.S. manufacturing industries by 25% in 10 years, as well as contributing significant reductions in greenhouse gas (GHG) and other emissions, said DOE.
According to DOE, the industrial sector consumes approximately one-third of the energy used in the U.S. and accounts for 28% of domestic GHG emissions.
The DOE Industrial Technology Program (ITP) Energy Intensive Processes Initiative seeks to reduce carbon emissions and improve energy efficiency across the most energy-consuming manufacturing processes.
The ITP approach is to increase efficiency while applying the best energy management to help industry save energy, improve productivity and stimulate growth.
Pending Congressional approval, the $26.6 million provided by the DOE will leverage an additional $15.3 million in cost-share funds provided by the award recipients and their industry partners for the following eight awards:
Energy Reduction and Advanced Water Removal via Membrane Solvent Extraction Technology - Estimated $5.6 Million
The 3M Company, in collaboration with Archer Daniels Midland Company, the DOE National Renewable Energy Laboratory and Karges-Faulconbridge Inc., will develop the concept of the membrane solvent-extraction technology for water removal and verify the technology at a pilot scale for bio-ethanol production to increase energy and water savings. According to DOE, water removal is the most energy intensive stage in conventional bio-ethanol production.
R&D and Field Testing of Thermochemical Recuperation for High Temperature Furnaces - Estimated $4.6 Million
American Iron and Steel Institute will team up with Gas Technology Institute, Thermal Transfer Corporation, U.S. Steel, ArcelorMittal, Republic Engineered Products, Steel Manufacturing Association and Ohio Department of Development to develop and test thermochemical recuperators for steel reheating furnaces to increase waste heat recovery and reduce natural gas use. A thermochemical recuperator uses the partial oxidation of a fuel to recover energy from heating processes.
Paired Straight Hearth Furnace Transformational Ironmaking Process - Estimated $1.5 Million
American Iron and Steel Institute, in partnership with McMaster University, U.S. Steel, Bricmont and Harper International, will work to optimize the Paired Straight Hearth (PSH) furnace technology and to establish its scalability potential from the bench-scale stage. The PSH furnace is an alternative to the energy and carbon-intensive blast furnace commonly used to make steel.
Induction Consolidation/Molding of Thermoplastic Composites Using Smart Susceptors - Estimated $4.1 Million
The Boeing Company will lead a team of Ford Motor Company, Vestas, Ajax Tocco, Steeplechase, Temper and Cytec to establish the technical and economic viability of induction consolidation of thermoplastic composites to fabricate aerospace, automotive and wind turbine components in an energy efficient manner. Induction consolidation uses the electrical conductivity properties of the thermoplastic materials to soften them and allow them to be formed.
Prototyping Energy Efficient Thermo-Magnetic and Induction Hardening for Heat Treat and Net-Shape Forming Applications - Estimated $4.4 Million
Eaton Corporation will lead a team of Oak Ridge National Laboratory, American Magnetics, Ajax Tocco, Dura-Bar, Ohio State University and North Western University to develop and test a hybrid thermo-magnetic and induction hardening technology to replace conventional heat treatment processes in forging applications. This technology uses the magnetic and electrical conductivity properties of a material to change its surface hardness.
Electrohydraulic Forming of Near-Net Shape Automotive Panels - Estimated $3.7 Million
Ford Motor Company will work with U.S. Steel, Troy Tooling, Pacific Northwest National Laboratory and Iap Research to develop and demonstrate this forming technology as an alternative to conventional stamping technology to form automotive panels. Electrohydraulic forming uses intense pressure waves to force the automotive panels into the proper shapes.
Inorganic Membranes for Refinery Gas Separations - Estimated $897,000
Media and Process Technologies Inc., working with Chevron and the University of Southern California, will develop and performance test hydrogen selective inorganic membranes for in-situ hydrogen recovery and recycling for improved refinery hydrotreating applications. The membrane will allow recovery of hydrogen formerly lost from the hydrotreating processes, with significant energy savings, said DOE.
Ultra-Efficient and Power Dense Electric Motors for the U.S. Industry -Estimated $1.9 Million
Reliance Electric Company will collaborate with Colfax Pumps, Howden Fan, DuPont, The Dow Chemical Company, Duke Energy, American Electric Power and Emeren Power to develop general purpose, permanent magnet electric motors that are more efficient, smaller and lighter than National Electrical Manufacturers Association (NEMA) premium efficient induction motors.
"The projects demonstrate a shared public-private commitment to advance development of energy efficient industrial technologies to help reduce our dependence on foreign oil while also confronting the serious challenge of global climate change," DOE Principal Deputy Assistant Secretary of Energy Efficiency and Renewable Energy John Mizroch said. "The department is committed to the research, development and deployment of cleaner, more efficient technology options for American industry, from laboratory to the plant floor."
Source: U.S. Department of Energy (DOE).