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Office of Industrial Technologies (OIT): Profiles and Partnerships

Description: A 126-page brochure that describes the Office of Industrial Technologies' (OIT) Industries of the Future (IOF) Strategy. Through the IOF initiatives, OIT partners with the nation's nine most energy intensive industries to improve their energy and cost efficiencies.
Date: January 17, 2001
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Partner: UNT Libraries Government Documents Department

Flash High-Pressure Condensate to Regenerate Low-Pressure Steam: Office of Industrial Technologies (OIT) Steam Energy Tips Fact Sheet

Description: BestPractices Steam tip sheet about recovering low-pressure steam by flashing high-pressure condensates in plant-wide steam systems.
Date: May 11, 2001
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Partner: UNT Libraries Government Documents Department

Glass--Industry of the Future; Industrial Partnerships: Advancing Energy and Environmental Goals

Description: This tri-fold brochure describe the partnering activities of the Office of Industrial Technologies' (OIT) Industries of the Future (IOF) for Glass. Information on what works for the Glass industry, examples of successful partnerships, and benefits of partnering with OIT are included.
Date: February 12, 2001
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Partner: UNT Libraries Government Documents Department

Recovery of Valuable Chlorosilane Intermediates by a Novel Waste Conversion Process

Description: From 1994 to 2001, Dow Corning studied a waste recycling process to recover direct process residues (DPR) resulting from the production of silicone precursors. Over the course of eight years, Dow Corning constructed and operated a pilot plant, a small scale commercial plant, and a full scale plant. The process reacts DPR with hydrogen and chlorosilane monomers at high temperature and high pressure. The process converted 85% of the DPR to valuable chlorosilane monomers such as dimethyldichlorosilane and methyldichlorosilane. When feeding methyltrichlorosilane, the process converted 30% of the MeSiCl3 to other monomers. Alternate co-feed monomers were tested. By converting waste DPR to valuable intermediates, the technology significantly reduces waste from the basic silicones manufacturing process.
Date: June 20, 2002
Creator: Brinson, J. Ashley
Partner: UNT Libraries Government Documents Department

American Institute of Chemical Engineers Final report for Office of Industrial Technologies, U.S. Department of Energy. Collaborative research (DE-FC02-94CE41107) [Technology transfer and educational activities in the area of industrial waste reduction and pollution prevention]

Description: The report discusses various programs undertaken by various industry consortia to develop tools and methodologies useful for driving energy efficiency and pollution prevention initiatives.
Date: January 1, 2003
Creator: Rogers, Joseph E.L.
Partner: UNT Libraries Government Documents Department

Recovery of Valuable Chlorosilane Intermediates by a Novel Waste Conversion Process, Phase IIIB (Progress)

Description: From June 1998 through September 1999, direct process residue (DPR, a waste byproduct) hydrogenolysis has been studied at a large pilot plant within Dow Corning's Carrollton, KY, facility. The system reacts filtered DPR with chlorosilane monomers at high temperature and pressure. The process routinely demonstrates DPR conversions from 59% to 89% on a monthly basis. The reaction product contains high concentrations of valuable monomers such as dimethyldichlorosilane and methyldichlorosilane. An expansion of the current unit's capacity is planned to be on-line by the end of CY2000. Furthermore, a larger DPR hydrogenolysis reactor based on these results is being designed for operation in Europe at Dow Corning's Barry, Wales, site.
Date: March 31, 2000
Creator: Anderson, Kurt E.
Partner: UNT Libraries Government Documents Department

Energy use in the U.S. steel industry: a historical perspective and future opportunities

Description: The U.S. steel industry has taken enormous strides over the past decades to reduce its energy consumption; since the end of World War II, the industry has reduced its energy intensity (energy use per shipped ton) by 60 percent. Between 1990 and 1998 alone, intensity has dropped from 20 to 18 million Btu (MBtu) per ton. This figure is projected to decrease to 15 MBtu/ton by 2010 with an asymptotic trend towards 14 MBtu/ton. Domestic shipments are projected to flatten out over the next decade to around 105 million tons which means that total energy consumption will also decrease. Historically, the steel industry has accounted for about 6 percent of U.S. energy consumption. Today, that figure is less than 2 percent and will decrease further to 1.5 percent by 2010. The primary causes for the decrease in energy consumption since WWII are: The use of pellets in the blast furnace and the application of new technology in the ironmaking process to further reduce fuel rates per net ton of hot metal (NTHM); The total replacement of the open hearth process by basic oxygen and electric furnaces; The almost total replacement of ingot casting by continuous casting (which improved yield dramatically and thus reduced the tons of raw steel required per ton of shipments); and The growth of the electric furnace sector of the industry at the expense of hot metal-based processes (which has also stimulated scrap recycling so that about 55 percent of ''new'' steel is now melted from scrap steel). This report focuses on the concept of good practices (i.e., those that are sustainable and can use today's technology). If all the industry could operate on this basis, the additional savings per ton could total 2 MBtu, As further restructuring occurs and the swing from hot metal-based to electric ...
Date: September 1, 2000
Creator: Stubbles, John
Partner: UNT Libraries Government Documents Department

Low NOx Burner Development Program - Final Report - 09/15/1996 - 09/30/2000

Description: This report describes the work performed to develop and demonstrate the VISTA combustor. The development effort was planned for three phases. Laboratory testing at a 1.5 and 6 MMBtu/hr scale was performed at thermo Power Corporation during the first phase. Also during the first phase, analytic modeling was performed to guide the design modifications evaluated in the experimental testing. Toward the end of the first phase, John Zink Company entered the program to participate in the design, evaluation, testing, and demonstration of a 30 MMBtu/hr combustor. The results of the second phase testing were to be used in the demonstration of the 30 MMBtu/hr combustor in a Koch Industries boiler. The program proceeded into the second phase. Two models of the VISTA combustor were tested. Measurements of the first stage NOx production were in the range anticipated to achieve the program goals, based on analytical modeling results. While testing the VISTA combustor at the John Zink facility, John Zink elected to discontinue the development of the VISTA combustor in favor of an alternative in-house concept. As a result, this program was terminated.
Date: September 30, 2000
Creator: McClaine, Andrew W.
Partner: UNT Libraries Government Documents Department

Comparison of Advanced Distillation Control Methods, Final Technical Report

Description: Detailed dynamic simulations of three industrial distillation columns (a propylene/propane splitter, a xylene/toluene column, and a depropanizer) have been used to evaluate configuration selections for single-ended and dual-composition control, as well as to compare conventional and advanced control approaches. In addition, a simulator of a main fractionator was used to compare the control performance of conventional and advanced control. For each case considered, the controllers were tuned by using setpoint changes and tested using feed composition upsets. Proportional Integral (PI) control performance was used to evaluate the configuration selection problem. For single ended control, the energy balance configuration was found to yield the best performance. For dual composition control, nine configurations were considered. It was determined that the use of dynamic simulations is required in order to identify the optimum configuration from among the nine possible choices. The optimum configurations were used to evaluate the relative control performance of conventional PI controllers, MPC (Model Predictive Control), PMBC (Process Model-Based Control), and ANN (Artificial Neural Networks) control. It was determined that MPC works best when one product is much more important than the other, while PI was superior when both products were equally important. PMBC and ANN were not found to offer significant advantages over PI and MPC. MPC was found to outperform conventional PI control for the main fractionator. MPC was applied to three industrial columns: one at Phillips Petroleum and two at Union Carbide. In each case, MPC was found to significantly outperform PI controls. The major advantage of the MPC controller is its ability to effectively handle a complex set of constraints and control objectives.
Date: November 30, 2000
Creator: Riggs, Dr. James B.
Partner: UNT Libraries Government Documents Department

Spray Forming Aluminum - Final Report (Phase II)

Description: The U.S. Department of Energy - Office of Industrial Technology (DOE) has an objective to increase energy efficient and enhance competitiveness of American metals industries. To support this objective, ALCOA Inc. entered into a cooperative program to develop spray forming technology for aluminum. This Phase II of the DOE Spray Forming Program would translate bench scale spray forming technology into a cost effective world class process for commercialization. Developments under DOE Cooperative Agreement No. DE-FC07-94ID13238 occurred during two time periods due to budgetary constraints; April 1994 through September 1996 and October 1997 and December 1998. During these periods, ALCOA Inc developed a linear spray forming nozzle and specific support processes capable of scale-up for commercial production of aluminum sheet alloy products. Emphasis was given to alloys 3003 and 6111, both being commercially significant alloys used in the automotive industry. The report reviews research performed in the following areas: Nozzel Development, Fabrication, Deposition, Metal Characterization, Computer Simulation and Economics. With the formation of a Holding Company, all intellectual property developed in Phases I and II of the Project have been documented under separate cover for licensing to domestic producers.
Date: July 8, 1999
Creator: Leon, D. D.
Partner: UNT Libraries Government Documents Department

Sustainable Steelmaking Using Biomass and Waste Oxides (TRP9902)

Description: A new process for ironmaking was proposed to employ renewable energy in the form of wood charcoal to produce hot metal. The process was aimed at the market niche of units ranging from 400,000 to 1 million tons of hot metal a year. In the new process, a Rotary Hearth Furnace (RHF) would be combined with a smelter to produce hot metal. This combination was proposed to overcome the technical hurdles of energy generation in smelters and the low productivity of RHFs, and also allow the use of wood charcoal as energy source and reductant. In order to assess the feasibility of the new process, it was necessary to estimate the productivity of the two units involved, the RHF and the smelter. This work concentrated on the development of a productivity model for the RHF able to predict changes in productivity according to the type of carbon and iron oxides used as feed materials. This model was constructed starting with the most fundamental aspect of reduction in composites measuring intrinsic rates of oxidation of different carbons in CO{sub 2}-CO atmospheres and reduction of different oxides in the same atmospheres. After that, a model was constructed considering the interplay of intrinsic kinetics and the transfer of heat to and within pellets such as used in the RHF. Finally, a productivity model for the RHF was developed based on the model developed for a pellet and the differences in heat transfer conditions between the laboratory furnace and the actual RHF. The final model produced for the RHF predicts production rates within 30% of actual plant data reported with coal and indicates that productivity gains as high as 50% could be achieved replacing coal with wood charcoal in the green balls owing to the faster reaction rates achieved with the second carbon. This ...
Date: September 30, 2004
Creator: Fruehan, Richard J.
Partner: UNT Libraries Government Documents Department

TRP 9904 - Constitutive Behavior of High Strength Multiphase Sheel Steel Under High Strain Rate Deformation

Description: The focus of the research project was to systematically assess the strain rate dependence of strengthening mechanisms in new advanced high strength sheet steels. Data were obtained on specially designed and produced Duel Phase and TRIP steels and compared to the properties of automotive steels currently in use.
Date: March 31, 2005
Creator: Matlock, David & Speer, John
Partner: UNT Libraries Government Documents Department

TRP0033 - PCI Coal Combustion Behavior and Residual Coal Char Carryover in the Blast Furnace of 3 American Steel Companies during Pulverized Coal Injection (PCI) at High Rates

Description: Combustion behavior of pulverized coals (PC), gasification and thermal annealing of cokes were investigated under controlled environments. Physical and chemical properties of PCI, coke and carbon residues of blast furnace dust/sludge samples were characterized. The strong influence of carbon structure and minerals on PCI reactivity was demonstrated. A technique to characterize char carryover in off gas emissions was established.
Date: April 15, 2005
Creator: Sahajwalla, Veena & Gupta, Sushil
Partner: UNT Libraries Government Documents Department

FINAL REPORT: Reduction in Energy Consumption and Variability in Steel Foundry Operations

Description: This project worked to improve the efficiency of the steel casting industry by reducing the variability that occurs because of process and product variation. The project focused on the post shakeout operations since roughly half of the production costs are in this area. These improvements will reduce the amount of variability, making it easier to manage the operation and improve the competitiveness. The reduction in variability will also reduce the need for many rework operations, which will result in a direct reduction of energy usage, particularly by the reduction of repeated heat treatment operations. Further energy savings will be realized from the reduction of scrap and reduced handling. Field studies were conducted at ten steel foundries that represented the U.S. steel casting industry, for a total of over 100 weeks of production observation. These studies quantified the amount of variability, and looked toward determining the source. A focus of the data collected was the grinding operations since this is a major effort in the cleaning room, and it represents the overall casting quality. The grinding was divided into two categories, expected and unexpected. Expected grinding is that in which the location of the effort is known prior to making the casting, such as smoothing parting lines, gates, and riser contacts. Unexpected grinding, which was approximately 80% of the effort, was done to improve the surfaces at weld repair locations, to rectify burnt on sand, and other surface anomalies at random locations. Unexpected grinding represents about 80% of the grinding effort. By quantifying this effort, the project raised awareness within the industry and the industry is continuing to make improvements. The field studies showed that the amount of variation of grinding operations (normalized because of the diverse set of parts studied) was very consistent across the industry. The field studies identified ...
Date: May 24, 2005
Creator: Peters, F.
Partner: UNT Libraries Government Documents Department

Thin Wall Cast Iron: Phase II

Description: The development of thin-wall technology allows the designers of energy consuming equipment to select the most appropriate material based on cost/material properties considerations, and not solely on density. The technology developed in this research project will permit the designers working for the automotive industry to make a better informed choice between competing materials and thin wall cast iron, thus decreasing the overall cost of the automobile.
Date: July 21, 2005
Creator: Stefanescu, Doru M.
Partner: UNT Libraries Government Documents Department

Modeling of Glass Making Processes for Improved Efficiency

Description: The overall goal of this project was to develop a high-temperature melt properties database with sufficient reliability to allow mathematical modeling of glass melting and forming processes for improved product quality, improved efficiency and lessened environmental impact. It was initiated by the United States glass industry through the NSF Industry/University Center for Glass Research (CGR) at Alfred University [1]. Because of their important commercial value, six different types/families of glass were studied: container, float, fiberglass (E- and wool-types), low-expansion borosilicate, and color TV panel glasses. CGR member companies supplied production-quality glass from all six families upon which we measured, as a function of temperature in the molten state, density, surface tension, viscosity, electrical resistivity, infrared transmittance (to determine high temperature radiative conductivity), non-Newtonian flow behavior, and oxygen partial pres sure. With CGR cost sharing, we also studied gas solubility and diffusivity in each of these glasses. Because knowledge of the compositional dependencies of melt viscosity and electrical resistivity are extremely important for glass melting furnace design and operation, these properties were studied more fully. Composition variations were statistically designed for all six types/families of glass. About 140 different glasses were then melted on a laboratory scale and their viscosity and electrical resistivity measured as a function of temperature. The measurements were completed in February 2003 and are reported on here. The next steps will be (1) to statistically analyze the compositional dependencies of viscosity and electrical resistivity and develop composition-property response surfaces, (2) submit all the data to CGR member companies to evaluate the usefulness in their models, and (3) publish the results in technical journals and most likely in book form.
Date: March 31, 2003
Creator: III, Thomas P. Seward
Partner: UNT Libraries Government Documents Department

Quantifying the Thermal Behavior of Slags (TRP 9903)

Description: Successful operation of a continuous caster is based upon control of heat transfer in the mold. The mold slag is a key component in the success of continuous casting; however, the phenomena that occur in the gap between the shell and the mold are largely unknown as until recently there have been no techniques that allowed visualization and quantification of the solidification behavior of liquid slags. This has lead to slag design being an empirical science or art. Recently a new experimental technique, called Double Hot Thermocouple Technique (DHTT), was developed at Carnegie Mellon University that allowed the solidification behavior of a slag to be observed and quantified under conditions that simulate the thermal conditions that occur in steelmaking environments. This technique allows ladle, tundish and mold slags to be characterized under extreme conditions including those found between the mold wall and the growing shell of a continuous caster. Thus, a program is initiated, under this grant, to quantify and describe the phenomena that occur during the solidification of a slag in a steel mill environment. This will allow slag design to become an engineering science rather than an empirical exercise. The project deliverables were as follows: (1) The further development of a tool that will have broad use in the quantification of slag melting and solidification behavior; and (2) The development of a set of meaningful design criteria for slag application in steel mill environments. The project was broken down into a number of objectives: (a) Develop a systematic understanding of the effect of cooling rate on slag solidification; (b) Develop a systematic understanding on the effect of slag chemistry changes on slag solidification behavior; (c) Develop a method to characterize slag melting; (d) Develop an understanding of the role of the environment on slag solidification and melting; (e) ...
Date: May 30, 2003
Creator: Cramb, Alan W.
Partner: UNT Libraries Government Documents Department

Plant Line Trial Evaluation of Viable Non-Chromium Passivation Systems for Electrolytin Tinplate, ETP (TRP 9911)

Description: Plant trial evaluations have been completed for two zirconium-based, non-chromium passivation systems previously identified as possible alternatives to cathodic dichromate (CDC) passivation for electrolytic tinplate (ETP). These trials were done on a commercial electrolytic tin plating line at Weirton Steel and extensive evaluations of the materials resulting from these trials have been completed. All this was accomplished as a collaborative effort under the AISI Technology Roadmap Program and was executed by seven North American Tin Mill Products producers [Bethlehem Steel (now acquired by International Steel Group (ISG)), Dofasco Inc., National Steel (now acquired by U.S. Steel), U.S. Steel, USS-Posco, Weirton Steel, and Wheeling-Pittsburgh Steel] with funding partially from the Department of Energy (DOE) and partially on an equal cost sharing basis among project participants. The initial phases of this project involved optimization of application procedures for the non-chromium systems in the laboratories at Bethlehem Steel and Betz Dearborn followed by extensive testing with various lacquer formulations and food simulants in the laboratories at Valspar and PPG. Work was also completed at Dofasco and Weirton Steel to develop methods to prevent precipitation of insoluble solids as a function of time from the zirconate system. The results of this testing indicated that sulfide staining characteristics for the non-chromium passivation systems could be minimized but not totally eliminated and neither system was found to perform quite as good, in this respect, as the standard CDC system. As for the stability of zirconate treatment, a method was developed to stabilize this system for a sufficient period of time to conduct plant trial evaluations but, working with a major supplier of zirconium orthosulfate, a method for long term stabilization is still under development.
Date: June 30, 2003
Creator: Sinsel, John A.
Partner: UNT Libraries Government Documents Department

Textures in Strip-Cast Aluminum Alloys: Their On-Line Monitoring and Quantitative Effects on Formability. Final Technical Report

Description: Aluminum sheets produced by continuous casting (CC) provide energy and economic savings of at least 25 and 14 percent, respectively, over sheets made from conventional direct chill (DC) ingot casting and rolling. As a result of the much simpler production route in continuous casting, however, the formability of CC aluminum alloys is often somewhat inferior to that of their DC counterparts. The mechanical properties of CC alloys can be improved by controlling their microstructure through optimal thermomechanical processing. Suitable annealing is an important means to improve the formability of CC aluminum alloy sheets. Recrystallization of deformed grains occurs during annealing, and it changes the crystallographic texture of the aluminum sheet. Laboratory tests in this project showed that this texture change can be detected by either laser-ultrasound resonance spectroscopy or resonance EMAT (electromagnetic acoustic transducer) spectroscopy, and that monitoring this change allows the degree of recrystallization or the ''recrystallized fraction'' in an annealed sheet to be ascertained. Through a plant trial conducted in May 2002, this project further demonstrated that it is feasible to monitor the recrystallized state of a continuous-cast aluminum sheet in-situ on the production line by using a laser-ultrasound sensor. When used in conjunction with inline annealing, inline monitoring of the recrystallized fraction by laser-ultrasound resonance spectroscopy offers the possibility of feed-back control that helps optimize processing parameters (e.g., annealing temperature), detect production anomalies, ensure product quality, and further reduce production costs of continuous-cast aluminum alloys. Crystallographic texture strongly affects the mechanical anisotropy/formability of metallic sheets. Clarification of the quantitative relationship between texture and anisotropy/formability of an aluminum alloy will render monitoring and control of its texture during the sheet production process even more meaningful. The present project included a study to determine how the anisotropic plastic behavior of a continuous-cast AA 5754 aluminum alloy depends on quantifiable ...
Date: July 27, 2003
Creator: Man, Chi-Sing
Partner: UNT Libraries Government Documents Department

Intelligent Potroom Operation

Description: The Intelligent Potroom Operation project focuses on maximizing the performance of an aluminum smelter by innovating components for an intelligent manufacturing system. The Intelligent Potroom Advisor (IPA) monitors process data to identify reduction cells exhibiting behaviors that require immediate attention. It then advises operational personnel on those heuristic-based actions to bring the cell back to an optimal operating state in order to reduce the duration and frequency of substandard reduction cell performance referred to as ''Off-Peak Modes'' (OPMs). Techniques developed to identify cells exhibiting OPMs include the use of a finite element model-based cell state estimator for defining the cell's current operating state via advanced cell noise analyses. In addition, rule induction was also employed to identify statistically significant complex behaviors that occur prior to OPMs. The intelligent manufacturing system design, concepts and formalisms developed in this project w ere used as a basis for an intelligent manufacturing system design. Future research will incorporate an adaptive component to automate continuous process improvement, a technology platform with the potential to improve process performance in many of the other Industries of the Future applications as well.
Date: July 29, 2003
Creator: Berkow, Jan & Banta, Larry
Partner: UNT Libraries Government Documents Department

Final Report for DOE Project DE-FC07-99CH11010

Description: Department of Energy award number DE-FC07-99CH11010, Enhanced Utilization of Corn Based Biomaterials, supported a technology development program sponsored by Cargill Dow LLC from September 30, 1999 through June 30, 2003. The work involved fundamental scientific studies on poly lactic acid (PLA), a new environmentally benign plastic material from renewable resources. DOE funds supported academic research at the Colorado School of Mines and the National Renewable Energy Laboratory (NREL), and industry cost share was directed towards applied research into new product development utilizing the fundamental information generated by the academic partners. Under the arrangement of the grant, the fundamental information is published so that other companies can utilize it in evaluating the applicability of PLA in their own products. The overall project objective is to increase the utilization of PLA, a renewable resource based plastic, currently produced from fermented corn sugar.
Date: October 22, 2003
Creator: Randall, Jed & Kean, Robert
Partner: UNT Libraries Government Documents Department

Development of Screenable Pressure Sensitive Adhesives

Description: An industrial research area of high activity in recent years has been the development of pressure sensitive adhesive (PSA) products that do not interfere with the processing of post-consumer waste. The problem of PSA contamination is arguably the most important technical challenge in expanding the use of recycled fiber. The presence of PSAs in recovered paper creates problems that reduce the efficiency of recycling and papermaking operations and diminish product quality. The widespread use of PSAs engineered to avoid these problems, often referred to as environmentally benign PSAs, could greatly increase the commercial viability of utilizing secondary fiber. Much of the research efforts in this area have focused on the development of PSAs that are designed for enhanced removal with cleaning equipment currently utilized by recycling plants. Most removal occurs at the pressure screens with the size and shape of residual contaminants in the process being the primary criteria for their separation. A viable approach for developing environmentally benign PSAs is their reformulation to inhibit fragmentation. The reduction of adhesives to small particles occurs almost exclusively during repulping; a process in which water and mechanical energy are used to swell and reduce paper products to their constituent fiber. Engineering PSA products to promote the formation of larger adhesive particles during repulping will greatly enhance their removal and reduce or eliminate their impact on the recycling process.
Date: November 29, 2003
Creator: Severtson, Steven J.
Partner: UNT Libraries Government Documents Department

Reducing the Variability of HSLA Sheet Steels (TRP 9807)

Description: The sensitivity of the yield strength of a 70 ksi HSLA steel to changes in processing variables was investigated using a laboratory hot-rolling mill. Along with a detailed examination of the hot-rolled microstructures, auxiliary experiments were conducted to determine how the decomposition of the austenite phase and the occurrence of ultra-fine precipitate formation could account for the yield strength variability. A set of guidelines was recommended for the reduction of the yield strength variability.
Date: March 12, 2004
Creator: DeArdo, Dr. Anthony J.
Partner: UNT Libraries Government Documents Department