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Startup Company to Develop Wireless Sensors

The June 1998 UFTO Report on Oak Ridge National Lab has this brief entry in the section on Instrumentation & Controls:

… “Wireless Sensors: Spread-spectrum technology is being used in conjunction with sensors-on-a-chip to eliminate instrumentation-related wiring in a plant. Sensors can be added or moved as needed. There is a potential for coupling with global positioning system (GPS) technology, so that the sensor can report its exact location, in addition to other measured data. ” …

I recall being intrigued with the idea that sensors could be deployed inexpensively, almost on the spur of the moment, and in as many inaccessible places as you wanted, throughout a power plant or substation — to monitor temperature, noise, vibration or any other parameter. It makes a lot of sense.

The group at Oak Ridge has continued work on the concept, but hasn’t been able to move forward on building actual devices, for lack of funding and external partners. A nice presentation can be found at http://www.ornl.gov/orcmt/wireless.
An acrobat presentation of theirs can be downloaded at:
http://www.ornl.gov/orcmt/wireless/measurement&control.pdf

Independently, a new company, Sensitron, was formed here in Silicon Valley. The founders had come up with the same concept, and they’re pursuing it vigorously. Oak Ridge has indicated they’re more than willing to work with them to turn this into a reality.

Their schedule is ambitious: 3 months to breadboard demo, 12 months to field testing of prototype, 18 months to production, 24 months to integrated 2nd generation design.

One of the principals approached me (at our daughters’ Y-Basketball game!) to explore whether UFTO utilities might be interested in working with them (a good example of how UFTO is always on the lookout!).

Here is their summary. Please let me know if you’re interested.
Or you can contact: Blake Putney, 650-960-5948, putneyb@hotmail.com

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Wireless Monitoring Systems to Reduce Utility Maintenance Costs while Increasing Reliability

Recent developments in semiconductor, spread spectrum communications and micro-sensor standards and technology have made it possible to create complete wireless monitoring systems (WMSs) on a single chip the size of a dime. These sensor systems will be capable being cheaply deployed and connected with computer networks. Users will be able quickly deploy these systems to monitor virtually anything anywhere. Our system uses unlicensed communications bands that can be deployed on a site by site basis, without requiring an investment in a wide area cellular communications network. The potential market for these sensors in enormous, from industry, military, hospitals to home applications. The widespread availability of these systems has the potential to impact society in a similar manner as the Internet.

Although the technical feasibility of these systems has been demonstrated, a number of barriers exist for this technology to become a viable business. Existing markets are fragmented, revenue streams from near term applications are insufficient to attract investments from large organizations, and few sensor-oriented companies have the expertise in the technologies necessary to create an integrated product in silicon.

The initial market chosen for the sensors is to monitor conditions of equipment, and locations within electric utilities’ facilities. Deregulation is forcing electric utilities to get the most out of their equipment and staff. Our system will provide a utility the ability to track the health of all their assets remotely and provide the immediate access to information via their computer network. The sensors needed include temperature, vibration, and stress monitors.

This market was chosen because of the simple design requirements for the sensors, high value of these facilities, and the large expense of installing existing instrumentation solutions (up to $1000 per foot of cable). By reducing the cost of connecting a sensor to less than $150 per point, our wireless system will revolutionize maintenance practices at these facilities. The sales potential for WMSs in this market is over $250M at very high margins.

A key aspect of success is to create a complete system that minimizes the needs for components to be developed by third parties. Our system will involve subsystems for the sensor, field deployment and database configuration, and a receiver that collects data and is connected to an Ethernet. For the sensor subsystem, we are creating a modular CMOS chip design including each of the required elements (Micro Electro-Mechanical Systems (MEMS), Controllers, and R-F). The installation of this system will be simple enough to be deployed directly by end-users.

Sensitron is looking to attract utility partners that are interested in deploying wireless sensors to reduce operations and maintenance costs, while enhancing system reliability. Our utility partners will gain early benefits of deploying the system, and have the opportunity for equity participation in our enterprise.

Gridcom Powerline Sensors

A remarkable new type of low cost and easily installed intelligent powerline sensors are nearing commercial readiness. They come in three flavors:

– Medium Voltage Single Phase Overhead (4 – 69 KV)
– Medium Voltage Single Phase Underground
– Low Voltage Single and Multi-phase Underground (e.g., 208 V)

The medium voltage devices simply clamp on the cable, and measure voltage and current without a connection to ground or a phase-to-phase connection. There is no penetration of cable voltage insulation. (It is not applicable to coax or multiple conductor configurations–only single unshielded cables.) The underground units are self-powered by the power line, and the overhead ones use batteries that will last 5 years or more.

They are said to be approximately ten times cheaper to buy and install, and offer far greater capabilities than anything else on the market. Measurement accuracies (I, V, P) are quoted at better than 3%, though the units invariably do much better. It is not a revenue meter, however.

Evaluation units are available now, and the first production units will be ready before the end of the year. Five utilities (including one or two UFTO companies) have been testing overhead sensors.

The sensors measure current and voltage and can be equipped to measure and/or detect a number of additional conditions or quantities including temperature, moisture, specific substances, light, acceleration, and vibration. Underground sensors utilize two-way powerline carrier communications over the existing lines and overhead sensors communicate through two-way low power RF systems.

Each sensor has its own local on-board intelligence to perform data processing and analysis. In typical applications the sensors calculate true rms voltage and current, power factor and harmonic content. Peak rms quantities and fault recognition capabilities can also be employed.

The sensors report by exception, when polled, or at determined times. Since data is processed at the sensors, communications bandwidth requirements are relatively low. Only processed data or observed data related events (like faults, voltage dips, or high current limits) are reported — not extensive strings of raw data.

Typical functions of these sensors (both overhead and underground) include:

– Detection and location of faults
– Measurement of power quality
– Identification of grounding and cable insulation issues
– Detection of non-technical losses
– Detection of unanticipated loads
– Confirmation of recloser, sectionalizer and other switch operations
– Support capacitor switching algorithms
– Monitoring distributed generation

APPLICATIONS

Infrastructure Monitoring
– Distribution Automation
– Operations Support
– Fault Detection, Classification and Location
– Power-line losses
– Power Factor and VAR Monitoring
– Switch Operation Confirmation
– Planning Studies
– Circuit Design

Condition Based Maintenance
– Cable Burnout and Circuit Limiter Detection (low voltage U/G)
– Equipment Health Status (Fuse, Cutout, Transformer, Switch)
– Tree Trimming Effectiveness

Beyond the Meter Services
– Power Quality
– Sub-metering and Beyond-the-Meter Distribution Networks
– Harmonic Analysis

The underground sensors were initially developed for Consolidated Edison’s Secondary Underground Network Distribution Automation System (SUNDAS). The objective was to develop a comprehensive sensing system that would be relatively inexpensive to purchase, install, operate and maintain.

Con Ed has tested experimental versions of the low voltage underground sensors in their Battery Park City and Harlem networks. These tests demonstrated the capabilities of these sensors to monitor powerline conditions and to detect variations in line conditions associated with circuit limiter loss, arcing faults, changes in network protector relay status and unusual changes in power flow patterns. Based on the performance of the experimental sensors, Con Edison will install GridCom sensors throughout the Hunter network with installations beginning this fall.

US Patent No. 5,892,430: Self-powered powerline sensor
The company’s website has a lot of information and pictures:
http://www.gridcom.com

Contact: Rich Wiesman, 781-684-4387 rwiesman@foster-miller.com

Argonne Visit notes

This is a quick highlights memo about the UFTO visit to Argonne, July 15, 16. A full report will be forthcoming early this Fall.

For the first time, a sizable contingent of UFTO member companies was present for the whole visit. I hope this can become our standard practice, with even a bigger attendance. Argonne made excellent presentations for us. We all agreed that it was a good *beginning* of what must become an ongoing dialogue.

If you want a headstart on some of Argonne’s work, here are a few things we heard about that really piqued the group’s interest:
———————————-

— GASMAP
Comprehensive GIS with massive data on gas system. See separate NOTE, or go to this webpage: http://www.dis.anl.gov/disweb/gasmaptt
**User Access is available on request, on a collegial basis.** The limitation is server capacity, so ANL is not in a position to throw it wide open. They are also very open to any companies that want to provide better data on their own gas T&D systems–which can be kept confidential.
Contact Ron Fisher, 630-252-3508, refisher@anl.gov
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— Ice Slurry District Cooling
UFTO reported on this back in 93/94. It is now privately funded, and has advanced considerably. Ice slush dramatically increases the capacity of new or retrofitted central cooling distribution systems.
Contact Ken Kasza, 630-252-5224, ke_kasza@qmgate.anl.gov
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— On-Line Plant Transient Diagnostic
Uses thermal-hydraulic first principles, along with generic equipment data, in a two-level knowledge system. Neural net models of the system can rapidly indicate what’s causing a transient, e.g. water loss, heat added, etc., and identify where in the system the problem lies. The system wouldn’t need to be custom built for each plant, except to incorporate the plant’s schematics. It’s been run in blind tests at a nuclear plant. Next step is to hook it up to a full scale simulator, and then go for NRC approval. A fossil application would be much easier.
Contact Tom Wei, 630-252-4688, tcywei@anl.gov
or Jaques Reifman 630-252-4685, jreifman@anl.gov
———————————-

— Advanced NOx Control with Gas Co-firing
Closed-loop controller adjusts furnace control variables to get optimal distribution of gas injection to yield greatest NOx reduction. Typical systems use gas at 20% of heat input, but this system gets same or better NOx levels with only 7%. Joint effort with ComEd, GRI, and Energy Systems Assoc.
Contact Jaques Reifman 630-252-4685, jreifman@anl.gov
or Tom Wei, 630-252-4688, tcywei@anl.gov
———————————-

— MSET
Sensor monitor and fault detection system knows if the system is misbehaving or the sensor is wrong. Can see slow drift, signal dropout, and noise, giving early indicators of sensor failure, and providing assurance that the process itself is operating normally, thus reducing unneeded shutdowns. It also can monitor the process itself, for wide ranging quality control applications. MSET stands for Multivariate State Estimation Technique. A model learns expected relationships among dozens or hundreds of sensor inputs, and makes predictions for what each sensor should say, and this is compared with the actual sensor signal. Argonne has patented a unique statistical test for residual error (the difference) which replaces the usual setting of fixed limit levels. There are also important innovations in the neural net modeling, which is completely non-parametric.

Applications range from the NASA shuttle engine, to several power plants, to the stock market.
ANL contacts are Ralph Singer, 630-252-4500, singer@ra.anl.gov
Kenny Gross 630-252-6689, gross@ra.anl.gov

A spin off company is doing applications in everything else but electric generation. (Think of the possibilities in T&D!!) They call the product ProSSense. Website is at http//:www.smartsignal.com.
Contact Alan Wilks, Smart Signal Corp, Mt. Prospect IL 847-758-8418, adwilks@smartsignal.com).

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–TOPIC CAPABILITY SHEETS
Here is the text of ANL’s overview “Topic Capability Sheet”. Many of you got hardcopies of the complete set in the mail. They’re still available from Tom Wolsko (tdwolsko@anl.gov). I’ve also posted them on the UFTO website, until Argonne puts a final verion up on their own website.
———————————-

Argonne National Laboratory:
A Science and Technology Partner for the Energy Industry

Argonne is a multidisciplinary science and technology organization that
offers innovative and cost-effective solutions to the energy industry.

— Introduction
Argonne National Laboratory understands that energy companies must meet growing customer demand by creating, storing, and distributing energy and using the most efficient, cost-effective, environmentally benign technologies available to provide those services. We also understand that they must use increasingly more complex information for decision-making, comply with a multitude of environmental regulations, and adjust to a rapidly evolving marketplace.

Argonne has more than 50 years of experience in solving energy problems and addressing related issues, for both its customers and its own needs. Combining specialities such as materials science, advanced computing, power engineering, and environmental science, Argonne researchers apply cutting-edge science and advanced technologies to create innovative solutions to complex problems.

— Argonne Solutions
Recent applications of that expertise include
– A Spot Market Network model that simulates and evaluates short-term energy transactions.
– A “fuel reformer” that allows fuel cells to use a wide variety of hydrocarbon fuels to make electricity.
– Advisory systems for plant diagnostics and management based on sensors, neural networks, and expert systems.
– MSET, a real-time sensor validation system that provides early warning of sensor malfunction.
– Decontamination and decommissioning techniques developed for Argonne’s own facilities.
– Advanced materials for system components, batteries, ultracapacitors, flywheels, and hazardous waste encapsulation.

— Contacts
Argonne’s Working Group on Utilities:
– Dick Weeks, 630-252-9710, rww@anl.gov
– Tom Wolsko, 630-252-3733, tdwolsko@anl.gov

For technical information, contact the person listed under the category of interest.

Nuclear Technology
David Weber, 630/252-8175, dpweber@anl.gov
– Operations and Maintenance
– Materials
– Reactor Analysis
– Safety
– Spent-Fuel Disposition

Fossil Technology
David Schmalzer, 630/252-7723, schmalzer@anl.gov
– Basic and Applied Research
– Technology Research and Development
– Market, Resource, and Policy Assessments

Transmission and Distribution
John Hull, 630/252-8580, john_hull@qmgate.anl.gov
– System Components
– Energy Storage
– Distributed Generation
– Data Gathering and Analysis
– Biological Effects

Energy Systems and Components Research
Richard Valentin, 630/252-4483, richv@anl.gov
– Component Reliability
– Sensors
– Systems Analysis

Materials Science and Technology
Roger Poeppel, 630/252-5118, rb_poeppel@qmgate.anl.gov
– Materials Characterization
– Modeling and Performance
– Advanced and Environmental Materials
– Materials Properties
– Superconductivity

Fuel Cell Research and Development
Walter Podolski, 630/252-7558, podolski@cmt.anl.gov
– Fuel Processing
– System Design, Modeling, and Analysis
– Testing
– Energy-Use Pattern Analysis

Advanced Concepts in Energy Storage
K. Michael Myles, 630/252-4329, myles@cmt.anl.gov
– Secondary Batteries
– Ultracapacitors and High-Power Energy Storage
– Flywheels
– Superconducting Magnets

Information Technology
Craig Swietlik, 630/252-8912, swietlik@dis.anl.gov
– Computer Security and Protection
– Independent Verification and Validation
– Information Management
– Advanced Computing Technologies

Environmental Science and Technology
Don Johnson, 630/252-3392, don_johnson@qmgate.anl.gov
– Environmental Characterization
– Process Modifications
– Emissions Controls
– Waste Management
– Site Management

Environmental and Economic Analysis
Jerry Gillette, 630/252-7475, jgillette@anl.gov
– Electric System Modeling and Analysis
– Risk Assessment and Management
– Environmental Assessment
– Cost and Economic Analysis
– Legal and Regulatory Analysis

Decontamination and Decommissioning
Tom Yule, 630/252-6740, tjyule@anl.gov
– Operations
– Technology
– Technical Analysis

End-Use Technologies
William Schertz, 630/252-6230, schertzw@anl.gov
– Plasma Processes
– Ultrasonic Processing
– Electrodialysis Separation Processes
– Recycling Technologies
– Aluminum and Magnesium Production

Thermal Energy Utilization Technologies
Kenneth Kasza, 630/252-5224, ke_kasza@anl.gov
– Compact Heat Exchangers
– Ice Slurry District Cooling
– Advanced Thermal Fluids

For information on working with Argonne, contact Paul Eichamer, Industrial Technology Development Center, Argonne National Laboratory, Bldg. 201, 9700 South Cass Avenue, Argonne, Illinois 60439; phone: 800/627-2596; fax: 630/252-5230, pdeichamer@anl.gov

DOE SBIR Commercialization Forum

Subject: UFTO Note – DOE SBIR Commercialization Forum
Date: Wed, 23 Oct 1996 09:21:35 -0700
From: Ed Beardsworth <edbeards@batnet.com>

————————————————————–
| * UFTO * Edward Beardsworth * Consultant
| 951 Lincoln Ave. tel 415-328-5670
| Palo Alto CA 94301-3041 fax 415-328-5675
————————————————————–

Abstracts for 40 companies which were presented at the:

“Dawnbreaker DOE Commercialization Opportunity Forum”,
Washington DC, Oct. 8-9, 1996

These are small businesses that have received DOE SBIR funding, and who are seeking investors or business partners (or customers).

– Each one has prepared a business plan, with coaching by DOE commercialization consultants.
– The companies appear in order of interest to utilities–most interesting first (not a rigorous ranking).
– Last paragraph of text (appearing before Company name and address) was prepared by company itself.
– Other comments are by UFTO.
– You may disregard numbers appearing after title (n//m) :
n = interest rank ordering, and m = company # as listed in program materials.
– Companies are separated by a line that starts with two back-slash characters, which you can use to parse this long text record if you need to.

———————
Plant Environmental and Cost Optimization System (PECOS) ™: On-line software to minimize power generation cost
1//3 VERY Interesting
Integrates coal yard, boiler & NOx control, steam side operation and byproducts into a single cost function. (Competitors treat only one part) One year payback. Doing Coal Monitor Wkstn with TVA. (EPRI members can use TC $ towards installation.) Impressive and convincing story.

This company’s product is unique in its comprehensive approach, cost focus, and distributed architecture. This on-line software advises plant operators on settings to minimize controllable costs of power generation. The software covers all areas of plant operations such as dynamic coal sorting and blending, efficiency, control of all emissions, and disposal/sale of byproducts. The company has strong ties in the utility industry. It is currently testing the product on-line at two power stations, and sales to other plants are in negotiation. The software can also be adapted for other process industries. The company seeks a strategic partner which is either a utility or other organization with an existing base of services and/or sales in the utility industry to participate in an emerging market with a total size of $200,000,000 in the U.S. The partner will profit through appreciation of shares in a dynamic company by generating revenues through sales and implementation services for the product and by the synergistic growth of its other related businesses in the utility industry. (FOSSIL)

Praxis Engineers
Randhir Sehgal, President
852 N. Hillview Dr.
Milpitas CA 95035
408-945-4282
408-263-2821
———————
Cost-effective retrofit, ultra low-NOx coal burner which also removes SOx and ash
1//11 VERY Interesting
Retrofit replacement for PC burners at $60-90/kw installed (cheaper than scrubbers, GTs, buying credits or low S coal).
Rotating drum creates artificial x10 gravity for mini-fluid bed gasifier. Removes ash! NOx below 100ppm and SOx is 90% controlled. Use crush/pellet coal not pulverized. Good with RDF.

The Company has developed its patented Rotary Combustor (RC) to allow electric utilities to refire boilers to meet Clean Air Act emissions standards for the year 2000 and to improve efficiency at cost significantly lower than any alternative solution. The RC is an ultra low-NOx burner which also removes SOx in the combustion process. Refiring with the RC competes effectively in cost and performance in the combined $1 billion market for scrubbing equipment, low-NOx burners, and SCR systems. We are seeking a strategic partner to help manufacture and market the RC and related technologies. (NOX & SOX, FOSSIL)

Spinheat Ltd.
Michael Virr, President
1222 Bronson Rd.
Fairfield CT 06430
203-259-6101
203-255-4482
VIRRMJ@aol.com
———————
NDE Systems for monitoring age degradation and manufacturing quality
1//16 Very Interesting
As one example, inexpensive sensor could be left installed under piping insulation; connect instrument to take reading. Has EPRI $ for validation of real-time imaging in power plants. Information pkg available–looks solid.

This company’s patented technology provides breakthrough capabilities in quantitative nondestructive characterization. Portable systems integrate thin and conformable electromagnetic sensors, model-based GridStation TM software, and board-level instrumentation. Rapid scanning for clusters of microcracks, precrack fatigue damage monitoring and coating characterization are examples of the new capabilities offered by this proprietary technology. Fully integrated systems are being demonstrated at trade shows and sold to target customers for pilot-plant testing. Target markets for products and services exceed $300 million. This company seeks strategic alliances with market leading service providers, and an infusion of capital to finance manufacturing scale up and the expansion of field capacity, to meet current and expanding demand. (NUCLEAR, FOSSIL)

JENTEK Sensors
Neil J. Goldfine, President
Watertown MA 02172
617-926-8422
———————
Cost-effective electrochromic windows
1//24 Very Interesting
The only U.S. company to focus solely on this technology. First patent for ceramic thin film coatings. Use several coatings on glass. Pass DC current for 90% blockage of visible and 100% of IR and UV for sophisticated lighting and HVAC control.

This company has developed a patented ceramic thin-film electrochromic technology that gives users the ability to adjust the level of tinting of their glass from nearly clear to very dark. This gives the user the ability to effectively control glare and heat gain in windows. Sageglass delivers the durability, pleasing visual characteristics, low cost and customer benefits required for the architectural window markets. This company projects sales of $80 million in the year 2002. The company seeks a strategic partner in the glass window or energy management industry to scale up manufacturing for commercial product introduction. (END USE)

SAGE Electrochromics, Inc.
Mike Myser, Director Marketing and Sales
Piscataway NJ 088540-0278
908-699-1100
908-699-1101
———————
Landfill gas (LFG) to products, using carbon dioxide (CO2) wash technology
2//28 Very interesting
Land Fill Gas to Methane, and Liquid CO2, where some of the LCO2 is used to wash contaminants out of the gas. Looking for partners.

Company conceived, developed, patented, and demonstrated carbon dioxide (CO2) wash technology which converts landfill gas (LFG) to products including electricity, medium Btu gas, pipeline gas, liquid methane, liquid CO2, and methanol. Company was founded in 1989 for the advancement of innovative gas separation technology for high CO2 streams. There are 2,900 active landfills in the U.S. which could use this technology. Average investment is $7.5 million with payback under 3 years. Company offers the only technology which (1) derives the separating agent (CO2) from LFG, (2) is insensitive to changes in contaminant composition and concentration of LFG, (3) produces liquid CO2 from LFG, and (4) allows multiple end uses for LFG.

Acrion Technologies
Bill Brown, President
Cleveland OH
216-573-1197
———————
Highly graphitic carbon fiber reinforcement
2//29 INTERESTING
Vapor grown carbon fiber, low cost, simple continuous process. Very different from other fibers. High effective surface area. Injection moldable, smooth finish. Can be used in major quantities to reinforce tires, wood products, concrete(including ash-based?). Made from Hi Sulfur Coal, with methane as by product.

This company has developed a proprietary, highly graphitic carbon fiber reinforcement having a diameter of 0.2 microns, a length of 100 microns, and a low production cost. The unique combination of small size, high reinforcement value, and low cost enables broad use in EMI–shielding, friction products, batteries, engineered plastics and rubber for the automotive industry. A market demand of 120 million lbs./yr. for these specialized applications have been identified. The company is seeking an investor or joint venture partner from the automotive or energy industries to scale up for product introduction in mid 1988.

Applied Sciences, Inc.
Max L. Lake, President
Cedarville OH 45314
513-766-2020
———————
Advanced dry sorbent systems for air pollution control applications
2//30 Very interesting
Chemistry systems on vermiculite substrate for duct injection and easy recovery.
1. “Fluesorbent” SO2 control for retrofit in older small plants. (EPRI tested at Ohio Edison) Byproduct is a licensed agric. soil amendment.
2. “Mercsorbent” Air Toxic control, duct injected works at low temp., is recoverable. Will demo at Ft. Dix. Need Coal fired demo site.
3. “JetSorb” NOx control. First application at jet engine test cells.

This is a new kind of company: a supplier of multiple advanced sorbent systems for air pollution control applications. Each of the firm’s technologies are waste-free, retrofitable, and either low in total cost or low in capital cost – quite a contrast to existing market offerings. Specifically targeted markets are: 1) SO2 control for older, smaller plants, where scrubbers are uneconomic; 2) NOx control for stationary and mobile diesels; and 3) mercury air-toxic control. With six issued and four pending U.S. patents, the company is now scaling up and demonstrating its systems in the field. It is seeking funds and strategic alliances with large and mid-sized engineering or air pollution control firms to assist in marketing and product introduction programs. (NOX & SOX)

Sorbent Technologies Corp.
Sid Nelson, VP
Twinsburg OH
216-425-2354
———————
Supersonic air jet and vacuum transport for safe excavations using supersonic air jet
2//31 Very interesting
Did prototype with EPRI. Can be operated remotely (robotic). Safe, productive, precise, safe, efficient, flexible. Won’t harm any impermeable surface. Can even dig around tree roots.

Our Safe Excavation technology employs a proprietary, synergistic combination of supersonic jets of air and pneumatic vacuum transport to uncover any type of buried object without fear of accident or inadvertent damage. Industrial market applications involve urban and suburban excavations for new installation or repair of telecommunication. electric, or gas utility lines. Commercial needs range from agriculture to environmental remediation and recovery of hazardous or radioactive waste. Military usee include retrieval of unexploded ordnance or removal of buried land mines. We have designed, built, and tested hand-held, portable, and backhoe sized prototype equipment for each of these market segments. Market forecasts for our larger equipment are approximately two thousand units in a mature market annually. We desire an investor or commercial partner to help us begin to manufacture and sell into these market segments. (T&D)

Concept Engineering Group Inc.
Richard D. Nathenson, President
Pittsburgh PA
———————
Portable imaging nuclear survey meter
2//17 Interesting
Pre production units available for purchase. $75-100K each expensive but price is competitive and there is big savings in labor.

An established nuclear detector R&D and instrument manufacturing firm has developed an instrument that provides a picture of the distribution, intensity, and energy of gamma radiation sources. It is a self-contained system having two cameras, one for the nuclear image and one for the video. A black and white video image is produced with the nuclear image superimposed over it in color. The instrument addresses the $600 million nuclear radiation detection and monitoring market. The focus is on three major market segments that total $120 million: the nuclear industry, including nuclear power plants, nuclear material producers, and nonproliferation of nuclear weapons; the medical industry, including nuclear medicine and radiation oncology; radiation safety, including universities, industry, and hospitals. The firm is seeking a strategic alliance with a partner having an established marketing and distribution network. (NUCLEAR)

Radiation Monitoring Devices
Michael Squillante, VP Research
Watertown MA
617-926-1167
———————
Ground penetrating radar for underground imaging and site characterization

3//2 Interesting
Has significant utility contacts (see EPRI Journal 10/96 pg 38) Image processing needs to be faster. Digital wideband radar, airborne or truckmount, to 30 ft. depth, tie to GPS for 5 cm location accuracy. Plans for U/G Database Service.

A Silicon Valley high technology company has developed and demonstrated a patented Standoff Ground Penetrating Radar which can produce high resolution 3 dimensional images. A rapidly growing demand exists for underground site characterization and assessment for environmental, construction, utility, and defense customers for the location and classification of buried objects. The company projects sales in excess of $50 million per year by 2002 with an estimated growth of 15%-20% annually. Patented hardware, copyrighted software, and proprietary imaging algorithms insure significant market dominance. Equity investment is sought along with strategic alliances to accelerate product launch and early market penetration. (T&D)

Mirage Systems Inc.
Robert Ziernicki, President
Sunnyvale CA
408-752-1600
———————
Removal and recovery of mercury found in flue gases
3//10 Interesting
New subsidiary, Mercu-RE Inc., formed to pursue Mercury removal.

ADA is a engineering consulting service firm specializing in troubleshooting and analysis of emisssion control systems.
This company offers a process that takes mercury out of flue gases and recovers it as liquid elemental mercury suitable for commercial recycling and produces no secondary wastes. A regenerable sorbent (patent pending) is at the heart of the process. Available alternatives, such as activated carbon, are expensive and produce mercury-contaminated solid or liquid wastes. The parent company has over ten years of experience in air pollution control technology and offers units to DOE site clean-up efforts planned for Oak Ridge and other former weapon-making facilities. The firm is looking for a marketing, sales, and distribution partner with access to key markets, such as commercial and municipal waste incinerators. The ideal partner would also have knowledge of process engineering equipment. The technology would be a valuable asset to the portfolio of a partner with existing interests in air pollution control equipment and services. Sales over $10 million per year can be realized as a result of the hundreds of incinerators that are subject to mercury emission regulations, leading potentially to even larger markets in coal-fired power plants. (FOSSIL, ENVIRONMENT)

ADA Technologies
Daryl L. Roberts, Vice President
Englewood CO 80112
303-792-5615
———————
Integrated sensors for air quality and safety monitoring
3//15 Interesting
Low cost, mass-produceable planar thick film membrane, for application in indoor air quality. Stable over long time. Parent company Giner is specialty R&D company in electrochemistry and materials science–PEM, O2 generators, sensors, etc.

The company, a spin-off of an electrochemical and materials research firm, is targeting the annual $20 million U.S. indoor air quality and safety monitoring market. A unique patent-pending sensor design enables a manufacturing process for mass-production of high-quality, low-cost electro-chemical gas sensors. Manufacturing costs can be reduced to one-tenth of current costs. In addition, the new design will allow integration of sensors for simultaneous monitoring of combinations of gasses, such as CO, CO2, NO, NO2, and SO2, with sensitivities in the low-ppm range. Separate smoke detector and air quality monitor functions can now be combined into one new instrument to serve the target market. The company is seeking an investment for manufacturing set-up, and possibly a strategic alliance for distribution and marketing capability. (END USE)

Giner, Inc.
Anthony LaConti, President
14 Spring Street
Waltham MA 02154
617-899-7270
———————
Lumber utilizing a low-cost industrial by-product feedstock (incl. flyash)
3//26 Very interesting
Patented resin binder systems, can use multiple feedstocks including flyash. Fire resistant due to hi mineral content and closed cell structure. Process is exothermic. Product is moldable into shapes (e.g. moldings).

This innovative firm has developed a multi-patented cost competitive composite decking material. Ecodeck is non-warping, wood grained, moisture and insect resistant, and paintable. It can be cut and assembled with conventional tools and is produced with commercially available machinery. Ecodeck lumber utilizes a low cost industrial by-product feedstock and is cost competitive in the $580MM market for select grades of pressure treated southern yellow pine. The company is seeking strategic partners in the electrical utility and building materials industries and venture capital for remaining development and manufacturing scale up. (FOSSIL)

Ecomat, Inc.
John Mushovic, Exec. VP
Poughkeepsie NY
914-473-8777
———————
Thermoelectric modules for power generation and waste heat recovery

3//4 Interesting
Driving down mfg. cost of traditional 5-6% thermoelectric devices. Wide range of applications. Have prototype alternator replacement for diesel trucks.

Thermoelectric power generators for converting waste heat into electricity are available for U.S./overseas markets which range up to $1B. Cost-effective modules (one third competitors’ price) can be utilized for a broad spectrum of products: self-powered furnaces, engine alternator replacements, remote power and power generation for urban incinerators. Fourteen and twenty watt modules are in limited production. These modules can be used individually or in multikilowatt generators. A two Watt generator is planned that can outperform chemical batteries. We are seeking strategic partners and venture capital for scale up of manufacturing and rapid market penetration. (DU)

Hi-Z Technology, Inc.
Norbert Elsner, President
San Diego CA
619-695-6660
———————
Microprocessor technologies for the purpose of power monitoring
3//18 Interesting
Unique current sensor replaces conventional CTs. One fourth the size. No need to disconnect wire to install it. They have not explored any possible T&D grid applications.

This privately held company has developed products which combine unique and patented current sensors with custom developed VLSI and microprocessor technologies for the purpose of power monitoring. The products are based on more than 10 years of R& D, production and direct marketing experience. These technologies will provide a company with a competitive lead by reducing size, cost and installation time 50+%. Additional high-margin products, in design, will effectively and efficiently instrument commercial buildings, industrial processes and homes.. Of the overall USA Electrical Measuring Instrument Market (SIC 3825, $8+ Billion), the company is focused on market niches that total $130 million. These markets include Energy Service Company applications, commercial tenant submetering, industrial equipment monitoring and control and Utility Demand Side Management, Load Research, Time Of Day metering and Customer Service applications. The company seeks partners who bring established distribution channels and capital for production and marketing. (END USE)

Energy Teller, Inc.
Tim Michels, President
2718 Sutton Blvd
St. Louis, MO 63143
314-644-2629
314-644-0691
———————
Hazardous and radioactive waste treatment
3//23 Interesting —
“DeTox” wet oxidation to destroy organic compouns at low temperature. Difficult to judge — one of many contenders in this field.

With eleven years of operating history, patents issued in the U.S. and seven major industrial countries, and a full-scale demonstration project funded by the Department of Energy, this innovative and dynamic corporation has established its wet chemical oxidation technology at the forefront of hazardous and radioactive waste treatment options for government and industrial markets. The total U.S. environmental market is $165.5 billion. Our company is focusing on the market segments of hazardous waste management, remediation and industrial services, and process and prevention technology development which together comprise a $4.2 billion market. Established and potential customers find the advantages of transportability for on-site treatment, alternative permitting options, safe (low temperature and low pressure) operating conditions, broad ranged applications, and benign secondary wastes to be significant improvements over incineration and other alternative waste treatment technologies. Partnership with a leading environmental management firm is sought for $1 million equity participation, $3 million project financing for an existing customer, and marketing and sales assistance in implementing the commercialization plan involving the sale of plants and services. (ENVIRONMENT)

Delphi Research, Inc.
Terry W. Rogers, President
Albuquerque, NM
505-243-3111
———————
Breakthrough material to remove radionuclides, metals, and organics from contaminated waters
3//39 Interesting
Humasorb, made from coal, simultaneously captures both metals and organics. Can be used as a liquid or solid filter. Could handle coal pile run off. Co. a spinoff from Atlantic Research Corp in 1987.

A unique material has been developed for the single-step removal of radionuclides, metals, and organics from contaminated waters. This versatile new material replaces traditional sequential processing approaches making it cost-effective as a permeable barrier to remove and capture plume contaminants and for surface treatment operations. Applications are targeted at the water pollution prevention and remediation markets estimated to exceed $600 million per year. Technology to produce the new material is protected by pending patents and trade secrets gained over a 5-year period of development by a company that has a successful record of commercializing new technologies. Investors and strategic alliances are sought to support the commercialization of the material on a site-specific or application basis. (NUCLEAR, FOSSIL, ENVIRONMENT)

ARCTECH, Inc.
Harry R. Johnson, Technical Director
Chantilly VA 20151
703-222-0280
———————
Large-scale advanced vitrification technologies for site remediation and waste treatment
3//40
Subsidiary of Battelle is commercializing this DOE technology. Tested and licensed. Clear focus on markets, and good grasp of who competitors are.

This international Company holds an exclusive worldwide IP position in the field of large-scale advanced vitrification technologies for site remediation and waste treatment. The Company has over $20 million in current backlog, is profitable, has worldwide growth opportunities, and it’s proven technologies possess excellent regulatory and public acceptance. The Company plans to acquire more than $50 million of sales from the DOE environmental restoration marketplace within the next three years. The Company seeks a strategic partner, that is established or entering the DOE ER/WM marketplace, to augment its operations and marketing capabilities as needed to secure large ($20 to 100 million) waste remediation and treatment projects within the DOE, other government, and private remediation markets. Benefits to the partner include increased market potential, a strong vitrification technology base, and strategic access to the Company’s parent, which is a leading environmental technology company. The Company poses an attractive opportunity for $8 million of second stage equity investment followed by an IPO for support of further growth. (NUCLEAR, ENVIRONMENT)

Geosafe Corp
James E Hanson, Vice President
Richland WA
509-375-0710
———————
Solid-Gas sorption refrigeration, consumer products
5//19 (Not presented — “Already found financing or strategic arrangments”)

The company is a thermal product development firm with an excellent reputation in the commercial HVAC&R industry. It is seeking an equity investment to launch the OEM manufacture of small packaged refrigeration and heat battery modules for already existing and future appliance manufacturing customers. The technology is based on a sorption process which provides refrigeration without moving parts and yields unmatched rechargeable thermal battery energy densities. The market applications include consumer products, medical and automotive appliances. The initial focus is on small refrigerators/freezers and an automotive application with existing customers. Anticipated fourth year OEM sales volume is $25,000,000. (END USE)

Rocky Research
Dr. Uwe Rockenfeller
1598 Foothill Dr.
Boulder City NV 89006
702-293-0851
702-293-0854
———————
Continuous removal of coatings for aircraft, bridge & environmental applications
5//20 Interesting.
Unique capability to remove paints and coatings with one step process, quickly and less expensively. Can even remove one layer at a time!

Very broad applicability. Company focusing on airplane depainting, so opportunity to pick up on other fields of use.
A small business that develops commercial applications of laser-based systems is seeking an equity investment to commercialize their proven technology for removal of coatings from various kinds of surfaces for multiple applications in the commercial marketplace. This technology uses lasers and robotics to provide the most efficient, environmentally-sensitive and cost-effective process for removing paint from aircraft, bridges, and radioactively-contaminated facilities. The annual target market for these applications is $4.5 billion. By year 4, the projected sales for these applications are estimated to be $70 million.

F2 Associates, Inc.
Joyce Freiwald, President
14800 Central SE
Albequrque, NM 87123
505-271-0260
———————
A system for recycling acids used for metal surface preparation
5//27
Interesting (?) Hard to judge

The Pickliq process is a patented system for recycling acids used for surface preparation in the metals processing industries. The process produces salable solid metal salts as by-products. The company employs highly experienced people that have an investment stake. The people work with Engineering and Construction firms and their clients to implement the process. The firm qualifies and supervises sub-contractors who construct the skid mounted units of the system. Data to date indicate a $15 – 20 million/yr market for the system after year four is possible. Further process development is funded by the US DOE through an ERIP grant. The company is obtaining working capital from small investors. It is looking for alliances with Engineering and Construction firms with clients in the steel and wire industry to exploit domestic and international markets. (ENVIRONMENT)

Green Technology Group
Douglas Olsen
Pawling NY
914-855-5488
———————
Position sensors in and around underground storage tanks, buried pipelines and below buildings.
5//36 Interesting

The Steerable Vibratory System (SVS) is the only way to accurately position sensors in and around underground storage tanks, buried pipelines and below buildings. The SVS is made up of a lightweight rig, a steerable tip, the patented navigational system and penetrometer rods with unique joints. It is not affected by magnetic anomolies and will not bring contaminated cuttings to the surface or contaminate other layers. The more accurate delineation of plumes will save money in clean-up. The firm has worked closely with customers in the underground industry for over 15 years. Our market includes Superfund sites and underground storage tanks (>295,000). The company will manufacture the SVS and seeks licensees with established distribution networks for marketing and sales. (ENVIRONMENT)

UTD Incorporated
Barney Harris, Vice President
Newington VA 22122
412-429-9496
———————
Treatment of radioactive, hazardous and mixed waste
5//14 (Not presented — “Already found financing or strategic arrangments”)

This environmental technology company has developed and commercialized its patented steam reforming technology in the paper industry. The company is now expanding by applying its unique non-incineration technology to the treatment, volume reduction, and disposal of radioactive, hazardous and mixed radioactive/hazardous wastes. Tests are underway in a1 ton per day facility demonstrating the destruction of hazardous compounds (greater than 99.99%) and the isolation of radionuclides in an environmentally superior final waste form. This is opening the door to the burgeoning DOE market, commercial ion exchange resin market, and industrial hazardous waste market. The company is seeking a joint venture arrangement with a strategic ally/investor to commercialize the technology in these new applications. The combined potential market exceeds $350 million per year. (NUCLEAR, ENVIRONMENT)

ThermoChem, Inc.
Gary Voelker, COO
10220-H Columbia Rd
Columbia MD 21046
410-720-6100
410-312-6303
———————
Multimedia training in technical subjects
5//21
Company combines expertise in both instructional material preparation and technology. Not particularly different from other suppliers.

This company creates multimedia training packages in scientific and engineering disciplines for use within the DOE complex, by accelerator manufacturers, and in higher education. Its unique combination of scientific expertise, software skills, and the needs of the DOE complex makes it the vendor of choice for training for environmental cleanup and production of special materials, such as tritium. Multimedia training rapidly raises the level of competency and quality of technicians and engineers, leading to a more effective work force. For example, a tutorial in development on accelerator physics can serve as a basis for specialized training programs in companies manufacturing accelerators for industrial and medical applications. Opportunities for a publisher include marketing as a standalone software piece, bundling with a textbook, and teaming to develop new educational tools.

WhistleSoft, Inc
Richard R. Silbar, President
Los Alamos NM
505-662-7309
silbar@whistlesoft.com
———————
Electrical energy storage/ hydrogen production
5//35 Interesting, but doubtful
This uses a solar heated furnace to drive water+ Br –> HBr reaction, and electrochemical cell using the reversible H + Br <–> HBr reaction to store and release electrical energy. Provides on peak electicity and H2 for sale. Have strong DOE support.

From 03-14-96 The Financial Times:
“Solar Reactor Technologies has entered into a $2.5m (#1.6m) co- operative agreement with the US Department of Energy for its system for producing renewable hydrogen and combined electrical storage. Hydrogen is generated by means of solar energy concentrated onto bromine and water which forms hydrogen bromide and oxygen. The former is then split at night using low cost off-peak electricity in an electrochemical cell to produce hydrogen, and regenerate the bromine. The end result is that water is split into hydrogen and oxygen, but using one third of the electricity required for conventional water electrolysis.

By storing extra hydrogen and bromine and recombining these in the cell, electricity is generated. This in effect permits the storage of off-peak power for use at any time. The system is potentially very attractive to large electrical consumers. However, the economic generation of hydrogen would also be very significant for vehicle companies looking to the longer- term future. BMW has been experimenting with hydrogen fuelled vehicles since the late 1970s while Mercedes is one of a number of companies which is taking the development of hydrogen fuel cell vehicles very seriously.”

This company is focused on the development and commercialization of renewable energy technologies. One of these is a patented solar-electrochemical system which links utility scale electrical energy storage with the production of hydrogen and oxygen from water. The system will provide peak electrical power and hydrogen with no greenhouse emissions. The process is competitive with existing combustion technologies. Sales potential for the electrical energy storage market in the U.S. is estimated at $100 -$200 million per year. To fund its commercialization program, the company is seeking a relationship with an investor and/or strategic partner. (DU)

Solar Reactor Technologies, Inc.
Harley L. Heaton, Vice President
3250 Mary Street, #407
Miami FL 33133
305-442-9966
———————
Remote power generation, residential cogeneration and cryogenic cooling products
5//42 (Not presented — “Already found financing or strategic arrangments”)

Two distinct lines of products, using the same basic technology, have been developed by this eleven year old company. The RG-350TM uses heat from any source to produce electricity for the remote power market (estimated at $30 million annually) while the RG-1000TM will use propane/natural gas to create combined heat and power for the residential cogeneration market (independently assessed to exceed $1 billion annually in ten years). Additional advantages derived from these products include higher fuel efficiency and reliability with lower maintenance, noise, and emissions than any existing products. The company is also manufacturing its BeCOOLTM cryocoolers for use in the computer, superconductivity and sensor cooling markets. Teaming partners are being sought for marketing, distribution and new product development while investor funding will be used for pre-production and manufacturing activities. (DU)

Stirling Technology Co.
Mr. Jeffrey Lubeck, Controller
4208 W Clearwater Ave
Kennewick WA 99336-2626
509-735-4700
509-736-3660
———————
Low-cost fiber optic chemical sensors–Smart Cable ™ detects leaks along long distance pipelines
6//13 (did not consider)

This company is dedicated to developing and licensing low-cost fiber optic chemical sensors for environmental monitoring and medical diagnostics.The first generation, developed for the detection and discrimination of water and hydrocarbons, is elegant in its simplicity and has been field tested by an independent third party. The corporation has already produced sales of related environmental products. These revolutionary, patented sensors provide continuous monitoring for environmental contamination at very competitive costs. Installed in fuel tanks, pipelines, and landfills, sensor networks provide realtime indications of contaminants and leaks over large and remote geographic areas. Additionally, sensors are being adapted for use in hospitals and medical laboratories to detect the presence of specific biochemicals in bodily fluids. This corporation seeks licensees with strong presence in environmental remediation and potential licensees which will fund continued development of the sensor family in exchange for exclusive licensing rights. (ENVIRONMENT, T&D)

Noverflo, Inc.
Dr. Joe Hopenfeld
Rockville MD
301-340-1625
———————
Wireless identification (RFID) tagging for asset management
6//37 Interesting
May have applications in asset tracking, remote metering.

The company has developed an exciting wireless technology, called RFID, derived from R&D grants by the Department of Energy. This technology has enormous commercial potential for applications such as asset management and transportation operations. The company chairs the ANSI technical sub-committee for RFID standards. Multiple patent and trademark applications have been filed. The product currently is in beta testing at DOE’s Savannah River site and is ready for use in all DOE sites. A trucking demonstration system is on display at Andersen Consulting’s transportation center in Atlanta. The management team, with over 35 years of RF, business, and finance experience, is poised to aggressively penetrate the current $250,000,000 market for RFID equipment, growing at an annual rate of 25%. The company is forming alliances with major corporations to accelerate growth and is seeking equity investment of $1,000,000 to support that growth. Various exit strategies will be entertained for equity investors including acquisition or IPO.

RANDTEC, Inc.
Alan C. Hurkamp, Chariman
Fairfax VA 22030
703-352-0833
———————
Thermophotovoltaic (TPV) generation of electricity from flame heat
6//41 Interesting
TPV device with their own patented emitter and cells. Original technology licensed from Boeing. Claim ing advantage over competitors. “Mini-cogen” – devices at 2, 50, and 150 watt elec –“wall heater” Their approach to the market is arguable.

Using its infrared-sensitive photovoltaic cells coupled with a fuel-fired emitter, this company fabricates Midnight Sun® cogenerators of electricity and heat. These cost-effective units feature quiet, reliable, efficient, and clean operation. With a strong patent position, military contracts, and an operating cell manufacturing facility, the company is positioned to capture a large share of the emerging market for remote and mobile cogeneration. Homes off the electric grid are targeted first, with a five year plan to take the company public and enter the much broader on-grid residential market. Investors are sought to rapidly scale up manufacturing capabilities; of particular interest are utilities pursuing growth in unregulated operations and furnace manufacturers considering self-powered heating systems. (DU)

JX Crystals, Inc.
Dr. Lewis M. Fraas, President
Issaquah, WA 98027
206-392-5237
———————
Metal coated fine powders
7//5
POWDERMET is a new spinoff that will be doing this work. ULTRAMET is the established company.

Ni and Co coatings on nanograin tungsten carbide, using “fast fluid bed chemical vapor deposition”
The company is a commercial spin-off of an established medical and aerospace materials firm. We are seeking an equity partner to launch the large scale manufacture and marketing of metal coated powders for the ordinance, tool, and die markets. Metal coated sub micron powders represent a revolutionary advancement in powder metallurgy, enabling a 30-50% increase in cemented carbide and tungsten alloy performance at equal or lower cost to current products. This investment partnership opportunity will leverage over $1 million in signed, development contracts to achieve projected revenues of $20 million in a $120M market within 5 years. This breakthrough patent pending technology is currently operational in the pilot plant stage. All proprietary rights, developmental, and pilot plant equipment has been negotiated for assignment to the company.

ULTRAMET
Andrew Sherman, Marketing Mgr.
12173 Montague St
Pacoima CA 91331
818-899-0236
818-890-1946
———————
Fiber optic sensing
8//7 (did not consider)

This company has developed and demonstrated proprietary technologies encompassing components and system building blocks enabling production of low cost interferometric fiber optic sensors. The technology is applicable to inertial, intrusion, vibration, acceleration, acoustic, strain and electro-magnetic sensing in formats of single element, multi-channel distributed, and remote configurations. The company seeks an equity investment from a partner to spin off a business for the purpose of producing components and instruments based on the proprietary technologies and marketing them to sensor manufacturers in their respective fields. Expected sales for these ground breaking products will exceed $10 million per year by year 5.

Optiphase, Inc.
Jeff Bush, President
Van Nuys CA
818-782-0997
———————
Direct Load Control switches for plug connected appliances
8//25
Plug connected “smart” switch, remote controlled via one-way radio. Device stores data on operating history. (Hopelessly naive and out of date DSM device)

Manufacturers of electric utility load management controls will find this exclusive licensing opportunity of unique value. The Company has patented and field tested a microprocessor-based electric Direct Load Control (DLC) switch for plug connected appliances. The switch is designed to improve residential DLC program effectiveness; and economically collect comprehensive market intelligence on end-use appliance operation. The Company is looking to form a strategic alliance with a manufacturer interested in increased market share through the development of a “family” of DLC and home automation related products which complement the licensee’s current product line. The licensee’s product development costs would be reduced through follow-on licensing agreements with the Company.

Automated Energy Management Systems
Frank Rudden
E. Northport NY
212-460-6511
———————
Open-path atmospheric pollution monitor, detection of hazardous air pollutants
8//33 (did not consider)

The open-path atmospheric pollution monitor being developed for DOE integrates a CO2 laser and an acousto-optic tunable filter into a single instrument which measures pollutant concentrations in the optical path to any topological object. The range is over 4 times longer than existing monitors, thereby eliminating the need for multiple monitors and reducing costs. The estimated environmental and process control market is over $100 million within 5 years with the potential for ~$400M for military applications. A large defense contractor seeks to license a company to commercialize this monitor. The licensee will have exclusive use of the basic patent and unlimited access to the filter for which the contractor is the only supplier in the world. (ENVIRONMENT)

Northrop Grumman STC
Dr. Lyle H. Taylor, Fellow Scientist
Pittsburgh, PA
412-256-1650
———————
Pyridines from kerogen oil
9//34 (did not consider)

Kerogen oil, derived from Western Green River oil shale, is rich in pyridines (~20% of the raw oil). These pyridines can be produced and refined at costs substantially lower than current manufacturing costs for synthesis routes. A strategic partner and project financing are sought to develop a Kerogen Products Extraction (KPX) venture which will annually produce 25,000 tons of pyridine products and 300,000 tons of petroleum products. Annual revenues are projected at $150 million yielding more than 30% internal rate of return on an investment of $75 million. Pre commercial milestones will be achieved through an existing DOE contract and phased project financing. Product development opportunities in higher alkyl pyridines, pyrroles, indoles, phenols and quinolines offer additional long-term growth potential.

James W Bunger & Assoc. Inc.
West Valley City, UT 84119
801-975-1456
———————
Electromagnetic Sensors For Chemical Analysis
9//38 (did not consider)

A well established research laboratory is forming a subsidiary company to manufacture and market proprietary sensors for continuous chemical analysis. This innovative technology utilizes eddy current properties in an advanced electromagnetic sensor to identify chemical constituents. Advantages of this patented approach include exceptional resistance to fouling, low system cost, high sensitivity, compatibility with digital integrated circuitry, and high selectivity. The newly formed company will acquire all of the intellectual property and over 14 years of related experience. Equity or strategic partners are sought to participate in launching the new product line. Potential instrumentation markets for the sensor include process control, environmental monitoring, and biotechnology. The measurement of wastewater pH alone is anticipated to be a $100 million market by the year 2000 and should conservatively generate $10 million dollars revenue.

American Research Corp of Virginia
Howard J. Moses, Director, Business Development
Radford VA 24143-3406
540-731-9655
———————
A compact, high-yield, HGA synchrotron X-ray lithography source
10//1 (did not consider)

The mission of this company is to become a leading supplier of high-intensity synchrotron x-ray source machines for lithography of Giga-bit class memory chips with resolution at or below 0.18 micron to meet the emerging global demand. The product makes use of a compact electron injector based on a high–gradient accelerator (HGA) combined with a superconducting synchrotron radiation ring, resulting in increased resolution, lower capital cost, lower production cost per chip, and lower cost of ownership. The company seeks $10 million from joint venture partners and investors for the completion of the first machine to be sold in 1999.

DULY Research
Rancho Palo Verdes CA
301-548-7123
———————
Portable fiber optic phase fluorometer
10//6 (did not consider)

This company, a leader in cutting-edge optics, optoelectronics and monitoring instrumentation technologies, has developed the only portable fiber optic phase fluorometer (FOPhase) instrument available in the market. This patent protected technology addresses the environmental safety ($50 million), process control ($100 million), R&D ($50 million), and medical markets ($200 million), for fluorescence detection monitoring. Owing to the high market demand for a low cost fluorescence lifetime spectrometer in various market segments, the company is searching for a strategic partner to market and distribute the FOPhase Technology. The sales forecast for 2000 is $26 million or 6.5% of the total market.

Physics Optics Corp
Torrance CA 90501
310-320-3088
———————
Interdisciplinary science education software
10//8 (did not consider)

Our firm will become the premier source of interdisciplinary science education software. We seek a partnership with a forward looking company in the communication, hardware or software industry that wishes to raise the level of scientific preparedness of the next generation of students and increase the use of computer and communication technology. Our partner will manage the distribution of our product line to expedite market penetration of our first product ready for introduction in January 1997. Over the next two years we will introduce a series of products utilizing CD-ROM and Internet data sets. Titles include: El Niño, Ozone and Monsoon, and are designed to teach Science from grade 6 to college level. Our series is a set of virtual research expeditions in which students use satellite observations of the Earth and data from climate models to study the Earth as a system of interacting components. It brings science alive.

Plant Earth Science
Dr Catherine Gautier-Downes
Santa Barbara CA
805-730-1622
———————
Interactive display software for hospitality industry
10//9 (did not consider)

This Company is developing interactive display software that provides electronic guest services for the national and international hospitality industry. These proprietary technologies allow hotels to integrate this software into their front desk operations, reducing overhead, increasing productivity, and enhancing guest services. Notable electronic services include express check-in/out, account transactions, services and events locators, interactive maps, and business services. The total available market for this kiosk technology is $2.8 billion. The high-end hotel market, the primary focus of this business plan, is $1.2 billion. This Company is seeking equity financing and a strategic partner for development, manufacturing and distribution.

Scientific Digital Visions, Inc.
San Jose CA
408-289-8494
———————
De-contaminating concrete; in-situ cleanup of soil
10//12 (did not consider)

This company is forming a spin-off to commercialize novel patented electrokinetic technologies developed under DOE funding. We plan to license to major site management contractors who are involved in remediation of DOE sites. This will be a good opportunity for entry into a sizable industrial market as well. This technology provides the only available approach to an in-situ cleanup of soil contaminated with heavy metals. It also provides a cost-effective technique for decontaminating concrete. The industrial opportunity is extensive in that it applies to the many entities which must deal with aqueous waste streams. The company is receptive to developing a creative package that recognizes investor’s risk and provides for exit when performance objectives are met. (ENVIRONMENT)

ISOTRON Corp.
New Orleans LA
504-254-4624
———————
Computer mapping software for petroleum industry
10//22 (did not consider)

The company develops advanced technologies to assist the petroleum industry with exploration and production (E&P) problems. Their product, Gviz, is state-of-the-art computer mapping software, coded in C++, that interpolates spatial data to estimate interwell reservoir properties. E&P professionals purchase $48 million annually in mapping software. This company maintains proprietary expertise, keeping them ahead of the market with improvements to their software. They plan a series of releases leading to an integrated reservoir management package in five years. The company seeks an alliance with an oilfield E&P software vendor who can bring financial resources, marketing, and distributing expertise to our commercialization effort. In return the strategic ally will receive exclusive right to the product.

Correlations Co.
William Weiss, President
Socorro NM
505-838-1910
———————
Advanced quantum chemistry software package
10//32 (did not consider)

This company has developed an advanced quantum chemistry software package allowing industrial, government and academic researchers in the chemical, biochemical, pharmaceutical and materials sciences, among others, to address far larger molecular structures and complete calculations faster on smaller molecular structures than is currently possible. This innovative package will afford users significantly reduced run times and lower processing and manpower costs. The market size for sophisticated molecular modeling software is estimated at $58 million with the quantum chemistry software niche occupying $8 million and an annual market growth rate of 8%. The company seeks an equity investment for commercialization, marketing and sales operations.

Q-Chem, Inc.
Benny Johnson, President
Pittsburgh PA 15218
412-828-7106
———————

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 – Sandia

UFTO

PROPRIETARY

Final Report

Technology Transfer Opportunities in the National Laboratories

Sandia National Laboratories

Albuquerque, New Mexico

& Livermore, CA

July 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
1. Sandia Organization
2. Sandia Technologies & Programs
11. Sandia 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 Sandia National Laboratories (Sandia) that might be of strategic interest to electric utilities. It is based on visits to Sandia in March 1995, as part of the UFTO multiclient project.

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.

Sandia Organization

Sandia began in 1945 as a small part of Los Alamos Laboratory, and in 1949 became a separate laboratory managed by AT&T. (The University of California, which manages Los Alamos, did not want to become involved in the actual manufacture of weapons.) Due to AT&T’s culture and management approach, Sandia grew up with an organizational style similar to Bell Labs, and quite different from the other national labs. There is a line management structure, and from the beginning, a strong “industrial R&D” approach that emphasizes practical results and getting them into use.

AT&T has managed Sandia (as a public service, for $1 per year) from 1949 until 1993, when Martin Marietta won the bid to take over. Martin (now Lockheed Martin) has a subsidiary company called Sandia Corporation that manages the laboratory (similar to the arrangement at ORNL and INEL).

Sandia is located on Kirtland Air Force Base in Albuquerque, and at Livermore California (across the street from L. Livermore National Lab). Total staff number about 8500 people, with about 1000 in California. About 60% of the staff are in technical and scientific positions.

Managers of “directorates” or “centers” have a fair degree of autonomy, and report up to a “sector” vice president level which in turn report to Al Narath, the president and lab director.

The sectors include:

Defense Programs (the largest), which does engineering and design for weapons systems,

Energy & Environment, led by Dan Hartley, deals with all other areas of the Dept. of Energy, with programs in Applied Energy, Nuclear Waste Management, Environment, Nuclear Energy, and Energy Research.

Work for Others (other government agencies) also known as Systems Applications and Research & Exploratory Technology

Sandia has specific major cross-cutting initiatives in agile manufacturing, electronics, and advanced information processing.

A general point of information: each lab 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.

Sandia Technologies & Programs

 

Covered in this section:

  • Combustion Research
  • Advanced Batteries and SupercapacitorsUtility Batteries/Storage/UBG
  • Renewables
  • Fuel Cells
  • Robotics
  • High Consequence Operations
  • High Performance Computing
  • Distributed Information Technologies (NII)
  • Sensors
  • Materials
  • Reliability/Decision Making
  • Micro SMES
  • HyMelt
  • High power switching

General Telephone # is (501) 844-5678
In Livermore, CA (510) 294-3000

Programs of greatest direct applicability to utilities are in the:
Applied Energy Program Dan E. Arvizu, Director 505-845-8336

 

Three major program areas:

1. Renewable Energy: solar thermal, PV, wind, geothermal, biomass

2. Energy Efficiency: utility energy management, materials & manufacturing processes, combustion technologies, transportation batteries, superconductivity

3. Fossil Energy: coal combustion, oil & gas production, strategic petroleum reserve
Industry collaborations involve many electric utility companies and manufacturers.

• Combustion Research Don Hardesty, Manager, Combustion Research 510-294-2321

Charles M. Hartwig 510-294-3047

Over 1000 Sandia employees are located in facilities in Livermore California, and operate several special facilities, one of which is the Combustion Research Facility, the only one of its kind in DOE. Can handle industrial scale burners to 3 million BTU/hour. It is a “user facility” and outside visitors and users are encouraged. Partnerships with industry include GM, Cummins and Beckman Instruments and many others. Developed a number of specialized flame/combustion observational, measurement and diagnostic techniques. Provided fuel blending strategies to midwest utilities to meet SOx requirements.

The Burner Engineering Research Laboratory is a user facility for industrial burner manufacturers, is booked for a year in advance. Wide range of studies include air toxics modeling

NOx program addresses measurement and prediction of NO formation in turbulent flames.

Sensors for steel industry for in situ measurement of CO and CO2 in furnaces.

Combustion properties of biomass derived fuels and char.

Laser and remote atmospheric sensing (invented Lidar).

The Engine Combustion Technology Program involves all the major car and engine makers, universities and other labs.

In Hydrogen, work in progress on combustion, engines, storage, and hydrides.

Publications: CRF News published bimonthly. Contact William J. MacLean, 510-294-2687

 

• Advanced Batteries and Supercapacitors

Electrochemical R&D for DOE is longstanding and diverse, meeting many needs for high quality and reliable systems for weapons programs, and working at the forefront in many nonweapons areas of technology. Lawrence Berkeley Lab is well known for fundamental research, and Sandia for devices, having supplied all the power supplies for nuclear weapons systems since the 1950s.

Until a reorganization on July 1, Sandia’s work in battery technology was part of a larger activity called the “Electronic Components Center”, which includes microelectronics, modules, optoelectronics, components and reliability. Full fabrication capability. [This Center could be a valuable resource for a utility’s customers in these industries. Ray Bair, Director, 505-844-1912.]

Battery programs now reside in the “Energy Components Center” (Joan Woodard, Director 505-845-9917) along with work in explosives and neutron generators, though personnel will continue their close coordination with the Electronics Center.

There are four battery development groups at Sandia, each with a different emphasis, but closely interrelated. The department heads form a coordinating team.

Dan Doughty Battery Programs 505-845-8105

Ken Grothaus Battery Research 505-844-1654

Dennis Mitchell Battery Development 505-844-8656

Paul Butler Testing Program 505-844-7874

(Full range of performance, abuse, failure, and qualification testing. Extensive facilities.)

 

– Work in Zinc/Silver Oxide, Sodium Sulfur, Zinc Air, Zinc Bromine, Advanced Lead Acid, Nickel Hydrogen, Nickel Cadmium, Lithium/Sulfur Dioxide, Supercapacitors

– USABC CRADA, with automakers, lithium rechargeable battery development and testing

– Implantable long life battery development for medical application

– Battery Technology Initiative — funds-in CRADA with 4 companies for consumer batteries

– Ultracapacitor — thin film to get 1000 F in a D cell.

– Reserve Batteries — primary energy sources; one-shot devices activated by external means. For weapons systems; not likely to have commercial application.

 

• Utility Battery Storage Program Paul Butler, 505-844-7874 Abbas Akhil, 505-844-3353

Battery technology development (Pb-acid with GNB, Sodium sulfur with Silent Power, etc.), modular systems (AC Battery/Delco), systems studies (SDG&E, Chugach, Oglethorpe, BPA), feasibility studies (SMUD, Chugach), test & demos (PG&E, Metlakatla Alaska, PREPA) subsystems engineering, integration, industry outreach.

Strictly electric power industry oriented. About half of budget goes to industry in heavily cost shared projects. Sandia sees utility applications as being very nearly ready for take off. (Phase 2 of “Opportunities” project just getting underway–needs industry participation! Phase 1 report available from Paul Butler.) Broad view of potential emphasizes T&D benefits, DSM and UPS/Power Quality applications, which don’t require very large scale demos. Problems with large scale installations leading to new approach to do smaller units that are flexible or transportable. More of a T&D asset like a transformer. Puerto Rico’s experience with 20 MW unit has them convinced to meet their estimated need of 100 MW with turnkey units.

 

Provide support to the Utility Battery Group (UBG)

[An excellent and very cost effective way for utilities to stay abreast of developments; controlled by its utility members Many UFTO members already active. Contact Rick Winters, UBG chairman (PG&E/Endicon) 510-867-0904, or Paula Taylor, Energetics, 410-290-0370.]

• Renewables Paul Klimas, Manager, Renewable Energy Office, 505-844-8159

Sandia’s goal is to develop commercially viable energy technologies based on solar, wind and geothermal resources so they beocme significant domestic and international supplies. They have a long-term focus on the utility sector, expecting remote markets to play a key role in supporting the industry.

Photovoltaics Marjorie Tatro 505-844-3154

Activities in all aspects, from cell development to system applications. Work closely with industry on technology development for crystalline silicon cells and modules and other systems components (e.g. inverters, battery charge controllers and controls), and with the systems integration industry and users through the PV Design Assistance Center. The Center did a thorough evaluation of existing installations and identified new opportunities for the National Park Service. They have an extensive publications list (including some on utility interconnection issues), and provide support to project developers here and abroad.

In the past, Sandia had a number of partnerships under an initiative on concentrators, but chose not to support this work when funding levels were reduced in 1993. The only concentrator effort funded through FY94 was the low concentration line focus concept advanced by SEA Corp.

In one-sun cell development, Sandia emphasizes crystalline silicon, working on cell designs and processes. (NREL tends to be more involved in advanced materials and thin film.) Sandia believes their broad resources in manufacturing are valuable, bringing optimized high temperature processes, surface treatments and reduced waste streams to the manufacturers of cells.
Solar Thermal Craig Tyner 505-844-3340

Manage the conversion of Solar One (still operational!) to Solar Two. IR 100 awards for Solar Detox and Dish-Stirling. $150 million jointly funded program with utilities and manufacturers on Dish Stirling engines (Cummins 7 kW remote power unit is making good progress, and there are two other larger system efforts, both with utility involvement). (“Compendium of Solar Dish/Stirling Technology”, SAN93-7026 Printed Jan. 1994, by W.B. Stine and R.B. Diver, a new report surveys international state of the art.)

The National Solar Thermal Test Facility has an array of heliostat, dish and trough systems for running tests of various kinds.

The Solar Thermal Design Assistance Center provides technical assistance, helping clients select and apply solar thermal technology. (Contact David Menicucci, 505-844-3077).
Wind Henry Dodd, 505-844-5253

Historically, Sandia’s emphasis was on the vertical axis concept, however they have a new initiative to approach wind with a systems view, and have worked on materials and blade design improvements for all wind machines.
Geothermal Jim Dunn, 505-844-4715

Working to reduce costs — developing down hole instrumentation to reduce loss circulation, and”slim-hole” technology that could cut cost of drilling by 1/2 (appropriate for remote village applications). Also working on geothermal ground source heat pump concept (drilling, placement and heat exchanger design). Helped commercialize new drill bit.
• Fuel Cells Gary Carlson, Manager, Fuel Science Dept. 505-844-8116

This is a small program, using most internal lab directed funds, except for work for the DOE Office of Transportation Technology on advanced concepts. Goal is to develop partnerships with industry, and capitalize on Sandia’s capabilities in batteries, catalysis, and especially manufacturability. Note need for better materials to get long term performance. Sandia/Livermore is doing some work in PEM thin films, applying membrane supported catalysis to enable on board hydrogen production.

 

They see special opportunity to develop a small fuel cell (less than 1 KW) for remote applications, to compete with PV and batteries. One application could be gas pipeline condition monitoring.

Sandia has a broad capability to tailor properties of carbon foams, as applied to supercapacitors, advanced (Li) batteries, and fuel cells.

 

• Robotics Sandia Intelligent Systems and Robotics Center, Phil Bennet, 505-845-8777

Sandia is at the forefront of bringing defense and weapons related “Intelligent Systems and Robotics” to bear on commercial needs, and has grown to be the leading robotics R&D effort in the U.S. They focus on critical national needs (hazardous waste clean up and manufacturing competitiveness), reducing the time and cost to develop applications of advanced technology into practical systems, and improving the speed, quality and safety of operations. There is a strong emphasis on working with industry, universities and other government facilities.

Their approach is based on an open-architecture communications-based integration of sensors, mechanisms and software. Computer-model and realtime sensor-based control strategies make off-line programming possible, speeding the development of applications and systems.

Historically, DOE’s internal need for systems to handle small production lots led to the development of ways to reduce the costs of programming and fixturing.

Specific projects relevant to utilities include robotic welding of spent fuel barrels, saving on the order of $250 million and thousands of man rems of exposure. Another involves hot repairs to boilers — in fossil plants (proprietary — with an unnamed utility)!

This Center is clearly a potentially valuable resource for automating utility operations, as well as for industrial customers who develop or use robotics. A good overview is contained in a booklet called “Sandia is Changing the Way the U.S. Does Robotics.” Sandia staff have also authored a number of papers at robotics conferences.

 

• High Consequence Operations Russ Skocypec, 505-845-8838

Sandia’s Engineering Sciences Center encompasses computation, testing, and validation, enabling design trade-offs to be confidently evaluated. Evolving from a historical mission to support systems design and safety for nuclear munitions, they now can offer industry a means to quantify efficiency and safety issues pertaining to industrial accident phenomenology. Detailed risk assessment and coupled analysis and testing provide understanding of the physics of fires, crashes and blasts, enabling better decisions about prevention and response.

 

• High Performance Computing Sudip Dosanjh, 505-845-7018

DOE operates the Massively Parallel Computing Research Laboratory (MPCRL) at Sandia, which applies these new levels of computing power to a broad array of scientific and engineering problems, ranging from structural mechanics and acoustics to chemical reaction dynamics, genome mapping and astrophysics. In the last 4 years alone, the computational speeds have increased by a factor of 100. In collaboration with the University of New Mexico, Sandia has developed a unique operating system called SUNMOS, and their own linear equation problem solver gives them powerful capabilities in parallel computing.

A newletter called the MPCRL Research Bulletin is available.

[Perhaps a place to try some new approaches in power system modeling? Particularly in connection with the next item.]

 

• Distributed Information Technologies,

Rich Palmer, Manager, California Program Development, 510-294-13126

Sandia has a major role in developing technologies for distributed information systems that will contribute to building the “National Information Infrastructure.” Industry has needs similar to DOE’s Defense Programs to use cost-effective distributed information systems to access and process information. The issues are the same: manipulating large data sets, moving them around efficiently, and dealing with privacy and security issues. DOE labs have developed synthetic data sets as benchmarks for participants to perform their own validations and comparisons. The goal is to be able to run problems on very large parallel or distributed systems via high-speed networks.

Sandia has also built extensive testbeds to develop and evaluate distributed applications over Asynchronous Transfer Mode (ATM) networks tying together distributed computing resources. The testbeds include long-link emulators that simulate delays and errors encountered in wide-area networks over large distances. To complement those testbeds, Sandia has also developed a Monte-Carlo simulation based modeling capability for studying realistic network component performance and issues such as congestion control mechanisms for large networks. By including the proper physical representations of traffic models for sources and sink, the same modeling capability could by used to simulate the performance, utilization, and potential overload of wide-area electrical transmission grids.

 

• Sensors Marion Scott, Manager, Sensor Programs Dept., 505-845-8146

Sandia’s work in microsensor development includes acoustic, micro machine/micro electronics, fiber optics, and micro impedance techniques. They have their own complete CMOS IC fabrication capability in-house, as well as for gallium arsenide, enabling them to undertake unique development challenges, such as combining micro machined structures and associated electronics on an IC.

– A bulk quartz resonator can look at the condition of oil in situ. Other possible applications–monitor the state of charge of a Pb acid battery or the capacity of coolants.

– Surface acoustic wave devices coated with chemically sensitive films can sense chemical species in gas at parts per million by looking at resonance changes. With multiple coatings and using pattern recognition techniques it’s possible to distinguish multiple species. Has been packaged in a down hole tool for pollutant sensing.

-Hydrogen sensor on a chip uses special alloys that change their resistivity with maximum sensitivity to H2 concentration.

– Fiber optics offer another technique to sense a wide range of chemicals, such as hydrogen, mercury, SO2, chlorine, and various oxidants. The end of the fiber is coated with a thin chemically sensitive film that changes its reflectivity. CRADA underway with the JW Harley & Assoc to develop a H2 sensor for utility transformers.

– Micro impedance and capacitive sensors can measure physical features for manufacturing applications, e.g. detecting surface flaws in real time. This has been applied to textiles.

– Accelerometers measure vibration indicating structural changes. Sandia has developed a fiber optic/micro machine hybrid device.

• Materials Jim Jellison, Manager, Technical Business Operations,
Materials & Process Sciences, 505-844-6397

Sandia’s Materials Science and Technology program has 600 staff, and is the largest in DOE. Originally developed to provide non-nuclear components for weapons, it now offers services to a wide range of government customers and private industry. The forte is concurent design of the product and the process to make it.

Expertise includes welding, especially cold welding, and soldering; mechanics; tribology, especially lubricant free, with a focus in electromechanical devices; corrosion, emphasis on electronics (e.g., fluxes on circuits, dissimilar metals, batteries); corrosion kinetics, atmospheric testing facility (sensitivities in ppb); aluminum coatings–developing replacement process with less environmental impact; laser surface ablation.

Smart Processes — predictive models using phenomenological data enhances casting, heat treatment, welding, induction heating, etc.

Aging of organic/polymer materials-accurately accelerated aging tests. Applied to electrical cable in work for the NRC

• Reliability/Decision Making

Robert Cranwell, Manufacturing Systems Reliability, (505)844-8368

Industry and the nuclear weapons complex (NWC) rely upon the availability and reliability of equipment which can greatly influence operational costs. Equipment design, reliability, maintenance strategies, and spares inventories all contribute to the cost-of-ownership of factory or plant equipment. Sandia has developed capabilities to assist industry and the NWC in “design for reliability”, equipment improvement analyses, creation of maintenance strategies, and optimization of spares inventories. These capabilities have been broadly applied throughout industry, including the U.S. semiconductor industry, biomedical industry, machine tool industry, automotive and aircraft manufacturing industries, and solar power industry. The capabilities include custom reliability analysis software, optimization analysis techniques, predictive maintenance capabilities, and cost-of-ownership analysis tools. Key partners include SEMATECH and several of its member companies, Cincinnati Milacron, McDonnell Douglas, and USCAR (a consortia of the “big three” auto makers).

Sandia has been working with several major companies, including Motorola and Texas Instruments, to evaluate and qualify new environmentally conscious “no clean” soldering technologies that do not require subsequent cleaning of newly soldered printed wiring assemblies. These new processes are being used extensively throughout industry with great success (Two reports, 11/92 and 6/95, describing these efforts have been issued.)

The Energy Analysis Diagnostic Center (EADC) is a DOE/Office of Industrial Technology program at 30 universities around the U.S., which perform energy audits of companies. In conjunction with this program, Sandia is working with two of the NIST Manufacturing Technology Centers (MTCs) to develop an integrated energy, environment and manufacturing (EEM) assessment tool, the concept being that these three areas (energy, environment, and manufacturing) need to be assessed on an integrated basis, as an attempt to optimize in one area could cause problems in the others. This integrated tool would be used by MTC field agents to assist U.S. manufacturers in EEM related issues, and is being piloted in SIC codes 345, 346 and 347 (screw machines, stampings and forging and metal coating). The Sandia/MTC program is jointly funded by EPRI, NIST, EPA, DOE/OIT, and Sandia.

Follow-on opportunities are needed.

Detailed briefings or information are available on request.

[Perhaps this group would be a good resource to go after the T&D maintenance issue?]

• Micro SMES, Dean Rovang, 505-845-8277

Both Sandia and Los Alamos have a hand in this program to build a SMES unit that would be about 10x larger than Superconductivity, Inc.’s unit, and smaller than the B&W/Anchorage device. The application is Power Quality for industrial customers, and/or at the substation level — on the order of 10’s of MW for seconds. This is seen as a development project, not a research one, with the goal to learn if such a device is the solution to an industry problem.

CRADA negotiations are underway with one utility already, however there is very likely a way for other utilities to participate, if only by providing modest funding for a seat at the table.

• HyMelt, Stuart Purvis, 505-845-8392

The technology makes it possible to convert low grade hydrocarbon feedstocks (or fossil fuels) directly into Hydrogen and Carbon Monoxide (separate product streams!) while sequestering impurities, even producing elemental sulfur. There is no stack, and no emissions.

Ashland wants this technology for its refineries, to deal with the sour crude it often must buy, to produce hydrogen, and to handle refinery “bottoms”, which are a costly disposal headache. As a Hydrogen producer, HYMELT is estimated to be 30% cheaper than steam reforming when using the same feedstock, i.e. fuel gas. It is cheaper still when a waste stream is used as the feedstock instead.

Ashland Oil has demonstrated proof of concept in their labs, and has funding committed for a production installation. What’s missing is the piece in the middle — the intermediate scale demonstration R&D. Sandia is proposing to DOE/Fossil to fund the government side of a CRADA with Ashland, but with budget cuts, funds might not be available. Ashland has asked Sandia to look discretely for a partner interested in other fields of use, and who could put up $800k/year for 3 years, leveraging the many $ millions that Ashland has spent and committed.

[This information should be handled with discretion.]

Contact Al Sylwester Tel # 505-844-8151
• High power switching Don Cook, 505-845-7446

Sandia has developed very fast, very high power switching capabilities in connection with pulsed particle accelerators for fusion research and other work requiring fast pulses. For example, they can make a 20 megavolt, 10-20 megamp pulse with a 50 nsec. risetime.

It has been suggested that this technology might be applicable to utility needs, however an initiative would be needed to establish a dialogue between the developers and someone from the utility industry to explore the possibilities.

Sandia Contacts
General Telephone # is (505) 844-5678
In Livermore, CA (510) 294-3000

The primary contacts for UFTO are:
Alan P. Sylwester, Technology Integration Dept., 505-844-8151
Dan E. Arvizu, Director, Applied Energy Program 505-845-8336
Technology Transfer: 505-271-7888

Information Source Contacts / Technical Information Services:

Office of Public Relations and Communications : 505-845-7759

Publications:
“Laboratory Publications” 505-844-4902
Technical Publications 505-844-9285
Technical Library 505-845-8364