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

Transcription

1 Leveraging Information Technology for Manufacturing Innovation at the U.S. Department of Energy FOCAPO / CPC 2017 Tucson, AZ Mark Johnson Director Advanced Manufacturing Office January 9 th, Energy Efficiency and Renewable Energy eere.energy.gov

2 A little history: The Start of a pair of Revolutions Lexington & Concord 1775 Watt, Boulton & Co (intelligence: steam regulation for external combustion engines) 2

3 US Manufacturing Strategy for First Industrial Revolution 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 ( ) Reports to Congress First Report on the Public Credit Second Report on Public Credit Report on the Subject of Manufactures

4 Second Industrial Revolution Electrification Process Scaling Energy & Materials Standardization & Assembly Line 4

5 Energy Intensive Industries -Today 5 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 Third Industrial Revolution - Now Microprocessor Integrated Centralized Scaled-out Intensified Generalized How will Manufacturing, Economy and Security of the Nation depend on Information, Actuation and Communication Technology in the 21 st Century? 6

7 Overview of DOE Advanced Manufacturing Office Technology Assistance Programs Research and Development Projects Research and Development Consortia 7

8 Energy and Manufacturing: Nexus of Opportunities Economy Competitiveness in energy products Domestic jobs Security Advanced Manufacturing and Energy Technology Energy independence Stable, diverse energy supply Environment Clean Air Clean Water Focus on: Technology Innovation impacting Manufacturing and Energy (Energy Efficiency and Life-Cycle Energy Costs) Technology RD&D + Talent (People) 8

9 Advanced Manufacturing Strategic Framing Authorizations EPAct2005 and EISA2007 Advanced Manufacturing Partnership (AMP2.0) 1) Broadly Applicable Energy Efficiency Technologies for Energy Intensive and Energy Dependent Manufacturing Strategic Plans (DOE 2014 & EERE 2016) Quadrennial Technology Review (DOE / Science and Technology 2015) 2) Platform Materials, Process and Information Technologies for Manufacturing with Sustainable Life-Cycle Impact 9

10 More Advanced Manufacturing Issues Quadrennial Energy Review (QER): Manufacturing for Infrastructure and the Grid Water-Energy Nexus: Water for Energy & Energy for Water Energy Productivity 2030: Double GDP/kJ Economy from Energy Innovation Strategy: Technology, Workforce & Capabilities Job Training and Apprenticeship: Advanced Manufacturing Skills and Opportunities Revolution Now: Cost Effective New Technologies 3) Responsible & Effective Integration of US Manufacturing to our Diverse & Abundant Energy Resources 4) Partnerships for Energy Technology and Practices Dissemination in Manufacturing 5) Tools, Training & Human Capital Development 10

11 11 Energy Use in the US Economy

12 2010 MECS Total Emissions (Onsite + Offsite) Primary Energy & energy-related Emission by Sector MMT 40.0 MMT MMT 35.0 MMT 30.0 MMT 25.0 MMT Cement Plastics and Rubber Products Transportation Equipment Electronics Aluminum Petroleum Refining Chemicals 20.0 MMT MMT 15.0 MMT Machinery Glass Textiles 10.0 MMT Foundries MMT 5.0 MMT 100 TBtu 200 TBtu 300 TBtu 400 TBtu 500 TBtu 600 TBtu 700 TBtu MMT Food & Beverage Other Manufacturing Forest Products 50.0 MMT Iron & Steel 0.0 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 2010 MECS Onsite Energy Consumption 12

13 Processes for Clean Energy Materials & Technologies Energy Dependence: Energy Cost Considered in Competitive Manufacturing Solar PV Cell Carbon Fibers Light Emitting Diodes Electro-Chromic Coatings Membranes EV Batteries Multi-Material Joining 13 Water Desalination

14 Manufacturing Bandwidth Studies: Energy Savings Potential 14 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 15 Deeper Look at Energy in Manufacturing

16 Quadrennial Technology Review: Manufacturing Efficiency Technologies Flow of Material thru Industry (Sustainable Manufacturing) Critical Materials Direct Energy Conversion Materials (Magnetocaloric, Thermoelectric, etc) Enabling Platform Technologies Combined Heat and Power Wide Bandgap Power Electronics Waste Heat Recovery Advanced Sensors, Controls, Modeling & Platforms Process Heating Materials for Harsh Service Conditions Advanced Materials & their Manufacture Additive Manufacturing Process Intensification Roll-to-Roll Processing Composite Materials 16 Information Processes Materials Energy & Resource Management Advanced Manufacturing Processes Materials Development

17 17 Advanced Manufacturing Office Multiyear Program Plan (draft) Areas

18 Impact Areas of Cross-Cutting Efficiency Technology for Energy Intensive Industry Sectors Chemicals & Biochemicals Petroleum Refining Primary Metals Forest & Food Products Clean Water SMART Manufacturing Process Intensification CHP & Grid Integration Sustainable Manufacturing Sector Specific Roadmaps Developed with Industrial Sector Partnerships 18

19 Overview of DOE Advanced Manufacturing Office Technology Assistance Programs Research and Development Projects Research and Development Consortia 19

20 Technical Assistance: Better Plants Program Key component of Better Buildings Initiative to improve energy efficiency of commercial and industrial buildings by 20% by 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) 20

21 ISO 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 specifies requirements for establishing, implementing, maintaining and improving an EnMS. It does not prescribe specific energy performance improvement criteria. Light blue text represents new data-driven sections in ISO that are not in ISO 9001 & ISO

22 Superior Energy Performance SEP is a certification program that helps facilities meet the ISO 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 ISO is a foundational tool that any organization can use to manage energy ISO Components in place: Top Management Energy Team Policy Planning Baseline Performance Metrics Superior Energy Performance ISO Single facility ISO conformance with verified energy performance improvement 22

23 Technical Assistance: Industrial Assessment Centers Energy Assessments & Student Training University-based Industrial Assessment Centers Support for small/medium sized manufacturing Energy.gov/IAC 23

24 Overview of DOE Advanced Manufacturing Office Technology Assistance Programs Research and Development Projects Research and Development Consortia 24

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. Protective coating materials for high-performance membranes, for pulp and paper industry. Image courtesy of Teledyne Energy-efficient large thin-walled magnesium die casting, for 60% lighter car doors. Graphic image provided by General Motors. A water-stable protected lithium electrode. Courtesy of PolyPlus 25

26 R&D Projects: Combined Heat & Power (CHP) & Grid Integration of Manufacturing Advanced MicroTurbine System (AMTS) R&D Program Advanced Reciprocating Engine Systems (ARES) R&D Program QSK60G engine C200 MicroTurbine Engine Capstone photos source: capstoneturbines.com 26

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 27

28 Manufacturing Demonstration Facility Supercomputing Capabilities Spallation Neutron Source Arcam electron beam processing AM equipment Microstructure Control During Metal Additive Deposition Goal is to accelerate the manufacturing capability of a multitude of AM technologies utilizing various materials from metals to polymers to composites. 28

29 Additive Rapidly Developing Technology Big-Area Additive Manufacturing (BAAM) Printed Cobra Project: Design to Prototype Six (6) people in six (6) weeks. Developed Surface Process (with Tru-Design Inc.) Crowdsource Design & Build EV (with Local Motors Developed blended polymer / fiber (with Sabic & Techmer Inc.) Developed Unique 3D Printing Tool (with Cincinnati Inc.) Designed & Printed Car Prototype (with Shelby Inc.) 29 29

30 Partnerships with Vehicles and Buildings R&D 3D Printing of Large Area Structures Partnership with Designers, Manufacturers, Universities, Laboratories and Suppliers 30

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 31

32 HPC for Manufacturing Program teams manufacturers with DOE s network of National Labs Applying High Performance Computing to face critical manufacturing challenges 32

33 High Performance Computing for Manufacturing Apply modeling and simulation capabilities to manufacturing challenges A computer simulation of the virtual blast furnace. Image courtesy of Purdue University Calumet/Northwest. 33 Industry defined challenges Businesses Partner with National labs Business-friendly terms and streamlined partnering process

34 Applied R&D for Materials Genome Initiative (MGI) Coordinated resource network with a suite of capabilities for advanced materials R&D Predictive Simulation Across Scales Synthesis & Characterization Rapid Screening End Use Performance Process Scalability Process Control Real-time Characterization Reliability Validation MGI - Framework Data Management & Informatics 34 New Material Innovations for Clean Energy 2X Faster and 2X Cheaper

35 Cyclotron Rd and Lab Embedded Entrepreneurial Partnership Lab Embedded Accelerator Model: Let the nation s energy innovators spin in to national labs Corp. M&A Licensing 1 2 Recruit the world s Leverage 3 Deploy people, best energy technology innovators experts and facilities at a world-class R&D institute IP, and technology to the marketplace First pilot phase spurred $10 million in follow-on funding and launched privately-funded startups VC 35 FY17: extend to more labs & projects 35

36 Overview of DOE Advanced Manufacturing Office Technology Assistance Programs Research and Development Projects Research and Development Consortia 36

37 R&D Facilities & Consortia Address market disaggregation challenge to the industrial commons Then Now OEM Tier 1 Tier 1 Tier 2 Tier 2 Tier 2 Ford River Rouge Complex, 1920s Photo: Library of Congress, Prints & Photographs Division, Detroit Publishing Company Collection, det 4a Tier 3 Tier 3 Tier 3 37 How could we get innovation into manufacturing today? - RD&D Consortia - Workforce Development and Education - Public-private Partnership to Scale

38 Applied Research Basic Research Deployment Demonstration Development Manufacturing Technology Maturation Technology Needs and Requirements Technology Capabilities and Opportunities Industry Partnerships End-Use Adoption TRL 6/7: System Testing in Production Relevant Environment MRL 6/7: System Components made in Pilot Environment TRL 5/6: Hardware-in-Loop System Testing in Laboratory MRL 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 38 Lab Facilities TRL 1-3: MRL 1-3: Foundational Science

39 13 Manufacturing Innovation Institutes launched to date LIFT Light/Modern Metals Detroit, MI REMADE Sustainable Materials Rochester, NY AIM Photonics Photonics Rochester, NY 39 NextFlex Flex. Electronics San Jose, CA DMDII Digital Mfg. Chicago, IL America Makes Additive Mfg. Youngstown, OH AFFOA Adv. Textiles 39 Smart Mfg. 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 Process Intensification RAPID Institute IACMI Adv. Composites Knoxville, TN Power America Power Electronics Raleigh, NC

40 Industry-Academia-Government Partnership 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 Consortia are open new members able to join 40 40

41 DOE Institute #1: PowerAmerica (Raleigh, NC) Launched in January 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 41

42 DOE Institute #1: PowerAmerica (Raleigh, NC) PowerAmerica: Develop advanced manufacturing processes that will enable large-scale production of wide bandgap semiconductors. 42

43 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 Read More at:

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 44

45 Institute for Advanced Composite Materials Innovation (IACMI) Objective Develop and demonstrate innovative technologies that will, within 10 years, make advanced fiber-reinforced polymer composites at 50% Lower Cost Using 75% Less Energy And reuse or recycle >95% of the material 45

46 DOE NNMI Institute #2 Carbon Fiber Composites (Oak Ridge, TN) Established regional centers of excellence across a number of fiber composite applications 46

47 Institute #3 Smart Manufacturing (SMLC/UCLA) CESMI Institute Advanced sensors and controls for real-time process management 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 47

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 48

49 Cost of Deploying Manufacturing IT Deployment Cost for Energy Productivity Improvement Platform Costs: Zeroth of Kind Deployment NRE Costs: First of Kind Deployment 2x 5x Above Parity NRE Costs: Nth of Kind Deployment Hardware & Installation O&M Costs Today Future Energy Cost Parity Cost Parity For Investment Recovery ($/MBTU, /kwh) 49

50 SMART Systems - Significant Technical Challenges Platform Challenges 1 st of Kind Demonstration N th of Kind Demonstration Hardware & Deployment High Fidelity Modelling X X X O&M Data Architecture & Platforms Sensor Development & Qualification Algorithms, Controls and Data Demonstration Testbeds (1 st of Kind) X X X X X X X X X X X X X X X 50

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. December 2016: RAPID/American Institute of Chemical Engineers (AICHE) New York, NY (Lead Organization) 51 Example Possible Application: Gas to Liquids

52 Material Process Flows REMADE Institute Reducing EMbodied-energy And Decreasing Emissions in materials manufacturing Enabling Technology Needs Foundational Knowledge Needs Metals Polymers Fibers E-Waste Information Collection, Standardization & Design Tools for Material Utilization Rapid Gathering, Identification and Sorting 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 Separating Mixed Materials Highly Throughput Chemical Selective Separation Advanced Physical/Mechanical Selective Separation Recovery of High-Value Components Advanced Melting, Distillation and Crystallization Removal of Trace Contaminants Robust & Cost Effective Reprocessing & Disposal Methods 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 Applied Sciences: Separation Chemistry, Data Analytics, Visualization & Decision Science, Multi-Spectral Sensing, Robotics & Automation, Materials Processing, Bio- Chemistry, Membrane and Fiber Science, Resource Economics 52 January 2017: Sustainable Materials Innovation Alliance Rochester, NY (Lead Organization)

53 Eliminate materials criticality as an impediment to the commercialization of clean energy technologies for today and tomorrow. 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 Initial Support $120M for R&D June 2013-June

54 Clean Water Hub: Water-Energy Technology Innovation 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) Energy Inputs Electricity, Waste Heat, Pressure Water Sources Seawater Surface Lake Brackish Processes Produced From Pretreatment through Reverse Osmosis including intake, pumps, separations, and effluent management Output Municipal Industrial Agricultural Goals: Pipe Parity Primary Energy, Cost and Carbon Neutral 54 54

55 Summary 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 55

56 What does Success Look Like? Energy Products Invented Here And Competitively Made Here! 56

57 Thank You Questions? 57