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EPRI Distributed Resources Venture Forum

— Business Venture Forum for Emerging Distributed Resources Technology Companies, Investors, and Market Channels
— 7/25/2001 – 7/26/2001

Agenda download is still available:
http://www.epri.com/attachments/262909_FinalAgendaVentureforum.pdf

EPRI solutions’ Second Annual Business Forum was designed to bring together leading Distributed Resource (DR) technology companies, the energy utility industry, and energy industry investors for the exchange of information related to business and investment opportunities. The Forum was structured as a venture fair with 15-minute presentations from 13 leading DR companies, followed by an afternoon of “breakout” sessions, for small group/individual meetings with the company representatives.

EPRI will issue a CD with all the presentations. Most were provided in hard copy in a binder. Additional company materials were selectively provided at the breakout sessions.

We’ve seen a number of the presenting companies before, as they’ve appeared at other similar events over the last couple of years. Side conversations also led to some interesting additional leads.

These notes are intentionally brief. If you’re interested in contacts or more details for any of these companies, let me know.

— COMPANIES —

Dais Analytic – yet another small company pushing PEM. Distinctions include “great” reformer technology, about which nothing was disclosed, and a proprietary membrane material. The membrane is the subject of a major JV with a major chemical company (unnamed), and holds great promise in an air-to-air heat exchanger, MERV, which exchanges not only heat, but also water vapor. MERV greatly reduces heating and A/C loads by preconditioning incoming fresh air. This company’s “dual” play is either appealing or not, depending on your investment philosophy (and your view of PEM’s prospects). MERV appears to offer prospect of early real revenues while awaiting PEM to ripen. On the other hand, it’s two different businesses, which can be hard for a small company to do effectively.
http://www.daisanalytic.com/

Candent Technologies – a brand new stealth (til now) arrival on the microturbine front. Very experienced personnel coming out of Rolls Royce, (which decided not to do a microturbine) take a different design approach, and will target a 750 KW unit size, eventually as low as $350/KW. They specifically are avoiding the use of recuperators, as expensive and unreliable, and will use a high pressure spool instead. No new technology is involved, so they’re projecting a rapid development, direct to beta pre-production stage, skipping a prototype. Looking for $3 Million now, and $20 M in another round following demonstration.

PEPCo Technologies – GenerLink. Spinoff of PEPCo, selling an standby generator interface for homeowners. Said they have 2 investors that are going ahead (one is strategic, the other a VC). I have to agree with what I heard most people say– it’s hard to imagine there are very many people who would want this.
http://www.generlink.com

Pentadyne Power Corp. High speed flywheel, continuing development work by Rosen Motors. Targeting high power/short duration ride-through application. First units will be 120 KW for 20 seconds. Novel approach to safety containment using double shell with liquid in-between (originally conceived for onboard vehicle use, where heavy shielding is not possible). Claim very low standby loss/idling load, and low cost once in large quantity production.
http://www.pentadyne.com

Powerco US/Ocean Power — a new private marketing arm, formed as subsidiary to Ocean Power (NASDAQ PWRE). Initial focus on small stirling engine they acquired in Norway, but parent company has too many breakthrough technologies in its arsenal to believe, ranging from diesel CHP, dish PV, fuel cells…and they didn’t even mention desalination, another area they claim to have cornered. http://www.powerco.com/

Ceramic Fuel Cells Ltd — Solid Oxide FC contender in Australia that appears quite credible. In the breakout session they showed a new all-ceramic stack configuration that is looking very promising. Market entry product is a 40 KW generator, to operate on straight methane (SOFC is autoreforming, so no fuel processor needed). http://www.cfcl.com.au/content.htm

BCS Technology — a tiny company from Texas, founded 1990, with “self-humidified” PEM fuel cell stacks and MEAs. They’ve sold over 100 small stacks.

ALM Turbine — This company looked overly ambitious when they started raising money 1-2 years ago, but they say their progress is on track. Their first engine is just about ready for tests, and preliminary emissions data for their burner technology is promising. Their engine is completely scalable in size, from 25-350 KW, and they claim high efficiency, and high part load performance. Design relies heavily on exhaust gas recirculation. http://www.almturbine.com

Sixth Dimension — Until recently, it was difficult to understand what this company did, but they’re doing better at explaining it now. They’re a “network operating system” for communicating with any/all types, brands etc of energy producing, consuming and monitoring devices, e.g. meters, gensets, building control systems, energy analytics systems, etc. They put a “gateway” box on site which they call “Embedded Site Server”, to which 16 devices can be connected. Each device gets a smaller box called the “Power Tone Adapter” which can be outside or inside the device. The system of proprietary hardware and software makes possible all manner of clever monitoring and control functions. This sounds like what Encorp says, but they say Encorp can only do these things if you have Encorp switchgear. 6th is far more equipment-agnostic.
http://www.sixthdimension.com

Alternative Designs Inc — ADI has unique stirling engine technology enabling operation at much higher temperatures, attaining efficiencies of 50% and greater. Other enhancements include an advanced regenerator, and simplified heater head design, leading to big cost reductions and higher reliability. [I am an advisor to this company.]

DayStar Technologies — Unique PV cell technology. Company first developed a “flat-plate concentrator” technology that was clever and intriguing, but would require extensive capital development. DayStar is now focused primarily on their own cadmium-telluride “thin-film-on-metals” solar cells. The cells are manufactured in sheets, which can be used whole, or cut into cells which can be a direct “replacement” for Si cells, at half the cost.
http://www.daystartech.com

Rolls Royce — as noted above, RR decided not to pursue a microturbine development, despite having invested quite a bit of money in it. Instead, they’re going for a special purpose turbine to be combined with their own planar SOFC. Program began in 1992. This 1 MW hybrid is to be ready by 2005. RR will fund most of the program internally, but will seek strategic partners for funding, and technical/marketing support, leading to a possible spinoff company.

Vanteck(VRB) Technology Corp. — (public company, CNDX symbol VRB ) commercializing the vanadium redox battery technology, and in particular VESS, for Vanadium Energy Storage Systems. The company is in the midst of straightening out a particularly messy history of corporate ownership of IP and market rights, but assuming that can be done, are focusing on the US market. This is flow-battery has some uniquely attractive features, including high round trip efficiency, and freedom to size a system’s power (KW) and capacity (KWH) separately (either aspect can be added to over time). In concept, this is very similar to the Regenesys battery, but with different chemistry, and targeted at smaller systems. The first commercial installation outside Japan is starting up now — a 250 KW/ 520KWH unit at ESKOM, in South Africa.
http://www.vanteckvrb.com/

Technology Transfer Opportunities – Pacific Northwest Laboratory


UFTO

PROPRIETARY

Final Report

Technology Transfer Opportunities in the National Laboratories

Pacific Northwest Laboratory

Richland, WA

August 1995

Prepared for:

Utility Federal Technology Opportunities (UFTO)

By:

Edward Beardsworth

Consultant

 

This report is part of a series examining technology opportunities at National Laboratories of possible interest to electric utilities

Contents:

1. Summary
2 PNL Organization
3. PNL Technologies & Programs
14. PNL Contacts

 

 

This report is proprietary and confidential. It is for internal use by personnel of companies that are subscribers in the UFTO multi-client program. It is not to be otherwise copied or distributed except as authorized in writing.

 

Summary

 This report details findings about technology and technology transfer opportunities at the Pacific Northwest Laboratory (PNL)that might be of strategic interest to electric utilities. It is based on a visit to PNL in March 1995, as part of the UFTO multiclient project, and on extensive contacts with PNL to track the major changes there between April and August.

Background

Noting the tremendous scope of research underway in the research facilities of the U.S. government, and a very strong impetus on the government’s part to foster commercial partnering with industry and applications of the technology it has developed, the UFTO program has been established as a multi-client study of the opportunities thus afforded electric utilities.

PNL Overview

The Richland “Tri-Cities” area is home to a number of reactor and weapons materials production facilities, the first of which was the Hanford Site, established in 1943 as part of the Manhattan project. The Pacific Northwest Laboratory (PNL) is a separate multipurpose federal laboratory operated for the DOE by the Battelle Memorial Institute (BMI). Battelle, founded in the 1920’s as a not-for profit, also operates its own laboratory at its headquarters in Columbus OH. BMI took over the management of PNL as a “GOCO” (government owned contractor operated) in 1965. PNL has over 4000 people and a budget of $500 million/year, although downsizing and budget cuts are underway.

PNL’s GOCO arrangement is unique in having two kinds of contracts with DOE. One, called “1830”, is just like other DOE labs, with the usual direct funded work for DOE, work for others, CRADAs, licensing etc. The second type of contract, called “1831”, enables PNL to perform strictly commercial proprietary work for private industry, paying a use fee to DOE for the use of the facilities and overhead. 1831 programs comprise less than 10% of the total activity at PNL, and involve slightly higher rates together with the better business terms for outside clients.

Commercialization is strongly encouraged at PNL, as is multi disciplinary harvesting and reapplication of results and technology from across all areas of the lab, including “black” programs.

Several years ago, PNL made a specific long term commitment to energy, investing its own lab-directed funds (LDRD) and Battelle’s IR&D in such areas as EMF mitigation and Real Time Control of Power Systems. The primary focus has moved distinctly away from generation, and towards T&D and end-use, with continuing strong emphasis on environmental impacts and restoration and on planning and analysis.

PNL’s core competencies relevant to energy include:

Energy Systems Research: Power Systems, distributed utilities, automated diagnostics

Process Technology: Polymer coatings, reaction engineering, and process design tools

Integrated Environmental Assessment: EMF Effects, Global Modeling, Oil & Gas Cleanup.

PNL’s approach to the utility industry, which it has specifically identified as a major program direction, is to support enhanced asset utilization in the near term while preparing a leadership role in the “utility of the future”, involving real time control, distributed utility, new products, and risk/strategic environmental management.

PNL’s Commercial and Industrial efforts already have a long history with the gas industry (GRI and gas/combination utilities), working on pipelines, appliances, etc. and providing product development and commercialization support, problem solving, life/prediction/failure mode analysis, efficient repair technology, and safety and inspection technology.

PNL Organization

PNL has just completed (July 1995) a major reorganization and downsizing (with the help of McKinsey), eliminating nearly 2/3 of the upper management, and going to more of a line organization. (The “Technical Centers,” matrixed with “Business Directorates,” are no longer.) In the new order of things, “lines of business” are the major focus, drawing on personnel and capabilities across the lab, to address their particular sectors.

The technical Divisions are: Environmental and Energy Sciences, Environmental Technology, Energy, Health, National Security, and Emerging Technologies. These divisions each have a number of departments. The names of both divisions and departments are in many cases not a good indication of what goes on in them, so the best strategy for an outsider is to rely on a personal point of contact to reach the personnel and resources that are appropriate to a given topic.

PNL is strengthening its already substantial commitment (including internally funded development projects) to expanding the commercial side of the business, and seeks increased contact with private industry. The Energy Division might better be called the “Commercial and Industrial Division”. Merwin Brown, formerly of PG&E, now heads the Energy Technology Department and Line of Business, which indicates PNL’s resolve to serve the utility industry. They of course will draw on people and talents across the entire lab to meet the needs of utility clients.

PNL’s Utility Strategy

PNL and its parent, Battelle Memorial Institute, have provided significant R&D contributions to the utility industry over the past several decades. BMI is the largest contractor to GRI, and PNL alone currently serves over 30 utility clients with a range of products and services. In addition to utility support, PNL provides support to DOE’s Office of Utility Programs. PNL’s energy strategy has identified the deregulation sweeping the utility industry as a key driver for technology needs over the next several decades. In response, PNL has increased its emphasis on the needs of the utility industry. PNL’s utility industry has two primary foci:

1. Help increase asset utilization in gas and electric utilities, and

2. Provide technology leadership in distributed energy systems.

PNL’s offerings for utilities include:

• Advanced power systems, transmission and distribution technologies and services

• Operations and Maintenance technologies and services

• Technology development and competitive analysis for new energy products and services

• Environmental Management

• Organizational Effectiveness assistance

[UFTO’s contact is Carl Imhoff, who reports to Merwin Brown.]

PNL Technologies & Programs

 

Covered in this report:

Page

  • Decision Support for Plant Operation & Maintenance (DSOM) 4
  • Process Science & Engineering — Electrochemical Processes 5
  • Power Systems 6
  • Federal Emergency Management Information System (FEMIS) 8
  • Building Energy Standards Program 8
  • Sensors 9
  • Coatings and Thin Films 10
  • Planning & Analysis 11
  • Strategic Environmental Management 12
  • Environmental Technologies 12
  • Waste Fate & Transport 12
  • Fisheries and Water Resources 13
  • Operational Effectiveness 13

• Decision Support for Plant Operation & Maintenance (DSOM)
Principal Investigators: Don Jarrell 509-372-4096
Dick Meador 509-372-4098

PNL has fully developed this AI software system that provides on-line engineering expertise to assist operators and maintenance personnel. It uses a proven root-cause analysis methodology, RCM techniques, plant aging experience and advanced instrumentation technology, all in an easy to use GUI package.

The first major application, in use at two military bases for theircentral heating plants, is saving $ millions in the first year alone. (The Marine Corp had asked them to help with aging, poorly performing plants, based on PNL’s earlier work on root cause analysis for the military.)

A second application, already developed, is a Pump Motor Diagnostic Model, that provides operators (not engineers) with diagnostics that recognize stresses early, before failure. It uses fuzzy logic and neural net analysis of existing sensor data.

The capabilities appear to go well beyond anything else that is commercially offered, providing a far more sophisticated and complete solution.

A brochure on DSOM (pronounced “dee som”) is available from PNL:

  • A new service business opportunity for utilities — putting this system in at commercial and industrial central heating facilities (a typical site requires several man months to set up). It’s all ready to go.
    The capability could be applied to any process, utility or customer’s. PNL could help develop applications.
    Applicable to utility power plant operations.
    Perhaps a good place to start a T&D RCM development.

• Process Science & Engineering
Electrochemical Processes Ed Baker (Principal Investigator) 509-376-1494

Waste Acid Recovery

Based on the development of a polymer heat exchanger that can withstand 200 ˚C, this is a commercially available system that recovers process acids, and separates metals from waste streams. It is already in use in a few places, and is very broadly applicable, e.g. to galvinizers, platers, and innumerable other industrial processes. It would help keep a customer competitive, by reducing waste disposal costs.

The vendor is Viatec Recovery Systems, in Hastings MI and Richland WA. They are small, and would probably be interested in some kind of teaming to give them access to markets and capital.

Alkox

Alkane oxidation for partial conversion of methane to methanol. Catalyst is regenerated electrochemically. Could help fill in the summer slump for natural gas demand, making oxygenate for gasoline. Also use at oil wellhead, to capture flared gas. Needs $300-500K for proof of concept. (pat. pend.)

Near Critical Water Oxidation

(TEES, for thermochemical environment and energy system) converts organics to methane and CO2 with high pressure, high temperature water–both energy production and cleanup! Applicable to aqueous waste streams with organics, e.g. food processors could lower costs and even do some cogeneration. Sludges and slurries OK. There’s a small licensee in Southern California.

Supercritical CO2 cleaning —

replaces solvents (e.g. CFCs, carbon tet, trichlor, etc.) The trick is to recover energy during pressurization/depressurization. A DOE funded demo is going in at a foundry in Portland, OR, and a transportable demonstration unit for parts cleaning is on the road, traveling to trade shows. No licensee as yet.

Catalysts by design

For example, membranes reactor to generate hydrogen from methane, avoiding the need for a reformer — important implications for PEM fuel cells.

• Power Systems

Landis Kannberg, Program Manager, 509-375-3919
John DeSteese, Sr. Research Engineer, 509-375-2057
John Hauer, Sr. Program Manager, 509-375-4340

PNL has a long history in RD&D for power systems. They had an active role in power systems since the 70’s, working closely with EPRI and with BPA. Earlier work included studies like estimating the savings from improved voltage regulation, distribution system modernization, evaporative cooling of underground transmission, and future trend assessment for DOE.

More recently, they have been involved in superconductor applications, the distributed utility concept, advanced computation particularly for transmission system dynamic analysis, and a range of special studies, including one on the need for power in the former soviet union.

Superconducting Transformer Evaluation with HTSCs … takes the view that discrete devices like transformers are a better application of superconductors than transmission lines. They found that HTSC transformers would be viable even with a conventional HTSC stability design, in the 30-1000 MVA range. ABB will build one in Europe next year. A likely early justification would be for use as a transportable spare.

PNL suggests an interesting first step: start by cooling an existing conventional Cu transformer with liquid nitrogen, gaining a 2x increase in power density. The next step is to redesign.

(A preprint is available from DeSteese, titled “High Temperature Superconducting Transformer Evaluation”).

Distributed Utility (DU) … PNL was part of the group (with EPRI, NREL, and PG&E) that started an informal collaboration to study DU. PNL’s work was funded by internal “lab directed R&D” (LDRD) money. One of the staff (Kannberg) went on loan to PG&E for a time, to manage the overall effort. Their particular interest is on the effects that implementing a lot of DU resources would have on stability and performance of the transmission system.

PNL did a DU Feeder Analysis for PG&E, using a “synthetic” load data set for each feeder. Based on load duration curves for a given feeder, the estimated the amount of distribution asset deferral possible from adding DU resources to trim the peak load, until load growth becomes overwhelming. This effort included the development of a short term load forecast using load shapes and cluster analysis to generate typical customer profiles. This was used to estimate the potential for DU and DSM and the value of retail distribution wheeling.

Contact Rob Pratt, 509-375-3648
Benefit Cost Analysis of Storage is pursued “technology-blind”, i.e. without a preference for any particular means for storage. A series of studies have focused on SMES. One evaluated SMES in a number of system-specific scenarios for BPA. (J DeSteese, et.al., Applied Superconductivity, Vol 1, # 7-9, pp. 1425, 1993) Others looked at wind integration, and other utility systems. They found that some earlier analyses tended to underestimate SMES benefits because multiple benefits were not evaluated.

Real-Time Power Systems Control (RTPSC) is a big issue for the industry, especially on the question of whether utilities will be willing to share the data needed. A control based strategy will need an extensive information infrastructure, and it needs a fall-back capability, perhaps including repair SWAT teams. There must be complete buy-in to the whole idea, and the conversion may take as much as 2-3 decades.

There appear to be two competing scenarios–one holding that DU will obviate the need for more transmission capacity, and FACTs, which has its own large information needs. PNL prepared a White Paper (Version 1.0 dated March 3, 1994). It outlines a phased strategy for the development and deployment of RTPSC. (It is available from the contacts listed above. A revised version is in progress.)

Workshops held in recent years have reached a consensus on the R&D needs, which include the need for: gaining a better understanding of optimal power system operation, a new generation of on-line sensing, advanced technology, local adaptive computer control, and systems wide engineering research into new algorithms and modeling approaches.

System Monitoring and Control … While some utilities have remote system monitors, there isn’t a comprehensive means to use this data in real time for system operation and control. Everyone from expansion planners to system operators needs measurement-based information.

PNL has developed a Portable Power System Monitoring Unit (Interactive Measurement & Analysis Workstation) which operates over a wide area network. It provides flexible trigger logic and GPS synchronized/phasor measurements, in an integrated open statistical and analytic environment. The workstation also provides dynamic analysis and design.

Visualization …. In comparing model-based vs. data based analysis, it’s been noted that the models tend to be more pessimistic about system behavior when problems occur. Operators need to be able to visualize model outputs, so they can understand, interpret and compare. PNL has applied commercially available visualization packages to represent power system simulation results. As one example, a graphics tool has been used to display output from the Extended Transient Midterm Stability package (ETMSP) from EPRI. This is seen as a first step towards a fully graphic based interface where one environment provides data entry, simulation control and analysis, using the models no longer require separate procedural steps.

Power Conversion … PNL has built and is testing a 5 kW power converter using Pulse Amplitude Synthesis Control. It promises better integration of a variety of DC generators and storage sources with diverse characteristics, making them appear as one integrated resource on the grid. (Visualize a transformer with multiple primaries and a single secondary.) The principal advantage is that the power converter is not dependent on the operation of each of the DC supplies.

They are in the process of lining up a CRADA partnership with a wind power manufacturer who only wants to license it, so other interested parties would be welcome.
• Federal Emergency Management Information System (FEMIS)
Tom Coonelly, Computer Sciences Department, 509-375-6480

FEMIS is an automated decision support system which integrates all phases of emergency management. It was developed for the U.S. Army to deal with chemical weapons, but it is a generic set of tools that can be adapted to any emergency response situation, providing planning, coordination, response, training and exercise support for emergency managers. FEMIS enables the integration and use of real-time data from outside sources (e.g. weather monitors), which can be displayed in geographical and/or tabular form. It tracks resources, task lists, and organizations; it provides event logs; it reminds the user about overdue tasks; and it reports on the status of wide variety of items. FEMIS uses commercial software in a distributed system architecture.

It is a general, “vanilla” capability to bring in information from over a large geographical area and respond to it. One important element–it can provide systematic coordination of different agencies and jurisdictions, i.e. company, local, county, state and federal.

Possibilities for utilities–a new breed of nuclear plant emergency response tools, application to transmission grid management (operations and emergency planning, e.g. storms). Discussions are underway with several potential commercializers, and a helpful overview brochure is available.

 

• Building Energy Standards Program (BESP)
Jeffery A. Johnson, Program Manager, 509-375-4459

Building Energy Codes Hotline: 1-800-270-2633 answers questions from state and local code officials, builders and others.

BESP did a survey in 1994 of utilities, to find out what strategies are currently being used to promote energy-efficient building design and construction (sponsored by the DOE Office of Codes and Standards). The complete report is available: PNL-9976, “Lessons Learned from New Construction Utility DSM Programs and Their Implications for Implementing Building Energy Codes”

The Advanced Energy Design and Operation Technologies (AEDOT) project focuses on developing advanced, computer based building-energy design tools, incorporating new energy-efficiency expertise into systems architects and engineers use to design and operate buildings. A CRADA is underway with the University of Oregon and Softdesk, Inc. to integrate energy analysis into a CAD tool. The product, “Softdesk Energy”, will be distributed to all users of AutoCAD with Softdesk–over 100,000 users. It automatically transfers building geometry data to the energy analysis software, enabling the user to obtain energy load estimates at any time, using the ASHRAE Simplified Energy Analysis Method for heating and cooling anywhere in the U.S.

Contact: Michael Brambley, AEDOT Program Manager, 509-375-6875.

 

BESP publishes a newsletter “Building Systems Update” Contact C.J. Belcher PNL, Box 999, K5-02, Richland WA 99352, FAX 509-375-3614

Also, a new brochure “Enhancing Today’s Buildings, Inventing Tomorrow’s Buildings” will appear next month giving a detailed overview of the work in codes, standards, compliance modeling, building (life-cycle!) energy analysis, metering, data-logging, retrofit analysis, building operations and maintenance assessments, etc..
• Sensors John Hartman, Leader, Electro-Optic Systems Group, 509-375-2771

There is no specifically organized function to manage sensor development at PNL. Instead, there are a large number of informally linked “islands” of expertise across the lab’s organization. John Hartman offers to help pull together the appropriate people to address any particular need or application.

It’s also important to note that sensors are only one of a long list of technical areas that comprise PNL’s “Automation and Measurement Sciences Department”, including robotics, imaging, NDE, instrumentation, and applied mechanics.

PNL views sensors in the context of the entire process and environment they operate in. Starting with a long list of basic sensing mechanisms, a cost-effective and practical device must be developed, together with the associated components to form a sensor system. The sensor system in turn must fit functionally into the larger system of which it is a part.

Thus, the development of a sensor system must draw on a wide range of talents.

Mechanisms include electrochemical, electromagnetic, chemical interaction, mechanical, optical, radiological interaction, electromechanical, and thermoelectric. Practical sensors measure the presence, amount or concentration of chemical species or radiation, mechanical strain, moisture, crack growth, acoustics, fluid flow properties, temperature, em fields, or corrosion.Implementation must take into account materials, signal characteristics, response rates, fabrication, stability, on-board signal handling, packaging, power requirements, calibration, etc. Finally, the balance of system must deal with how the sensor data is transferred and used, in terms of the process hardware, software and human interaction.

Some examples:

Fiber-optic Chemical sensors monitor ground water contamination, using emission, absorption or color-change phenomena.

Piezoelectric Chemical sensors detect small quantities of a chemical species with selective coatings.

Acoustic and Ultra acoustic sensors are applied in diverse areas such as sonar, materials inspection, and near-surface geophysical exploration. Measuring the time of flight of a sound pulse, PNL developed a system to measure the internal temperature of steel at temperatures up to 2000 ˚F. It is now is use in a steel plant’s continuous caster.

Optical sensors have applications ranging from power-beaming in space, to high speed production inspection, to remote temperature measurement.

[For further inquiry: H2 detection is very important for Hanford, and a group at PNL probably has done work in this area that might prove useful for nuclear power plants.]

• Coatings and Thin Films
John Affinito, Staff Scientist, Materials Sciences Dept. 509-375-6942

PNL has developed new processes for rapid vacuum deposition of multilayer polymer and metal films, and is pursuing applications in Li batteries, solar thermal reflector films, magnetic shielding, electrochromic films, supercapacitors, and non-linear optical devices. They achieve higher quality and production rates hundreds of times higher than other methods.

In the Polymer Multi-Layer (PML), monomer fluids are vacuum flash evaporated on the substrate. The fluid condenses as a liquid film and then is radiation cross linked to form a solid polymer film. In a second process, called Liquid Multi-Layer (LML), the liquid is directly coated onto the substrate by extrusion, rollers, spraying or other means, and then is radiation cross linked. Both of these processes are novel, fast, and compatible with simultaneous high rate in-line deposition of other layers by conventional vacuum coating processes (evaporation , sputtering, or plasma enhanced chemical vapor). Several licenses have already been granted.

The supercapacitor consists of thousands of thin alternating layers of polymer and aluminum, and can go to very high voltage. The PML/LML processes inherently eliminate pinholes and other micro defects that can have a significant effect on the properties of the film. There is a licensee — AVX in South Carolina.

The solar reflector film has higher reflectivity and is cheaper than other alternatives, using acrylic/silver/acrylic layers on a polyester substrate.

Optical coatings have been done on elements 2 meters in diameter.

Electrochromic heat mirror film can become cost effective due to the high rate of production.

Micro Heat Exchanger/Heat Pump Kevin Drost, 509-375-2017

PNL is developing a miniaturized vapor-compression cycle heat pump smaller than a dime that could be fabricated by the hundreds in thin layers on a single sheet. Such sheets could be incorporated into walls of buildings, replacing conventional HVAC.

They’ve had success with the evaporator and condenser components, attaining heat transfer rates of 100 watts/cm2. The compressor is more of a challenge. Work is proceeding on two fronts, one a chemical absorption cycle, driven by heat, and the other a miniature electromechanical pump, which is showing earlier promise. Without the compressor, the evaporator and condenser could be configured as a thermo siphon for cooling electronics.

This work is definitely in the “potentially revolutionary” category, though actual commercial applications are years away. Possible uses: Controlling chemical processing very precisely, which for example could make it possible to make a very high performance reformer for use with fuel cells or at the wellhead. Another application: cooling for protective clothing for use in hazardous environments.
• Planning & Analysis Ron Nesse, Sr. Program Manager, 509-376-4217

Until the most recent reorganization (7/95), the Technology Planning & Analysis Center (TPAC) was a part of Battelle matrixed to PNL, with some staff located in Richland and a group in Seattle. As of this writing, the designation TPAC is no longer operative. Many of the people have been assigned to the new Energy Division and some to the Environment Division.

The focus is management of technology, as distinct from technology itself, supporting DOD and DOE in policy, system models, technology assessment, organization design, human factors and legal and regulatory analysis. (Battelle Columbus has a separate commercial consulting practice that does “Technology Management”. Due to common interests, there’s a fair amount of informal collaboration, but no direct reporting relationship.)
Organizational Consulting for the Utility Industry

Jon Olson, Assoc. Center Manager, TPAC (Seattle), 206-528-3200

The Seattle group is focusing more on private industry than do the people in Columbus, and has specifically targeted the utility industry, manufacturing, and biotech. Noting the dramatic changes, new pressures and new business options utilities are facing, they offer services in organizational effectiveness, process redesign, implementation, and leadership training. In addition to on-site consulting and training, they offer training courses and seminars. The group also does Human Factors and Social Research Support of the Nuclear Industry — safety analyses, plant aging, and procedures design for nuclear utilities here and abroad.
Management Analysis Program (MAP) Linda Fassbender, Project Manager, 509-372-4351

MAP has been instrumental in the ongoing reorganization and strategic planning process for the Office of Energy Management in the DOE Office of Utility Technology. MAP facilitated a stakeholder meeting (4/94), provided issue background analyses, and prepared a Strategic Plan document. The Issue papers offered a succinct analysis of economic, environmental, regulatory, institutional and technological trends and issues in the energy industry for Hydrogen, Electricity, Thermal Energy, and Natural Gas. A second stakeholder meeting was planned for mid 1995, however it has been postponed pending the outcome of higher level DOE reorganization and budgetary uncertainties. DOE and PNL want a far greater participation by the utility industry in these deliberations in the future.

Facility Energy Decision Screening (FEDS) is a comprehensive approach to facility energy management developed for DOE and DOD. The software is fuel and technology independent, and optimizes life-cycle cost/savings considering all interactions, including utility rebates. Used at many sites and facilities in conjunction with the Federal Energy Management Program (FEMP) [see the UFTO NREL report], it has shown that modernization investments of 1-2 times annual energy costs can effectively provide lower costs and increased reliability. Training is available.

Global Change Policy Analysis Tools — for EPRI, EPA, DOE, and others. PNL is the heart of a world-wide “virtual ” center on integrated assessment of climate change issues. Perform policy analysis, technology analysis and social science research. Second generation model integrates emissions carbon cycle, climate modeling, ecosystem response, oceans, and human dimensions.

 

• Strategic Environmental Management

“Life Cycle Assessment” is the new buzzword for analysis of all aspects of a process or technology –cradle-to-grave, overall infrastructure, all the way up and down stream.. Internationally, the ISO 14000 movement (see below) is gathering momentum, and this is in much the same spirit.

DOE, DOD and EPA are sponsoring the Life Cycle Computer Aided Data Project, which includes separate groups for each of a number of various industries. The idea is to create a generic modeling system that more detailed individual process models can fit into.

Contact is Ken Humphreys, 509-372-4279

Battelle Labs (contract manager of PNL) offers consulting inStrategic Environmental Management, which helps companies get beyond the reactive mode and into a proactive “competitive-advantage-mode” on managing their environmental issues.

They and PNL have an initiative to put together the “Industrial Consortium for Environmental Standards, Science and Technology” (ICES). This is a novel approach to creating networks of already existing groups to be a part of the international ISO 14000 efforts. [If you’re familiar with ISO 9000 — the European total quality program that the US just waited to get hit by, this is the environmental analog, being vigorously pursued in 24 countrieswithout government involvement! There is an ad hoc network of US participants, and ICES is a way to get linked into it.] Contact is Gary Morgan. 509-375-2373
• Environmental Technologies Jim Hartley, 509-372-4428

PNL has an extensive program in technology for managing wastes and performing remediation, and in analytical risk-based decision support tools, such as the Remedial Action Assessment System (RAAS), Remedial Options (a database available commercially from Battelle), Multi-media Environmental Pollutant Assessment System (MEPAS — prioritizes risk).

As one example, the SAFER code for site characterization was developed at PNL, and CH2M Hill uses it commercially. PNL’s tools have credibility, and DOD buy-in, for evaluating remediation alternatives. They provide support to DOE’s cleanup efforts in the form of products and services. They also do restoration and cleanup work for almost all government sites, usually partnering with vendors. Key Battelle technologies for remediation include:

Soil: Vitrification*, soil washing , bioventing, chemical stabilization, insitu corona, six phase heating**

Water: Chemical barriers, Bio barriers, Extraction/Injection network, electrochemical oxidation

*Terra-Vit is a versatile low cost waste vitrification melter can transform waste into products

**ERACE heats the soil electrically to free less volatile contaminants.

Fate & Transport Management of Electric Utility Wastes

Dhanpat Rai, PI, and Andy Felmy, Group Manager, 509-372-6296 (?)

PNL has performed many projects for EPRI for over 12 years in geohydrochemical analysis, e.g. for coal ash leachates and other utility waste streams. Their expertise includes laboratory and field studies on leaching and modeling (FASTCHEM, FOWL, CHROMAT) etc. The group has published widely — a list of publications is available.

• Fisheries and Water Resources

Marshal Richmond, Sr. Research Engineer, 509-372-6241

Duane Neitzel, Staff Scientist, Aquatic Ecology Group, 509-376-0602

Part of the Earth and Environmental Sciences Center, which encompasses Hydrologic Processes, Marine & Environmental Chemistry, Ocean Processes, and Marine Ecological Processes. Research Facilities include Aerosol Wind Tunnel, Arid Land Ecology Reserve, Geochemistry Lab, Geoscience Visualization Lab, Subsurface Environmental Research Facility, Fish Hatchery and Wet Lab, Remote Sensing, Marine Sciences Lab, Airborne Laboratory

Fisheries: Hatchery and Wet Lab provide controlled conditions, making possible precise determination of impacts on fish populations from such phenomena as O2 deprivation.

River Simulation: system of models that simulate flow hydraulics (flood wave), non uniform sediment transport, contaminant transport. Can handle branched and looped channel systems, operations of dams and reservoirs, heat transport and transfer, and river bed accumulation of sediment and contaminants. It features long term multi year simulation and system operation simulation.

Watershed Modeling: detailed integrated representation of watershed processes. Includes two layer canopy model for evapotranspiration, energy balance for snow accumulation and melt, a two-layer rooting zone model and a saturated subsurface flow model. The landscape is divided into grid cells on Digital Elevation Model data nodes, used to model absorbed radiation, precipitation, air temperature, and down-slope water movement. When linked to a regional climate model, it can generate snow pack, soil moisture and stream flow information that can be used to manage water resources.
• Operational Effectiveness

The Operational Effectiveness Department works for DOE and other governmental clients and private industry on policy and regulatory management, operational assessments and training and evaluation.

Operations Technology Group — testing support to NRC Operator Licensing, direct PNL internal operations assessment, support DOE re operations. Reactor safety evaluation, individual plant evaluations.

Safety & Health Technology Group — develop OSH policy, accident investigation, OSH compliance inspections, training, decontamination and decommissioning support

Safeguards and Security Group — Domestic and international safeguards, protection programs, information security, physical security and protective force support, multimedia training

PNL Contacts

General phone # 509-375-2121

Mailing Address:
Pacific Northwest Laboratories
Battelle Boulevard
P.O. Box 999
Richland WA 99352
The primary contacts for UFTO are:

Carl Imhoff 509-375-4328 ch_imhoff@pnl.gov

Energy Programs Manager
Merwin Brown 509-372-6323 ml_brown@pnl.gov
Director, Energy Technologies Dept.

 

Information Source Contacts
Katie Larson 509-375-3698 kj_larson@pnl.gov

Energy Division Communications
Media Relations: Jerry Holloway 509-375-2007

Technology Transfer Opportunities – Argonne National Laboratory

by Edward Beardsworth
September 1994

Summary

This report details findings about technology and technology transfer opportunities at the Argonne National Laboratory (ANL) that might be of strategic interest to electric utilities. It is based on two visits to ANL near Chicago Illinois (in November 1993 and May 1994), as part of a project for PSI Energy, which had the additional goal to establish relationships that will enable PSI to monitor developments and gain access on an ongoing basis.

Background
Noting the tremendous scope of research underway in the research facilities of the U.S. government, and a very strong impetus on the government’s part to foster commercial partnering with industry and applications of the technology it has developed, PSI Energy supported this project to become familiar with the content and process of those programs, and to seek out opportunities for collaboration, demonstration or other forms of participation that will further the business objectives of PSI. PSI has agreed to make these results available to the participants in UFTO.

ANL Organization

Similar to other DOE labs, ANL has a matrix organizational structure of “Divisions” and “Programs”. The divisions are aligned by programmatic area, and have the people, projects and budgets. Programs are mainly to coordinate the Laboratory’s efforts across divisions. In a few instances, programs take on a larger role, e.g. in the case of fuel cells.

Both divisions and programs live in research “ALD’s” or Associate Laboratory Directorates, headed by Assoc. Lab Directors who along with other administrative and support groups report to the Laboratory Director (Alan Schriesheim).

Argonne’s four research ALD’s are:
– Physical Research (basic research in fundamental sciences)
– Advanced Photon Source (a new high energy x-ray facility for basic research)
– Engineering Research (mostly advanced nuclear and national security)
– Energy & Environmental Science & Technology (EEST)
(name recently changed from “Energy, Environmental and Biological Research”)

Of these, virtually all work of potential interest to utilities is in EEST. However it’s important to understand that EEST has Programs that are carried out by cross-ALD, cross-divisional teams. For example the work of the Electrochemical Technology Program involves major participation by staff from the Chemical Technology Division of the Engineering Research ALD.

ANL has a number of “User Facilities” and “Centers” that focus on particular subjects, and make special equipment, facilities and expertise available to outside users, on a fee or collaborative basis. These are housed within programs and divisions.

ANL also takes on a program management role nationally on behalf of DOE, for some aspect of a DOE program, e.g. supporting PETC or METC or the DOE program office directly, or in collaboration with another national lab.

One other general point: each labs annually publishes an “Institutional Plan”, which is organized according to which DOE Program Office supports the work, not the lab’s own organizational structure. Thus a “mapping” between the two structures is required to be able to see the work of the groups within a lab. In most instances, divisions and programs also publish annual progress reports, providing detailed though not always current accounts of the work

EEST itself is divided into 3 areas reporting to “General Managers”, and then into the divisions and Programs:

1. Energy & Industrial Technologies (Richard W.Weeks, General Manager, 252-9710)
(approx. # people)
Energy Systems Division (Norm Sather, Director, 252-3724) 200
Energy Technology Division (Roger Poeppel, Director, 252-5118) 120
(formerly called Materials & Component Technology Division)

Energy Efficiency and Renewable Energy Program (William Schertz)
Electrochemical Technology Programs (Mike Myles)
Fossil Energy Programs (David Schmalzer)
Industrial Technology Development Center (Don Mingesz) (acting)
(formerly called the Technology Transfer Center)

2. Environmental Sciences (Terry Surles, General Manager)
Environmental Research Division (Chris Reilly, Director)
Environmental Assessment Division (Anthony Dvorak, Director) 170
Decision & Information Sciences Division (Paula Scalingi, Director) 150

Environmental Technology & Restoration Program (James Helt)
Global Climate Research Programs (Ruth Reck)

3. Center for Mechanistic Biology & Biotechnology (E Huberman, Director)

Area Code is (708)
ANL Technologies & Programs

Covered in this section:

• Fossil Energy Program
• Advanced Cogeneration
• Plasma Chemistry
• Waste Mgt & Bioengineering
• Environmental Control Technology
• Geographic Information Systems and Environmental Capabilities
• MSW/Biomass Processing
• Advance Heat Exchangers
• Technology Evaluation
• Energy Technology Division Capabilities
• Measurement and NDE
• Superconductivity
• Ice Slurry/District Cooling
• Fuel Cells
• Batteries
• Environmental Assessment Div.
• Decision and Information Sciences Div.
• Global Climate Change Program

Telephone Area Code is (708)

• Fossil Energy Program Dave Schmalzer, Manager, 252-7723, or 202-488-2415 in Wash DC
Manages programs funded by DOE Fossil, including fuel cells. Also $$ from other sources.
Advanced Environmental Control Technology (under PETC). Increasing attention to air toxics, bag houses may be workable if adsorbents can be found. Coal Fired MHD a semi success technically, has been phased out by DOE. Direct Coal Turbine–ANL advisory to METC. Two approaches: UTC doing direct combustion of pulverized coal, and Foster Wheeler’s is mild pyrolysis, with char to be burned on water cooled walls (divides the coal into 2 parts).
Research on multi-phase flow — coal slurries. Also ion-exchange to put catalyst metals into the coal prior to liquefaction.

“Argonox” additives to reduce NOx — Pilot test at CG&E — Dave Livingood, 252-3737
Alkali control for PFBC — newly hot topic — Sheldon Lee, 252-4395
CO2 capture, utilization and disposal for IGCC — Richard Doctor (ESD)

• Advanced Cogeneration Roger Cole, 252-6245
O2 enriched air for diesels; H2O emulsified in fuel; low grade fuels
— research stage results –incr. power, reduce particulates, but incr. NOx
–Dupont looking at membranes to produce O2

HPSS (High performance steam system) hi pressure hi temp steam bottoming cycle for GT — DOE and Solar Turbine: Overall electric efficiency 55%, with flexible electricity/heat ratio — looking for industrial cogen demo site. OPPORTUNITY (may be too late)
Also can use it for stand-alone once-thru boiler–unique turbine, thick wall tubes in hi-temp section prevents H2 corrosion.

Tool/method to estimate “value” of steam from Cogen –> better pricing

• Plasma Chemistry John Harkness, 252-7636
Waste Treatment for H2S — big electric load– Based on Russian work — ANL has a proprietary position. Needs demo. Individual reactors 1-2 MW (EPRI/Houston & Ami Amarnath are aware of the project).
Destec gasifier repowering produces H2S — Microwave technology could recover chemical/fuel value of H2 (no current H2S treatment process can do this).

Other applications for plasmas and microwaves: degrading plastics for recycling, novel materials, hazardous waste disposal. (Research Cottrell/PETC project tried radio waves on stack gas, and got more NOx.)

• Waste Mgt & Bioengineering Jim Frank, 252-7693
Keen to solve problems! New aggressive group looking for business. Combined multidisciplinary group to develop better solutions for waste treatment problems, source reduction, and high-value by-product production. Doing projects for EPRI: Arsenic removal (Mary Maclearn) Corrosion, microbial (Joe Gilman).

Other areas of work include: removing impurities from Al scrap, removing lead from brass and bronze scrap, recovering plastics from auto scrap; recovery of H2S — H2 and S; converting food wastes. Also soil remediation, membrane separations, air toxics treatment, remediation sensor development, environmental biotech.

• Environmental Control Technology Dave Livingood, 252-3737
Test facility for dry scrubbing and spray drying –HANDBOOK — “5 yrs ahead of EPRI’s HSTF”. Combined NOx/SOx control –developed additives, systems for both wet and dry scrubbing at lab and pilot scale.

Dravo-Lime ThioNox (like Argonox but better) — add chemicals to wet scrubber to remove NOx along with SOx — it works! CG&E pilot will clarify economics in 1 yr.

Spray-dryer/fabric filter FGD for high sulfur coal — showed long term reliable operation

Air Toxics –have PETC to work with — how to capture heavy metals such as mercury.
dry sorbents (carbon) in wet scrubbers — waste testing (what’s in the output)
Activated carbon performance extreme variation depending on type/source

Sequestering CO2 from IGCC –system study of costs for METC. Estimate all costs, emissions from mining on. Don’t wait till the stack; modify the plant with a shift reactor to H2, and capture the CO2. Algae approach unrealistic.– paper 11/93 at Dallas PowerGen.Conference.

• Geographic Information Systems and Environmental Capabilities Pat Wilkey, 252-6258
Innovative Spatial Analysis system, began work 5 years ago for GRI on pipeline right-of-ways. Provides visualization of various “false terrains” e.g. when cost or other impact factors replace elevation as the z-variable. Allows routes to be optimized against different scenarios and tradeoffs. Graphic imaging to model the visual impact of projects (e.g. a transmission tower) against the “view-shed”. GIS can be a logical extension of CAD-AM/FM systems, as an integrated system.

Argonne also has extensive multi-disciplinary capabilities for analysis and field work in site rehabilitation and restoration.

• MSW/Biomass Processing Ole Ohlsson, 252-5593
Fuel pellets from MSW to cofire with coal–handles like coal — OK in cyclone or grate, not PC.
In ’87, tested 100’s of binders–lime works the best. NSP (NRG Energy is unreg subsid) is building a facility–EPRI involved. CRADA with Otter Tail, — Archer Midland Daniels, Decatur, wants to cofire in their FBCs.

• Advance Heat Exchangers Tom Rabas, 252-8995
“Enhanced Tubes” for condensers — actively seeking new users — TVA (only utility so far) doing it in 18 units, starting 14 years ago — see Power Engineering July ’93 page 36. ANL has software to predict heat rate improvements. Heat transfer enhanced x1.7. NIPSCo has a program, Alabama Power did some tests a while back; NYPA and PP&L are interested.

Need host utilities to test tubes. ANL would facilitate and provide specs, measurements and test program OPPORTUNITY

– Proposed a plate/fin type heat exchanger for H2 – cooling in generators –could reduce costs of new units — Westinghouse contact. CRADA proposal not selected. (copy on hand).

– With PG&E, proposed a study of potential to improve cooling of transmission transformers to increase system capacity. CRADA proposal not selected. (copy on hand).

(Note: this program is funded by DOE Industrial, not power program — these ideas tend to fall in between.)

• Technology Evaluation Alan Wolsky, Director, Industrial Partnership Program, Energy Systems Div. 252-3783
Capabilities available to utilities: (Crada or hire ANL)
– Modeling combustion–esp. FBC, erosion, gas-solid flows.
– Studies on CO2 capture/use.
– Recover SO2 as salable liquid (proprietary-ANL is under nondisclosure to an outside co.)
– SMES Demo/test–ANL has an idle magnet — 180 MW sec– could do Power quality tests.
– Superconductivity–available to consult; internal study on future applications
– Scrap Metals recycling — Tom Sparrow at Purdue has studied this with utilities
– Coal Ash — general area of interest, e.g. metals recovery, other..

• Energy Technology Division Capabilities Roger Poeppel, Director, 252-5118
Ken Natesan, 252-5103

– Component Failure Analysis — standing agreement to do tests for Commonwealth Ed.
– Corrosion — alloys, coatings. Particular focus on combustion and power plants via DOE Combustion 2000 program funding — sulfur-bearing gases effects, erosion prevention, etc. In ’70s, developed refractories for coal gasification–resistance to corrosion and thermal shock–led into ability to do HTSC materials.
– All kinds of NDE
– Thermal Hydraulics and Fluid Mechanics — two phase flow, heat/mass transfer, flow-induced vibration ( issue for steam generators).
– Tribology — measure friction and wear; surface coating apparatus/techniques, lubricants

• Measurement and NDE Paul Raptis, 252-5930 & Stephen Dieckman, 252-5628
Acoustic leak detection (for Con Ed) Put microphones in the system — Identifying noise signatures for Steam Leaks. Some big wins finding leaks. NSP involved in testing. (Valves, boilers–straightforward, EPRI doing it.) Can apply to any steam system, not just distribution systems. Working on ASME guidelines. Next area for study is water leaks. Applicable in power plants!
Non-intrusive viscometer–good at high viscosity have working prototype — several manufacturers. interested.
Surface Wave Chemical Detector–exists commercially, but needs applications development, e.g. for stack gases.
Mass Spectrometer fits in a briefcase, measures to ppb; more sensitive than current CEM methods.
MM wave sensor chemical spectroscopy- recently declassified arms control spin-off. Can look at large spaces, e.g. plumes–wide angle, and as good as Lidar.
Measurement, generally — flow, density, concentration, on line NMR (chemistry), NDE via optics, acoustics neutrons, microwaves. Effluent detection. Stress analysis.

• Superconductivity John Hull, 252-8580, and Ken Uherka, 252-7814
High Temperature SuperConductors (HTSC) — 3 distinct areas of work: (all projects are with outside companies!)
1. Basic theory — physics and chemistry
2. Materials fabrication — wire and tape for devices (with mfgs.) largest Federal program center for measuring samples. Use high flux neutrons to look deep in metals; look for O2. Adding particulate Silver to increase fracture resistance. Alloy, draw, roll and heat treat–need grains aligned. Wire development getting close to practical for devices.
3. Applications (notably in the electric utility industry)
– Intermediate link for existing Low temp (liquid He) SC applications, as current leads to the outside, to get lower cooling and insulation needs — for SMES w/ Superconductivity Inc’s 1 MW-1 sec. UPS. Also for B&W 1/2 MW-hr (@ sev. MW for 5-10 min) SMES for Anchorage Electric (TRP/DOE funding).
– Fault current limiter–limits by going from superconducting to normal, limiting rather than interrupting–allows higher transmission line loading. Issues whether to interrupt all 3 phases, and question whether application limited to large concentrated loads.
– Levitation — very different materials requirement–don’t need to align grains! For very low friction bearings, flywheel energy storage program for large diurnal storage systems (with Comm Ed).
(DOE solicited teams 1 year ago for Superconducting Partnership Initiative to develop applications. ANL proposal with Allied Signal unsuccessful–had found sev. utilities willing to invest–Comm Ed, Southern, C&SW, NiMo…)

• Ice Slurry/District Cooling Ken Kasza, 252-9260 (additional info on hand)
Advanced energy transmission fluids–study for DOE — phase change and particulates in water
Additives to reduce friction in flow — very effective

Pelletized ice can be pumped with water in existing chilled water systems or new systems–greater heat transfer capacity & reduced pumping load, and customer storage volume is reduced by factor of 10. Small scale field demo being built with EPRI and NSP–NRG (unreg) subsid has proprietary position–sees business oppty in engineering consulting, licensing and TOU rates.

Handbook done–design for slurries. Have plan to develop Engineering Design Database (whoever does this will control the technology).

Large scale demo will be at ANL–800 ton ice maker–looking for utility participation–need funding for detailed engineering, testing, analysis, etc. Proprietary rights available.

Window of Opportunity –Equipment makers/users will have to phase out CFCs! Utilities can offer central cooling–sell ice , do peak shaving on customer site. Unreg business to sell engineering, equipment, service.

• Friction & Wear Technology George Fenske 252-5190
Surface Modification and characterization, and friction and wear assessment

Protective Surface Modification for High Temp. Alloys — dramatic increase in corrosion resistance of protective scale, by vapor deposition of silicon and high temperature heat treatment–feasible for treating large areas. (Jong Hee Park 252-5104)

Boric-Oxide/Acid coatings-dramatically effective high temperature bearing lubricant (R&D 100)
Diamond-like carbon on steel or ceramics — reduce friction and wear in bearings, fuel injectors, etc.

• Fuel Cells Mike Myles, Director, Electrochemical Technology Program, 252-4329
Michael Krumpelt, Manager, Fuel Cell Technology, 252-8520
ANL does in-house research and is lead lab for DOE Fuel Cell Program and manages the fuel cell effort. Solid Oxide(SO) and Molten Carbonate( MC) for stationary power applic. As phosphoric acid (PA) is considered to be a commercial reality, the only work at ANL is some management activity.

Also Polymer Electrolyte and DOE Bus Program for Transportation. Ballard Technology and Dow aggressive on PEM — big R&D effort with Mercedes Benz and others. Ballard is sub to GM-Allison for DOE passenger car. (IFC pursuing with GE lic., as is Seimens) On-board methanol –>H2

Argonne does Systems Analysis for DOE and EPRI, and work on CO tolerant catalysts and partial oxidation reforming.

MC — gets most of the R&D funding. Some in-house, some to MC Power for electrode development–goal is longer life cathode–trying double doped materials and conductive ceramics. DOE program goals are to double the power density to over 3000 amps/m2 to reduce the plant footprint, to simplify the design and to reduce corrosion. 10 years ago, MC was thought to be the next generation of fuel cell. Not working out easily. Demos in 2-300kw to 2 MW. R&D to increase power density and new stack configuration for cheaper mfg.

SO — Westinghouse is the prime developer. 25-40KW system demos. Alternative for Distributed Generation. More entries internationally. In U.S., B&W with a major chem co. Also, Allied Signal is prime to ANL for work on “Monolithic SO”. Need to control shrinkage, flatness, match coeffic. of thermal expansion–going to thin layers.

ANL has some funding from SCE — opportunities in SO. EPRI forming consortium for new concept “Planar SO” (Rocky Goldstein and John O’Sullivan)

Suggest that in the long run MC may drop back and end up like phosphoric acid (basically leapfrogged) — remains to be seen! World competition is picking up, and U.S. losing lead. The Westinghouse SO technology is expensive. Utilities unwilling to pay higher initial cost of early systems, and private sector can’t do it by themselves (DOE study by Prof. Penner –why commercialization hasn’t happened). Need utilities to work with mg and govt. to commercialize existing systems and support new concepts — 3-way teams.

PEM, primarily being developed for transportation use, could reach low cost mass production first–despite disadvantages for stationary use. Dow is committed to be supplier of membranes –ANL to do concept design for stationary applications. OPPORTUNITY for a 3-way partnership–other utilities avoiding, due to belief that PEM not appropriate for stationary.

NREL/DOE solicitation on infrastructure for H2–utilities to have role in demos.

• Batteries Gary Henriksen, 252-4176
Most action is in transportation. Hybrids getting attention. High power requirement is a problem.
ANL has proposed a bipolar Li Sulfide battery–has small funding from USABC.
ANL has major battery test facility, able to handle anything from cells to systems. All work is tied to manufacturers, one way or another. ANL did ABC tests — results to be announced very soon.

• Environmental Assessment Div. Tony Dvorak, Director, Contact: Dale Pflug, 252-6682
Environmental Impact, Decision support software, Risk Management — lots of work for others

New program Technology Connection: Identify needs for restoration at DOE sites, and identify/inventory available technologies in DOE that can be used–verify claims. Also search for technology domestic and foreign–now monitoring over 800 items in Database.

Expedited Site Characterization — Shrink time and cost by 90% — first done for Dept. of Agric, now being implemented across DOE–accepted by EPA and state regulators. Looking of users, collaborators and trainees. Smart sampling schemes, based on other information.

“ConSolve-site planner” visualization tool
“Plume” licensable code, could add transport and ground water modeling
Chemical Risk Code based on radiation risk code
Geographic Information Systems: graphical interpretation for environ impact, planning.

• Decision and Information Sciences Div. Paula Scalingi, Director
Contact: Dave South, Technology and Environmental Policy, 252-6107

– Compliance with Environmental Mandates (e.g. CAA, CWA,CERCLA/RCRA, greenhouse gases, etc.) — Analysis of regulations, synergies and conflicts, trade-off analysis/ decision framework at the plant level of compliance strategies, vis a vis other business goals, rate regulation etc. A dynamic and complicated process. Models developed allow rapid assessment of scenarios, based on actual plant data.

– Incentive regulation–adoption of innovative technologies–detailed analyses.
– Integrated Resource Planning
– Technology Assessment (e.g. CFC replacement — utilities need to inventory commercial a/c installed base and plan a response.)
– AI applied to reliability/value based maintenance. Did earlier (non-AI) work on boiler aging/vintaging.

– R&D Portfolio Management–long standing program for Defense Nuclear Agency, and other applications (e.g. Wisc PUC!) –software and information gathering techniques. A rigorous approach using multi-attribute utility function decision techniques, for optimizing portfolio and prioritizing projects, against measurable objectives, as the situation changes.

• Global Climate Program Ruth Reck, Director (Contact David South)
Climate Processes, Societal and Environmental Impacts, Response Strategies and Assessment, and Data Management. Policy and Regulatory analysis; interactions between climate change and other environmental issues (domestic and international); voluntary/joint implementation. Publish an extensive quarterly report called “Global Change Scaler”.

ANL Contacts (general phone # is 708-252-2000)

The primary contacts for UFTO are:

Thomas J. Marciniak, Manager Industrial and Utility Technology, Energy Systems Division,
252-5860

David W. South, Technology and Environmental Policy Program, Decision and Information Sciences Division, 252-6107

Roger Poeppel, Director, Energy Technology Division, 252-511. Also Chuck Malefyt, 252-5125

Technology Transfer:

The Industrial Technology Development Center (ITDC) (formerly called the Technology Transfer Center) — Don Mingesz is the acting director; Primary contact is Shari Zussman (252-5230) — is administratively located in EEST, but serves the entire lab. It handles interactions with industry and DOE on all tech transfer matters. The ITDC has a Hotline 800#: 1-800-627-2596.

ITDC publishes a newsletter called Tech Transfer Highlights. Call the above hotline # to be put on the mailing list

There was recently a new program put in place to have each Division appoint a tech transfer point of contact. Most of these people, however, already have demanding full time jobs, some as heads of sizable research groups. Their role and way of working is just beginning to evolve.

Information Source Contacts / Technical Information Services:

Office of Public Affairs : 708-252-5575 — can provide general information, annual reports, etc.
They publish a biannual “Research Highlights” and a technical magazine called “logos”.