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DOE OSTI2021

Estimating the Value of Automation for Concentrating Solar Power Industry Operations (Final Report)

This report summarizes findings from a small, mixed-method research study examining industry perspectives on the potential for new forms of automation to invigorate the concentrating solar power (CSP) industry. In Fall 2021, the Solar Energy Technologies Office (SETO) of the United States Department of Energy (DOE) funded Sandia National Laboratories to elicit industry stakeholder perspectives on the potential role of automated systems in CSP operations. We interviewed eleven CSP professionals from five countries, using a combination of structured and open comment response modes. Respondents indicated a preference for automated systems that support heliostat manufacturing and installation, calibration, and responsiveness to shifting weather conditions. This pilot study demonstrates the importance of engaging industry stakeholders in discussions of technology research and development, to promote adoptable, useful innovation.

14 SOLAR ENERGY↗

DOE OSTI2022

West Virginia University Industrial Assessment Center (Final Progress Report)

The Industrial Assessment Center at West Virginia University has been successful in workforce development, and in generation of energy savings for manufacturing facilities during the period 2016 to 2021. Graduate and undergraduate students have benefited from energy assessment experience and most of them have found good positions as energy engineers and analysts in the industrial sector. Several peer reviewed research papers in archival journals as well as conference papers on the topic of energy engineering and assessment have been published. The implemented energy savings for manufacturing facilities have been significant in the areas of lighting, compressed air, process heating, steam, HVAC, chillers and cooling towers, and motors. In addition, water use reduction, smart manufacturing applications to save energy, cyber security evaluation, energy management, productivity improvements and waste reduction opportunities that lead to energy intensity reductions have been explored. The students have obtained an opportunity to interact with energy efficiency and productivity improvement professionals at various conferences and workshops and their research has generated important results. In summary, the West Virginia University Industrial Assessment Center (WVU-IAC) has fulfilled its mission in regard to workforce development, energy efficiency for manufacturing facilities, and laid a strong platform enhancing sustainability through reductions in carbon emissions achieved through energy efficiency and energy management initiatives and reductions in water usage and waste reduction. During the project period (2016-2021) the WVU-IAC has made numerous energy efficiency, water use reduction, waste reduction, and productivity improvement recommendations, a significant number of them having been implemented by the manufacturing facilities. The research adds significant understanding to the area of energy efficiency, water and waste reduction, and productivity improvement. The technical effectiveness and economic feasibility of the methods and techniques investigated and demonstrated through this project have been exemplary, resulting in significant recommended and implemented resource savings and reductions in carbon emissions. The project has been of significant benefit to the public owing to replication of results within the industrial sector, thus reducing operating costs for businesses that result in increase of growth and employment, as well as community benefits in terms of reductions in carbon emissions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

A Systems Engineering Analysis of National Ignition Facility Industrial Controls Systems and Safety Interlock Systems Remote Input/Output Networking Migration from ControlNet to EtherNet/IP

The ControlNet industrial communications protocol and modules used in the Industrial Control System (ICS) and Safety Interlock System (SIS) at the National Ignition Facility (NIF) are no longer necessary and the ICS and SIS would be better served by migrating the communications structure to use EtherNet/Industrial Protocol (IP) and EtherNet bridge modules instead. By the admission of the vendor of ControlNet hardware, Rockwell Automation, in literature by Bill Petro [1], “Moving forward, customers will be able to optimize their asset utilization better using EtherNet/IP protocol than with ControlNet.” The NIF is one of the key elements of the Inertial Confinement Fusion (ICF) program at Lawrence Livermore National Laboratory (LLNL), a federally funded research and development center (FFRDC). The NIF contains the systems and provides the operational capacity to perform ICF, high energy density (HED), and discovery science experiments utilizing 192 individual beamlines, a host of diagnostics, and all the industrial systems required to facilitate these beamlines and diagnostics. The industrial systems are governed by the ICS and SIS, with the ICS providing control and the SIS providing monitoring and permissives. Construction on the NIF began in 1997 and was certified complete in 2009 and, as a result, the ICS and SIS were developed during this time using the tools that were available then. This includes the communications structure and protocols for these systems, much of which was, and still is, ControlNet. ControlNet, particularly during the time that the ICS and SIS were being built, has several attractive features. ControlNet hardware is exclusive to Rockwell Automation, which was the automation hardware chosen for the ICS and SIS. One feature that could be considered an advantage or a disadvantage depending on the communication needs of the system is that ControlNet also utilizes no active network components, excluding repeaters which are not always necessary. According to the architect of the ICS system at the NIF, Gordon Lau, one of the most attractive features of the ControlNet protocol during development of the ICS and SIS was that it is deterministic, providing timing of data transfer that is executed exactly as it is defined by the developer.

42 ENGINEERING↗

DOE OSTI2022

Emerging Threats and Technology Investigation: Industrial Internet of Things - Risk and Mitigation for Nuclear Infrastructure

Industries supporting the global nuclear infrastructure striving for cost savings, expansions in efficiency, and convenience are likely to adopt components (e.g., hardware, software) that comprise the Internet of Things (IoT) and Industrial Internet of Things (IIoT). These devices offer potential improvements along with security challenges. Modern conveniences achieved through application of technology have propagated through society in the form of interconnected devices, from doorbells to microwave ovens, commonly referred to as IoT. IoT devices are often Internet-connected devices that are designed to send data back to a cloud-based server, where a smart phone application then presents device status and control options. Home-based IoT applications carry a different set of risks when compared to a business or security environment, where there is also a history of convenience and interconnection. Industrial settings have long relied on specifically designed Supervisory Control and Data Acquisition (SCADA) systems for process control where IIoT devices are intended to inform business decisions and augment traditional processes. A recent National Institute of Standards and Technology (NIST) report provides a distinction between process control and IIoT in that traditional process control is not replaced by IIoT, but rather IIoT devices are intended to enhance industrial processes through additional monitoring of various sensors and application of data analytics models using artificial intelligence (AI) and machine learning (ML) (Fagan, Marron, et al. 2021) (Ross, et al. 2021).

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2024

Supporting Growth of a Skilled Workforce in the Building Energy Efficiency Industry (Final Technical Report)

The Interstate Renewable Energy Council (IREC), having worked for well over a decade to develop national networks and best practices focused on attracting and training high quality workers for the clean energy industries, sought to address shortfalls in skilled workers who build, retrofit, operate, and maintain energy efficient buildings. Through this project, IREC created and promoted a Green Buildings Career Map (GBCM)—a career awareness and recruitment tool—that seeks to boost the nationwide growth of workers entering the energy efficiency (EE) industry. Working with a team of subject matter experts and our partner organizations—Building Performance Association (BPA), Building Performance Institute (BPI), Community Action Partnership (CAP), and the National Institute of Building Sciences (NIBS)—IREC produced an interactive, engaging career map to attract and motivate individuals into pursuing careers in energy efficiency, and in support of the Weatherization Assistance Program. The GBCM was designed for a broad audience including educators, career advisors, employers, policymakers, workforce professionals, and jobseekers who may otherwise have little or no awareness of the exciting and rewarding opportunities within targeted industry sectors. Most individuals seeking careers do not know about the breadth of careers awaiting them in the built environment and the same is true for most career and guidance counselors, educators, and parents. The GBCM provides this broad audience with a vision of the myriad jobs that could lead to a long-standing career in energy efficiency. The GBCM describes diverse occupations across the EE industry, charts possible progression between those occupations, and identifies the training, skills, and credentials necessary to do them well.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

The Coal Industry Perspective [Slides]

This report provides an overview of the global coal industry, with additional focus on the United States. Some of the areas it covers include coal prices, consumption, production, stockpiles, imports, exports, reserves, and productivity measures. It provides juxtapositions between the United States and other countries' coal industries. In addition to providing a current snapshot of the U.S. coal industry, this work portrays both historical and projected aspects of the coal industry.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

PFAS Waste Management for Industrial, Water, and Wastewater Treatment Facilities

Per- and polyfluoroalkyl substances (PFAS), including perfluorooctanesulfonic acid (PFOS) and perfluorooctanoic acid (PFOA), are widely used in industrial and consumer products due to their unique water and oil repelling properties. These slow-degrading and bio-accumulating compounds, often called "forever chemicals," are not typically removed by conventional industrial and municipal water/wastewater (W/WW) treatment. This tip of the month provides comprehensive strategies for managing PFAS-contaminated waste streams. Understanding the various types of PFAS waste streams is the first step in managing them. Primary PFAS waste includes contaminated process W/WW and solid materials directly from the production and processing of PFAS-containing materials. These might come from manufacturing facilities, firefighting training areas, or other industrial operations where PFAS compounds are used or were historically present. Secondary PFAS waste results from treatment and disposal mechanisms of primary PFAS waste streams, including spent activated carbon, used ion exchange resins, membrane reject streams, PFAS-laden backwash water, landfill leachate, incineration residuals, etc. TABLE 1 lists examples of the most common PFAS waste streams in different industrial facilities.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

In Situ High-Pressure Synthesis of New Outstanding Light-Element Materials under Industrial P-T Range

High-pressure synthesis (which refers to pressure synthesis in the range of 1 to several GPa) adds a promising additional dimension for exploration of compounds that are inaccessible to traditional chemical methods and can lead to new industrially outstanding materials. It is nowadays a vast exciting field of industrial and academic research opening up new frontiers. In this context, an emerging and important methodology for the rapid exploration of composition-pressure-temperature-time space is the in situ method by synchrotron X-ray diffraction. This review introduces the latest advances of high-pressure devices that are adapted to X-ray diffraction in synchrotrons. It focuses particularly on the “large volume” presses (able to compress the volume above several mm3 to pressure higher than several GPa) designed for in situ exploration and that are suitable for discovering and scaling the stable or metastable compounds under “traditional” industrial pressure range (3–8 GPa). We illustrated the power of such methodology by (i) two classical examples of “reference” superhard high-pressure materials, diamond and cubic boron nitride c-BN; and (ii) recent successful in situ high-pressure syntheses of light-element compounds that allowed expanding the domain of possible application high-pressure materials toward solar optoelectronic and infra-red photonics. Finally, in the last section, we summarize some perspectives regarding the current challenges and future directions in which the field of in situ high-pressure synthesis in industrial pressure scale may have great breakthroughs in the next years.

36 MATERIALS SCIENCE↗

DOE OSTI2019

The Critical Role of International Standards and Certification for the Marine Energy Industry

In 2007 the International Electrotechnical Commission (IEC) initiated Technical Committee (TC) IEC/TC 114 to develop standards for marine energy converters including wave, tidal and other water current converters. Following the inaugural plenary meeting in 2008, the first IEC/TC 114 Technical Specification (TS), Terminology, was published in 2011 and significant work on the development of other TSs is ongoing. Initial conformity assessment activities began in 2011 and the Marine Energy Operational Management Committee (ME-OMC) of the IEC Renewable Energy (IECRE) System was established in 2014. An update on the status of international, consensus-based, marine energy standards and certification deliverables will be provided, including the development of Renewable Energy Test Reports (RETRs) under the IECRE. Currently, IEC/TC 114 has fourteen participating member (P-Member) countries and thirteen observer member (O-Member) countries. Nine Project Teams (PTs), two Ad-hoc Groups (AHGs), and seven Maintenance Teams (MTs) are engaged in writing new TSs, assessing information on TS applications and preparing the published TSs for release of 2nd Editions. To date, IEC/TC 114 has published ten TSs covering subjects including wave and tidal energy converter performance assessment and wave and tidal resource assessment. Additional TSs are expected to be published in 2019 covering river and ocean thermal energy converters and resources, among others. TSs developed by IEC/TC 114 and applied by the industry are essential to reduce risk and increase confidence in marine energy systems. These TSs serve as the fundamental underpinnings of international, 3rd party conformity assessment systems, such as the IECRE. The IECRE is currently comprised of fifteen Member Bodies and operates three Sectors: Marine Energy (ME), Solar Photovoltaic (PV) and Wind Energy (WE). The IECRE ME sector has reached a critical milestone in the development of 3rd party conformity assessment deliverables for the marine energy industry. With the approval of IECRE 03 Ed. 2 and OD 300-200 Ed. 1, the ME Sector established a mechanism for the acceptance of Renewable Energy Test Laboratories (RETLs) with a scope in the IEC TS 62600-200 (Power Performance Assessment of Electricity Producing Tidal Energy Converters). A three-year transition period for test laboratory self- assessment based on ISO/IEC 17025 accreditation has been implemented to encourage RETL participation in the ME Sector. A detailed review of IEC/TC 114 and ME-OMC activities is provided and the critical connection between the development and implementation of international standards, and the associated conformity assessment rules and procedures, and the continued growth and commercial success of the marine energy industry is highlighted and examined. Emphasis is given to the role standards and certification play in risk reduction, improved quality and reliability, and increased confidence for the entire range of industry stakeholders.

16 TIDAL AND WAVE POWER↗

NASA NTRS1975

Conservation and the industry sector

The following six highly energy intensive industries were studied as targets of energy conservation opportunity: food and kindred products, paper and allied products, chemicals and allied products, petroleum and coal products, stone, glass and clay products, and primary manufacturing. After studying conservation actions within each industry the actions were grouped under three broad categories: increased combustion efficiency, process improvement, and good housekeeping. Some of the results were: (1) approximately 2.18 quads could be saved in 1980 and 2.57 quads in 1985 by installing cogenerative facilities in 50% of the industries, (2) regenerative air-preheaters could result in a 10-15% increase in furnace efficiency representing a 15-25% fuel savings (2.3 to 3.9 quads in 1980 and 2.7 to 4.5 quads in 1985), (3) several major industries have potential for energy savings by recycling-aluminum (0.2 quads), steel (1 quad), glass (0.006 quads), paper and cement (0.08 quads).

Source record↗

NASA NTRS1977

Space industrialization studies - An overview

An overview of NASA's current planning for a space industrialization program is described as an introduction to the papers on Space Industrialization being presented by Rockwell International Corporation and Science Applications Incorporated. Background information is presented that outlines the integrated planning process which resulted in specific long range goals and objectives being formulated for NASA programs in technology, environment, resources, earth science, communications, space exploration, aeronautics, and an expanded application of space called space industrialization. Program objectives for NASA's Industrialization of Space and studies on potential near term supporting elements (Space Platform, Large Space Structures, Orbital Operations Capabilities Development, Space Manufacturing Module) are discussed.

Priest, C.↗

NASA NTRS1977

Demandite, lunar materials and space industrialization

Terrestrial industry consumes a wide range of elements in producing the outputs which support and make industrial societies possible. 'Demandite' is a conceptual or synthetic molecule which is composed of the weight fractions of the major elements consumed by industry. Demandite needed for mature industrial activities in space will differ from the terrestrial composition because solar energy must replace hydrocarbon-energy, lunar and asteroidal bulk compositions are different from mineral deposits on the earth, and the major bulk processing in space will be the creation of radiation shielding for human habitats to provide real estate in space complete with water, atmosphere and life-stock elements. Demandite cost may be dominated by earth to deep space transport cost of minor elemental constituents depleted in the lunar soils unless careful attention is given to substitution of materials, searches of the moon (polar regions) and asteroids for the depleted elements, and continuing lowering of earth to deep space transport costs.

Criswell, D. R.↗

NASA NTRS1978

Solar energy in California industry - Applications, characteristics and potential

Results of a survey to determine the potential applicability of solar thermal energy to industrial processes in California are presented. It is found that if the heat for all industrial processes at temperatures below 212 F were supplied by solar energy, total state energy consumption could be reduced by 100 trillion Btus (2%), while the use of solar energy in processes between 212 and 350 F could displace 500 trillion Btus. The issues and problems with which solar energy must contend are illustrated by a description of fluid milk processing operations. Solar energy application is found to be technically feasible for processes with thermal energy requirements below 212 F, with design, and degree of technical, economic and management feasibility being site specific. It is recommended that the state provide support for federal and industrial research, development and demonstration programs in order to stimulate acceptance of solar process heat application by industry.

Barbieri, R. H.↗

NASA NTRS1981

The industrial processing of unidirectional fiber prepregs

Progress made in the industrial processing of preimpregnated composites with unidirectional fibers is discussed, with particular emphasis on applications within the aerospace industry. Selection of industrial materials is considered. Attention is given to the conditions justifying the use of composites and the properties required of industrial prepregs. The hardening cycle is examined for the cases of nonmodified and polymer modified resins, with attention given to the stabilization of flow, the necessary changes of state, viscosity control, and the elimination of porosity. The tooling necessary for the fabrication of a laminated plate is illustrated, and the influence of fabrication and prepreg properties on the mechanical characteristics of a laminate are indicated. Finally, the types of prepregs available and the processing procedures necessary for them are summarized.

Laird, B.↗

NASA NTRS1990

Industrializing the near-earth asteroids: Speculations on human activities in space in the latter half of the 21st century

The use of solar system resources for human industry can be viewed as a natural extension of the continual growth of our species' habitat. Motivations for human activities in space can be discussed in terms of five distinct areas: (1) information processing and collection; (2) materials processing; (3) energy production to meet terrestrial power needs; (4) the use of extraterrestrial materials; and (5) disaster avoidance. When considering 21st-Century activities in space, each of these basic motivations must be treated in light of issues likely to be relevant to the 21st-Century earth. Many of the problems facing 21st-Century earth may stem from the need to maintain the world population of 8 to 10 billion people as is projected from expected growth rates. These problems are likely to include managing the impact of industrial processes on the terrestrial biosphere while providing adequate energy production and material goods for the growing population. The most important human activities in space in the latter half of the 21st Century may be associated with harnessing the resources of the near-earth asteroids for industrial processes. These above topics are discussed with an emphasis on space industrialization.

Sercel, Joel C.↗

NASA NTRS1993

Industrial Hygiene Laboratory accreditation: The JSC experience

The American Industrial Hygiene Association (AIHA) is a society of professionals dedicated to the health and safety of workers and community. With more than 10,000 members, the AIHA is the largest international association serving occupational and environmental health professionals practicing industrial hygiene in private industry, academia, government, labor, and independent organizations. In 1973, AIHA developed a National Industrial Hygiene Laboratory Accreditation Program. The purposes of this program are shown.

Fadner, Dawn E.↗

NASA NTRS1995

Perspective on thermal barrier coatings for industrial gas turbine applications

Thermal Barrier Coatings (TBC's) have been used in high thrust aircraft engines for many years, and have proved to be very effective in allowing higher turbine inlet temperatures. TBC life requirements for aircraft engines are typically less than those required in industrial gas turbines. The use of TBC's for industrial gas turbines can increase if durability and longer service life can be successfully demonstrated. This paper will describe current and future applications of TBC's in industrial gas turbine engines. Early testing and applications of TBC's will also be reviewed. This paper focuses on the key factors that are expected to influence utilization of TBC's in advanced industrial gas turbine engines. It is anticipated that reliable, durable and high effective coating systems will be produced that will ultimately improve engine efficiency and performance.

Mutasim, Z. Z.↗

NASA NTRS1997

The Second ICASE/LaRC Industry Roundtable: Session Proceedings

The second ICASE/LaRC Industry Roundtable was held October 7-9, 1996 at the Williamsburg Hospitality House, Williamsburg, Virginia. Like the first roundtable in 1994, this meeting had two objectives: (1) to expose ICASE and LaRC scientists to industrial research agendas; and (2) to acquaint industry with the capabilities and technology available at ICASE, LaRC and academic partners of ICASE. Nineteen sessions were held in three parallel tracks. Of the 170 participants, over one third were affiliated with various industries. Proceedings from the different sessions are summarized in this report.

Girimaji, Sharath↗