1 | Energy Efficiency and Renewable Energy eere.energy.gov

Leveraging Information Technology for Manufacturing Innovation at the U.S. Department of Energy

FOCAPO / CPC 2017Tucson, AZ

January 9th, 2017

Mark Johnson

Director

Advanced Manufacturing Office

www.manufacturing.energy.gov

2

A little history: The Start of a pair of Revolutions

Lexington & Concord

1775

Watt, Boulton & Co.1775

(intelligence: steam regulation

for external combustion engines)

3

“… the encouragement of manufactures is the

interest of all parts of the Union.”

“Not only the wealth; but the independence and

security of a country, appear to be materially

connected with the prosperity of manufactures.“

“… it is the interest of a community with a view to

eventual and permanent economy, to encourage

the growth of manufactures.”

- Alexander Hamilton

US Treasury Secretary (1789-1795)

Reports to Congress

First Report on the Public Credit - 1790

Second Report on Public Credit - 1791

Report on the Subject of Manufactures - 1791

US Manufacturing Strategy for First Industrial Revolution

4

Second Industrial Revolution

ElectrificationProcess Scaling

Energy & Materials

Standardization &

Assembly Line

5

Energy Intensive Industries -Today

Primary Metals

1608 TBTU

Petroleum Refining

6137 TBTU

Chemicals

4995 TBTU

Wood Pulp & Paper

2109 TBTU

Glass & Cement

716 TBTU

Food Processing

1162 TBTU

Other Manufacturing

~1600 TBTU

6

How will Manufacturing, Economy and Security of the Nation depend on

Information, Actuation and Communication Technology in the 21st Century?

Third Industrial Revolution - Now

Scaled-out

Intensified

Generalized

Microprocessor

Integrated

Centralized

7

• Overview of DOE Advanced Manufacturing Office

• Technology Assistance Programs

• Research and Development Projects

• Research and Development Consortia

8

Focus on:• Technology Innovation impacting Manufacturing and Energy

(Energy Efficiency and Life-Cycle Energy Costs)

• Technology RD&D + Talent (People)

Advanced Manufacturing

and Energy Technology

Environment

Security

• Competitiveness in

energy products

• Domestic jobs

• Clean Air

• Clean Water

• Energy independence

• Stable, diverse energy

supply

Economy

Energy and Manufacturing: Nexus of Opportunities

9

Advanced Manufacturing – Strategic Framing

Advanced Manufacturing

Partnership (AMP2.0)

Strategic Plans

(DOE 2014 & EERE 2016)

Quadrennial Technology Review

(DOE / Science and Technology 2015)

1) Broadly Applicable EnergyEfficiency Technologies for Energy Intensive and Energy Dependent Manufacturing

2) Platform Materials, Process and Information Technologiesfor Manufacturing with Sustainable Life-Cycle Impact

Authorizations

EPAct2005 and EISA2007

10

More Advanced Manufacturing Issues

Quadrennial Energy Review (QER): 2015

- Manufacturing for Infrastructure and the Grid

Water-Energy Nexus: 2014

- Water for Energy & Energy for Water

Energy Productivity 2030: 2015

- Double GDP/kJ Economy from Energy

Innovation Strategy: 2015

- Technology, Workforce & Capabilities

Job Training and Apprenticeship: 2015- Advanced Manufacturing Skills and Opportunities

Revolution Now: 2015

- Cost Effective New Technologies

4) Partnerships for Energy Technology and Practices Dissemination in Manufacturing

5) Tools, Training & Human Capital Development

3) Responsible & Effective Integration of US Manufacturing to our Diverse & Abundant Energy Resources

11

Energy Use in the US Economy

12

ChemicalsPetroleum Refining

Forest ProductsFood & Beverage

Iron & Steel

Other Manufacturing

0.0 MMT

50.0 MMT

100.0 MMT

150.0 MMT

200.0 MMT

250.0 MMT

300.0 MMT

0 TBtu 500 TBtu 1,000 TBtu 1,500 TBtu 2,000 TBtu 2,500 TBtu 3,000 TBtu 3,500 TBtu 4,000 TBtu 4,500 TBtu 5,000 TBtu

20

10

MEC

S To

tal E

mis

sio

ns

(On

site

+ O

ffsi

te)

2010 MECS Onsite Energy Consumption

Plastics and Rubber

ProductsTransportation Equipment

Electronics

AluminumCement

GlassMachinery

Textiles

Foundries

5.0 MMT

10.0 MMT

15.0 MMT

20.0 MMT

25.0 MMT

30.0 MMT

35.0 MMT

40.0 MMT

100 TBtu 200 TBtu 300 TBtu 400 TBtu 500 TBtu 600 TBtu 700 TBtu

Primary Energy & energy-related Emission by Sector

13

Processes for Clean Energy Materials & TechnologiesEnergy Dependence: Energy Cost Considered in Competitive Manufacturing

Solar PV Cell

Carbon Fibers

Light Emitting Diodes

Electro-Chromic Coatings

Membranes

EV Batteries

Multi-Material Joining

Water Desalination

14

Manufacturing Bandwidth Studies: Energy Savings Potential

Current opportunities represent energy savings that could be achieved by deploying the most energy-efficient commercial technologies available worldwide. R&D opportunities represent potential savings that could be attained through successful deployment of applied R&D technologies under development worldwide

15

Deeper Look at Energy in Manufacturing

16

Quadrennial Technology Review: Manufacturing

Materials DevelopmentAdvanced Manufacturing Processes

Energy & Resource Management

Flow of Material thru Industry

(Sustainable Manufacturing)

Critical Materials

Direct Energy Conversion Materials(Magnetocaloric, Thermoelectric, etc)

Wide Bandgap Power Electronics

Materials for Harsh Service Conditions

Advanced Materials & their Manufacture

Additive Manufacturing

Composite Materials

Roll-to-RollProcessing

Process Intensification

Process Heating

Advanced Sensors, Controls, Modeling

& Platforms

Waste Heat Recovery

Combined Heat and Power

EfficiencyTechnologies

Enabling PlatformTechnologies

Information Processes Materials

17

Advanced Manufacturing Office Multiyear Program Plan (draft) Areas

18

Impact Areas of Cross-Cutting Efficiency Technology for Energy Intensive Industry Sectors

Chemicals & Bio-chemicals

PetroleumRefining

PrimaryMetals

Forest &Food Products

Clean Water

SMART Manufacturing

Process Intensification

CHP & Grid Integration

Sustainable Manufacturing

Sector Specific Roadmaps

Developed with Industrial Sector Partnerships

19

• Overview of DOE Advanced Manufacturing Office

• Technology Assistance Programs

• Research and Development Projects

• Research and Development Consortia

20

Technical Assistance: Better Plants Program

• Key component of Better Buildings Initiative to improve energy efficiency of commercial and industrial buildings by 20% by 2020.

• Voluntary pledge by manufacturers and industrial-scale energy users to reduce energy intensity

• DOE provides technical assistance to meet goals and firms report progress

• To date, Better Plants Partners have reported

(more than 0.45 Quads of energy)

21

ISO 50001–Energy Management Systems (EnMS)

International standard that draws from best practices around the world.

Developed with input from 56 countries, many countries now adopting it as

a national standard.

ISO 50001 specifies

requirements for establishing,

implementing, maintaining

and improving an EnMS.

Light blue text represents new data-driven sections in

ISO 50001 that are not in ISO 9001 & ISO 14001

It does not prescribe

specific energy performance

improvement criteria.

22

ISO 50001

Components in place:

• Top Management

• Energy Team

• Policy

• Planning

• Baseline

• Performance Metrics

Superior Energy Performance

Single facility ISO

50001

conformance with

verified energy

performance

improvement

ISO 50001ISO 50001 is a

foundational tool

that any

organization can

use to manage

energy

Superior Energy Performance™

• SEP is a certification program that

helps facilities meet the ISO 50001

energy management standard and

verify the savings they achieve

• 28 plants have been certified so far.

Nine improved energy performance

by an average of 10% and saved

over $500,000 per year

23

Technical Assistance: Industrial Assessment Centers

Energy Assessments & Student Training

University-based Industrial Assessment Centers

Support for small/medium sized manufacturing

Energy.gov/IAC

24

• Overview of DOE Advanced Manufacturing Office

• Technology Assistance Programs

• Research and Development Projects

• Research and Development Consortia

25

R&D Projects: Manufacturing Materials, Processes & Information Tools

Ultrafast, femtosecond pulse lasers

(right) will eliminate machining defects

in fuel injectors. Image courtesy of Raydiance.

Energy-efficient large thin-walled

magnesium die casting, for 60%

lighter car doors.

Graphic image provided by General Motors.

Protective coating materials for

high-performance membranes,

for pulp and paper industry.

Image courtesy of Teledyne

A water-stable

protected lithium

electrode. Courtesy of PolyPlus

26

R&D Projects: Combined Heat & Power (CHP) & Grid Integration of Manufacturing

Capstone photos source: capstoneturbines.com

Advanced MicroTurbine System (AMTS) R&D Program

Advanced Reciprocating Engine Systems (ARES) R&D Program

C200 MicroTurbine Engine

QSK60G engine

27

R&D: Next Generation Electric Machines (NGEM)

• Focus on developing energy efficient, high power density, integrated medium voltage drive systems.

Current efforts:

• Manufacturing of high performance thermal and electrical conductors

• Manufacturing of low-loss silicon steel

• High temperature superconducting wire manufacturing

• Manufacturing of other enabling technologies to increase performance.

Potential to save 1.6% of

28

Goal is to accelerate the manufacturing capability of

a multitude of AM technologies utilizing various

materials from metals to polymers to composites.

Arcam electron beam

processing AM equipment

Microstructure Control

During Metal Additive

Deposition

Manufacturing Demonstration Facility

Spallation Neutron Source

Supercomputing Capabilities

29 29

Additive – Rapidly Developing Technology –Big-Area Additive Manufacturing (BAAM)

Developed Unique 3D Printing Tool

(with Cincinnati Inc.)

Developed blended polymer / fiber

(with Sabic & Techmer Inc.)

Developed Surface Process

(with Tru-Design Inc.)

Designed & Printed Car Prototype

(with Shelby Inc.)

Printed Cobra Project: Design to Prototype

Six (6) people in six (6) weeks.

Crowdsource Design &

Build EV

(with Local Motors

30

Partnerships with Vehicles and Buildings R&D

3D Printing of Large Area

Structures

Partnership with Designers,

Manufacturers, Universities,

Laboratories and Suppliers

31

MDF: 3D Printing Wind Blade Molds

Bringing Manufacturing Innovation to the Renewable Energy Space

• Enable innovative blade designs

• Achieve lower overall costs and higher efficiencies

• Collaboration with Oak Ridge, Sandia, and TPI Composites

• Potential copper metal casting projects

32

HPC for Manufacturing

• Program teams manufacturers with DOE’s network of National Labs

• Applying High Performance Computing to face critical manufacturing challenges

33

High Performance Computing for Manufacturing

Apply modeling and simulation capabilities to manufacturing challenges

• Industry defined challenges

• Businesses Partner with National labs

• Business-friendly terms and streamlined partnering process

A computer simulation of the

virtual blast furnace. Image

courtesy of Purdue University –

Calumet/Northwest.

34

MGI - Framework

New Material Innovations for Clean Energy 2X Faster and 2X Cheaper

Predictive Simulation

Across Scales

Synthesis & Characterization

Rapid Screening

End Use Performance

Process Scalability

Process Control

Real-time Characterization

Reliability Validation

Data Management & Informatics

Coordinated resource network with a suite

of capabilities for advanced materials R&D

Applied R&D for Materials Genome Initiative (MGI)

35

Cyclotron Rd and Lab Embedded Entrepreneurial Partnership

Lab Embedded Accelerator Model:Let the nation’s energy innovators “spin in” to national labs

35

Recruit the world’s

best energy

technology

innovators

Leverage

experts and

facilities at a

world-class

R&D institute

Deploy people,

IP, and

technology

to the

marketplace

① ② ③

Licensing

Corp.

M&A

VC

http://www.cyclotronroad.org/

…First pilot phase spurred $10 million in follow-on funding and launched privately-funded startups

FY17: extend to more labs & projects

36

• Overview of DOE Advanced Manufacturing Office

• Technology Assistance Programs

• Research and Development Projects

• Research and Development Consortia

37

Address market disaggregation challenge to the industrial commons

How could we get innovation into manufacturing today?- RD&D Consortia- Workforce Development and Education- Public-private Partnership to Scale

R&D Facilities & Consortia

Ford River Rouge Complex, 1920sPhoto: Library of Congress, Prints & Photographs Division, Detroit Publishing Company Collection, det 4a25915.

Then Now

OEM

Tier 1

Tier 2

Tier 3

Tier 2

Tier 3

Tier 1

Tier 2

Tier 3

38

Manufacturing Technology Maturation

TRL 6/7: System Testing in Production Relevant EnvironmentMRL 6/7: System Components made in Pilot Environment

TRL 5/6: Hardware-in-Loop System Testing in LaboratoryMRL 5/6: Investigate Pilot Environment to Make Systems

TRL 4/5: System Technology Tested in Laboratory MRL 4/5: Investigate Pilot Environment to Make Components

TRL 3/4: Enabling Technology Tested in Laboratory MRL 3/4: Enabling Components Made in Laboratory

Foundational

Science

Dep

loym

ent

Dem

on

stra

tio

nD

evel

op

men

tA

pp

lied

Res

earc

h

Bas

ic

Res

earc

h

TRL 1-3:MRL 1-3:

End-Use Adoption

Tech

no

logy

Ne

eds

and

Re

qu

ire

me

nts

Tech

no

log

y C

apab

iliti

es a

nd

Op

po

rtu

nit

ies

Industry

Partnerships

Lab

Facilities

39

13 Manufacturing Innovation Institutes launched to date

39

America MakesAdditive Mfg.

Youngstown, OH

Power AmericaPower Electronics

Raleigh, NC

LIFTLight/Modern Metals

Detroit, MI

IACMIAdv. Composites

Knoxville, TN

DMDIIDigital Mfg.Chicago, IL

• Over $500 million federal funding catalyzed over $1.2 billion from consortia

• Institutes have attracted hundreds of companies and universities as active partners from across the country

NextFlexFlex. Electronics

San Jose, CA AFFOAAdv. Textiles

AIM PhotonicsPhotonics

Rochester, NY

Smart Mfg.

REMADESustainable Materials

Rochester, NY

Process IntensificationRAPID Institute

40

40

Institute has:

1) Clear, unique institute

focus

2) Clear industry value

proposition

3) Strong partnerships

4) Ability to address critical

challenges

5) A balanced portfolio

of projects

Industry-Academia-Government Partnership

Consortia are open—new members able to join

41

• Launched in January 2015

• 17 industry members, 7 universities and 3 national labs (ANL, NRL, NREL)

• $70 million Federal support matched by $70 million non-Federal

• Dramatically reduce costs of wide bandgap materials and devices

• Will enable higher temps, voltages, frequency, and power loads

DOE Institute #1: PowerAmerica (Raleigh, NC)

42

PowerAmerica: Develop advanced manufacturing processes that will enable large-scale production of wide bandgap semiconductors.

DOE Institute #1: PowerAmerica (Raleigh, NC)

43 Read More at: https://www.whitehouse.gov/blog/2016/04/04/depth-look-how-manufacturing-hubs-helped-business-innovate

Highlights: X-Fab Texas launches SiC Merchant Foundry

X-Fab Texas

• Using existing Si fab line, launched first available “merchant” SiC line

• Will dramatically reduce cost of SiC wafers for global power electronics market

• Supports 400 jobs in Lubbock, TX and will produce first device fall 2016

44

DOE Institute #2 – Carbon Fiber Composites (Oak Ridge, TN)

Institute for Advanced Composite Material Manufacturing (IACMI): Develop and demonstrate technologies to produce carbon fiber composites at 50% the cost and 75% less energy.

• Launched in January 2015

• $70 million Federal support matched by $180 million non-Federal

• 94 Total members including 72 industry members, 14 universities, and 2 national labs

• 46 Small and medium-sized industry partners

45

50% Lower Cost

Using 75% Less Energy

And reuse or recycle >95%

of the material

ObjectiveDevelop and demonstrate innovative technologies that will, within 10 years, make advanced fiber-reinforced polymer composites at…

Institute for Advanced Composite Materials Innovation (IACMI)

46

DOE NNMI Institute #2 – Carbon Fiber Composites (Oak Ridge, TN)

• Established regional centers of excellence across a number of fiber composite applications

47

Focus on Real-Time

For Energy Management Institute Goals

• >50% improvement in energy productivity

• >50% reduction in installation cost of Smart Manufacturing hardware and software

• 15% Improvement in Energy Efficiency at systems level

• Increase productivity and competitiveness across all manufacturing sectors

• Advanced sensors and controls for real-time process management

Institute #3 – Smart Manufacturing (SMLC/UCLA) – CESMI Institute

48

Energy Use in the Manufacturing Sector

Opportunity for Efficiency Through

How Manufacturing Systems are

Operated

Requires Improved Situational

Awareness and Decision Support

in Manufacturing Systems:

Intelligence in Manufacturing

49

Dep

loym

en

t C

ost

for

En

erg

y

Pro

du

cti

vit

y I

mp

rovem

en

t

NRE Costs: First of Kind

Deployment

NRE Costs: Nth of Kind Deployment

Cost of Deploying Manufacturing IT

Today Future

Hardware & Installation

O&M Costs

Energy Cost

ParityCost Parity For

Investment Recovery

($/MBTU, ¢/kWh)

2x–5x

Above

Parity

Platform Costs: Zeroth of Kind Deployment

50

SMART Systems - Significant Technical Challenges

PlatformChallenges

1st of Kind Demonstration

Nth of Kind Demonstration

Hardware &Deployment

O&M

High Fidelity Modelling X X X

Data Architecture & Platforms

X X X

Sensor Development & Qualification

X X X X

Algorithms, Controls and Data

X X X X X

DemonstrationTestbeds (1st of Kind)

X X X

51

RAPID (Rapid Advancement in Process Intensification Deploment) Institute - Modular Chemical Process Intensification

Process Intensification has significant potential to improves costs, increase scalability, improve safety and enhance technology for variety of energy intensive, energy related and clean energy manufacturing applications

• Applied research and development into the Equipment, Methods and Technologies: Catalysis, Reactions, Separation, Mixing, Hybrid or Integrated Processes, Heating/Cooling, Thermal Recovery, etc.

• Test-bed demonstration of PI in first-of kind applications

• Develop technologies for manufacturing of process intensified modules.

• Dissemination of knowledge, pre-competitive testing of standards and practices, and education of workforce

• Potential Impact on several key sectors:

Chemicals, Refining, Fiber (Pulp/Paper), Fuel Cells, Natural Gas, Environmental Management, Bio-Mass Processing, etc.

Example Possible Application: Gas to Liquids

December 2016: RAPID/American Institute of Chemical Engineers (AICHE)

New York, NY (Lead Organization)

52

REMADE Institute – Reducing EMbodied-energy And Decreasing Emissions in materials manufacturing

E-WasteMetals

Rapid Gathering, Identification and Sorting

Removal of Trace Contaminants

Separating Mixed Materials

Information Collection, Standardization & Design Tools for Material Utilization

Robust & Cost Effective Reprocessing & Disposal Methods

• Open Data on Materials Flow across Firms & Industries• Tools for Lifecycle Analysis of Embodied Energy in

Waste• Model Based Design Tools for Recovery of Embodied

Energy in Manufactured Products• High Speed Robotic and Vision Systems • Real-time in-situ Tools to Identify Composition• Rapid Particle Size / Morphology Detection

• Highly Throughput Chemical Selective Separation• Advanced Physical/Mechanical Selective Separation• Recovery of High-Value Components• Advanced Melting, Distillation and Crystallization

• Selective Elimination of Trace Metals and Compounds• Removal of Organic and Inorganic Residues• Advanced Membranes for Liquid Waste Separation

• Lower Energy Thermal Processes• Adaptive Processes for Multiple Feedstocks• Low Material and Energy Loss Processing

FibersPolymers

Mat

eri

al P

roce

ss F

low

s

Enab

ling

Tech

no

logy

Ne

ed

s

Applied Sciences: Separation Chemistry, Data Analytics, Visualization & Decision Science, Multi-Spectral Sensing, Robotics & Automation, Materials Processing, Bio-Chemistry, Membrane and Fiber Science, Resource Economics

Fou

nd

atio

nal

Kn

ow

led

ge N

ee

ds

January 2017: Sustainable Materials Innovation Alliance

Rochester, NY (Lead Organization)

53

Selected Goals

• Materials supply chains assured for clean energy

manufacturing in the US

• Commercialize at least one technology in each of

its three technical focus areas

• Develop updated criticality assessments to

ensure relevance of CMI research and identify

potential critical materials for clean energy

Eliminate materials criticality as an impediment to the commercialization of clean energy technologies for today and tomorrow.

Initial Support

• $120M for R&D June 2013-June 2018

54

54

…including intake, pumps, separations, and effluent

management

Water

SourcesOutput• Seawater

• Surface

• Lake

• Brackish

• Processes

• Produced

• Municipal

• Industrial

• Agricultural

From Pretreatment through Reverse Osmosis…

Energy Inputs

Electricity, Waste Heat, Pressure

• Address manufacturing barriers to producing low-energy, cost-competitive clean water

• Technology priorities arise from facility-level systems relevant challenges

• Leverage existing federal resources (e.g. DOI/Bureau of Reclamation testbeds)

Goals: Pipe Parity

Primary Energy, Cost and Carbon Neutral

Clean Water Hub: Water-Energy Technology Innovation

55

• Addressing Global Energy Challenges means Addressing the Energy

Challenges in Manufacturing

– Use of Energy in Sector & Embodied Energy in Products Used in All Sectors

• Manufacturing Energy Efficiency is Foundation for Economic

Competitiveness

• Technology Innovation Enables Both Economic and Energy Benefits

– Science and Technology Research Issues to Achieving these Energy Benefits

– Connect Science and Technology Advanced to Human Capital Development

• Tremendous Opportunity to Leverage Information Technology

Advances With Impact Across the Economy

– Cost Parity a Must

Summary

56

What does Success Look Like?

…And Competitively Made Here!

Energy Products Invented Here…

57

Thank You

Questions?