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New Design Methods And Algorithms For High Energy-Efficient And Low-cost Distillation Processes

Description: This project sought and successfully answered two big challenges facing the creation of low-energy, cost-effective, zeotropic multi-component distillation processes: first, identification of an efficient search space that includes all the useful distillation configurations and no undesired configurations; second, development of an algorithm to search the space efficiently and generate an array of low-energy options for industrial multi-component mixtures. Such mixtures are found in large-scale chemical and petroleum plants. Commercialization of our results was addressed by building a user interface allowing practical application of our methods for industrial problems by anyone with basic knowledge of distillation for a given problem. We also provided our algorithm to a major U.S. Chemical Company for use by the practitioners. The successful execution of this program has provided methods and algorithms at the disposal of process engineers to readily generate low-energy solutions for a large class of multicomponent distillation problems in a typical chemical and petrochemical plant. In a petrochemical complex, the distillation trains within crude oil processing, hydrotreating units containing alkylation, isomerization, reformer, LPG (liquefied petroleum gas) and NGL (natural gas liquids) processing units can benefit from our results. Effluents from naphtha crackers and ethane-propane crackers typically contain mixtures of methane, ethylene, ethane, propylene, propane, butane and heavier hydrocarbons. We have shown that our systematic search method with a more complete search space, along with the optimization algorithm, has a potential to yield low-energy distillation configurations for all such applications with energy savings up to 50%.
Date: November 21, 2013
Creator: Agrawal, Rakesh
Partner: UNT Libraries Government Documents Department

Development of Thin Section Zinc Die Casting Technology

Description: A new high fluidity zinc high pressure die casting alloy, termed the HF alloy, was developed during laboratory trials and proven in industrial production. The HF alloy permits castings to be achieved with section thicknesses of 0.3 mm or less. Technology transfer activities were conducted to develop usage of the HF high fluidity alloy. These included production of a brochure and a one-hour webinar on the HF alloy. The brochure was then sent to 1,184 product designers in the Interzinc database. There was excellent reception to this mailing, and from this initial contact 5 technology transfer seminars were conducted for 81 participants from 30 companies across a wide range of business sectors. Many of the successful applications to date involve high quality surface finishes. Design and manufacturing assistance was given for development of selected applications.
Date: October 31, 2013
Creator: Goodwin, Frank
Partner: UNT Libraries Government Documents Department

Large-scale Manufacturing of Nanoparticulate-based Lubrication Additives for Improved Energy Efficiency and Reduced Emissions

Description: This project was funded under the Department of Energy (DOE) Lab Call on Nanomanufacturing for Energy Efficiency and was directed toward the development of novel boron-based nanocolloidal lubrication additives for improving the friction and wear performance of machine components in a wide range of industrial and transportation applications. Argonne�s research team concentrated on the scientific and technical aspects of the project, using a range of state-of-the art analytical and tribological test facilities. Argonne has extensive past experience and expertise in working with boron-based solid and liquid lubrication additives, and has intellectual property ownership of several. There were two industrial collaborators in this project: Ashland Oil (represented by its Valvoline subsidiary) and Primet Precision Materials, Inc. (a leading nanomaterials company). There was also a sub-contract with the University of Arkansas. The major objectives of the project were to develop novel boron-based nanocolloidal lubrication additives and to optimize and verify their performance under boundary-lubricated sliding conditions. The project also tackled problems related to colloidal dispersion, larger-scale manufacturing and blending of nano-additives with base carrier oils. Other important issues dealt with in the project were determination of the optimum size and concentration of the particles and compatibility with various base fluids and/or additives. Boron-based particulate additives considered in this project included boric acid (H{sub 3}BO{sub 3}), hexagonal boron nitride (h-BN), boron oxide, and borax. As part of this project, we also explored a hybrid MoS{sub 2} + boric acid formulation approach for more effective lubrication and reported the results. The major motivation behind this work was to reduce energy losses related to friction and wear in a wide spectrum of mechanical systems and thereby reduce our dependence on imported oil. Growing concern over greenhouse gas emissions was also a major reason. The transportation sector alone consumes about 13 million barrels of crude oil ...
Date: September 26, 2013
Creator: Erdemir, Ali
Partner: UNT Libraries Government Documents Department

Millisecond Oxidation of Alkanes

Description: This project was undertaken in response to the Department of Energy's call to research and develop technologies 'that will reduce energy consumption, enhance economic competitiveness, and reduce environmental impacts of the domestic chemical industry.' The current technology at the time for producing 140 billion pounds per year of propylene from naphtha and Liquified Petroleum Gas (LPG) relied on energy- and capital-intensive steam crackers and Fluidized Catalytic Cracking (FCC) units. The propylene is isolated from the product stream in a costly separation step and subsequently converted to acrylic acid and other derivatives in separate production facilities. This project proposed a Short Contact Time Reactor (SCTR)-based catalytic oxydehydrogenation process that could convert propane to propylene and acrylic acid in a cost-effective and energy-efficient fashion. Full implementation of this technology could lead to sizeable energy, economic and environmental benefits for the U. S. chemical industry by providing up to 45 trillion BTUs/year, cost savings of $1.8 billion/year and a combined 35 million pounds/year reduction in environmental pollutants such as COx, NOx, and SOx. Midway through the project term, the program directive changed, which approval from the DOE and its review panel, from direct propane oxidation to acrylic acid at millisecond contact times to a two-step process for making acrylic acid from propane. The first step was the primary focus, namely the conversion of propane to propylene in high yields assisted by the presence of CO2. The product stream from step one was then to be fed directly into a commercially practiced propylene-to-acrylic acid tandem reactor system.
Date: September 30, 2011
Creator: Han, Scott
Partner: UNT Libraries Government Documents Department

Prototyping Energy Efficient Thermo-Magnetic & Induction Hardening for Heat Treat & Net Shape Forming Applications

Description: Within this project, Eaton undertook the task of bringing about significant impact with respect to sustainability. One of the major goals for the Department of Energy is to achieve energy savings with a corresponding reduction in carbon foot print. The use of a coupled induction heat treatment with high magnetic field heat treatment makes possible not only improved performance alloys, but with faster processing times and lower processing energy, as well. With this technology, substitution of lower cost alloys for more exotic alloys became a possibility; microstructure could be tailored for improved magnetic properties or wear resistance or mechanical performance, as needed. A prototype commercial unit has been developed to conduct processing of materials. Testing of this equipment has been conducted and results demonstrate the feasibility for industrial commercialization.
Date: August 3, 2012
Creator: Ahmad, Aquil
Partner: UNT Libraries Government Documents Department

Development of a Very Dense Liquid Cooled Compute Platform

Description: The objective of this project was to design and develop a prototype very energy efficient high density compute platform with 100% pumped refrigerant liquid cooling using commodity components and high volume manufacturing techniques. Testing at SLAC has indicated that we achieved a DCIE of 0.93 against our original goal of 0.85. This number includes both cooling and power supply and was achieved employing some of the highest wattage processors available.
Date: December 10, 2013
Creator: Hughes, Phillip N. & Lipp, Robert J.
Partner: UNT Libraries Government Documents Department

Multiphase Nano-Composite Coatings for Achieving Energy Optimization

Description: UES Inc. and ANL teamed in this work to develop novel coating systems for the protection of surfaces from thermal degradation mainly in two applications; Machining and Die casting. These coatings were specifically designed for the purpose by incorporating required material phases and the overall architecture, which led to reduce the energy usage and increase efficiency of the operations. Following the UES/ANL'™s feasibility work, the coatings were developed utilizing High power impulse magnetron sputtering (HiPMS) and Large area filtered arc deposition (LAFAD) techniques. Toughness, hardness and oxidation resistance: contrasting qualities have been mixed in the right proportion to attain the suitable material characteristic for the cause. Hafnium diboride (HfB2) based materials provided such a system and its properties were tamed to attain the right combination of toughness and hardness by working on the microstructure and architecture of coatings. An effective interfacing material (graded concentrations of topcoat) was also achieved in this work to provide the required adhesion between the substrate and the coating. Combination of an appropriate bond coat and a functional top coat provided the present thermal degradation resistant coating for cutting tools and die-casting applications. Laboratory level performance tests and industrial level application tests by partner companies (Beta Site Testing) were used for the development of these coatings.
Date: March 26, 2012
Creator: Nainaparampil, Dr. Jose
Partner: UNT Libraries Government Documents Department

Ultracoatings: Enabling Energy and Power Solutions in High Contact Stress Environments through next-generation Nanocoatings Final Technical Report

Description: A review of current commercially available, industrial-grade, low friction coatings will show that interfacial contact pressures nearing 1GPa ({approx}150ksi) inherently limit surface engineering solutions like WC, TiN, TiAlN, and so forth. Extremely hard coatings, then, are often pursued as the principle path, although they too are not without significant limitations. A majority of these compounds are inherently brittle in nature or may not pair well with their mating substrate. In either case, their durability in high contact stress environments is compromised. In parallel to thin film coatings, many conventional surface treatments do not yield an interface hard enough to withstand extreme stresses under load. New research into advanced, nanocomposite materials like (Ti, Zr)B2 shows great promise. Bulk compacts of this compound have demonstrated an order of magnitude better wear resistance than current offerings, notably materials like tungsten carbide. At a laboratory level, the (Ti,Zr)B2 nanocomposite material exhibited abrasive and erosive wear resistance nearly ten times better than existing mixed-phase boride systems. In ASTM abrasion and erosion testing, these new compositions exhibit wear resistance superior to other known advanced materials such as RocTec 500 and 'Borazon' cubic boron nitride. Many significant challenges exist for mass production of (Ti, Zr)B2, one of which is the necessary processing technology that is capable of minimizing deleterious impurity phases. Secondly, this material's performance is derived from a synergistic effect of the two materials existing as a single phase structure. While the individual constituents of TiB2 and ZrB2 do yield improvements to wear resistance, their singular effects are not as significant. Lastly, deposition of this material on a commercial level requires thorough knowledge of nanocomposite boride solids; the benefits associated with these innovative new materials are just being realized. Advancing this technology, called Ultracoatings, through initial development, scale up, and commercialization to a variety of markets ...
Date: March 20, 2012
Creator: III, Clifton B. Higdon
Partner: UNT Libraries Government Documents Department

Super Boiler: Packed Media/Transport Membrane Boiler Development and Demonstration

Description: Gas Technology Institute (GTI) and Cleaver-Brooks developed a new gas-fired steam generation system—the Super Boiler—for increased energy efficiency, reduced equipment size, and reduced emissions. The system consists of a firetube boiler with a unique staged furnace design, a two-stage burner system with engineered internal recirculation and inter-stage cooling integral to the boiler, unique convective pass design with extended internal surfaces for enhanced heat transfer, and a novel integrated heat recovery system to extract maximum energy from the flue gas. With these combined innovations, the Super Boiler technical goals were set at 94% HHV fuel efficiency, operation on natural gas with <5 ppmv NOx (referenced to 3%O2), and 50% smaller than conventional boilers of similar steam output. To demonstrate these technical goals, the project culminated in the industrial demonstration of this new high-efficiency technology on a 300 HP boiler at Clement Pappas, a juice bottler located in Ontario, California. The Super Boiler combustion system is based on two stage combustion which combines air staging, internal flue gas recirculation, inter-stage cooling, and unique fuel-air mixing technology to achieve low emissions rather than external flue gas recirculation which is most commonly used today. The two-stage combustion provides lower emissions because of the integrated design of the boiler and combustion system which permit precise control of peak flame temperatures in both primary and secondary stages of combustion. To reduce equipment size, the Super Boiler's dual furnace design increases radiant heat transfer to the furnace walls, allowing shorter overall furnace length, and also employs convective tubes with extended surfaces that increase heat transfer by up to 18-fold compared to conventional bare tubes. In this way, a two-pass boiler can achieve the same efficiency as a traditional three or four-pass firetube boiler design. The Super Boiler is consequently up to 50% smaller in footprint, has a ...
Date: April 17, 2013
Creator: Liss, William E & Cygan, David F
Partner: UNT Libraries Government Documents Department

Novel Catalytic Membrane Reactors

Description: There are many industrial catalytic organic reversible reactions with amines or alcohols that have water as one of the products. Many of these reactions are homogeneously catalyzed. In all cases removal of water facilitates the reaction and produces more of the desired chemical product. By shifting the reaction to right we produce more chemical product with little or no additional capital investment. Many of these reactions can also relate to bioprocesses. Given the large number of water-organic compound separations achievable and the ability of the Compact Membrane Systems, Inc. (CMS) perfluoro membranes to withstand these harsh operating conditions, this is an ideal demonstration system for the water-of-reaction removal using a membrane reactor. Enhanced reaction synthesis is consistent with the DOE objective to lower the energy intensity of U.S. industry 25% by 2017 in accord with the Energy Policy Act of 2005 and to improve the United States manufacturing competitiveness. The objective of this program is to develop the platform technology for enhancing homogeneous catalytic chemical syntheses.
Date: October 1, 2010
Creator: Stuart Nemser, PhD
Partner: UNT Libraries Government Documents Department

NanoComposite Stainless Steel Powder Technologies

Description: Oak Ridge National Laboratory has been investigating a new class of Fe-based amorphous material stemming from a DARPA, Defense Advanced Research Projects Agency initiative in structural amorphous metals. Further engineering of the original SAM materials such as chemistry modifications and manufacturing processes, has led to the development of a class of Fe based amorphous materials that upon processing, devitrify into a nearly homogeneous distribution of nano sized complex metal carbides and borides. The powder material is produced through the gas atomization process and subsequently utilized by several methods; laser fusing as a coating to existing components or bulk consolidated into new components through various powder metallurgy techniques (vacuum hot pressing, Dynaforge, and hot isostatic pressing). The unique fine scale distribution of microstructural features yields a material with high hardness and wear resistance compared to material produced through conventional processing techniques such as casting while maintaining adequate fracture toughness. Several compositions have been examined including those specifically designed for high hardness and wear resistance and a composition specifically tailored to devitrify into an austenitic matrix (similar to a stainless steel) which poses improved corrosion behavior.
Date: July 25, 2012
Creator: DeHoff, R. & Glasgow, C. (MesoCoat, Inc.)
Partner: UNT Libraries Government Documents Department

Wide-Area Thermal Processing of Light-Emitting Materials

Description: Silicon carbide based materials and devices have been successfully exploited for diverse electronic applications. However, they have not achieved the same success as Si technologies due to higher material cost and higher processing temperatures required for device development. Traditionally, SiC is not considered for optoelectronic applications because it has an indirect bandgap. However, AppliCote Associates, LLC has developed a laser-based doping process which enables light emission in SiC through the creation of embedded p-n junctions. AppliCote laser irradiation of silicon carbide allows two different interaction mechanisms: (1) Laser conversion or induced phase transformation which creates carbon rich regions that have conductive properties. These conductive regions are required for interconnection to the light emitting semiconducting region. (2) Laser doping which injects external dopant atoms into the substrate that introduces deep level transition states that emit light when electrically excited. The current collaboration with AppliCote has focused on the evaluation of ORNL's unique Pulse Thermal Processing (PTP) technique as a replacement for laser processing. Compared to laser processing, Pulse Thermal Processing can deliver similar energy intensities (20-50 kW/cm2) over a much larger area (up to 1,000 cm2) at a lower cost and much higher throughput. The main findings of our investigation; which are significant for the realization of SiC based optoelectronic devices, are as follows: (1) The PTP technique is effective in low thermal budget activation of dopants in SiC similar to the laser technique. The surface electrical conductivity of the SiC samples improved by about three orders of magnitude as a result of PTP processing which is significant for charge injection in the devices; (2) The surface composition of the SiC film can be modified by the PTP technique to create a carbon-rich surface (increased local C:Si ratio from 1:1 to 2.9:1). This is significant as higher thermal and electrical conductivities ...
Date: September 30, 2011
Creator: Duty, C. & Quick, N. (AppliCote Associates, LLC)
Partner: UNT Libraries Government Documents Department

Research and Development of a New Silica-Alumina Based Cementitious Material Largely Using Coal Refuse for Mine Backfill, Mine Sealing and Waste Disposal Stabilization

Description: Coal refuse and coal combustion byproducts as industrial solid waste stockpiles have become great threats to the environment. To activate coal refuse is one practical solution to recycle this huge amount of solid waste as substitute for Ordinary Portland Cement (OPC). The central goal of this project is to investigate and develop a new silica-alumina based cementitious material largely using coal refuse as a constituent that will be ideal for durable construction, mine backfill, mine sealing and waste disposal stabilization applications. This new material is an environment-friendly alternative to Ordinary Portland Cement. The main constituents of the new material are coal refuse and other coal wastes including coal sludge and coal combustion products (CCPs). Compared with conventional cement production, successful development of this new technology could potentially save energy and reduce greenhouse gas emissions, recycle vast amount of coal wastes, and significantly reduce production cost. A systematic research has been conducted to seek for an optimal solution for enhancing pozzolanic reactivity of the relatively inert solid waste-coal refuse in order to improve the utilization efficiency and economic benefit as a construction and building material.
Date: June 29, 2012
Creator: Sun, Henghu & Yao, Yuan
Partner: UNT Libraries Government Documents Department

Recovery Act: SeaMicro Volume Server Power Reduction Research Development

Description: Cloud data centers are projected to be the fastest growing segment of the server market through 2015, according to IDC. Increasingly people and businesses rely on the Cloud to deliver digital content quickly and efficiently. Recovery Act funding from the Department of Energy has helped SeaMicro's technologies enhance the total cost of operation, performance and energy efficiency in large data center and Cloud environments. SeaMicro's innovative supercomputer fabric connects thousands of processor cores, memory, storage and input/output traffic. The company's fabric supports multiple processor instruction sets. Current systems featuring SeaMicro technology typically use one quarter the power and take one sixth the space of traditional servers with the same compute performance, yet deliver up to 12 times the bandwidth per core. Mozilla and eHarmony are two customers successfully using SeaMicro's technology. Numerous non-public customers have been successfully using the SeaMicro product in test and production facilities. As a result of the Recovery Act funding from the U.S. Department of Energy, more than 50 direct jobs were created at SeaMicro. To date, they primarily have been high-value, engineering jobs. Hardware, software and manufacturing engineering positions have been created, as well as sales and sales engineering. The positions have allowed SeaMicro to significantly accelerate engineering development and accelerate commercialization. As a result, commercialization and delivery to market are months ahead of initial schedule. Additional jobs were indirectly created through the development of the SeaMicro product. Through many years of research and hard work prior to receipt of public funding, SeaMicro was awarded 2 patents for its work. SeaMicro's product led the way for industry leaders to reconsider the market for low power servers and create new product lines. With valuable support of the U.S. Department of Energy and through SeaMicro's product, the market has been reshaped by the company's unique approach and ...
Date: March 22, 2012
Creator: Lauterbach, Gary
Partner: UNT Libraries Government Documents Department

Power Minimization techniques for Networked Data Centers.

Description: Our objective is to develop a mathematical model to optimize energy consumption at multiple levels in networked data centers, and develop abstract algorithms to optimize not only individual servers, but also coordinate the energy consumption of clusters of servers within a data center and across geographically distributed data centers to minimize the overall energy cost and consumption of brown energy of an enterprise. In this project, we have formulated a variety of optimization models, some stochastic others deterministic, and have obtained a variety of qualitative results on the structural properties, robustness, and scalability of the optimal policies. We have also systematically derived from these models decentralized algorithms to optimize energy efficiency, analyzed their optimality and stability properties. Finally, we have conducted preliminary numerical simulations to illustrate the behavior of these algorithms. We draw the following conclusion. First, there is a substantial opportunity to minimize both the amount and the cost of electricity consumption in a network of datacenters, by exploiting the fact that traffic load, electricity cost, and availability of renewable generation fluctuate over time and across geographical locations. Judiciously matching these stochastic processes can optimize the tradeoff between brown energy consumption, electricity cost, and response time. Second, given the stochastic nature of these three processes, real-time dynamic feedback should form the core of any optimization strategy. The key is to develop decentralized algorithms that can be implemented at different parts of the network as simple, local algorithms that coordinate through asynchronous message passing.
Date: September 28, 2011
Creator: Low, Steven & Tang, Kevin
Partner: UNT Libraries Government Documents Department

Dry Kraft Pulping at Ambient Pressure for Cost Effective Energy Saving and Pollution Deduction

Description: Sponsored by the DOE Industrial Energy Efficiency Grand Challenge program, our research team at the Georgia Institute of Technology conducted laboratory studies and confirmed the concept of making wood pulp using a dry pulping technology. This technology is a new process different from any prior pulping technology used in Kraft and CTMP pulping. Three different kinds of dry pulping methods were investigated. (a) Dry Pulping at Atmospheric Pressure: The first one is to dry and bake the pretreated woodchips in a conventional oven at atmospheric pressure without the use of a catalyst. (b) Dry Pulping at Reduced Pressure: The second method is to dry the pretreated woodchips first in a vacuum oven in the presence of anthraquinone (AQ) as a pulping catalyst, followed by baking at elevated temperature. (c) Liquid Free Chemical Pulping, LFCP. The third method is to first remove the free water of pretreated woodchips, followed by dry pulping using a conventional Kraft pulping digester with AQ and triton as additives. Method one: Experimental results indicated that Dry Pulping at Atmospheric Pressure could produce pulp with higher brightness and lower bulk than conventional Kraft pulp. However, tensile strength of the acquired pulp is much lower than traditional Kraft pulp, and their Kappa number and energy consumption are higher than conventional Kraft pulp. By fully analyzing the results, we concluded that wood fibers might be damaged during the drying process at elevated temperature. The main reason for wood fiber damage is that a long drying time was used during evaporation of water from the woodchips. This resulted in an un-uniform reaction condition on the woodchips: the outside layer of the woodchips was over reacted while inside the woodchips did not reacted at all. To solve this problem, dry pulping at reduced pressure was investigated. Method two: To achieve uniform ...
Date: August 28, 2012
Creator: Deng, Yulin & Ragauskas, Art
Partner: UNT Libraries Government Documents Department

Efficient One-Step Electrolytic Recycling of Low-Grade and Post-Consumer Magnesium Scrap

Description: Metal Oxygen Separation Technologies, Inc. (abbreviated MOxST, pronounced most) and Boston University (BU) have developed a new low-cost process for recycling post-consumer co-mingled and heavily-oxidized magnesium scrap, and discovered a new chemical mechanism for magnesium separations in the process. The new process, designated MagReGenTM, is very effective in laboratory experiments, and on scale-up promises to be the lowest-cost lowest-energy lowest-impact method for separating magnesium metal from aluminum while recovering oxidized magnesium. MagReGenTM uses as little as one-eighth as much energy as today's methods for recycling magnesium metal from comingled scrap. As such, this technology could play a vital role in recycling automotive non-ferrous metals, particularly as motor vehicle magnesium/aluminum ratios increase in order to reduce vehicle weight and increase efficiency.
Date: July 19, 2012
Creator: Adam C. Powell, IV
Partner: UNT Libraries Government Documents Department

Final Scientific Report (FSR)

Description: The Flambeau River Papers “Manufacturing Conversion for Energy Efficiency” Project has identified the following goals and objectives: 1. A low pressure accumulator tank will be installed to capture low pressure gases for reuse. The estimated cost is $2.1 million with an energy savings of $500,000 annually or enough natural gas savings to heat 590 average Wisconsin homes. 2. Replace the steam turbine and upgrade Paper Machine #3, the largest of Flambeau River Papers machines, at a cost of $6.265 million. The result will save enough natural gas to heat 141 average homes, or about $1.2-million each year. 3. Install a new cyclonic and cell fracturing technology dryer to reduce moisture in both sludge and biomass wastes. The estimated cost of this task is $1.5-million with an annual energy savings of $700,000. It will also eliminate all coal burning at Flambeau River Papers (7,200 tons of coal annually).
Date: November 29, 2010
Creator: Granzin, Bill
Partner: UNT Libraries Government Documents Department

Crude Glycerol as Cost-Effective Fuel for Combined Heat and Power to Replace Fossil Fuels, Final Technical Report

Description: The primary objectives of this work can be summed into two major categories. Firstly, the fundamentals of the combustion of glycerol (in both a refined and unrefined form) were to be investigated, with emphasis of the development of a system capable of reliably and repeatedly combusting glycerol as well as an analysis of the emissions produced during glycerol combustion. Focus was placed on quantifying common emissions in comparison to more traditional fuels and this work showed that the burner developed was able to completely combust glycerol within a relatively wide range of operating conditions. Additionally, focus was placed on examining specific emissions in more detail, namely interesting NOx emissions observed in initial trials, acrolein and other volatile organic emissions, and particulate and ash emissions. This work showed that the combustion of crude glycerol could result in significantly reduced NOx emissions as a function of the high fuel bound oxygen content within the glycerol fuel. It also showed that when burned properly, the combustion of crude glycerol did not result in excessive emissions of acrolein or any other VOC compared to the combustion from more traditional fuels. Lastly however, this work has shown that in any practical application in which glycerol is being burned, it will be necessary to explore ash mitigation techniques due to the very high particulate matter concentrations produced during glycerol combustion. These emissions are comparable to unfiltered coal combustion and are directly tied to the biodiesel production method. The second focus of this work was directed to developing a commercialization strategy for the use of glycerol as a fuel replacement. This strategy has identified a 30 month plan for the scaling up of the laboratory scale burner into a pre-pilot scale system. Additionally, financing options were explored and an assessment was made of the economics of replacing ...
Date: October 31, 2012
Creator: ROberts, William L.
Partner: UNT Libraries Government Documents Department

Clean Technology Evaluation & Workforce Development Program

Description: The overall objective of the Clean Technology Evaluation portion of the award was to design a process to speed up the identification of new clean energy technologies and match organizations to testing and early adoption partners. The project was successful in identifying new technologies targeted to utilities and utility technology integrators, in developing a process to review and rank the new technologies, and in facilitating new partnerships for technology testing and adoption. The purpose of the Workforce Development portion of the award was to create an education outreach program for middle & high-school students focused on clean technology science and engineering. While originally targeting San Diego, California and Cambridge, Massachusetts, the scope of the program was expanded to include a major clean technology speaking series and expo as part of the USA Science & Engineering Festival on the National Mall in Washington, D.C.
Date: December 1, 2012
Creator: Glaza, Patricia
Partner: UNT Libraries Government Documents Department

Final Technical Report - Advanced Optical Sensors to Minimize Energy Consumption in Polymer Extrusion Processes

Description: Project Objective: The objectives of this study are to develop an accurate and stable on-line sensor system to monitor color and composition on-line in polymer melts, to develop a scheme for using the output to control extruders to eliminate the energy, material and operational costs of off-specification product, and to combine or eliminate some extrusion processes. Background: Polymer extrusion processes are difficult to control because the quality achieved in the final product is complexly affected by the properties of the extruder screw, speed of extrusion, temperature, polymer composition, strength and dispersion properties of additives, and feeder system properties. Extruder systems are engineered to be highly reproducible so that when the correct settings to produce a particular product are found, that product can be reliably produced time after time. However market conditions often require changes in the final product, different products or grades may be processed in the same equipment, and feed materials vary from lot to lot. All of these changes require empirical adjustment of extruder settings to produce a product meeting specifications. Optical sensor systems that can continuously monitor the composition and color of the extruded polymer could detect process upsets, drift, blending oscillations, and changes in dispersion of additives. Development of an effective control algorithm using the output of the monitor would enable rapid corrections for changes in materials and operating conditions, thereby eliminating most of the scrap and recycle of current processing. This information could be used to identify extruder systems issues, diagnose problem sources, and suggest corrective actions in real-time to help keep extruder system settings within the optimum control region. Using these advanced optical sensor systems would give extruder operators real-time feedback from their process. They could reduce the amount of off-spec product produced and significantly reduce energy consumption. Also, because blending and dispersion of ...
Date: July 24, 2012
Creator: Foulk, Susan J.
Partner: UNT Libraries Government Documents Department

Advanced Distillation Final Report

Description: The Advanced Distillation project was concluded on December 31, 2009. This U.S. Department of Energy (DOE) funded project was completed successfully and within budget during a timeline approved by DOE project managers, which included a one year extension to the initial ending date. The subject technology, Microchannel Process Technology (MPT) distillation, was expected to provide both capital and operating cost savings compared to conventional distillation technology. With efforts from Velocys and its project partners, MPT distillation was successfully demonstrated at a laboratory scale and its energy savings potential was calculated. While many objectives established at the beginning of the project were met, the project was only partially successful. At the conclusion, it appears that MPT distillation is not a good fit for the targeted separation of ethane and ethylene in large-scale ethylene production facilities, as greater advantages were seen for smaller scale distillations. Early in the project, work involved flowsheet analyses to discern the economic viability of ethane-ethylene MPT distillation and develop strategies for maximizing its impact on the economics of the process. This study confirmed that through modification to standard operating processes, MPT can enable net energy savings in excess of 20%. This advantage was used by ABB Lumus to determine the potential impact of MPT distillation on the ethane-ethylene market. The study indicated that a substantial market exists if the energy saving could be realized and if installed capital cost of MPT distillation was on par or less than conventional technology. Unfortunately, it was determined that the large number of MPT distillation units needed to perform ethane-ethylene separation for world-scale ethylene facilities, makes the targeted separation a poor fit for the technology in this application at the current state of manufacturing costs. Over the course of the project, distillation experiments were performed with the targeted mixture, ethane-ethylene, as ...
Date: March 24, 2010
Creator: Fanelli, Maddalena; Arora, Ravi; Tonkovich, Annalee; Marco, Jennifer & Rode, Ed
Partner: UNT Libraries Government Documents Department

Microchannel Reactor System for Catalytic Hydrogenation

Description: We successfully demonstrated a novel process intensification concept enabled by the development of microchannel reactors, for energy efficient catalytic hydrogenation reactions at moderate temperature, and pressure, and low solvent levels. We designed, fabricated, evaluated, and optimized a laboratory-scale microchannel reactor system for hydrogenation of onitroanisole and a proprietary BMS molecule. In the second phase of the program, as a prelude to full-scale commercialization, we designed and developed a fully-automated skid-mounted multichannel microreactor pilot plant system for multiphase reactions. The system is capable of processing 1 – 10 kg/h of liquid substrate, and an industrially relevant immiscible liquid-liquid was successfully demonstrated on the system. Our microreactor-based pilot plant is one-of-akind. We anticipate that this process intensification concept, if successfully demonstrated, will provide a paradigm-changing basis for replacing existing energy inefficient, cost ineffective, environmentally detrimental slurry semi-batch reactor-based manufacturing practiced in the pharmaceutical and fine chemicals industries.
Date: December 22, 2010
Creator: Lawal, Adeniyi; Lee, Woo; Besser, Ron; Kientzler, Donald & Achenie, Luke
Partner: UNT Libraries Government Documents Department

ULTRACOATINGS: Enabling Energy and Power Solutions in High Contact Stress Environments through Next-Generation Nanocoatings

Description: This industry-driven project was the result of a successful response by Eaton Corporation to a DOE/ITP Program, Grand Challenge, industry call. It consisted of a one-year effort in which ORNL participated in the area of friction and wear testing. In addition to Eaton Corporation and ORNL (CRADA), the project team included: Ames Laboratory, who developed the underlying concept for titanium- zirconium-boron (TZB) based nanocomposite coatings; Borg-Warner Morse TEC, an automotive engine timing chain manufacturer in Ithaca, New York, with its own proprietary hard coating; and Pratt & Whitney Rocketdyne, Inc., a dry-solids pump manufacturer in San Fernando Valley, California. This report focuses only on the portion of work that was conducted by ORNL, in a CRADA with Eaton Corporation. A comprehensive final report for the entire effort, which ended in September 2010, has been prepared for DOE by the team. The term 'ultracoatings' derives from the ambitious technical target for the new generation of nanocoatings. As applications, Eaton was specifically considering a fuel pump and a gear application in which the product of the contact pressure and slip velocity during operation of mating surfaces, commonly called the 'PV value', was equal to or greater than 70,000 MPa-m/s. This ambitious target challenges the developers of coatings to produce material capable of strong bonding to the substrate, as well as high wear resistance and the ability to maintain sliding friction at low, energy-saving levels. The partners in this effort were responsible for the selection and preparation of such candidate ultracoatings, and ORNL used established tribology testing capabilities to help screen these candidates for performance. This final report summarizes ORNL's portion of the nanocomposite coatings development effort and presents both generated data and the analyses that were used in the course of this effort. Initial contact stress and speed calculations showed that laboratory ...
Date: September 30, 2011
Creator: Blau, P.; Qu, J. & Higdon, C. III (Eaton Corp.)
Partner: UNT Libraries Government Documents Department