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Technology Transfer Opportunities – Oak Ridge National Laboratory

UFTO

PROPRIETARY

Final Report

Technology Transfer Opportunities in the Federal Laboratories

Oak Ridge National Laboratory

Oak Ridge, Tennessee

June 1998

Prepared for:

Utility Federal Technology Opportunities (UFTO)

By:

Edward Beardsworth

Consultant

Contents:
Summary
Overview & Organization
Technologies & Programs

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

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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.

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Summary

This report details findings about technology and technology transfer opportunities at the Oak Ridge National Laboratory that might be of strategic interest to electric utilities. It is a major update and revision materials developed previously, and is based on a visit to the lab in April 1998, and also draws from various publications, collateral information and website content.

Acknowledgments:

A special note of thanks to Marilyn Brown for arranging the agenda and her gracious and tireless support, and to all the ORNL staff who gave generously of their time and attention.

Also to Mr. Scott Penfield of Technology Insights, who accompanied the visits (as a representative of one of the UFTO utilities) and kindly provided his written account of the meetings for use in the preparation this report.

ORNL — Overview & Organization

Oak Ridge National Laboratory (ORNL) is a “GOCO” lab (government-owned, contractor operated). Lockheed Martin Energy Research Corp. is the contractor that manages ORNL. (Lockheed Martin also manages the Y-12 Plant in Oak Ridge, Idaho National Engineering Lab and Sandia National Lab.)

ORNL has a matrix organizational structure, where “divisions” aligned primarily by discipline have the people, and “programs” have the projects and budgets. On some occasions, divisions do get funds and projects of their own. ORNL finds that matrix management can work well if there is a balance of power and the right incentives.

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

ORNL’s four research ALD’s are:

=> Energy and Engineering Sciences — Gil Gilliland 423-574-9920

(Div: Engineering Technology, Fusion., Instrum & Control)

(Prog: Energy Effic/Renew Energy, Energy Technology, Fossil Energy, Nuc Technol)

=> Life Sciences and Environmental Technologies

(Div: Chemical Technol, Energy, Environmental Sci, Life Sciences)

=> Adv. Materials, Physical and Neutron Sciences

(Div: Metals & Ceramics, Physics, Solid State, Chemical/Analytical Sci . . .)

=> Computing, Robotics, and Education

(Div: Computer Science and Mathematics, Robotics and Process Systems…)

There is work in all four ALDs of potential interest to utilities. The point of contact for this study was established through the Energy Efficiency and Renewable Energy Program, which oversees activities involving 11 different research divisions. Contact was also made with the Fossil Energy Program, with a similarly broad scope. Divisions encountered include Engineering Technology, Instrumentation & Control, Metals & Ceramics, and others.

Staffing level is now at approximately 5000, of which 1500 are scientists, of which about 1/2 are PhDs. ORNL’s 1997 budget was about $550 million. Of this amount, the largest program areas were Energy Research (28%), Environmental Management (25%) and Energy Efficiency (16%). Nuclear programs, which were once the principal focus of the Laboratory, are identified at a level of 4% in the overall budget; however, when supporting research topics (e.g., High Flux Isotope Reactor (HFIR), materials, NRC Programs, etc.) are included, some $100 million can still be identified as nuclear related.

A major new initiative at ORNL is the Spallation Neutron Source facility. The 1999 budget year will constitute a major test for this project, as it will include a construction line item for the first time. If approved, construction is expected to take 6-7 years. A new ORNL directorate has been established to oversee the Spallation Neutron Source project.

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Key Contacts:

Website: http://www.ornl.gov

Primary UFTO contact:

Energy Efficiency and Renewable Energy Program:

A.C.(Tony) Schaffhauser, Director, 423-574-4826, schaffhausac@ornl.gov

Marilyn Brown, Deputy Director, 423-576-8152, brownma@ornl.gov

Working with ORNL:

Technology Transfer: (Licensing and CRADAs)

Dean Waters, Acting Director, Office of Technology Transfer,

423-576-8368, watersda@ornl.gov

Sylvester Scott, Director, Licensing, 423-576-9673, scotts@ornl.gov

Partnerships: (CRADAs, User Program, Personnel Exchanges, Guest Research Assignments)

Louise B. Dunlap, Director, Office of Science and Technology Partnerships,

423-576-4221, dunlaplb@ornl.gov

Public Relations: Joe Culver, Director, Public Affairs,

423-576-0235, culverjw@ornl.gov

Partnership Mechanisms

ORNL makes use of an increasingly broad array of contracting mechanisms, including CRADAs, Work for others, User Facility Agreements, etc. Greater use of simpler standard formats makes the process much quicker than in the past.

They are seeing an increasing number of “100% funds-in CRADAs” (i.e. no cost sharing by the lab) from industry, as a cheaper alternative to work-for-others with essentially equivalent intellectual property rights. The Lab also will have as many as 4000 guest assignments per year, 1/4 of which are from industry, where visitors use the facilities or work with staff on CRADAs, etc.

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Energy Efficiency and Renewable Energy Program

Tony Schaffhauser, Director 423-574-4826 schaffhausac@ornl.gov

Marilyn Brown, Deputy Director 423-576-8152 brownma@ornl.gov

The EE/RE Program is a matrix organization that draws on several line divisions at ORNL for the majority of its personnel and technical facility resources, to set up multi disciplinary teams. DOE is the sponsor for most of the work, but they see industry and the public as the real customer.

ORNL budget expenditures controlled through the EE/RE Program office amount to some $80 million. The ORNL Energy Efficiency/Renewable Energy (EE/RE) budget was lower in 1996, but the level now appears to be stable.

Major Research and Development Areas

=> Transportation systems, including advanced automotive technologies, advanced materials, utilization of alternative fuels including biofuels, and transportation data.

=> Efficient building systems and for state and community programs, including heating, cooling, and refrigerating equipment; roofs, walls, and foundations; insulating materials; technology transfer; and retrofit of existing residential and commercial structures.

=> Industrial processes, such as bioprocessing, electric motor systems, advanced turbine systems, advanced materials, industrial heat pumps, and evaluations of energy-related inventions.

=> Utilities, including high-temperature superconductors (for transformers and transmission cables), power transmission and distribution systems, electric and magnetic field effects, biomass for power generation, and international programs (including IEA and APEC programs).

Technologies & Programs

Superconducting Technology Program for Electric Energy Systems

Fossil Energy Technologies

Real-Time Corrosion Monitoring

Hot Gas Filters

Materials R&D

Furnace Wall Corrosion with retrofit low-NOx burners

Effects of Coal impurities on fireside corrosion

Improved Stainless Steels

“Perfect Microstructures”

Nickel-Aluminide Alloys

Sulfidation Resistant Alloys

Building Technology Center

Frostless Heat Pump

High Efficiency Refrigerator (1 kwh/day)

Power Systems Technology Program

Energy Conservation Standards for Distribution Transformers

Flywheels and Energy Storage Technologies

Utility Restructuring and Electric Power Ancillary Services

Grid Reliability-Control Center Survey

Electric and Magnetic Fields Bioeffects

Research and Public Information Dissemination (RAPID) Program

Advanced Turbine Systems

Bioenergy Program

Motor, Steam, and Compressed Air Challenge Programs

Oak Ridge Centers for Manufacturing Technology (ORCMT)

Electric Machinery Center

Power Electronics Technology Center and Inverter Technology

Instrumentation & Controls

Machine Condition Monitoring and Diagnostics

Electrical Signature Analysis (ESA) for Utility Applications

Nonlinear data analysis–Component Failure Prediction

NRC/INPO plant database

Photonics and Hybrid Lighting

Superconducting Technology Program for Electric Energy Systems

Bob Hawsey 423-574-8057 hawseyra@ornl.gov

Web sites: http://www.ornl.gov/HTSC/htsc.html

http://www.eren.doe.gov/superconductivity/

(See special report and series of articles on “Superconductivity in Electric Power,”

pp 18-49, IEEE Spectrum, July 1997)

The discovery of high-temperature (i.e., above the boiling temperature of liquid nitrogen) superconductor materials dates to 1986. Since that time, the challenge has been to develop these brittle, ceramic-based materials into a form that can be produced and practically used. DOE research in this area has taken a major step increase, from $19 million in 1997 to $32 million in 1998. (By comparison, Japan is investing $100 million/year in superconductor research.)

DOE HTS Program

Contacts:

Jim Daley, Team Leader, 202-586-1165, james.daley@ee.doe.gov

or Joe Mulholland, Utility Liaison

202-586-1491, joseph.mullholland@hq.doe.gov

The DOE HTS program supports a balanced technology development effort. Wire and device technologies are developed through a large number of collaborative projects between U.S. national laboratories and industry, and systems technologies are supported through the SPI and other vertically integrated project teams.

DOE’s Superconducting Partnership Initiative (SPI) is a systems technology program designed to accelerate the development of HTS electric power systems. Begun in the fall of 1993, the SPI encourages the formation of vertically integrated teams comprised of partners who usually do not interact in the development cycle, involving close collaboration among system integrators, wire and device manufacturers, end-users (typically electric utilities)

Major projects include

– 5,000 hp high-temperature superconducting (HTS) motor

– 100 MVA HTS generator,

– 115 kV and 12.5 kV HTS transmission cable (2 projects)

– 5/10 MVA HTS transformers (2 projects)

– 15 kV HTS fault current limiter (2.4 kV successfully tested in 9/95 at a utility host site)

Fault Current Limiter

Later this year, pre-commercial (alpha) prototype will be tested by So Cal Edison and Lockheed Martin. Rating is 15-kV, normal 2 kA, intercepts/reduces by 80% a 20-kA peak symmetric or 45 kA peak assymmetric fault. Also functions as a 1/2 cycle circuit breaker. If demo successful, Edison will install it at a substation, and anticipates $1million in savings from avoiding need for a second bus. Next stage will be beta units.

Contact: Eddie Leung, Lockheed Martin program manager

619-874-7945, ext. 4636, eddie.leung@lmco.com

ORNL is participating in two of these partnerships.

Transformers — There is a strong need for medium power transformers (10-150 MVA) that are smaller, more efficient and free of fire hazard, to meet the growth in urban power density. These transformers will go inside building and in multistory substations, and provide higher ratings from existing substations.

— Waukesha Electric Systems (WES), Waukesha, WI

For the Waukesha program, ORNL is responsible for the engineering, design and science of the cooling system, while Intermagnetic General is producing the HTSC coil. WES did the core, instrumentation tank, pumps and test rig. An initial 1 MVA prototype has been constructed and entered testing at WES in February 1998. Initial results are good–the first operational US HTSC transformer easily sustains 2X overloads. Rochester Gas & Electric (RG&E) and Rensselaer Polytechnic Institute (RPI) participated in this initial demonstration.

The next step will be a 5 MVA system, which will provide power to the WES plant beginning in 1999. A larger utility advisory group is participating in this second step (includes several UFTO members). The initial commercial target is a transformer in the range of 10-30 MVA.

Contact: Pat Sullivan, VP Marketing, Waukesha, 414-547-0121, x 1531.

There is a separate transformer development effort that involves ABB, EdF, Los Alamos National Lab (LANL) and American Superconductor.

Cable — HTSC Cables hold the promise of far greater capacity– 5X the power in the same 8″ diameter pipe of conventional buried cable, and without the losses, heat, oil and range limitations.

— Southwire,Carrolton, GA

The Southwire HTSC cable project is expected to culminate in an initial demonstration at Southwire in 1999. The planned 100 ft, 3-phase, 12.4 kV, 1250 Amp cable will provide power (30 MVA) to Southwire facilities. Southern Co, Georgia Transmission Co, and So Cal Edison are partners. DOE is providing half of the $14 million. Southwire has built a 200 ft clean room manufacturing facility, and recently delivered a 5 meter test cable to ORNL for testing.

Pirelli and Los Alamos are pursuing a parallel HTSC cable initiative, with participation by Detroit Edison. The initial objective is a 25 kV line.

Other HTSC development initiatives mentioned include motors/generators (including flywheel motors/generators under development at Boeing) and kaolin magnetic separation equipment being developed by Dupont for the paper industry.

NOTE- More uility participation is needed–to provide advice, and as partners, cofunders and beta test hosts. Any kind of innovative proposal is more than welcome.

RABiTS (TM) Process for Coated High-Temperature Superconductors

http://www.ornl.gov/~vhk/rabits.html

Oak Ridge researchers have produced a roll-textured, buffered metal, superconducting tape with a critical current density of 300,000 amperes per square centimeter in liquid nitrogen, which may pave the way for the future manufacture of practical yttrium- or thallium-based conductors for electric power applications.

To produce a superconducting wire sample, the ORNL researchers first developed a process called rolling-assisted biaxial textured substrates, or RABiTS(TM), which enables the superconducting materials to have a high degree of grain alignment in all directions, a necessary condition for more efficient current flow through the superconductor.

MicroCoating Technologies (MCT) in Atlanta and ORNL announced on April 16 that MCT has licensed key patents. “MCT scientists within a six-month period have successfully deposited both HTS coatings and oxide “buffer layers” on several single crystal oxide substrates. MCT also successfully deposited buffer layer on textured nickel. The epitaxy of some buffer layers is as good or better than with any other deposition technique to date. In addition, MCT’s open atmosphere process can meet or exceed industry-wide cost targets to enable commercial-scale production of superconductor technology.”

Other licensees include Midwest Superconductivity and Oxford Superconducting Technology, with two more pending.

Fossil Energy Technologies

Rod Judkins 423-574-4572 judkinsrr@ornl.gov

ORNL described some additional advancements in materials and technology for fossil and related applications that were not addressed in the ORNL survey of utilities (developed by Technology Insights and sent to UFTO members in mid 1997). Some examples are:

Real-Time Corrosion Monitoring: A flash of laser light is impinged on a fossil boiler wall. By observing the infrared response of the area, corrosion related effects, such as thinning, debonding and delamination can be inferred.

Hot Gas Filters: In partnership with manufacturers, ORNL has developed two distinct classes of hot gas clean up filters.

– A ceramic composite (SiC-based) filter developed with 3-M is primarily targeted to fluidized bed combustion applications. The filter has been tested in AEP’s Tidd Plant and a Studvik incinerator in S. Carolina. It is available through 3-M. Contact Ed Fisher, 612-736-1005

– A lower temperature (700 – 1000 deg C) iron-aluminide filter, with high resistance to sulfidation, has been developed in partnership with Pall Corp. (Portland NY) and is nearing commercial introduction. An alternative to ceramics, it can be made with standard manufacturing equipment. Tests at the University of Cinncinnati show excellent corrosion resistance. Coal gasification is the target application.

Materials R&D

Ron Bradley 423-574-6095 bradleyra@ornl.gov

Ian Wright, 423-574-4451 wrightig@ornl.gov

Furnace Wall Corrosion with retrofit low-NOx burners — root cause is flame licking walls, so that control of flame characteristics using sensor-feedback arrangements should be the best solution. Hence, there is a need to develop sensors to monitor flame condition as input to control mechanism. ORNL has approaches for this, using chaos theory to analyse the flame signatures, for instance (Stuart Daw, David Schoenwald). There will also be a continuing practical need for diagnostics, coatings, repair techniques, etc., since not all boilers will be amenable to combustion control, and the use of multiple and varying coal sources will lead to continuing corrosion problems in some parts of the furnace wall. Sulfidation-resistant ferritic alloys (ORNL’s iron aluminides) promising as overlay/cladding, but difficult to apply reproducibly. Development program with Lehigh Univ-utility boiler consortium (Prof. Arnie Marder) is showing good promise.

Effects of Coal impurities on fireside corrosion — Chlorine limits based on fundamental misunderstanding–only a problem when other combustion problems (flame impingement) present. Developing in situ probes to measure short-term corrosion.

DOE 11 Lab Study on technology, greenhouse gases

At long last, DOE’s “11 Lab” study has been released.
The DOE press release is attached below.

The report is on the web (pdf acrobat format) at
http://www.ornl.gov/climate_change

Oak Ridge will have hardcopies available shortly.
Contact Brenda Campbell, 423-574-4333, xbd@ornl.com

Here’s a part of an UFTO Note (11/97).
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The work began in June 96 following Clinton’s speech to the U.N. Each of the 11 labs that worked on the study took the lead on a specific technology area, such as efficiency in buildings, efficiency in transportation, fossil power generation, nuclear, renewables, cross-cutting areas, basic research, and carbon sequestration. It was a bottom-up effort, looking in depth at the technology itself. There was no analytical modelling of the overall energy system or economy.

NREL and ORNL were the lead labs for the effort, with direction and involvement at the lab director level.

The report concludes that science and technology can do a lot, but that appropriate policies and funding are needed for commercialization. Appendices detail 50 separate technology categories, with order-of-magnitude range estimates of carbon emission reductions to the year 2030 and beyond. ————

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| ** UFTO ** Edward Beardsworth ** Consultant
| 951 Lincoln Ave. tel 650-328-5670
| Palo Alto CA 94301-3041 fax 650-328-5675
| http://www.ufto.com edbeards@ufto.com
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FOR IMMEDIATE RELEASE April 22, 1998

WIDE RANGE OF TECHNOLOGIES COULD REDUCE GREENHOUSE-GAS EMISSIONS, STUDY FINDS

National Laboratories Highlight Pathways to Cleaner Environment

The United States has many options for reducing greenhouse gas emissions through new, cleaner energy technologies, the directors of 11 of the Department of Energy’s national laboratories conclude in a study released today. The directors recommend aggressively developing a wide range of technologies over the next several decades.

The directors’ report, Technology Opportunities to Reduce U.S. Greenhouse Gas Emissions, outlines almost 50 technology pathways that could eliminate the emissions of hundreds of millions of tons of carbon per year. They include such near-term practical technologies as electric hybrid vehicles, high-efficiency lighting, super-insulating windows, and passive solar heating and cooling of buildings. They also include mid-term to longer term technologies that need further development, such as fuel cells for transportation, microturbines, broad use of biomass fuels and hydrogen-fueled energy systems.

“Technologies already being developed by industry and by national laboratories are key to meeting President Clinton’s challenge to reduce greenhouse gases while contributing to economic growth,” said Secretary of Energy Federico Pe–a. “This report lays out what we need to do to bring our nation’s best scientific and engineering talent to bear on solving this problem. With the support of American consumers and businesses, we can have a major impact on the kind of world we leave for future generations.”

The 11 laboratory directors recommend that the federal government lead a vigorous national push to develop energy technologies during the next three decades to achieve a major reduction in the risk of global warming. While the study does not recommend specific funding levels for technology research, development and deployment, it estimates some increases will be needed to push critical technologies to the commercialization stage. A report issued last year by the President’s Committee of Advisors on Science and Technology reached a similar conclusion about the need for increased investment in energy research and development. Also, government-industry partnerships are essential, the laboratory study says, to overcome scientific, technical and commercial challenges to developing the recommended technologies.

The United States emits 23 percent of the world’s carbon dioxide and other greenhouse gases. Some 90 percent of those emissions come from energy use, and about 85 percent of the carbon dioxide released into the atmosphere comes from burning fossil fuels. The study examines technologies that can reduce emissions in three ways — by using energy more efficiently, reducing the amount of carbon released through energy use and increasing the amount of carbon dioxide absorbed from the atmosphere.

Technologies to reduce greenhouse gas emissions will become available at different times over the next 30 years, according to the study. In the first decade, significant advances in energy efficiency technologies — such as in appliances, heating and cooling systems, and transportation — would produce the greatest reductions in emissions. During the following 10 years, research-based advances in clean energy technologies could greatly reduce greenhouse gas emissions. These could include high-efficiency natural gas systems, renewable energy such as solar and wind, and fuel cells. And by 2030, research in carbon sequestration — carbon storage, carbon absorption and carbon removal by oceans, forests and soils — could produce valuable results.

The study stresses the importance of pursuing a number of technologies at each stage to provide choices and flexibility for energy users. The 47 options the lab directors recommend cover almost all sectors of the economy, including buildings, industry, transportation and agriculture.

Admiral Richard Truly, director of the National Renewable Energy Laboratory, and Dr. Alvin Trivelpiece, director of the Oak Ridge National Laboratory, co-chaired the technology study. The participating labs were Argonne National Laboratory, Brookhaven National Laboratory, E.O. Lawrence Berkeley National Laboratory, Federal Energy Technology Center, Idaho National Engineering and Environmental Laboratory, Los Alamos National Laboratory, Lawrence Livermore National Laboratory, National Renewable Energy Laboratory, Oak Ridge National Laboratory, Pacific Northwest National Laboratory and Sandia National Laboratories.

NOTE: The study, Technology Opportunities to Reduce U.S. Greenhouse Gas Emissions, is on the World Wide Web at: http://www.ornl.gov/climate_change The files are in PDF format and can be read in Acrobat Reader.
-DOE-

R-98-051

Second DOE study on Greenhouse Gases

DOE is preparing another major study on greenhouse gases for release by the end of Novermber, called “Technology Opportunities to Reduce U.S. Greenhouse Gas Emissions”, also known as the “11-Lab Study”.

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| This is separate from the “5-Lab Study” released in September
| (see UFTO Note Sept 10)
| “Scenarios of U. S. Carbon Reductions Potential Impacts of Energy-
| Efficient and Low-Carbon Technologies by 2010 and Beyond”
| Full text available in pdf Acrobat at
| http://www.ornl.gov/ORNL/Energy_Eff/CON444/
| Copies available on request from Tonia Edwards, 423-241-5961
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The work began in June 96 following Clinton’s speech to the U.N. Each of the 11 labs that worked on the study took the lead on a specific technology area, such as efficiency in buildings, efficiency in transportation, fossil power generation, nuclear, renewables, cross-cutting areas, basic research, and carbon sequestration. It was a bottom-up effort, looking in depth at the technology itself. There was no analytical modelling of the overall energy system or economy.

NREL and ORNL were the lead labs for the effort, with direction and involvement at the lab director level.

The report concludes that science and technology can do a lot, but that appropriate policies and funding are needed for commercialization. Appendices detail 50 separate technology categories, with order-of-magnitude range estimates of carbon emission reductions to the year 2030 and beyond.

Principal contact for the study at DOE is:
Robert San Martin
Office of the Assistant Secretary for Energy Efficiency
202-586-9277 fax 202-586-9260
robert.sanmartin@hq.doe.gov

Request for copies can go to his office, once the report is released.