ogy successes emerging from OIT’s RD&Dportfolio!

The report identifies and describes about 120OIT-supported “emerging technologies”expected to be commercialized within thenext year or two.

“There’s no doubt that in recent years wehave had a higher percentage of ‘hits,’ withgreater numbers of readily commercializabletechnologies in our RD&D pipeline,” notedSwink. “We attribute this to implementationof our ‘Industries of the Future’ strategy. Thisunique new way of doing business helpsensure that the technologies we champion arethe key ones in high demand by the industrieswe serve.”

A few of the “emerging technologies” listedin Impacts are summarized briefly below. Youcan get your own copy of Impacts by callingOIT’s Resource Center at 202-586-2090.

Forest Products: Innovative tree debarkingCurrently, timber is debarked by rotating logsinside large cylindrical drums—heavyequipment with significant power demand.Dieter Bryce Inc., a participant in OIT’sInventions and Innovation Program, hascome up with a better way. “We use theweight of the logs themselves as the debark-ing force, dropping them down the side of anopen, stationary drum,” explained PrincipalInvestigator Jeff Sasko. “The process takesabout the same amount of time, but withoutthe need to rotate the heavy mass we canreduce energy use by 70%. In addition, theopen design provides better control of theprocess leading to higher yields.” Now thatthe technology is proving out, Sasko notesthat he is fielding inquiries from mills on adaily basis—a situation very different fromjust a few years ago. “There wasn’t much

Over 120 new OIT-supportedtechnologies nearingcommercialization

“Impacts” shows benefitsof “Industries of the Future”strategy

Since the mid-1990’s, OIT has been operatingunder an innovative, industry-driven,customer-focused strategy known as “Indus-tries of the Future.” Under this strategy, OITbrings together stakeholders in energy-intensive industries—including companiesthat may otherwise be competitors—to createa strategic “vision” of the future of theirindustry and “roadmaps” to help themachieve their vision. This strategy enablesOIT and other technology-supportingorganizations to better target their customers’needs and make best use of limited resources.

“It’s a way of working that’s both simple andrevolutionary at the same time,” said DeniseSwink, DOE’s Deputy Assistant Secretary forIndustrial Technologies. “It acknowledgesthat no one knows more about what theindustries need than the industries them-selves. With OIT’s impartial facilitation, wecan get members of the industry together totalk about common, pre-competitive goals,

and then help make them happen.”

While many people agree that the “Industryof the Future” strategy is both innovativeand praiseworthy, some have asked “Butare the results any different than the oldway of doing business?”

A recently published OIT report titled“Impacts–Summary of Program Results”

helps answer this question with a resounding,“Yes!” Impacts helps document the fact thatsince OIT began using its customer-focused“Industry of the Future” strategy, indeed, theresults are different: There has been a trulydramatic increase in the number of technol-

INSIDE

2, 4Initial Mining, Agriculture Teamprojects to be announced soon

2-4Inventions, NICE3, Combustion andSensors & Control solicitationsopen up

5New Petroleum Refining teamcreated

11Prices for IOF industry productsdeclining

Vol. 2, No. 4

OFFICE OF INDUSTRIAL TECHNOLOGIES • www.oit.doe.gov/oittimesENERGY EFFICIENCY AND RENEWABLE ENERGY • U.S. DEPARTMENT OF ENERGY

THE OIT TIMES“Turning Industry Visions into Reality”

SUMMER 1999

(continued on page 6)

Facilitated by OIT’sMining Team, the miningindustry has recentlypublished its crosscuttingroadmap that identifiesnumerous high priority

technologies applicable to both coal and hardrock mining. It’s available at the Team’swebsite at www.oit.doe.gov/mining.... TheTeam issued two solicitations for R&Dproposals addressing the needs identified inthe crosscutting roadmap. One of thesolicitations calls for industry-ledprojects while the other callsfor National-Lab ledprojects. Funding selec-tions will be announcedshortly.... Working withthe National MiningAssoc., the Team iscoordinating efforts tocreate additionalroadmaps focused on R&Dneeds in Digging andMaterials Handling and PostMining Processes.... The Team participatedin the TMS annual meeting in San Diego andthe SME annual meeting in Denver. Teammembers gave presentations, exhibiteddisplays and took part in a variety of outreachactivities. (Contact: Toni GrobsteinMarechaux, 202-586-8501)

The Steel Team plans to soon releaseits “Energy & Environmental Profileof the U.S. Steel Industry, 1999.” Thedocument synthesizes informationfrom a variety of sources into a singlereport, providing valuable

benchmarking energy and emissions data for all keysteelmaking processes. Updating an earlier report, thenew version provides more detail on all processes,including the addition of CO2 emissions data. Thereport will be available from OIT’s Resource Center

at 202-586-2090.... In a joint project involvingOIT, Los Alamos National Lab and

Inland Steel, researchers recentlyinstalled a Hot Blast Stove

Process Model and Model-Based Controller on a hugeblast furnace at Inland’s EastChicago mill. The companyhas reported a 5% reduction innatural gas use, saving

$30,000/month. The technologyhas potential application to all

blast furnaces. A detailed report onthe project will be released in August,

and a technical paper will be presented at anAISE conference in September.... Joined by col-leagues from the NICE3, Inventions & Innovation ,and Sensors & Controls programs, the Team hosteda booth at the Ironmaking/Steelmaking Conference inChicago. Details of various opportunities from OIT’sprograms were described. (Contact: Scott Richlen,202-586-2078)

The Motor Challenge andCompressed Air Challengeprograms sponsored a money-saving training program, “Funda-mentals of Compressed AirSystems” at several sites. The

one-day workshop provided plant engineers andmaintenance supervisors with best practicesinformation on improving industrial compressedair systems efficiency and performance.... Theprogram is sponsoring a cost-shared solicitationfor plant-wide assessments. It aims to encouragemanufacturers to work with service and equipmentsuppliers to identify opportunities for emergingtechnologies and to take a systems approach toprocess optimization.... Page 8 in this issuedescribes several Motor Challenge success stories.(Contact: Paul Scheihing, 202-586-7234)

With support from a

NICE 3 grant, Solex

Robotics developed arobotic tank inspection

system known as

“Maverick” that was

recently demonstrated at

BP Amoco’s Texas CityRefinery. Utilizing

ultrasonic sensors, the

innovative system can

confirm the integrity of a

full tank of gasoline orjet fuel. The system

provides a practical way

to protect against fuel

tank leakage without

requiring human

inspection. Maverickwas recently featured on

CNN’s Science and

Technology Week....

NICE 3 and Inventionsand Innovation solicita-tions opened concur-

rently this year to

provide small business

innovators with a wider

range of potentialfunding sources.

Developers of energy

efficient, clean produc-

tion technologies,

especially those impact-ing one or more of the

IOFs, are encouraged to

submit proposals. NICE 3

maximum grants have

increased to $525,000for this solicitation.

(Contact: Lisa Barnett,

202-586-2212)

SteelUpdated “Energy andEnvironmental Profile” coming

2

The Industrial Assessment CenterProgram is undergoing an extensivereview to finetune metrics used todetermine the energy savings,waste-reduction and productivity

improvements enabled by IAC plant audits.... Anumber of firms, including Johnson Controls, haverequested access to the IAC listserv to post jobopenings for graduating seniors, a testament to thequality and experience of IAC student assessors....In August, more than 60 IAC Directors and otherstakeholders will meet in Kennebunkport, ME, forthe annual Directors Meeting.... Denise Swink andOIT Office Director, Marsha Quinn, presentedOutstanding Service Awards to San Diego StateUniv. and San Francisco State Univ. for participa-tion in OIT’s IAC program. (Contact: ChuckGlaser, 202-586-1298)

Quarterly Highlights

MiningRoadmap released, firstprojects to be selected shortly

3

THE OIT TIMES/SUMMER 1999

The Inventions & Innovation program“Class of 99” recipients attended a commer-cialization strategy workshop in March. Thenew projects include a low frequency mixingsystem that has the potential to improve

productivity and reduce energy consumption in a wide varietyof applications; a new wear- and corrosion-resistant refrac-tory material for use in lining heavy equipment such as hightemperature lime kilns; and a new method for making steelstrapping that results in a higher quality product whilereducing energy usage by 32%.... The Program is sponsoringa series of conferences to help familiarize inventors and smallbusinesses with the needs expressed in IOF industryroadmaps.... I&I’s FY00 solicitation will be open until July30. The maximum amount of I&I grants has doubled to$200,000. The solicitation document can be found atwww.oit.doe.gov/inventions. (Contact: Sandy Glatt,202-586-3897)

The Aluminum Team has selected fournew R&D projects for negotiation pursu-ant to award. The projects selected are: (1)“Development of a Novel Non-Consum-able Anode for Electowinning Primary

Aluminum,” (2) “Integrated Numerical Methods andDesign Provisions for Aluminum Structures,” (3) “Intelli-gent Potroom Operation,” and (4) “Spray Rolling Alumi-num Strip.” R&D partners, who include private firms,universities and trade associations, will cost-share 30% ormore of total project costs.... In recognition of the highconcentration of aluminum firms in Kentucky and theimportance of the industry to the state’s economy, theUniv. of Kentucky has created the “Southeast Center forAluminum Technology.” One of its initialactivities was sponsorship of the KentuckyAluminum Technology RoadmapWorkshop in March. Represen-tatives from the state’saluminum industry, the U ofK, and OIT attended. Thegroup will publish an alumi-num industry technologyroadmap specific to Kentuckythat will serve as a starting point fordiscussion of the regional industry’s R&Dpriorities. (Contact: Sara Dillich, 202-586-7925)

Steam Challenge will hold its next SteeringCommittee Meeting on July 22. The semi-annual event will bring together steam-related associations, State energy organiza-tions, steam equipment suppliers and steam

users to provide suggestions to the OIT Program Team, aswell as suggest activities for the Committee’s six subcom-mittees. The meeting will focus on methods to promotesteam efficiency awareness by steam system operators,facility managers and industry executives.... Programrepresentatives presented a paper at the Air & WasteManagement Assoc. Conference in Chicago. The presenta-tion informed participants on how to benefit from OIT’ssteam efficiency programs and other energy-savingresources and opportunities.... A similar presentation will bemade at the TAPPI ’99 conference in September to benefitthe pulp and paper industry, a major steam user. (Contact:Fred Hart, 202-586-1496)

AluminumFour new projectsselected

MetalcastingCupola control software nowcommercially available

Developed by the American Foundrymen’sSociety in partnership with the MetalcastingTeam, the AFS Cupola Simulation and ControlSoftware can help foundries produce higherquality iron, optimize energy use, and maxi-

mize profitability. The new user-friendly modeling softwarecan help iron foundries predict results over a wide range ofcomplex operational variables, making it an invaluable toolfor fine-tuning cupola furnace operation. For more informa-tion, contact AFS at 1-800-537-4237.... The Team’s newprojects for FY00 will soon be announced. Funding of $2

million will be provided to R&D projects in areasidentified as high priority in themetalcasting industry roadmap. The Teamanticipates making 5-10 cooperativeagreement awards.... Denise Swink

represented the Team as keynote speaker atthe Worcester Polytechnic Institute/Metal

Processing Institute annual symposium. Swink’spresentation described how joint OIT/industry

efforts could help address the Symposium theme of“Technological Challenges and Opportunities for Net

Shape Manufacturing in the 21st Century”.... Mrs.Swink was recognized by the AmericanFoundrymen’s Society for her vision and commit-ment to improving the metalcasting industry.

(Contact: Harvey Wong, 202-586-9235)

4

The Forest Products Team hasbeen reviewing R&D projectrecommendations made by itspartners at AF&PA. Research-ers submitted more than 280proposals in the six technology

areas identified in the Forest Products Vision2020. Project selections are expected to beannounced in July.... Gasification technologywas identified as a major R&D need by theindustry. In response, the Team may sponsora separate solicitation focusing on projects inbiomass and black liquor gasification.

Contact OIT’s Tom King at 202-586-2387.... Members of the six Forest

Products technology areas pre-sented annual status reports onmore than 65 projects to OITstaff, representatives of AF&PAand others. Industry groupswill provide feedback andrecommendations.... TheTeam had a very successfulpresence at the TAPPI

Mega-conference in March,with high booth traffic reported throughoutthe show. Team members were joined bycolleagues from the NICE3, I&I and MotorChallenge programs to provide showattendees an “integrated” view of theresources and opportunities availablethroughout OIT. (Contact: Valri Robinson,202-586-0937)

The Advanced IndustrialMaterials program will hold itsannual review meeting June 21-23. Approximately 20 industrialpartners will brief theProgram’s Guidance & Evalua-

tion Board on the status of active R&Dprojects. The Board, a group of industry,academic and government stakeholders,provides suggestions about how to better meetcustomer needs.... The Chemicals Team isnow funding demonstration of two successfulAIM R&D projects. They are “Electrochemi-cal Reactors for Chlor-alkali Process”, and aproject involving development of a membranetechnology for separating paraxylene.(Contact: Charlie Sorrell, 202-586-1514)

The Combustion program releasedits vision and roadmap, prioritizingR&D needs based upon industryconsensus. The documents areavailable at www.oit.doe.gov/

combustion.... A solicitation for projects address-ing key needs identified in the roadmap is openthrough August 2. The solicitation is located atwww.id.doe.gov/doeid/PSD/proc-div.html....Presentations on the roadmap were made at theAmerican Flame Research Committee SpringMeeting and the International Energy Agency’sEnergy Conservation and Emissions Reductionin Combustion Meeting. Highlighted was theimportance of optimizing fuel usage and mini-mizing emissions in combustion systems.(Contact: Gideon Varga, 202-586-0082)

OIT’s Agriculture Team andits industry partners areevaluating R&D proposalssubmitted in response to itsfirst solicitation. The projectsfocus on the “Processing”

and “Utilization” barrier areas prioritized in theindustry roadmap. Funding recipients were tobe announced in June with details posted onthe team’s website at www.oit.doe.gov/agriculture. The industry roadmap and visionare also at the website.... A second solicitation,using FY00 funds, will be announcedsoon. OIT’s budget requestcalls for a doubling ofteam funding inFY2000.... OITstaff made presen-tations at theBiotechnologyByproducts Consortium,hosted by the Univ. of Iowa,and the International StarchTechnology Conference at the Univ. ofIllinois... Assistant Secretary Dan Reicher’sBioenergy Initiative has begun with the hostingof a “visioning” meeting in St. Louis in March.More than two dozen leaders in the use ofbiomass for fuels, power and industrialproducts conceptualized an integrated industryvision which was reviewed in Washington,DC, in June. (Contact: Doug Faulkner,202-586-2119)

Forest ProductsGasification technologymay be targetedThe Sensors and Controls

program announced that 13Small Business TechnologyTransfer and 69 SBIR Phase Igrant applications werereceived in response to theFY99 topic areas (measure-ment and control technologiesfor industrial applications).The list of awards will bepublished in the next issue ofThe OIT Times.... The S&Cprogram held its first annualmeeting on May 4 in Balti-more. Principal investigatorsof the seven S&C projectsbegun in FY99 briefed theirindustry customers, and factsheets and presentationmaterials for each project weredistributed. These usefulmaterials are also available onthe S&C Web site atwww.oit.doe.gov/sens_cont....The S&C Steering Committeeconvened to assess the high-priority S&C technologyneeds identified in IOFindustry roadmaps. TheCommittee’s assessment willhelp determine the topic areasfor upcoming solicitations,including the S&C programFY00 solicitation and theSBIR/STTR grant applica-tions. The Committee includesexperts from OIT teams, NSFCenters, NIST’s ProcessMeasurements Div., and theDOE Laboratory CoordinatingCouncil.... The S&C FY00solicitation should be open bythe time you read this. Visitthe Team’s website for details.(Contact: Eric Lightner, 202-586-8130)

Quarterly Highlights

Renewable BioproductsNew projects to beannounced soon

5

The Continuous Fiber Ceramic Compos-ite (CFCC) program has successfullycompleted over 5000 hours of combustionsimulation testing at Oak Ridge NationalLab. The tests involve various CFCC

materials manufactured by partners includingAlliedSignal Composites, B. F. Goodrich, Boeing,Composites Optics Inc., Dow Corning, and GeneralElectric. These tests support field testing of SolarTurbine’s low NOx ceramic combustors in their CentaurEngine. In addition, there has been a series of successfultests on CFCC shroud materials at the GE CorporateResearch Center. Both tests simulate the pressures andhigh temperatures in a gas turbine environment. (Contact:Debbie Haught, 202-586-2211)

OIT has formed a new Petroleum RefiningTeam to work with this energy-intensiveindustry in addressing its high priority technol-ogy needs. The Team released a new report,“Energy and Environmental Profile of the U.S.Petroleum Refining Industry.” The report

presents benchmark energy use and emissions data for eachof the industry’s major unit processes, as well as the industryas a whole. Copies are available from the OIT ResourceCenter at 202-586-2090.... Represented by the AmericanPetroleum Institute and National Petrochemical and RefinersAssoc., the industry has recently created its industry-widestrategic vision which is expected to be releasedin the near future.... Representatives fromthe industry, academia and NationalLabs met in a roadmappingworkshop near Chicago thisSpring to develop a list of“most-needed” technolo-gies. (Contact:Gideon Varga, 202-586-0082)

THE OIT TIMES/SUMMER 1999

After successfully demonstrating a 5000 hour run ofthe continuous fiber ceramic composite liners devel-oped with partner Solar Turbines, OIT’s DistributedGeneration program will next demonstrate the linersin operation in a commercial gas turbine for 8000

hours in Malden Mills, MA. The liners enable NOx emissionsbelow 15 ppm and will ultimately help reduce emissions for onsitepower producers.... The program will begin two other importantdemonstrations this Fall. Rochelle (IL) Municipal Utilities willbegin using the Solar Turbine Mercury 50 Advanced TurbineSystem (ATS) engine in a cogeneration system. Goals include a40%+ efficiency level and emissions of 10 ppm.... Exxon willdemonstrate a ceramic turbine vane developed by Allison Corp. inMobile, AL. The goal is to further prove the efficacy of ceramiccomponents in a hot section environment over a 4000 hour test run.(Contact: Pat Hoffman, 202-586-6074)

Petroleum RefiningNew team created,industry “Profile” published

ChemicalsTeam active in ClimateChange Initiative

In conjunction with the AIChE, ACS,CMA, CCR and EPA, the Chemicals Teamparticipated in a workshop on “CarbonReduction Technology Opportunities forthe Chemical Process Industries” in

March. A response to the White House Task Force onClimate Change, the workshop convened experts to helpidentify and prioritize key technologies that could generatesignificant reductions in greenhouse gas emissions. A reporthighlighting both technology and policy options has beenpublished by EPA.... The Team will be soliciting proposedR&D projects until August 6, 1999 (approximate). About

$4 million is available to support advanced chemicalindustry R&D projects. For additional informa-

tion, go to www.ch.doe.gov/business/acq/chem…. Posters featuring more than 60

Technology Vision 2020 R&D projectsfrom OIT, Commerce’s ATP, and a

joint EPA/NSF program wereexhibited at the I&EC Divisionand SCI-MIX sessions at theSpring ACS meeting inAnaheim. (Contact: HankKenchington, 202-586-1878)

6

interest in doing prototype work in our industry; withoutOIT stepping up, this project would never have happened,”he said. “Now, anyone who processes timber can use theCradle Debarker™ to save energy and boost productivity.”

Chemicals: Nontoxic replacements for toxic solventsPetroleum-derived solvents are ubiquitous building blocksof products ranging from paints to adhesives to recycledpaper. Manufacturers have long sought an alternativeprocess to reduce environmental impact as well as petro-leum dependence, but no cost-effective or practical candi-date has been found. A partnership involving OIT’sChemicals Team, Argonne National Lab and NTEC Inc. ishelping to change this. They are using an innovative,membrane-based process to manufacture lactate esters—versatile solvents that are nontoxic and biodegradable—thatcuts the production costs of these safer solvents in half.

Glass: Making better use of waste heat gasesA partnership between OIT’s Glass Team, Corning, GasResearch Institute, New York Gas Group, NYSERDA,Praxair and Thermo-Power Corporation is working tocommercially demonstrate the viability of Raining BedBatch and Cullet Preheater technology. This energy-savingheat exchange system recovers otherwise-vented hot fluegases and uses them to preheat the glass furnace charge,raising the temperature of batch/cullet particles to greaterthan 1000o F, and reducing the energy needed to melt glassby 25%. The process lowers glass production costs signifi-cantly while increasing the longevity of the oxyfuel gasfurnace, a significant capital investment.

Aluminum: Improved scrap decoatingThough aluminum is one of the most recycled materials, theprocess of decoating—removing the organic paints andlacquers on the metal before processing—has long been an

(continued from page 1) expensive and dirty headache. To help solve this problem,Energy Research Co. with support from OIT’s NICE3Program, is demonstrating its first indirect-fired, controlledatmosphere (IDEX™) kiln at Philips Service Corp. “Theyhave an IDEX kiln working around the clock, and the plantpersonnel are extremely happy with it,” said Lead Investiga-tor Bob De Saro. “We’re happy too because of the numberswe’re seeing.” According to De Saro, the IDEX is demon-strating NOx, SOx and VOC emissions levels that aresignificantly below the most stringent EPA regulations.Indeed, he quotes VOC emissions as only 2% of the EPAstandard. In addition, it’s helping reduce both energy use andproduct waste. “When it comes to R&D, everyone wants tobe second—not first—to support a new idea,” said De Saro.“OIT and NICE3 bravely stepped forward first to supportIDEX, and that led others to support it as well. The result, Ibelieve, is a technology that can substantially benefit both thealuminum industry and the environment.”

Steel: Improved quality through superior controlsIn manufacturing, typically the more effectively one controlsthe process, the higher the quality of the product and thelower the cost. Perhaps nowhere is this axiom as vital as inthe highly competitive steel industry, with the U.S. industrylooking to gain an edge as the most technologically-advancedand energy-efficient in the world. An OIT project withSandia National Lab and the steel industry is developinglaser-based sensors to help better monitor BOF steelmaking,allowing product optimization and minimized energy usage.The innovative process uses an infrared laser beam and aspectrometer to measure the composition of offgases,providing an early, direct and highly accurate indication ofprocess status.

CollectionLens

Detector

Computer

Slag

Tuyeres

InfraredLaser

Iron/Carbon Melt

O Lance2

N Injection2

Laser-based Sensor for steelBasic Oxygen Furnace

Dieter Bryce, Inc.’s new Cradle Debarker™

Quarterly Highlights

7

THE OIT TIMES/SUMMER 1999

GlassIndustry debates R&D priorities

Several industry representatives workedtogether to prioritize R&D needs in fourglass industry roadmap areas: (1) ProductionEfficiency, (2) Energy Efficiency, (3)Environmental Protection & Recycling and

(4) Innovative Uses. These priorities will guide the GlassTeam’s next solicitation. The roadmap is expected to befinalized at the Glass Problems Conference in October, andwill be published soon after that.... Michael Greenman, ActingExecutive Director of the new Glass Manufacturers IndustryCouncil (410-750-1226), recently met with AISI, the Aluminum Associa-tion and AF&PA to learn more about activities of these organizations.Discussions are underway to create an ongoing “association of associations” to discuss common goals.... GMIC has alsobegun a dialog with several other government agencies involved with glass industry R&D, including the Dept. of Commerceand the NSF. A possible large, multi-agency meeting later in the year is also being explored.... Efforts are underway with theLaboratory Coordinating Council to streamline the procedures by which the private sector can form joint R&D partnershipswith DOE’s National Labs. (Contact: Theodore Johnson, 202-586-6937)

Metalcasting: Improving control of “lost foam” processLost foam casting is a new technology allowingmetalcasters to create complex parts with minimal post-castmachining and reduced material waste and emissions.Molten metal is poured into a specially-treated foampattern; the foam vaporizes, leaving a replica of the patternin metal. The process is proven, but work is underway tobetter control the process and make it practical for wide-scale use. A diverse team, including the Univ. of Alabama/Birmingham, the Cast Metal Coalition and the AmericanFoundrymen’s Society, have made significant progress indeveloping process control measures that are leading toimproved analysis and control at every stage of thisinnovative process.

CFCCs/Distributed Generation: Developing new hightemperature engine materialsThe higher the operating temperature, the more efficientand clean-burning the engine. Current engines use metalcomponents almost exclusively, and blowers cool thecomponents to keep them from melting—a process thatlimits engine efficiency. OIT’s CFCC and DistributedGeneration programs are investigating a better way: Usingcombustion liners made of high temperature ceramiccomposites. “Regardless of the potential benefits, enginecompanies see a huge technical risk in the use of newmaterials,” explained Principal Investigator Phil Craig ofAlliedSignal Composites Inc., “We’re helping industry gain

greater confidence in these materials in real worldapplications. OIT is providing a great service—they’repulling together a diverse group of professionalsinterested in advanced materials who would never havecome together before. Now we’re all working togetherto develop a beneficial new technology.”

Combustion: Reducing burner emissionsIn total, steam generation uses more energy than anyother single industrial process. No wonder then that theClean Air Act places stringent requirements on boileremissions. “While significant progress has been made,most burners can reach required NOx emissions levelsonly through expensive and inefficient post-combustioncontrol systems such as selective catalytic reduction,”explained OIT Combustion Program Manager GideonVarga. “The Forced Internal Recirculation Burner beingdeveloped at the Institute of Gas Technology provides amuch less expensive way for industry to comply withNOx emission regulations. And, as a bonus, the FIRburner happens to operate most efficiently at relativelylow excess air levels, so there is less heat wasted goingup the stack,” he said. In testing, the FIR burnerdemonstrated NOx emissions of well under 10 ppm, asignificant improvement over incumbent technologies.IGT is gearing up for a demonstration of the burnerwith partner Detroit Stoker at a facility in SouthernCalifornia.

8

The front page of this issue of The OIT Times highlights afew of the dozens of promising R&D projects OIT iscurrently supporting that are beginning to approach com-mercialization. But OIT’s portfolio also addresses opportu-nities that can enable firms from numerous industries tostart benefitting right now by adopting technologies andbusiness practices that are already available.

Since its inception in 1993, Motor Challenge has helpedhundreds of motor systems users achieve virtually immedi-ate improvement in plant productivity and reliability. PaulScheihing, Motor Challenge Program Manager, notes that,“Efficient motor systems use 20% less energy than conven-tional systems on average. Motor Challenge is helpingindustry to achieve these energy savings.” Chevron,Cummins Engine Co., and Blue Circle Aggregates Quarryhelp illustrate how Motor Challenge is helping firms reducetheir energy use and save money.

New optimized pump systems saving Chevron $700,000Chevron, one of the largest U.S. refiners, completed amotor system efficiency improvement project at its Rich-mond, CA, refinery that is resulting in savings of $700,000annually. The refinery wanted to downsize the pumps in thediesel fuel hydrotreater (which treats raw diesel fuel toproduce a finished product), because many of the pumpsoperated below peak efficiency and unreliably. A nation-wide energy services company—Planergy (in conjunctionwith Pacific Gas and Electric Co.)—approached Chevronwith an offer to provide variable speed drives and pumpupgrades at no cost to Chevron. Planergy benefits throughcost-sharing with Chevron.

According to Art Mares, Reliability Analyst, “Because ofthe high vibrations caused by running the pumps soinefficiently, we would typically repair a mechanical seal orbearing about once a year. Since the pumps were started, wehave had no repairs of any kind.”

Motor Challenge: Impacting industry’s bottom line today!

Chevron’s diesel hydrotreater team.

Assembly line at Cummins EngineCompany Inc.- Columbus, IN.

Motor system upgrades at Georgia quarryIn February, 1997, the Industrial Assessment Center at theGeorgia Institute of Technology completed an assessmentof the Blue Circle Aggregates Quarry in Lithonia, GA.Based on their assessment, the Georgia Tech faculty andstudents at EEMC recommended three motor systemupgrades for the Lithonia quarry. These include reducinghorsepower of water pumps, lowering hydro-cycloneelevation and replacing four motors with energy efficientmotors.

Implementing the motor system upgrades has reducedyearly energy consumption at the quarry by nearly250,000 kWh resulting in cost savings of over $21,000 peryear. These energy and demand savings are 6.2 percentand 16 percent of their respective annual figures.

For more information about Motor Challenge, visit itsWeb site at www.motor.doe.gov/ or call the program’sInformation Clearinghouse at 800-862-2086.

Cummins motors investments pay offUsing DOE Motor Challenge tools and resources,McBroom Electric Co.—an Allied Partner—manageda million-dollar installation of nearly 800 new energy-efficient motors totaling over 13,000 horsepower atthe Cummins Engine Co. assembly plant in Colum-bus, IN. By installing new energy-efficient motors inboth existing and new machining lines, McBroomsaved Cummins an estimated $200,000 per year inannual motor system energy costs.

Quarterly Highlights

9

New NICE 3 projects announced; successfulproject showcased at April event

According to Lisa Barnett, NICE3 Program Manager, “The availability of funds fordemonstration can sometimes mean the difference between a good idea that nevercatches on and a proven, marketable technology. That’s where NICE3 comes in.”The grant program provides funding to state/industry partnerships to demonstrateadvances in energy efficiency and clean production technologies.

In April, the program announced that six projects were selected to receive FY 1999solicitation awards—one-time NICE3 grants ranging from $211,000 to $425,000.Award recipients will cost-share at least 50% to project costs. In making its selec-tions, the program focused on promising technologies with multiple applications andapplications that cross industry lines. Winning projects are listed in the box below.

NICE 3 FY 1999 Projects Partners

MBA Polymers, Inc., Richmond, CA,California Energy Commission

North American Die Casting Association, Rosemont, IL,Illinois Dept. of Commerce and Community Affairs

Alcoa, Warrick, IN,IN Dept. of Commerce, Energy Policy Division

Increasing Productivity and Reducing EmissionsThrough the Enhanced Application Control ofDie Casting Die Lubricants

Demonstration of a High Temperature, CorrosiveResistant Recuperator for the Metals Industry

Plastic Manufactured from RecoveredPost-Consumer Durable Goods

Industrial Microwave Systems Inc., Research TrianglePark, NC, NC Dept. of Environment and Natural Resource

A Device for Efficiently and Uniformally DryingNonwoven Materials Using Microwave Technology

Air Products and Chemicals, Inc., Allentown, PA,Ohio Dept. of Development’s Office of Energy Efficiency

Cryogenic Separation of Foundry Sands andReuse of Reclaimed Streams

Weirton Steel Corporation, Weirton, WV,West Virginia State Energy Office

Hot Mill Transfer Bar Rapidfire™Edge Heat Project

In April, the NICE3 program showcased one of its many successes, a textilefinishing process. Speakers at the event, which was held in N. Dartmouth,MA, included Congressman Barney Frank (D-MA) and David Leiter, DOE’sPrincipal Deputy Assistant Secretary for EERE. Brittany’s innovative processinvolves applying finishing chemicals—which improve shrinkage control,softness and stain resistance—as a foam, rather than a liquid. The processdecreases natural gas consumption and increases production speed.

For more information on Brittany Dye’s textile finishing process, FY 1999winners or the FY 2000 solicitation, visit OIT’s website at or contact LisaBarnett at (202) 586-2212.

Innovative textile finishing process showcased

THE OIT TIMES/SUMMER 1999

Foam Finishing Applicator at BrittanyDyeing and Printing Corp. improves

fabric finishing system.

NICE3 FY00 solicitation now open

Solicitations for the Inventionsand Innovation (I&I) andNICE 3 programs were issuedconcurrently in May this year.I&I project proposals are due7/30/99 while NICE3 proposals aredue 9/1/99 to allow states time toprocess the NICE3 proposals.Selection announcements for bothsolicitations will be concurrent.

10

Information Corner

Advanced Industrial Materials Program Review, Jun 21-23,Pleasanton, CA

Fundamentals of Compressed Air Systems, Jun 22, OklahomaCity, OK, 800-862-2086

Fundamentals of Compressed Air Systems, Jun 22, Tampa, FL,800-862-2086

Steam Challenge Steering Committee Meeting, Jul 22,Cleveland, OH

Start up of Mercury 50 turbine engine, Aug, Rochelle, IL

IAC Directors Meeting, Aug 9-11, Kennebunkport, ME

Understanding Pump Systems/PSAT Workshop, Aug 29, SanDiego, CA, 360-754-1097, ext. 100

Energy Efficiency Forum for Water/Waste Water Facilities, Aug29-31, San Diego, CA, 918-831-9179

Fourth Biomass Conference of the Americas, Aug 29-Sep 2,Oakland, CA

TAPPI Engineering Conference, Sep 12-16, Anaheim, CA

IEA Annex Meeting on Cogeneration, Sep 27-28, San Diego, CA

AISI’s Iron and Steel Show, Sep 27-30, Cleveland, OH

National Mining Assoc.’s Convention ‘99, Oct 10-13,St. Louis, MO

Copper ‘99, Oct 10-13, Phoenix, AZ

ASM Materials Conference, Nov 1-4, Cincinnati, OH

ATS Annual Program Review, Nov 8-10, Pittsburgh, PA

ACerS Refractory Ceramics Division Joint Meeting, Nov 14-16,Pittsburgh, PA

Calendar

Agriculture (FY99) Past Past 6/99 $2 mil —-Agriculture 9/99 11/99 1/00 $4 mil TBDAluminum 8/99 10/99 11/99 $4-7 mil TBDAluminum–Advanced Cell 8/99 10/99 11/99 $3 mil TBDChemicals Now Open 7/99 9/99 $4 mil www.ch.doe.gov/business/acq/chemForest Products Past Past 7/99 $4 mil —-FP—Biomass & black liquor gasification 7/99 9/99 11/99 $9 mil www.oit.doe.gov/forestForest Products (FY01) 8/99 10/99 7/00 $3 mil www.oit.doe.gov/forestGlass (FY01) 1/00 4/00 7/00 $3 mil TBDMetalcasting Past Past 7/99 $2 mil —-Metalcasting (FY01) 1/00 4/00 7/00 $2 mil TBDMining-Industry Now Open 7/99 8/99 $1-3 mil www.fetc.doe.gov/business/solicitMining-DOE Natl Labs only (FY99) Past Past 6/99 $1.8 mil —-Steel–AISI Past Past 7/99 $2 mil —-Inventions & Innovation Now Open 7/30/99 12/99 $2.3 mil www.oit.doe.gov/inventionsNICE3 Now Open 9/1/99 12/99 $4 mil www.oit.doe.gov/nice3Combustion (FY99) Now Open 8/2/99 9/99 $2.7 milwww.id.doe.gov/doeid/PSD/proc-div.html

Sensors & Controls Now Open 8/99 9/99 $1 mil www.oit.doe.gov/sens_contPlant wide assessments (FY99) Now Open 6/99 7/99 $500K- E-Mail: zmo@ornl.gov

$1,500K

Industry/AreaRequest ForProposals

ProposalsDue

SelectionAnnouncements

Funds(approx) URL

* As of 5/31/99. FY00 funds, unless indicated. Information in this table is periodically updated. See OIT’s Web site, www.oit.doe.gov/news/solicitations.shtml

Tentative OIT Solicitation Schedule *

Nurturing the Roots of aBio-based Economy

by Doug Faulkner,OIT Agriculture Team Leader

Weeding soybeans by hand for $1/hour as aboy in Illinois seems far removed fromleading a team promoting innovative, hightechnology industrial products from plants.Still—despite obvious distances in time andapproach—I find my current assignment inmany ways takes me back to my rural roots.

To strengthen ties across the agriculturalcommunity, we are building a network withcommodity farmer groups, non-profits,academia, and USDA. The forestry andchemical communities are also key players inthe unique coalition that has come togetheraround the strategic vision, “Plant/Crop-based Renewable Resources 2020” and itstechnology roadmap.

It seems like “deja vu all over again.” We arepicking up where Henry Ford left off in theearly years of this century with his short-lived dream of “growing” an American car.He wanted to use biomass to make and fuelhis new automobiles, but was sidetracked inpart by cheap oil.

Our biobased products coalition faces similarchallenges today. But we are bringing a freshapproach. New linkages and relationshipsneed to cut across scientific and academicdisciplines, industries and regions, levels andbranches of governments. Reinforcingcommon interests and leveraging resourcesthrough such steps as DOE AssistantSecretary Dan Reicher’s BioEnergy Initiativewill also play a crucial role. Such integratingefforts can help us achieve the far-reachinggoals laid out in the vision, reduce ourgrowing reliance on foreign oil, and rejuve-nate our rural communities.

GUESTEDITORIAL

Industry Trends

11

THE OIT TIMES/SUMMER 1999

Doug Faulknerphoto

120%

110%

100%

90%

80%

70%

60%1995 1996 1997 1998 1999

(Preliminary)

Consumer PriceIndex for Services

Consumer Price Index

Chemicals & AlliedProducts

Paper & Allied Products

Refined Petroleum Products

Source: Bureau of Labor Statistics

120%

110%

100%

90%

80%

70%

60%1995 1996 1997 1998 1999

(Preliminary)

Consumer Price Index for Services Consumer Price Index

Glass Containers

Primary Aluminum

Metal Mining

Steel

Recent Price T rendsfor Selected Industrial

Commodities

States Corner

Office of Industrial Technologies, EE-20Energy Efficiency and Renewable EnergyU.S. Department of EnergyWashington, DC 20585www.oit.doe.gov

Deputy Assistant Secretary forIndustrial Technologies,Denise Swink

Managing Editor,Lou Sousa

Assistant Editor,Jill Fisher

ReporterGregg Siegel

Industry Trends,Keith Jamison, Paget Donnelly

Designer,Allen Austin

Content reprintable without permission.Correspondence, including requests foradditional copies, or to be added to ordeleted from the mailing list, may bedirected to:

Lou SousaFax: (202) 586-9234E-mail: lou.sousa@ee.doe.gov

THE OIT T IMES“Turning Industry Visions into Reality”

THE OIT TIMES/SUMMER 1999

OIT’s States Team will be announcing its FY99 funding awardsshortly. The Team primarily funds efforts intended to convenerepresentatives of an industry within a state or region. For informa-tion, see the Team’s website at www.oit.doe.gov/states.... One sucheffort, funded in FY98, is a regional consortium called the North EastRegional Industrial Collaborative, led by NYSERDA. The Collabora-tive, with representatives from NY, ME, VT, RI, MA, CT, and NH,holds regional forums to coordinate state industry activities, andsponsors technical assistance programs helping its local firms tapinto such energy-saving resources as OIT’s Motor Challenge andSteam Challenge programs. The Team will be co-hosting a meetingwith the Collaborative in Saratoga Springs, NY, June 15-18. Otherinformative States IOF meetings are planned; see the States Teamwebsite for a schedule.... More than 50 participants from stateagencies, universities, labs, non-profits, utilities, and private firmsattended the States Team meeting at OIT’s Expo in February.Presenters included: (1) Carl Irwin of West Virginia Univ. whodescribed IOF efforts in WV, one of the first and most active of theState-level IOF participants; (2) Dr. Sabodh Das of ARCO Aluminumwho gave the perspective of a state-level aluminum industry cham-pion for KY; (3) James Kiriazes of Commonwealth Edison whoexplained the role of his utility in putting together a new effort in IL;and (4) Lynnae Boyd of NREL who summarized support availablethrough the Inventions & Innovation’s new Regional ResourceCenters for Innovation. (Contact: Jim Quinn, 202-586-5725)

The new Combined Heat & Power (CHP)Challenge will hold its initial vision androadmapping workshop in early June. The U.S.CHP Assoc. is helping to organize the event,which should attract stakeholders from energyservice companies, IOF industries, government,architectural & engineering firms, and end users.This meeting will address technology, policy andoutreach efforts and should help contribute toAsst. Secretary Dan Reicher’s goal of doublingCHP in the U.S..... State-level CHP workshopshave been sponsored by Hofstra Univ., the Univ.of Maine, Univ. of Massachusetts and theChicago Energy Office, among others. (Contact:

Pat Hoffman, 202-586-6074)