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All sources NASA NTRS DOE OSTI

DOE OSTI2024

Industrial Assessment Center

Established in 1990, San Diego State University’s (SDSU) Industrial Assessment Center (IAC) is proud of its years of service. During this period, it has served over 620 small and medium-sized manufacturing plants in Southern California. SDSU/IAC’s efforts to transfer state-of-the-art technologies to industry have increased revenues, cultivated creativity, improved energy efficiencies, and benefited the environment. The Center has contributed to the region's economic growth and stability by assisting small and medium size companies to better compete in the global market. It has helped mitigate climate change by reducing greenhouse gas emissions. IAC activities have fostered productive relationships between the University and local industry, assisted industrial sectors to improve their energy efficiency and enhance their manufacturing productivity, in turn impacting the material and working conditions of their employees. In addition to financial savings and environmental benefits, we have trained tens of students who became energy specialists in various companies. Thus, a substantial benefit of the IAC has been the ongoing training of engineering faculty and students. All IAC graduates were offered jobs before or within weeks of their graduation. The activities of the SDSU/IAC have expanded the institutional expertise of the College and improved the knowledge base of the faculties involved leading to several related publications, master’s theses, and senior student projects. Significant number of peer-reviewed publications of the IAC director at SDSU have greatly benefitted from the experience of the Center. As a result of this extensive exposure to manufacturing processes, the SDSU/IAC has grown to be an integral component of SDSU’s engineering research and training. We have successfully built upon these established achievements and academic excellence. IAC service to industry is particularly vital in Southern California, a region with one of the highest manufacturing concentrations in the country. SDSU/IAC has understood and implemented the overall objectives of DOE’s IAC program and guidelines except for the pandemic years when the country’s manufacturing sector was put in dire stress. In addition to student training and service to industry, IAC’s contribution to state and local governments as well as utility companies to assess energy policies and design rebate and incentive strategies cannot be undermined.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Hazards and Probabilistic Risk Assessments of a Light-Water Reactor Coupled with Industrial Facilities

This report provides a roadmap and toolkit for site-specific risk assessments across a broad range of industrial customers co-located with nuclear power plants (NPPs). This report builds upon the body of work sponsored by the Department of Energy (DOE) Light-Water Reactor Sustainability (LWRS) Flexible Plant Operation and Generation Pathway that presented hazards assessment and generic probabilistic risk assessments (PRAs) for the addition of a heat extraction system (HES) to light-water reactors co-located with hydrogen production facilities. The report expands the hazards assessments to include other industrial facilities: an oil refinery, a methanol plant, a synthetic fuel (synfuel) plant, the production of synthetic gas (syngas) as part of the methanol and synfuel plants, and wood pulp and paper mills. All these facilities are specified through industrial process and requirements research performed by national laboratories, universities, and interaction with industry. Many of the processes used in this report are pre-conceptual designs to use for decarbonization of the current technology facilities. A process of failure modes and effects analysis (what can go wrong) and accidentology (what has historically gone wrong) was used to determine the hazards presented to the NPP by the addition of the HES and the industrial customer. Chemical properties of feedstocks and products are summarized as part of the hazards assessment. Example analysis procedures are provided for each of the hazard types identified. These deterministic analyses can be used to assess adherence to licensing criteria. They can also be used to meet other safety goals like protection of the public, workers, or industrial facility equipment. The probabilistic analysis consisted of three sizes of HESs modeled in a PRA to assess the impact on the initiating events (IE) and results of the PRA. The PRA results conclude that the resulting increases in IE frequencies are below the limits required for small changes to existing NPPs under 10 CFR 50.59.

08 HYDROGEN↗

DOE OSTI2019

Bimetallic Nanoparticles as a Model System for an Industrial NiMo Catalyst

An in-depth understanding of the reaction mechanism is required for the further development of Mo-based catalysts for biobased feedstocks. However, fundamental studies of industrial catalysts are challenging, and simplified systems are often used without direct comparison to their industrial counterparts. Here, we report on size-selected bimetallic NiMo nanoparticles as a candidate for a model catalyst that is directly compared to the industrial system to evaluate their industrial relevance. Both the nanoparticles and industrial supported NiMo catalysts were characterized using surface- and bulk-sensitive techniques. We found that the active Ni and Mo metals in the industrial catalyst are well dispersed and well mixed on the support, and that the interaction between Ni and Mo promotes the reduction of the Mo oxide. We successfully produced 25 nm NiMo alloyed nanoparticles with a narrow size distribution. Characterization of the nanoparticles showed that they have a metallic core with a native oxide shell with a high potential for use as a model system for fundamental studies of hydrotreating catalysts for biobased feedstocks.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Quantifying Annual Industrial Locomotive Energy Consumption in the United States

While US Class 1 railroad locomotive rosters and annual fuel consumption are well-documented, considerably less is known regarding the overall energy consumption of operations involving industrial locomotives. To determine the energy savings potential of this rail operating sector, the objective of this research is to develop an inventory of US industrial locomotives and a baseline estimate of their annual energy consumption. Creating an industrial locomotives roster from public data is challenging given their diverse ownership by shippers or leasing companies, and operating locales largely out of public view. By cross-referencing public data on locomotive reporting marks, serial numbers, online images and aerial images, the project team confirmed the age, model and horsepower of over one thousand industrial locomotives. Estimating energy consumption is complicated by the variability in industrial locomotive types and power ratings, and extreme differences in duty cycles and utilization. Given these limitations, using quantified case study examples and adjustments to standard EPA line-haul and switching duty cycles, bounds on the magnitude of annual US industrial locomotive energy consumption were estimated.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS2017

NewSpace: The Emerging Commercial Space Industry

We are at a turning point in the history of space exploration and development, where new industries are being born to use space in non-traditional ways. Established state-run industrial space sector is no longer the only game in town; commercial space is becoming competitive. Many new entrepreneurial companies, such as SpaceX, Deep Space Industries, etc. are developing new markets, such as Orbital, Suborbital, and Deep Space. Together, government and private industry can facilitate the birth of this new industry. The U.S. national policy on commercial space is to develop a robust and competitive U.S. commercial space sector and to energize competitive domestic industries to participate in global markets. NASA can do this by purchasing and using commercial space capabilities and services; exploring the use of nontraditional arrangements for acquiring space capabilities and services; refraining from activities that preclude, discourage, or compete with commercial space activities; and pursuing opportunities to transfer some functions to the commercial space sector, where beneficial. Commercial space must be competitive, while the government has other priorities such as safety, jobs, etc.

emerging industry↗

DOE OSTI2021

One of These Things IS Like the Other: Pursuing a New Taxonomy of Industry for Improved Energy System Modeling

Industrial processes drive the exchange of materials, energy, and currency throughout the economy. These processes are powered by electricity and direct combustion, with variation in their operation even within the same industry. This heterogeneity makes it difficult for large models, including the National Energy Modeling System (US), to project their energy use while remaining tractable. Decarbonization and ensuing changes to the energy system require changes to industrial processes while offering opportunities for process innovation, but the extent and nature of changes are difficult to model with current classification schemes and corresponding data. The North American Industrial Classification (NAICS) is an economic taxonomy of industries, but its categories are less meaningful from an energy and material flow perspective. For example, a facility that makes steel from iron ore in a blast furnace/basic oxygen furnace is categorized under the same NAICS code as a facility that makes steel from scrap in an electric arc furnace despite the scale, use of recycled scrap versus iron ore, and energy use differences in the two facility types. Exploratory analysis is performed on a large dataset used for plant-level energy assessment in order to detect clusters that can aid in better modeling of industry for energy analysis in an evolving system with breakthrough technologies.

28 EE - Advanced Manufacturing Office (EE-5A)↗

DOE OSTI2021

Renewable Energy for Industrial Environmental Management

Costs for renewable energy technologies have declined rapidly in the past decade and their use for residential, commercial, and utility scale electricity has grown exponentially as they become cost competitive. Simultaneously, industrial and manufacturing processes have been increasingly seeking ways to reduce emissions and operational costs in highly competitive sectors. With these combined drivers of lower cost and reduced environmental impact, renewable energy may become a viable energy provider for industrial processes such as oil and gas, mining, chemical refining, food production, and manufacturing. Renewable energy technologies may also partner with other reduced emission energy sources, such as small modular nuclear reactors and carbon capture and utilization, to create cleaner and circular industrial systems for reduced resource use. The Joint Institute for Strategic Energy Analysis (JISEA), which is a partnership of the National Renewable Energy Laboratory (NREL) and five universities and others, has been studying to potential for application of clean energy technologies to the heterogenous energy demands in industry. Dr. Jill Engel-Cox will present an overview of NREL and JISEA, the status and potential future of renewable energy technologies, and collaborations with the oil and gas industry and other industrial sectors to improve their environmental performance and reduce operational costs.

ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2015

What does the public really want when engaging with the nuclear industry? - 15087

The nuclear industry continues to evolve how it engages the public. A question to constantly ask is, 'What does the public really want when engaging with the nuclear industry?' This paper helps answer this question most specifically in the area of nuclear waste management, disposal and remediation. It offers multiple theories from the social sciences, most notably the theory of 'Dominating Concepts'. This is the theory that ideas that dominate the general thinking in an industry exert a powerful influence on how people think and act. By examining an industry's Dominating Concepts, it becomes possible to recognize the unintended (undesirable) consequences. This awareness can be a catalyst for the adoption of changes to the general thinking --- of new and more useful Dominating Concepts. In this paper, one Dominating Concept widely held in the nuclear industry is examined and it becomes possible to understand why the public may not respond to scientific explanations, why the public may distrust the nuclear industry, or why the public may engage the political process. In lieu of this Dominating Concept that produces these undesirable consequences, four new Dominating Concepts that lead to more desirable consequences are proposed. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Investing in STEM Benefits Community, Company, and Industry - 20243

Like many organizations and groups, the Department of Energy Environmental Management program and the nuclear industry are facing an aging employee population and record numbers of employee retirements. This 'silver tsunami' of retirees means the industry as a whole is recruiting graduates at a fast pace. So, how do we ensure the nuclear industry has a robust pipeline of graduates with the necessary background? Fluor Idaho's investment in science, technology, engineering, and mathematics (STEM) education programs helps promote the next generation of technical professionals, benefiting both the company and the industry. Through community outreach initiatives and student mentoring programs, Fluor Idaho promotes kids' interest in STEM. The programs are designed to spark STEM interest in grade school and then foster and grow that interest through high school and higher education. After igniting student excitement about STEM topics in school, Fluor Idaho focuses on providing work-specific opportunities including mentoring and intern programs. These programs give students a better look at real-world job opportunities while still stimulating their interest in STEM. These programs ultimately provide career opportunities for the students and a pipeline of workers. Fluor Idaho's strategy for its summer interns has been to place students in a wide variety of projects - from the commissioning of a first-of-a-kind nuclear processing facility, to operating nuclear waste management facilities, to developing computer programs and applications - and give them responsibilities that make them feel like valued contributors. This approach has created a positive and rewarding summer-intern program experience for the students. Fluor Idaho's investment in its future today is reducing the knowledge gap - or cliff - that many contractors in the nuclear industry are facing. It's a worthwhile investment that is readily visible within its many cleanup projects. The next generation of technical professionals is making an impact now - benefiting both the company and the nuclear industry. This paper will review Fluor Idaho's programs, including STEM community outreach and education and mentoring programs. It will also present statistics about the reach of those programs and their successes. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

The process heat applications of HTGR in petroleum refining industry: adaptability and economy - 18425

High Temperature Gas Cooled Reactor (HTGR) is considered as a kind of potential heat producer for industry. Since the industrial heat utilization takes 60% of heat supply in China, the process heat of HTGR is more suitable for industrial manufacturing as high temperature heat source. In this article, the adaptabilities of HTGR for heat supply to petroleum refining industry are analyzed and it is found that the joint of process heat of HTGR and chemical industry is most predictable in the near future. For case study, technical and economic analysis of process heat-supply proposal in a typical refinery in China is finished and it is shown that though there is some technical and conceptual challenge, the application of process heat of HTGR in petroleum refining industry is feasible and competitive in economics. (authors)

02 PETROLEUM↗

DOE OSTI2017

Industry analytics to optimize time based maintenance for I and C components - 363

Using Industry Analytics to optimize time based maintenance for I and C components allows a nuclear site to increase cost efficiency without impacting equipment reliability. Reductions in frequency or deletions for non-value based Preventive Maintenance (PM) improves cost efficiency by decreasing man-hours, parts costs, and planning costs of that PM; while maintenance performed too frequently can induce maintenance related failures. Benchmarking Industry PM Performance and Equipment Failure data allows sites to efficiently optimize time based maintenance frequencies. Equipment Failure history identifies gaps in maintenance frequencies as well maintenance-induced failures. Overlapping the PM frequency from a site with Industry PM Performance identifies opportunities to justify cost savings by reducing the PM frequency. The opportunities are then validated by the site's living PM program to ensure that the site can support the extension. This paper will discuss an Industry analytical technique used for maintenance frequency reductions. The major aspects evaluated under the technique are validation of the Industry data, review of the component's history and comparison of additional information. Industry data from 180 sites is used as a benchmark to identify opportunities for PM frequency extension on like-for-like components based on manufacturer/model and application. The component history composed of preventive maintenance feedback history and corrective maintenance history is reviewed to determine if the frequency can be extended without adversely affecting equipment reliability. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2016

Generation and Use of Thermal Energy in the U.S. Industrial Sector and Opportunities to Reduce its Carbon Emissions

This report quantifies greenhouse gas (GHG) emissions from the industrial sector and identifies opportunities for non-GHG-emitting thermal energy sources to replace the most significant GHG-emitting U.S. industries based on targeted, process-level analysis of industrial heat requirements. The intent is to provide a basis for projecting opportunities for clean energy use. This provides a prospectus for small modular nuclear reactors (including nuclear-renewable hybrid energy systems), solar industrial process heat, and geothermal energy. This report provides a complement to analysis of process-efficiency improvement by considering how clean energy delivery and use by industry could reduce GHG emissions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2016

Environmental assessment and investment strategies of provincial industrial sector in China — Analysis based on DEA model

As an energy-intensive industry, the industrial sector consumes 70% of energy consumption and causes serious environmental pollution in China. Also, the government emphasized the promotion of R&D investment in the industrial sector in China's National Plan on Climate Change (2014–2020). It is meaningful and contributes to assessing energy and environmental performance, as well as R&D and industrial pollution control (IPC) investment strategies of China's industrial sector. A non-radial DEA model, as with natural and managerial disposability, was adopted to evaluate this from provincial and regional perspectives during the 2008–2012 period. Energy and environmental performance was evaluated by unified efficiency under natural disposability (UEN), unified efficiency under managerial disposability (UEM), and unified efficiency under natural and managerial disposability (UENM). The empirical results indicated that Shandong and Hainan were efficient under natural and managerial disposability, while other provinces had the potential to improve their energy and environmental performance. The number of provinces that was fit for investments of R&D and IPC increased from 2008 to 2010, then decreased in 2011 and 2012. In spite of this, many provincial industrial sectors should make efforts to reduce pollution by investment on technology. Tianjin, Heilongjiang, Jiangxi and Henan were especially the best investment objects because investments of R&D and IPC turned to be effective for them during the whole study period. Moreover, western China had the highest average UENM, followed by eastern China and central China. Eastern China and central China were rewarding to expand investments. Coal consumption was the main factor to negatively affect unified efficiency whereas the increase in economic development level was primarily responsible for the improvement of unified efficiency. According to the results, differentiated suggestions to further improve energy and environmental performance were proposed.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2018

Metal(loid) bioaccessibility and inhalation risk assessment: A comparison between an urban and an industrial area

Highlights: • Metal(loid) bioaccessibility of PM{sub 10} was evaluated with simulated lung fluids. • Most studied metal(loids) were highly bioaccessible in artificial lysosomal fluid. • Metal(loid)s from the industrial site had the highest bioaccessibility. • Elevated non-carcinogenic risk associated with Mn was found at the studied area. • Carcinogenic risk was slightly exceeded for Cd exposure at the industrial location. The content of metal(loid)s in particulate matter (PM) is of special concern due to their contribution to overall (PM) toxicity. In this study, the bioaccessibility and human health risk of potentially toxic metal(loid)s associated with PM{sub 10} were investigated in two areas of the Cantabrian region (northern Spain) with different levels of exposure: an industrial area mainly influenced by a ferromanganese alloy plant; and an urban area consisting mainly of residential and commercial activities, but also affected, albeit to a lesser extent by the ferroalloy plant. Total content and bioaccessible fractions in simulated lung fluids (SLFs) of Fe, Mn, Zn, Ni, Cu, Sb, Mo, Cd and Pb were determined by ICP-MS. Gamble's solution and artificial lysosomal fluid (ALF) were used to mimic different conditions inside the human respiratory system. A health risk assessment was performed based on the United States Environmental Protection Agency's (USEPA) methodology. Most metal(loid)s showed moderate and high bioaccessibility in Gamble's solution and ALF, respectively. Despite the high variability between the samples, metal(loid) bioaccessibility was found to be higher on average at the industrial site, suggesting a greater hazard to human health in the proximity of the main metal(loid) sources. Based on the results of the risk assessment, the non-carcinogenic risk associated with Mn exposure was above the safe limit (HQ> 1) under all the studied scenarios at the industrial site and under some specific scenarios at the urban location. The estimated carcinogenic inhalation risk for Cd exposure at the industrial site was found to be within the range between 1.0 × 10{sup −6} to 1.0 × 10{sup −4} (uncertainty range) under some scenarios. The results obtained in this study indicate that Mn and Cd inhalation exposure occurring in the vicinities of the studied areas may pose a human health risk.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

A review on advances in oxidative coupling of methane (OCM) for industrial use and prospects of CO 2 –H 2 O splitting integration

The discovery of shale gas reserves has encouraged the development of direct methods for methane conversion into valuable chemicals, offering an alternative to indirect approaches that involve an energy-intensive and intermittent syngas production step, leading to high CO 2 emissions. Amongst the direct methods, the oxidative coupling of methane (OCM) is a potential pathway to reduce CO 2 emissions and can produce commodity chemicals such as ethylene, a chemical regarded as central to the petrochemical industry. Even though OCM has been studied for over four decades, the technology still has not found commercial application. Amongst the challenges regarding industrial deployment of OCM, the most significant one is the requirement of a high ethylene yield of 30 % which is currently reported to be around 20 %. Moreover, the highly exothermic nature of the process and controlling the carbon selectivity over oxides of carbon (COx) is the heart of the problem. Numerous researchers have presented promising results in terms of catalysts, reactor designs and feeding strategies for OCM. However, due to lack of inclusiveness in the results, none of the combination of catalysts, reactors and system optimizations has been able to bring about its industrial viability. The current paper presents an extensive review of the noteworthy attempts to achieve industrial targets for OCM. Moreover, a comprehensive criteria is presented which highlights the desired end state for the industrial deployment of OCM technology. Furthermore, the criteria is based on literature survey and a comparison with industrially deployed ethylene production plants i.e., naphtha or ethane steam cracker plants. Finally, a novel integration technology is presented which includes a combination of OCM and CO 2 -H 2 O splitting in a chemical looping reactor design to enable efficient energy utilization and minimal heat losses to the environment.

CO2 Splitting↗

DOE OSTI2018

Industry Energy Tool

The Industry Energy Tool (IET) is an open-source calculator tool designed for projecting energy and emissions impacts of industrial sector energy efficiency, material efficiency, and fuel switching. Projections are available at the county and Census Region levels. The IET is based on a detailed county-level energy data set for agriculture, mining, construction, and manufacturing industries. End use energy disaggregation is provided for manufacturing industries, and some agriculture and mining industries. Process temperature disaggregation is provided for most manufacturing industries.

McMillan, Colin↗

DOE OSTI2014

Estimating customer electricity savings from projects installed by the U.S. ESCO industry

The U.S. energy service company (ESCO) industry has a well-established track record of delivering substantial energy and dollar savings in the public and institutional facilities sector, typically through the use of energy savings performance contracts (ESPC) (Larsen et al. 2012; Goldman et al. 2005; Hopper et al. 2005, Stuart et al. 2013). This ~$6.4 billion industry, which is expected to grow significantly over the next five years, may play an important role in achieving demand-side energy efficiency under local/state/federal environmental policy goals. To date, there has been little or no research in the public domain to estimate electricity savings for the entire U.S. ESCO industry. Estimating these savings levels is a foundational step in order to determine total avoided greenhouse gas (GHG) emissions from demand-side energy efficiency measures installed by U.S. ESCOs. We introduce a method to estimate the total amount of electricity saved by projects implemented by the U.S. ESCO industry using the Lawrence Berkeley National Laboratory (LBNL) /National Association of Energy Service Companies (NAESCO) database of projects and LBNL’s biennial industry survey. We report two metrics: incremental electricity savings and savings from ESCO projects that are active in a given year (e.g., 2012). Overall, we estimate that in 2012 active U.S. ESCO industry projects generated about 34 TWh of electricity savings—15 TWh of these electricity savings were for MUSH market customers who did not rely on utility customer-funded energy efficiency programs (see Figure 1). This analysis shows that almost two-thirds of 2012 electricity savings in municipal, local and state government facilities, universities/colleges, K-12 schools, and healthcare facilities (i.e., the so-called “MUSH” market) were not supported by a utility customer-funded energy efficiency program.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2015

Opportunities for Automated Demand Response in California’s Dairy Processing Industry

During periods of peak electrical demand on the energy grid or when there is a shortage of supply, the stability of the grid may be compromised or the cost of supplying electricity may rise dramatically, respectively. Demand response programs are designed to mitigate the severity of these problems and improve reliability by reducing the demand on the grid during such critical times. In 2010, the Demand Response Research Center convened a group of industry experts to suggest potential industries that would be good demand response program candidates for further review. The dairy industry was suggested due to the perception that the industry had suitable flexibility and automatic controls in place. The purpose of this report is to provide an initial description of the industry with regard to demand response potential, specifically automated demand response. This report qualitatively describes the potential for participation in demand response and automated demand response by dairy processing facilities in California, as well as barriers to widespread participation. The report first describes the magnitude, timing, location, purpose, and manner of energy use. Typical process equipment and controls are discussed, as well as common impediments to participation in demand response and automated demand response programs. Two case studies of demand response at dairy facilities in California and across the country are reviewed. Finally, recommendations are made for future research that can enhance the understanding of demand response potential in this industry.

25 ENERGY STORAGE↗