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DOE OSTI2013

Nuclear Fabrication Consortium

This report summarizes the activities undertaken by EWI while under contract from the Department of Energy (DOE) Office of Nuclear Energy (NE) for the management and operation of the Nuclear Fabrication Consortium (NFC). The NFC was established by EWI to independently develop, evaluate, and deploy fabrication approaches and data that support the re-establishment of the U.S. nuclear industry: ensuring that the supply chain will be competitive on a global stage, enabling more cost-effective and reliable nuclear power in a carbon constrained environment. The NFC provided a forum for member original equipment manufactures (OEM), fabricators, manufacturers, and materials suppliers to effectively engage with each other and rebuild the capacity of this supply chain by : Identifying and removing impediments to the implementation of new construction and fabrication techniques and approaches for nuclear equipment, including system components and nuclear plants. Providing and facilitating detailed scientific-based studies on new approaches and technologies that will have positive impacts on the cost of building of nuclear plants. Analyzing and disseminating information about future nuclear fabrication technologies and how they could impact the North American and the International Nuclear Marketplace. Facilitating dialog and initiate alignment among fabricators, owners, trade associations, and government agencies. Supporting industry in helping to create a larger qualified nuclear supplier network. Acting as an unbiased technology resource to evaluate, develop, and demonstrate new manufacturing technologies. Creating welder and inspector training programs to help enable the necessary workforce for the upcoming construction work. Serving as a focal point for technology, policy, and politically interested parties to share ideas and concepts associated with fabrication across the nuclear industry. The report the objectives and summaries of the Nuclear Fabrication Consortium projects. Full technical reports for each of the projects have been submitted as well.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2012

Adaptive Liquid Crystal Windows

Energy consumption by private and commercial sectors in the U.S. has steadily grown over the last decade. The uncertainty in future availability of imported oil, on which the energy consumption relies strongly, resulted in a dramatic increase in the cost of energy. About 20% of this consumption are used to heat and cool houses and commercial buildings. To reduce dependence on the foreign oil and cut down emission of greenhouse gases, it is necessary to eliminate losses and reduce total energy consumption by buildings. To achieve this goal it is necessary to redefine the role of the conventional windows. At a minimum, windows should stop being a source for energy loss. Ideally, windows should become a source of energy, providing net gain to reduce energy used to heat and cool homes. It is possible to have a net energy gain from a window if its light transmission can be dynamically altered, ideally electronically without the need of operator assistance, providing optimal control of the solar gain that varies with season and climate in the U.S. In addition, the window must not require power from the building for operation. Resolution of this problem is a societal challenge and of national interest and will have a broad global impact. For this purpose, the year-round, all-climate window solution to provide an electronically variable solar heat gain coefficient (SHGC) with a wide dynamic range is needed. AlphaMicron, Inc. (AMI) developed and manufactured 1ft × 1ft prototype panels for the world’s first auto-adjusting Adaptive Liquid Crystal Windows (ALCWs) that can operate from sunlight without the need for external power source and demonstrate an electronically adjustable SHGC. This novel windows are based on AlphaMicron’s patented e-Tint ® technology, a guest-host liquid crystal system implemented on flexible, optically clear plastic films. This technology is suitable both for OEM and aftermarket (retro-fitting) lamination to new and existing windows. Low level of power consumption by ALCWs allows for on-board power electronics for automatic matching of transmission through windows to varying climate conditions without drawing the power from the power grid. ALCWs are capable of transmitting more sunlight in winters to assist in heating and less sunlight in summers to minimize overheating. As such, they can change the window from being a source of energy loss to a source of energy gain. In addition, the scalable AMI’s roll-to-roll process, proved by making 1ft × 1ftALCW prototype panels, allows for cost-effective production of large-scale window panels along with capability to change easily their color and shape. In addition to architectural glazing in houses and commercial buildings, ALCWs can be used in other applications where control of sunlight is needed, such as green houses, used by commercial produce growers and botanical gardens, cars, aircrafts, etc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2012

Process for Low Cost Domestic Production of LIB Cathode Materials

The objective of the research was to determine the best low cost method for the large scale production of the Nickel-Cobalt-Manganese (NCM) layered cathode materials. The research and development focused on scaling up the licensed technology from Argonne National Laboratory in BASF’s battery material pilot plant in Beachwood Ohio. Since BASF did not have experience with the large scale production of the NCM cathode materials there was a significant amount of development that was needed to support BASF’s already existing research program. During the three year period BASF was able to develop and validate production processes for the NCM 111, 523 and 424 materials as well as begin development of the High Energy NCM. BASF also used this time period to provide free cathode material samples to numerous manufactures, OEM’s and research companies in order to validate the materials. The success of the project can be demonstrated by the construction of the production plant in Elyria Ohio and the successful operation of that facility. The benefit of the project to the public will begin to be apparent as soon as material from the production plant is being used in electric vehicles.

25 ENERGY STORAGE↗
DOE OSTI2012

Advanced Battery Manufacturing (VA)

LiFeBATT has concentrated its recent testing and evaluation on the safety of its batteries. There appears to be a good margin of safety with respect to overheating of the cells and the cases being utilized for the batteries are specifically designed to dissipate any heat built up during charging. This aspect of LiFeBATT’s products will be even more fully investigated, and assuming ongoing positive results, it will become a major component of marketing efforts for the batteries. LiFeBATT has continued to receive prismatic 20 Amp hour cells from Taiwan. Further testing continues to indicate significant advantages over the previously available 15 Ah cells. Battery packs are being assembled with battery management systems in the Danville facility. Comprehensive tests are underway at Sandia National Laboratory to provide further documentation of the advantages of these 20 Ah cells. The company is pursuing its work with Hybrid Vehicles of Danville to critically evaluate the 20 Ah cells in a hybrid, armored vehicle being developed for military and security applications. Results have been even more encouraging than they were initially. LiFeBATT is expanding its work with several OEM customers to build a worldwide distribution network. These customers include a major automotive consulting group in the U.K., an Australian maker of luxury off-road campers, and a number of makers of E-bikes and scooters. LiFeBATT continues to explore the possibility of working with nations that are woefully short of infrastructure. Negotiations are underway with Siemens to jointly develop a system for using photovoltaic generation and battery storage to supply electricity to communities that are not currently served adequately. The IDA has continued to monitor the progress of LiFeBATT’s work to ensure that all funds are being expended wisely and that matching funds will be generated as promised. The company has also remained current on all obligations for repayment of an IDA loan and lease payments for space to the IDA. A commercial venture is being formed to utilize the LiFeBATT product for consumer use in enabling photovoltaic powered boat lifts. Field tests of the system have proven to be very effective and commercially promising. This venture is expected to result in significant sales within the next six months.

25 ENERGY STORAGE↗
DOE OSTI2013

Future Automotive Aftertreatment Solutions: The 150°C Challenge Workshop Report

With future fuel economy standards enacted, the U.S. automotive manufacturers (OEMs) are committed to pursuing a variety of high risk/highly efficient stoichiometric and lean combustion strategies to achieve superior performance. In recognition of this need, the U.S. Department of Energy (DOE) has partnered with domestic automotive manufacturers through U.S. DRIVE to develop these advanced technologies. However, before these advancements can be introduced into the U.S. market, they must also be able to meet increasingly stringent emissions requirements. A significant roadblock to this implementation is the inability of current catalyst and aftertreatment technologies to provide the required activity at the much lower exhaust temperatures that will accompany highly efficient combustion processes and powertrain strategies. Therefore, the goal of this workshop and report is to create a U.S. DRIVE emission control roadmap that will identify new materials and aftertreatment approaches that offer the potential for 90% conversion of emissions at low temperature (150°C) and are consistent with highly efficient combustion technologies currently under investigation within U.S. DRIVE Advanced Combustion and Emission Control (ACEC) programs.

Zammit, Michael↗
DOE OSTI2013

Characterization of Oxy-combustion Impacts in Existing Coal-fired Boilers

Reaction Engineering International (REI) managed a team of experts from University of Utah, Siemens Energy, Praxair, Vattenfall AB, Sandia National Laboratories, Brigham Young University (BYU) and Corrosion Management Ltd. to perform multi-scale experiments, coupled with mechanism development, process modeling and CFD modeling, for both applied and fundamental investigations. The primary objective of this program was to acquire data and develop tools to characterize and predict impacts of CO{sub 2} flue gas recycle and burner feed design on flame characteristics (burnout, NO{sub x}, SO{sub x}, mercury and fine particle emissions, heat transfer) and operational concerns (fouling, slagging and corrosion) inherent in the retrofit of existing coal-fired boilers for oxy-coal combustion. Experimental work was conducted at Sandia National Laboratories’ Entrained Flow Reactor, the University of Utah Industrial Combustion Research Facility, and Brigham Young University. Process modeling and computational fluid dynamics (CFD) modeling was performed at REI. Successful completion of the project objectives resulted in the following key deliverables: 1) Multi-scale test data from 0.1 kW bench-scale, 100 kW and 200 kW laboratory-scale, and 1 MW semi-industrial scale combustors that describe differences in flame characteristics, fouling, slagging and corrosion for coal combustion under air-firing and oxygen-firing conditions, including sensitivity to oxy-burner design and flue gas recycle composition. 2) Validated mechanisms developed from test data that describe fouling, slagging, waterwall corrosion, heat transfer, char burnout and sooting under coal oxy-combustion conditions. The mechanisms were presented in a form suitable for inclusion in CFD models or process models. 3) Principles to guide design of pilot-scale and full-scale coal oxy-firing systems and flue gas recycle configurations, such that boiler operational impacts from oxy-combustion retrofits are minimized. 4) Assessment of oxy-combustion impacts in two full-scale coal-fired utility boiler retrofits based on computational fluid dynamics (CFD) modeling of air-fired and oxygen-fired operation. This research determined that it is technically feasible to retrofit the combustion system in an air-fired boiler for oxy-fired operation. The impacts of CO{sub 2} flue gas recycle and burner design on flame characteristics (burnout, NO{sub x}, SO{sub x}, mercury and fine particle emissions, heat transfer) and operational concerns (fouling, slagging and corrosion) were minimal, with the exception of high sulfur levels resulting from untreated flue gas recycle with medium and high-sulfur coals. This work focused on combustion in the radiant and convective sections of the boiler and did not address boiler system integration issues, plant efficiencies, impacts on downstream air pollution control devices, or CO{sub 2} capture and compression. The experimental data, oxy-firing system principles and oxy-combustion process mechanisms provided by this work can be used by electric utilities, boiler OEMs, equipment suppliers, design firms, software vendors, consultants and government agencies to assess retrofit applications of oxy-combustion technologies to existing boilers and to guide development of new designs.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2013

Recovery Act - An Interdisciplinary Program for Education and Outreach in Transportation Electrification

1) How the project adds to the education of engineering students in the area of vehicle electrification: This project created and implemented a significant interdisciplinary curriculum in HEV engineering that includes courses focused on the major components (engines, battery cells, e-machines, and power electronics). The new curriculum, rather uniquely, features two new classes and two new labs that emphasize a vehicle level integration of a hybrid electric powertrain that parallels the vehicle development process used by the OEMs - commercial grade software is used to design a hybrid electric vehicle, hardware-in-the-loop testing is performed on each component until the entire powertrain is optimized, the calibration is flashed to a vehicle, ride-and-drives are executed including on board data acquisition. In addition, nine existing courses were modified by adding HEV material to the courses. 2) The educational effectiveness and economic feasibility of the new curriculum: The new courses are offered at both the undergraduate and graduate levels. They are listed across the college in mechanical, chemical, electrical, and materials science and engineering. They are offered both on campus and to distance learning students. Students across the college of engineering and at all degree levels are integrating these courses into their degree programs. Over the three year project the course enrollments on-campus has totaled 1,249. The distance learning enrollments has totaled 315. With such robust enrollments we absolutely expect that these courses will be in the curriculum for the long run. 3) How the project is otherwise of benefit to the public: One outcome of the project is the construction of the Michigan Tech Mobile Lab. Two complete HEV dynamometer test cells, and four work stations are installed in the 16.2 meter Mobile Laboratory and hauled by a class 8 truck. The Mobile Lab is used to teach the university courses. It is also used to deliver short courses to industry, K-12 outreach, and public education. In 2012 the Mobile Lab participated in 22 outreach events, locally, throughout Michigan, and including events in Washington DC, Illinois, and Wisconsin. The Mobile Lab is a hit wherever it goes. In 2013 we will partner with the US Army TARDEC and be featured in their Green Warrior Convoy, a ten city tour starting in Detroit and finishing in Washington DC.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2012

National Center of Excellence for Energy Storage Technology 168.10 (Final Report for Period 10/1/2010-12/31/2011)

This report documents the performance of the Ohio State University (OSU) and Edison Welding Institute (EWI) in the period from 10/1/2010 to 12/31/2012. The objective of the project is to establish a Center of Excellence that leverages the strengths of the partners to establish a unique capability to develop and transfer energy storage industries to establish a unique capability in the development and transfer of energy storage system technology through a fundamental understanding of battery electrical and thermal performance, damage and aging mechanisms, and through the development of reliable, high-speed processes for joining substrates in battery cell, module and pack assemblies with low manufacturing variability. During this period, the OSU activity focused on procuring the equipment, materials and supplies necessary to conduct the experiments planned in the statement of project objectives. In detail, multiple laboratory setups were developed to enable for characterizing the open-circuit potential of cathode and anode materials for Li-ion batteries, perform experiments on calorimetry, and finally built multiple cell and module battery cyclers to be able to perform aging campaign on a wide variety of automotive grade battery cells and small modules. This suite of equipment feeds directly into the development, calibration of battery models ranging from first principle electrochemical models to electro-thermal equivalent circuit models suitable for use in control and xEV vehicle simulations. In addition, it allows to develop and calibrate ‘aging’ models for Li-ion batteries that enable the development of diagnostics and prognostics tools to characterize and predict battery degradation from automotive usage under a wide array of environmental and usage scenarios. The objective of the EWI work scope is to develop improved processes for making metal-tometal joints in advanced battery cells and packs. It will focus on developing generic techniques for making functional (electrically conductive and mechanically robust) metal-to-metal joints between thin substrates. Joints with multiple layers and bimetallic constituents will be investigated. During the current period of performance, EWI has defined the test matrix to evaluate the application of different welding technologies (laser welding, ultrasonic welding, resistance welding) to specific components of battery cells and modules, such as foils-to-tabs, tabs-to-tabs, and tabs-to-bus bars. The test matrix also includes a range of substrates (aluminum 1145 and 1100, copper 110 and nickel 200 as substrates). Furthermore, a set of procedures was defined to perform mechanical and electrical testing of the samples, including metallography, and non-destructive evaluations. Both on the OSU and EWI, this project enabled to leverage very significant industrial collaborations with a wide array of companies ranging from battery manufacturers and pack integrator all the ways to Tier 1 automotive suppliers and OEMs during the period of exercise of the project, and in the future for years to come.

25 ENERGY STORAGE↗
DOE OSTI2014

U.S. Wind Energy Manufacturing and Supply Chain: A Competitiveness Analysis

The goal of the project was to develop a greater understanding of the key factors determining wind energy component manufacturing costs and pricing on a global basis in order to enhance the competitiveness of U.S. manufacturers, and to reduce installed systems cost. Multiple stakeholders including DOE, turbine OEMs, and large component manufactures will all benefit by better understanding the factors determining domestic competitiveness in the emerging offshore and next generation land-based wind industries. Major objectives of this project were to: 1. Carry out global cost and process comparisons for 5MW jacket foundations, blades, towers, and permanent magnet generators; 2. Assess U.S. manufacturers’ competitiveness and potential for cost reduction; 3. Facilitate informed decision-making on investments in U.S. manufacturing; 4. Develop an industry scorecard representing the readiness of the U.S. manufacturers’ to produce components for the next generations of wind turbines, nominally 3MW land-based and 5MW offshore; 5. Disseminate results through the GLWN Wind Supply Chain GIS Map, a free website that is the most comprehensive public database of U.S. wind energy suppliers; 6. Identify areas and develop recommendations to DOE on potential R&D areas to target for increasing domestic manufacturing competitiveness, per DOE’s Clean Energy Manufacturing Initiative (CEMI). Lists of Deliverables 1. Cost Breakdown Competitive Analyses of four product categories: tower, jacket foundation, blade, and permanent magnet (PM) generator. The cost breakdown for each component includes a complete Bill of Materials with net weights; general process steps for labor; and burden adjusted by each manufacturer for their process categories of SGA (sales general and administrative), engineering, logistics cost to a common U.S. port, and profit. 2. Value Stream Map Competitiveness Analysis: A tool that illustrates both information and material flow from the point of getting a customer order at the manufacturing plant; to the orders being forwarded by the manufacturing plant to the material suppliers; to the material being received at the manufacturing plant and processed through the system; to the final product being shipped to the Customer. 3. Competitiveness Scorecard: GLWN developed a Wind Industry Supply Chain Scorecard that reflects U.S. component manufacturers’ readiness to supply the next generation wind turbines, 3MW and 5MW, for land-based and offshore applications. 4. Wind Supply Chain Database & Map: Expand the current GLWN GIS Wind Supply Chain Map to include offshore elements. This is an on-line, free access, wind supply chain map that provides a platform for identifying active and emerging suppliers for the land-based and offshore wind industry, including turbine component manufacturers and wind farm construction service suppliers.

17 WIND ENERGY↗
DOE OSTI2012

Scientific and Technical Information (STI) for Financial Assistance and Non-M&O/M&I

BSST (hereafter referred to as Amerigon) began work in November 2004 under a cost share contract [1] awarded by the U.S. Department of Energy Freedom Car Office to develop a high efficiency Thermoelectric Waste Energy Recovery System for passenger vehicle applications. The system increases fuel economy by partially replacing the electric power produced by the alternator with electric power produced by conversion of exhaust gas in a Thermoelectric Generator (TEG). Amerigon’s team members included the BMW Group and Ford Motor Company, with both OEMs demonstrating the TEG system in their vehicles in the final program phase. Significant progress was made in modeling, building and testing the TEG system from the lowest subassembly levels through an entire vehicle system. By the program’s conclusion, the team had successfully overcome the challenges of integrating TE materials into an exhaust system component and evaluated the system behavior in bench and over the road testing for over six months.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2013

Recovery Act Final Project Report -- Transportation Electrification

ChargePoint America demonstrated the viability, economic and environmental benefits of an electric vehicle-charging infrastructure. Electric vehicles (EVs) and plug-in electric vehicles (PHEVs) arrived in late 2010, there was a substantial lack of infrastructure to support these vehicles. ChargePoint America deployed charging infrastructure in ten (10) metropolitan regions in coordination with vehicle deliveries targeting those same regions by our OEM partners: General Motors, Nissan, Fisker Automotive, Ford, smart USA, and BMW. The metropolitan regions include Central Texas (Austin/San Antonio), Bellevue/Redmond (WA), Southern Michigan, Los Angeles area (CA), New York Metro (NY), Central Florida (Orlando/Tampa), Sacramento (CA), San Francisco/San Jose (CA), Washington DC and Boston (MA). ChargePoint America installed more than 4,600 Level 2 (220v) SAE J1772™ UL listed networked charging ports in home, public and commercial locations to support approximately 2000 program vehicles. ChargePoint collected data to analyze how individuals, businesses and local governments used their vehicles. Understanding driver charging behavior patterns will provide the DoE with critical information as EV adoption increases in the United States.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2015

Advanced thermal barrier coatings for operation in high hydrogen content fueled gas turbines

The Center for Thermal Spray Research (CTSR) at Stony Brook University in partnership with its industrial Consortium for Thermal Spray Technology is investigating science and technology related to advanced metallic alloy bond coats and ceramic thermal barrier coatings for applications in the hot section of gasified coal-based high hydrogen turbine power systems. In conjunction with our OEM partners (GE and Siemens) and through strategic partnership with Oak Ridge National Laboratory (ORNL) (materials degradation group and high temperature materials laboratory), a systems approach, considering all components of the TBC (multilayer ceramic top coat, metallic bond coat & superalloy substrate) is being taken during multi-layered coating design, process development and subsequent environmental testing. Recent advances in process science and advanced in situ thermal spray coating property measurement enabled within CTSR has been incorporated for full-field enhancement of coating and process reliability. The development of bond coat processing during this program explored various aspects of processing and microstructure and linked them to performance. The determination of the bond coat material was carried out during the initial stages of the program. Based on tests conducted both at Stony Brook University as well as those carried out at ORNL it was determined that the NiCoCrAlYHfSi (Amdry) bond coats had considerable benefits over NiCoCrAlY bond coats. Since the studies were also conducted at different cycling frequencies, thereby addressing an associated need for performance under different loading conditions, the Amdry bond coat was selected as the material of choice going forward in the program. With initial investigations focused on the fabrication of HVOF bond coats and the performance of TBC under furnace cycle tests , several processing strategies were developed. Two-layered HVOF bond coats were developed to render optimal balance of density and surface roughness and resulted in improved TBC lifetimes. Processing based approaches of identifying optimal processing regimes deploying advanced in-situ coating property measurements and in-flight diagnostic tools were used to develop process maps for bond coats. Having established a framework for the bond coat processing using the HVOF process, effort were channeled towards fabrication of APS and VPS bond coats with the same material composition. Comparative evaluation of the three deposition processes with regard to their microstrcuture , surface profiles and TBC performance were carried out and provided valuable insights into factors that require concurrent consideration for the development of bond coats for advanced TBC systems. Over the course of this program several advancements were made on the development of durable thermal barrier coatings. Process optimization techniques were utilized to identify processing regimes for both conventional YSZ as well as other TBC compositions such as Gadolinium Zirconate and other Co-doped materials. Measurement of critical properties for these formed the initial stages of the program to identify potential challenges in their implementation as part of a TBC system. High temperature thermal conductivity measurements as well as sintering behavior of both YSZ and GDZ coatings were evaluated as part of initial efforts to undersand the influence of processing on coating properties. By effectively linking fundamental coating properties of fracture toughness and elastic modulus to the cyclic performance of coatings, a durability strategy for APS YSZ coatings was developed. In order to meet the goals of fabricating a multimaterial TBC system further research was carried out on the development of a gradient thermal conductivity model and the evaluation of sintering behavior of multimaterial coatings. Layer optimization for desired properties in the multimaterial TBC was achieved by an iterative feedback approach utilizing process maps and in-situ and ex-situ coating property sensors. Addressing the challenges pertaining to the integration of the two materials YSZ and GDZ led to one of most the critical outcomes of this program, the development of durable multimaterial, multifunctional TBC systems.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Corn Ethanol: The Surprisingly Effective Route for Natural Gas Consumption in the Transportation Sector

Proven reserves and production of natural gas (NG) in the United States have increased dramatically in the last decade, due largely to the commercialization of hydraulic fracturing. This has led to a plentiful supply of NG, resulting in a significantly lower cost on a gallon of gasoline-equivalent (GGE) basis. Additionally, NG is a domestic, non-petroleum source of energy that is less carbon-intensive than coal or petroleum products, and thus can lead to lower greenhouse gas emissions. Because of these factors, there is a desire to increase the use of NG in the transportation sector in the United States (U.S.). However, using NG directly in the transportation sector requires that several non-trivial challenges be overcome. One of these issues is the fueling infrastructure. There are currently only 1,375 NG fueling stations in the U.S. compared to 152,995 fueling stations for gasoline in 2014. Additionally, there are very few light-duty vehicles that can consume this fuel directly as dedicated or bi-fuel options. For example, in model year 2013Honda was the only OEM to offer a dedicated CNG sedan while a number of others offered CNG options as a preparation package for LD trucks and vans. In total, there were a total of 11 vehicle models in 2013 that could be purchased that could use natural gas directly. There are additional potential issues associated with NG vehicles as well. Compared to commercial refueling stations, the at-home refueling time for NG vehicles is substantial – a result of the small compressors used for home refilling. Additionally, the methane emissions from both refueling (leakage) and from tailpipe emissions (slip) from these vehicles can add to their GHG footprint, and while these emissions are not currently regulated it could be a barrier in the future, especially in scenarios with broad scale adoption of CNG vehicles. However, NG consumption already plays a large role in other sectors of the economy, including some that are important to the transportation sector. Examples include steam reforming of natural gas to provide hydrogen for hydrotreating unit operations within the refinery and production of urea for use as a reductant for diesel after treatment in selective catalytic reduction (SCR). This discussion focuses on the consumption of natural gas in the production pathway of conventional ethanol (non-cellulosic) from corn through fermentation. Though it is clear that NG would also play a significant role in the cellulosic production pathways, those cases are not considered in this analysis.

03 NATURAL GAS↗
DOE OSTI2015

Vehicle Lightweighting: 40% and 45% Weight Savings Analysis: Technical Cost Modeling for Vehicle Lightweighting

The U.S. Department of Energy’s Vehicle Technologies Office, Materials area commissioned a study to model and assess manufacturing economics of alternative design and production strategies for a series of lightweight vehicle concepts. The strategic targets were a 40% and a 45% mass reduction relative to a standard North American midsize passenger sedan at an effective cost of $3.42 per pound (lb) saved. The baseline vehicle was an average of several available vehicles in this class. Mass and cost breakdowns from several sources were used, including original equipment manufacturers’ (OEMs’) input through U.S. Department of Energy’s Vehicle Technologies Office programs and public presentations, A2Mac1 LLC’s teardown information, Lotus Engineering Limited and FEV, Inc. breakdowns in their respective lightweighting studies, and IBIS Associates, Inc.’s decades of experience in automotive lightweighting and materials substitution analyses. Information on lightweighting strategies in this analysis came from these same sources and the ongoing U.S. Department of Energy-funded Vehma International of America, Inc. /Ford Motor Company Multi-Material Lightweight Prototype Vehicle Demonstration Project, the Aluminum Association Transportation Group, and many United States Council for Automotive Research’s/United States Automotive Materials Partnership LLC lightweight materials programs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

Department of Energy. Jobs and Innovation Accelerator Challenge (JIAC) Program

1.1 NCMS Digital Manufacturing Initiative The people and businesses of Southeast Michigan have long been known for their prowess in the automotive industry, a sector built on the innovation of the assembly line and the rise of mass production as a manufacturing model. Just as the assembly line was the key to a strong manufacturing base a century ago, a digital manufacturing infrastructure is critical to the future of industry. Economic uncertainty has slowed innovation, but access to cutting-edge tools such as high performance modeling, simulation and analysis (MSA) provides a bold path forward, ensuring global competitiveness and transforming our manufacturing processes. Digital manufacturing is, essentially, the virtualization of processes that had been physical. Many larger manufacturers have embraced it, but the majority of small and medium-sized manufacturers (SMMs) have not. The Digital Manufacturing Initiative is a bold, national effort by the National Center for Manufacturing Sciences (NCMS) to put manufacturing innovation on fast forward, and bring the future of industry into the present. SMMs need a broader array of access options, training, support, and guidance. Providing access will supercharge any organization with tomorrow’s tools, as positively disruptive and potential-laden as the assembly line once was. Sustainable success in the State of Michigan requires the development of foundational infrastructure, the exploration of initial inroads with various manufacturers of all sizes, and the initiation of a prototype engagement mechanism applicable for other future regional efforts. To accomplish this NCMS leveraged complimen-tary State and Federal funding opportunities (shown in Figure 1) along with a coupled voice of industry market research study. A brief summary of each opportunity is found in Appendix A. At the heart of the Michigan effort was the development of an access portal (www.doitindigital.com) and the development of partnerships with local large manufacturers (OEMs) who could provide pull to encourage SMMs (current and future suppliers) to participate. Central to this entire effort was the opportunity that this Final Report documents corresponding to the specific tasks associated with the U.S. Department of Energy (DOE) funded component of the InnoState Jobs Innovation Accelerator Challenge (JIAC) Program.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2015

Thermoelectric Waste Heat Recovery Program for Passenger Vehicles

Gentherm began work in October 2011 to develop a Thermoelectric Waste Energy Recovery System for passenger vehicle applications. Partners in this program were BMW and Tenneco. Tenneco, in the role of TIER 1 supplier, developed the system-level packaging of the thermoelectric power generator. As the OEM, BMW Group demonstrated the TEG system in their vehicle in the final program phase. Gentherm demonstrated the performance of the TEG in medium duty and heavy duty vehicles. Technology developed and demonstrated in this program showed potential to reduce fuel consumption in medium and heavy duty vehicles. In light duty vehicles it showed more modest potential.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2012

Data Collection and Validation of Newport Beach Hydrogen Station Performance

The hydrogen fueling station located at 1600 Jamboree Road in Newport Beach, California was designed and built to refuel light duty fuel cell electric vehicles (FCEVs). The station features the on-site generation of hydrogen through a small scale natural gas steam methane reformer (SMR). All the hydrogen related equipment was added to an existing retail gasoline/diesel station. The station is an early demonstration of what the footprint and equipment arrangement of a retail on-site SMR facility might look like. Commercial customer FCEV leases have only just begun in the last two years or so. And, individual Original Equipment Manufacturer (OEM) vehicle lease fleets are relatively small. Only a few hundred FCEVs are on the road in California. As a result, hydrogen throughput is relatively low at the few early pre-commercial hydrogen stations that are currently open. Therefore the stations are underutilized. This project aims to collect additional station data to allow the operator to potentially adjust various operational parameters in order to improve the overall efficiency of the station and lower operation and maintenance costs and to help improve air quality and reduce greenhouse gas emissions. Due to unforeseen delays, technical challenges and personnel reassignments the project was delayed to the point that the award was allowed to expire.

08 HYDROGEN↗
DOE OSTI2017

What Fleets Need to Know About Alternative Fuel Vehicle Conversions, Retrofits, and Repowers

Many fleet managers have opted to incorporate alternative fuels and advanced vehicles into their lineup. Original equipment manufacturers (OEMs) offer a variety of choices, and there are additional options offered by aftermarket companies. There are also a myriad of ways that existing vehicles can be modified to utilize alternative fuels and other advanced technologies. Vehicle conversions and retrofit packages, along with engine repower options, can offer an ideal way to lower vehicle operating costs. This can result in long term return on investment, in addition to helping fleet managers achieve emissions and environmental goals. This report summarizes the various factors to consider when pursuing a conversion, retrofit, or repower option.

30 DIRECT ENERGY CONVERSION↗