Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities [1 ed.] 9780309576239
149 26 572KB
English Pages 85 Year 2000
Polecaj historie
![Materials Research Agenda for the Automobile and Aircraft Industries [1 ed.]
9780309573115, 9780309049856](https://dokumen.pub/img/200x200/materials-research-agenda-for-the-automobile-and-aircraft-industries-1nbsped-9780309573115-9780309049856.jpg)
![Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities [1 ed.]
9780309576239](https://dokumen.pub/img/200x200/materials-technologies-for-the-process-industries-of-the-future-management-strategies-and-research-opportunities-1nbsped-9780309576239.jpg)
Citation preview
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
i
MATERIALS TECHNOLOGIES FOR THE PROCESS INDUSTRIES OF THE FUTURE Management Strategies and Research Opportunities
Committee on Materials Technologies for Process Industries National Materials Advisory Board Commission on Engineering and Technical Systems National Research Council
NMAB-496 National Academy Press
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
ii
NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competencies and with regard for appropriate balance. This report was prepared with the support of the U.S. Department of Energy, Grant No. DE-FG41-95R110859. However, any opinions, findings, conclusions, or recommendations expressed herein are those of the authors and do not necessarily reflect the view of DOE. Available in limited suppply from: National Materials Advisory Board National Research Council 2101 Constitution Avenue, N.W. Washington, D.C. 20418 202-334-3505 [email protected] Copyright 2000 by The National Academy of Sciences . All rights reserved. Printed in the United States of America.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
iii
The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. Upon the authority of the charter granted to it by the Congress in 1863, the Acade my has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Bruce Alberts is president of the National Academy of Sciences. The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. William Wulf is president of the National Academy of Engineering. The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, upon its own initiative, to identify issues of medical care, research, and education. Dr. Kenneth I. Shine is president of the Institute of Medicine. The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Bruce Alberts and Dr. William Wulf are chair and vice chair, respectively, of the National Research Council. www.national-academies.org
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
iv
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
v
COMMITTEE ON MATERIALS TECHNOLOGIES FOR PROCESS INDUSTRIES JOSEPH G. WIRTH (chair), Raychem Corporation (retired), Mt. Shasta, California CORBY G. ANDERSON, University of Montana, Butte ORVILLE HUNTER, JR., A.P. Green Industries, Incorporated (retired), Columbia, Missouri SYLVIA M. JOHNSON, NASA Ames Research Center, Moffett Field, California HARRY A. LIPSITT, Wright State University (emeritus), Dayton, Ohio NICHOLAS MONTANARELLI, Ballistic Missile Defense Organization, Washington, D.C. ANATOLY NEMZER, FMC Corporation, Princeton, New Jersey HAROLD W. PAXTON, Carnegie-Mellon University, Pittsburgh, Pennsylvania PETER H. PFROMM, Institute of Paper Science and Technology, Atlanta, Georgia FREDERIC J-Y QUAN, Corning Incorporated, Corning, New York MICHAEL P. THOMAS, Alcan Aluminum Corporation, Farmington Hills, Michigan SHELDON M. WIEDERHORN, National Institute of Standards and Technology, Gaithersburg, Maryland National Materials Advisory Board Staff ARUL MOZHI, Acting Director and Senior Program Officer TERI THOROWGOOD, Research Associate PAT A. WILLIAMS, Administrative Assistant Government Liaisons MERRILL SMITH, U.S. Department of Energy, Washington, D.C. CHARLES A. SORRELL, U.S. Department of Energy, Washington, D.C.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
vi
NATIONAL MATERIALS ADVISORY BOARD EDGAR A. STARKE (chair) University of Virginia, Charlottesville EARL DOWELL, Duke University, Durham, North Carolina EDWARD C. DOWLING, Cleveland Cliffs, Inc., Cleveland, Ohio THOMAS EAGAR, Massachusetts Institute of Technology, Cambridge HAMISH L. FRASER, Ohio State University, Columbus ALASTAIR M. GLASS, Bell Laboratories, Lucent Technologies, Murray Hill, New Jersey MARTIN E. GLICKSMAN, Rensselaer Polytechnic Institute, Troy, New York JOHN A.S. GREEN, Aluminum Association, Inc., Washington, D.C. THOMAS S. HARTWICK, TRW, Redmond, Washington ALLAN J. JACOBSON, University of Houston, Houston, Texas MICHAEL JAFFE, New Jersey Institute of Technology and Rutgers, the State University of New Jersey, Newark SYLVIA M. JOHNSON, NASA Ames Research Center, Moffett Field, California SHEILA F. KIA, General Motors Research and Development Center, Warren, Michigan LISA KLEIN, Rutgers, the State University of New Jersey, Piscataway HARRY A. LIPSITT, Wright State University (emeritus), Dayton, Ohio ALAN G. MILLER, Boeing Commercial Airplane Group, Seattle, Washington ROBERT C. PFAHL, JR., Motorola, Schaumburg, Illinois JULIA PHILLIPS, Sandia National Laboratories, Albuquerque, New Mexico HENRY J. RACK, Clemson University, Clemson, South Carolina KENNETH L. REIFSNIDER, Virginia Polytechnic Institute and State University, Blacksburg T.S. SUDARSHAN, Materials Modification, Inc., Fairfax, Virginia JULIA WEERTMAN, Northwestern University, Evanston, Illinois National Materials Advisory Board Staff ARUL MOZHI, Acting Director
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
PREFACE
vii
Preface
The U.S. Department of Energy (DOE) Office of Industrial Technology (OIT) requested that the National Research Council, through the National Materials Advisory Board (NMAB), conduct a study to evaluate its crosscutting materials programs. The committee on Materials Technologies for Process Industries was established to review OIT’s materials programs and management strategies, identify research and application needs, and identify barriers to commercialization. In addition, the committee was asked to recommend criteria for selecting and prioritizating future research. The recommendations reflect OIT’s transition to the “marketpull”management strategy recently adopted by the Industries of the Future (IOF) Program. The following specific tasks were addressed by the committee through a three-day workshop: • Review the progress and accomplishments of OIT’s crosscutting materials technology programs. • Describe program-management strategies, such as criteria for project selection, plans for commercialization, and industry involvement. • Describe successful and unsuccessful efforts by OIT to develop commercial applications for new or advanced materials technologies. • Identify research opportunities or potential future applications in the OIT target industries. • Recommend criteria for selecting and prioritizing projects for further research and development of new or advanced materials technologies. The committee met with DOE program managers and industry representatives in Washington, D.C., on September 15, 16, and 17, 1999, to discuss progress, accomplishments, and strategies of OIT’s materials programs. This report includes reviews of workshop presentations and offers recommendations for strengthening and focusing OIT’s programs. The chair thanks the committee members for their participation in the workshop and their effort and dedication in preparing this report. The chair also thanks the
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
PREFACE
viii
speakers and participants in the workshop, as well as the staff of NMAB, especially Arul Mozhi, for arranging the workshop and providing substantial assistance in the preparation and publication of the committee’s report. Comments and suggestions can be sent via e-mail to [email protected] or by fax to (202) 334-3718. JOSEPH G. WIRTH, chair Committee on Materials Technologies for Process Industries
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
ACKNOWLEDGMENTS
ix
Acknowledgments
The Committee on Materials Technologies for Process Industries would like to thank all of the participants in the workshop, which was the principal data-gathering session for this study. The information and insight from the participants were invaluable to the committee. The committee would like to thank those individuals who prepared presentations for the workshop. Presenters included: Brent Hiskey, University of Arizona; Egon Wolff, Caterpillar, Inc; Mark J. Rigali, Advanced Ceramics Research, Inc.; Peter Pfromm, Institute of Paper Science and Technology; Homi Bhedwar, Dupont; Frederic Quan, Corning, Inc; John Green, The Aluminum Association; Jeffrey Smith, University of Missouri-Rolla; Raymond Donahue, Mercury Marine; George Mochnal, Forging Industry Association; Robert Gaster, John Deere and Company; Steve Furey, Sandusky International; William Werst, U.S. Advanced Ceramics Association; Phillip Craig, AlliedSignal Composites, Inc; Rich Goettler, McDermott Technologies; James Schienle, AlliedSignal Ceramic Components; Peter Angelini and Michael Karnitz, Oak Ridge National Laboratory; and William Parks, Charles Sorrell, Merrill Smith, Patricia Hoffman, Sara Dillich, and Toni Marechaux, U.S. Department of Energy Office of Industrial Technology. The committee is particularly grateful to Charles Sorrell and Merrill Smith of the Office of Industrial Technology for their technical assistance and Jim Quinn and Denise Swink of the Office of Industrial Technology for their support. This report has been reviewed by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the NRC’s Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the authors and the NRC in making the published report as sound as possible and to ensure that the report meets institutional standards for objectivity, evidence, and responsiveness to the study charge. The content of the review comments and draft manuscript remain confidential to protect the integrity of the deliberative process. We wish to thank the following individuals for their participation in the review of this report: Lisa Klein, Rutgers, The State University of New Jersey; Jay Lee, University of
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
ACKNOWLEDGMENTS
x
Wisconsin-Milwaukee; Francis McMichael, Carnegie-Mellon University; and John Green, The Aluminum Association. Although the reviewers listed above have provided many constructive comments and suggestions, they were not asked to endorse the conclusions or recommendations nor did they see the final draft of the report before its release. The review of this report was overseen by Norman Gjostein, Ford Motor Company (retired), appointed by the Commission on Engineering and Technical Systems, who was responsible for making certain that an independent examination of this report was carried out in accordance with institutional procedures and that all review comments were carefully considered. Responsibility for the final content of this report rests entirely with the authoring committee and the institution. Finally, the panel gratefully acknowledges the support of the staff of the National Research Council and National Materials Advisory Board (NMAB), including Arul Mozhi, study director; Thomas E. Munns, former NMAB associate director (now at ARINC); Teri Thorowgood, research associate; Patricia Williams, senior project assistant; and Carol R. Arenberg, editor.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
CONTENTS
xi
Contents
EXECUTIVE SUMMARY
1
1
INTRODUCTION Market-Pull Strategy, Characteristics of the Industries of the Future, Materials Programs and Crosscutting Technologies, Report Objectives,
9 9 12 12 15
2
MATERIALS NEEDS FOR THE INDUSTRIES OF THE FUTURE Corrosion Resistance, Wear Resistance, High-Temperature Materials, Materials Models and Databases, Issues That Impact Crosscutting Programs,
17 17 20 21 22 22
3
MATERIALS PROGRAMS Advanced Industrial Materials Program, Continuous Fiber Ceramic Composites Program, Industrial Power Generation Program,
27 27 30 31
4
MANAGEMENT STRATEGIES Program Management, Criteria for Project Selection, Commercialization Plans, Industry Involvement,
33 33 35 38 38
5
RESEARCH AND DEVELOPMENT OPPORTUNITIES Aluminum Industry, Chemical Industry, Forest Products Industry, Glass Industry, Mining Industry, Steel Industry, Heat-Treating Industry, Refractories: An Illustrative Crosscutting Area, Opportunities for Materials Research and Development,
41 41 44 45 49 51 51 53 54 58
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
CONTENTS
6
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
xii
OVERALL RECOMMENDATIONS Linkages between Industry Road Maps and Materials Programs, Materials Needs in Industry Road Maps, Market-Pull Strategy, Metrics, 59 59 60 60 61
REFERENCES 63
APPENDIXES
A Recommendations, 67
B Biographical Sketches of Committee Members, 69
ACRONYMS 73
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
EXECUTIVE SUMMARY
1
Executive Summary
The U.S. Department of Energy (DOE) Office of Industrial Technology (OIT) requested that the National Research Council, through the National Materials Advisory Board, conduct a study to evaluate its crosscutting materials programs (i.e., programs on materials applicable to more than one industry). The Committee on Materials Technologies for Process Industries was established to review OIT’s materials programs and management strategies, identify research and application needs, and identify barriers to the commercialization of new technologies. The committee met with OIT program managers and industry representatives in Washington, D.C., on September 15, 16, and 17, 1999, to discuss the progress, accomplishments, and strategies of OIT’s materials program. This report reviews the results of the workshop and offers recommendations for strengthening and focusing OIT’s materials technologies programs. Chapter 1 provides background on OIT’s Industries of the Future (IOF) Program and other activities. Chapter 2 is an overview of the materials needs of IOF member industries. Chapter 3 is an overview of OIT’s current materials programs. Chapter 4 presents the committee’s review of OIT’s management strategies. In Chapter 5, the committee identifies directions for materials research and development (R&D). Chapter 6 contains the committee’s recommendations for improving OIT’s materials programs. BACKGROUND TO INDUSTRIES OF THE FUTURE Chapter 1 describes OIT’s transition to a “market-pull” strategy, the unique characteristics of the IOF Program, the OIT materials programs, and the opportunities for developing crosscutting technologies. The nine IOF industries, which are all major energy consumers and major generators of wastes, are: agriculture, aluminum, chemicals, forest products, glass, metalcasting, mining, petroleum refining, and steel. OIT also supports some work in related industries (e.g., carbon products, forging, heat treating, and welding) when appropriate. The metal forging and heat-treating industries are included in the scope of this report.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
EXECUTIVE SUMMARY
2
Market-Pull Strategy Since 1993, OIT has been changing its R&D programs from a “technology-push” strategy, in which research projects are selected and prioritized primarily for their potential to reduce energy consumption and waste generation, to a market-pull strategy, in which R&D projects are selected and prioritized primarily for meeting identified industry needs and priorities. A critical element of the market-pull strategy has been a strong emphasis on team involvement in R&D projects. Team members may include national laboratories, universities, and industrial firms. OIT projects have been extended beyond technology development to include product development and demonstration, as well as early commercialization, in partnership with industry. However, industry is primarily responsible for commercialization, and OIT plays a supporting role. Characteristics of the Industries of the Future The nine IOF industries have several common characteristics: high capital intensity, global competition, cyclical business, production of commodity products (high product volumes, low prices, and low profit margins), and mature markets and technologies. These industries are also major energy consumers and generators of wastes. Current business realities have had profound effects on the availability of capital for industry to invest in product development, in the scale-up of new technologies, and in facilities necessary for commercialization. Cost and profitability pressures have limited investments by individual companies in R&D, as well as their ability to accept and implement new technologies and their willingness to take risks. An intangible but important barrier to the acceptance of a new technology is organizational resistance to technological change. When OIT selects industrial partners, it must take these factors into account to increase the probability of success. Crosscutting Technologies The concept of crosscutting is highly attractive as a way of broadening the impact, and thus the return on investment, of a particular technology. In some cases, the resources required to solve the materials problems of a single industry may be too great to be cost effective. However, if several industries will benefit, it may make “business sense” for the taxpayer to invest in its development. For example, the need for improved refractories is included in nearly all of the technology road maps for the IOF industries. However, because the operating environments and conditions of these industries differ greatly (e.g., glass and steel) materials compositions, performance requirements, and fabrication techniques for refractory materials also differ greatly.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
EXECUTIVE SUMMARY
3
MATERIALS NEEDS OF THE INDUSTRIES OF THE FUTURE Chapter 2 provides an overview of the materials needs of the IOF industries, especially crosscutting needs. The materials needs are documented in detail in the industry road maps developed for the IOF Program. Table ES-1 shows the most important materials needs of the IOF industries. Several interesting conclusions can be drawn from this table. First, many of the IOF industries have similar, if not identical, needs. Thus, selecting truly crosscutting R&D projects would not be difficult. Second, many areas for R&D are currently not considered interesting, exciting, or on the cutting edge of technology. Nevertheless, OIT project managers should take these areas into account in planning R&D programs. Third, a few areas of materials research are extremely important in ALL of the industry road maps. Therefore, progress in these areas (corrosion, wear, hightemperature materials [including refractories], and materials modeling/database development) would have the greatest effect on energy savings and waste reduction and would meet the needs of the IOF industries. Therefore, these areas are emphasized in this report. Finally, a number of common issues (predictability, producibility, productivity, pollution prevention, and performance) and emerging technologies will impact crosscutting materials programs. OIT MATERIALS PROGRAMS Chapter 3 provides an overview of OIT’s materials programs. The Advanced Industrial Materials (AIM) Program and the Continuous Fiber Ceramic Composites (CFCC) Program are focused principally on the development and commercialization of materials. As carryovers from prior years, the AIM and CFCC programs are only now being fully integrated into OIT’s market- pull strategy or coordinated with the technology road maps. The Industrial Power Generation Program includes the development and testing of materials to accelerate the development and commercialization of industrial power-generation equipment (e.g., advanced turbine systems [ATS] and microturbines). The Industrial Power Generation program has some areas of synergy with other OIT programs, especially with intermetallics (AIM) and ceramics (CFCC). Recently, the Industrial Power Generation program has transferred to DOE’s Office of Power Technologies.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
**
Abrasion of earthmoving parts
*
Wear
Examples
HighTemperature Materials (including refractories)
Examples
Modeling/ Database Development
*
Corrosion by agricultural chemicals
Examples
Examples
*
Corrosion
Agriculture
Long-term materials response to harsh environments
Modeling of castings, modeling of smelter cells
Corrosion modeling
**
Process modeling and refractory response
**
Refractories
Boilers
Containment vessels, refractories ***
***
Wear of refractories in tanks and on handling, molds, and process machinery
**
Molten glass attack on refractories
**
Glass
*
Wear of raw materials parts and abrasive wear during paper manufacture
***
Boilers, black liquor
***
Forest Products
**
Liquid/solid abrasion in pipes
**
Corrosion of reaction vessels and pipes
***
Chemicals
**
Refractories, anodes, cathodes
**
Wear of refractories
*
Liquid aluminum attack on refractories
**
Aluminum
TABLE ES-1 Importance of Selected Materials Needs to IOF Industries
Heat-flow modeling and design of gates and risers
**
Dies, refractories
**
Wear of dies
**
Molten metal attack on refractories
**
Metal Casting
Lifetime modeling of downhole materials
***
Tools and downhole equipment
**
Wear of drill bits
***
Drilling mud and effluent gases
***
Mining
Lifetime of materials used in handling
**
Better refractories
***
Wear of refractories and equipment for handling hot metal
***
Corrosion of refractories and mill equipment
**
Steel
Thermomechanical response of dies, etc.
*
Dies
**
Wear and cracking of dies
*
N/A
*
Forging
Thermal response of materials
*
Handling equipment
**
*
N/A
*
Heat Treating
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
EXECUTIVE SUMMARY 4
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
EXECUTIVE SUMMARY
5
MANAGEMENT STRATEGIES Chapter 4 discusses ways to improve OIT’s program management, the development of project selection criteria, commercialization plans, and industry involvement in OIT programs. The recommended management strategies will be applicable to crosscutting programs as OIT integrates its materials projects into the market-pull strategy. Program Management Based on the workshop presentations, OIT’s current strategies for program management are generally consistent with its objectives for the IOF Program. However, several improvements could be made. Recommendation. The Office of Industrial Technologies (OIT) should establish a permanent advisory panel of industry experts to work in parallel with OIT’s industry teams. Members of the panel could be drawn from these teams and should include at least one representative of each Industries of the Future member industry. The advisory panel would provide expert knowledge and advice to OIT program managers and ensure that the ultimate goals are kept in focus throughout the development cycle of a technology. The panel should perform the following functions: • rank industry priorities and select programs • assist in developing program metrics (to measure progress) • review programs annually Criteria for Project Selection The committee identified a number of ways the criteria for project selection could be improved. Currently, project selection appears to be greatly influenced by the program manager heading the IOF department associated with a particular industry. Although this arrangement may encourage accountability, it does not always result in the best selections. A panel of experts, which would include industry leaders, would be able to select projects of value to the industry that are also consistent with OIT’s objectives. As part of the selection process, the panel would assess the project’s potential economic payoff. OIT will play a critical role in funding and moving forward high-risk/high-payoff projects that are not supported at the commercial level because of competitive pressures.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
EXECUTIVE SUMMARY
6
Plans for Commercialization The committee found many ways the commercialization of new technologies could be improved. The process could be improved if it were given more support, including taking advantage of the expertise of the office of research and technology applications (ORTAs) at the national laboratories and the small business innovation research (SBIR) and small business technology transfer (STTR) programs. ORTA personnel could assist OIT in determining the economic impacts of new technologies on the IOF industries. Industry Involvement Truly effective research must be closely coupled to industry needs, in terms of both timing and technology. If the results of the research are not useful to industry, the economic payoff may be smaller than if it meets an identified industry need. If an R&D program does not appear to be focused on meeting an identified need, OIT may have to reevaluate its support for the program. The evaluation should be made by people with both industry and technological expertise and with the authority to make decisions about implementation. OPPORTUNITIES FOR RESEARCH AND DEVELOPMENT Chapter 5 discusses R&D opportunities for select IOF industries and crosscutting technologies, using refractories as an example. In keeping with the crosscutting theme of this report, the committee focused on materials technologies that would enable or improve the understanding and processing of existing and new products used by more than one IOF industry rather than on the development of industry-specific products. The R&D opportunities are summarized in the following recommendations. Recommendation. The Office of Industrial Technologies (OIT) should focus its materials technologies programs on a few high-priority areas that would meet the needs of several member industries of the Industries of the Future Program and, when warranted, develop crosscutting programs to address these areas. Areas to consider include: corrosion, wear, high-temperature materials (including refractories), and materials models and databases. OIT should use the panel of experts to identify materials-performance requirements and process parameters for each industry as a basis for selecting crosscutting technologies. OIT should then work with the panel to develop and select programs.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
EXECUTIVE SUMMARY
7
Recommendation. Funding by industry, universities, and the national laboratories for the development of improved refractories has been reduced although most of the members of Industries of the Future Program have identified a need for them. The Office of Industrial Technologies should consider starting a refractories initiative to encourage cooperative research and development agreements and other mechanisms that would promote cooperation between industry and government agencies. OIT should consider supporting research and development in the following areas: reducing corrosion/erosion high-temperature reactions between molten metal, glass, and refractories; reducing the buildup of materials on the surface of the refractories; clarifying the fundamentals of monolithic refractories (including drying mechanisms and new binder systems); and developing data for finite element analysis design. OVERALL RECOMMENDATIONS Recommendation. The Office of Industrial Technologies should coordinate its materials technology programs with the technology road maps developed for the Industries of the Future (IOF) Program. Unfinished road maps should be completed, and all road maps should be updated every two to three years. Requests for research proposals should be linked specifically to the highest priority needs of the IOF industries. Recommendation. The Office of Industrial Technology should determine the highest priority needs in the technology road maps as a basis for identifying opportunities for crosscutting research. Industry experts should be engaged to define the materials-performance requirements and operating environments. This information could then be used to develop new programs and evaluate current programs. Recommendation. Current and new materials technology programs should be fully integrated into the market-pull strategy. Proposals for new programs should be evaluated based on how they will meet the highest priority needs identified in the technology road maps. All programs should be reviewed annually. Those that support the highest priority needs should be strongly supported; those that do not should be refocused or discontinued. Recommendation. A clear definition of “success” should be established at the beginning of all contracts, and progress should be measured annually by established metrics. A process should be developed for reevaluating projects that have not met their goals to determine if they should be continued.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
EXECUTIVE SUMMARY
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
8
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
INTRODUCTION
9
1 Introduction
This chapter describes the U.S. Department of Energy (DOE) Office of Industrial Technology’s (OIT) transition to a “market-pull” strategy, the unique characteristics of the Industries of the Future (IOF) Program, OIT’s materials programs, and opportunities for developing crosscutting technologies (i.e., technologies applicable to more than one IOF industry). Finally, this chapter defines the objectives of this report. The industries that comprise the IOF are all major energy consumers and major generators of waste. In addition, they are important to the U.S. economy and national security. The seven original IOF industries were expanded to nine in 1997. Taken together, these nine industries account for more than 80 percent of the energy consumed and more than 90 percent of the manufacturing wastes generated by the industrial sector. The nine industries are: agriculture, aluminum, chemicals, forest products, glass, metalcasting, mining, petroleum refining, and steel. OIT also supports some work in related industries (e.g. carbon products, forging, heat treating, and welding) when it is of benefit to the IOF industries. The metal forging and heat-treating industries are included in this report. MARKET-PULL STRATEGY In 1993, OIT began a transition of its research and development (R&D) programs from a “technology-push” strategy, in which research projects were selected and prioritized primarily for their potential to reduce energy consumption and waste generation, to a “market-pull” strategy, in which research projects are selected and prioritized primarily for their potential to meet identified industry needs. This change is being accomplished through extensive cooperative efforts between IOF member industries first to generate “vision documents” ( Table 1-1 ), which must be approved by the respective industry associations and the chief executive officers (CEOs) and other high-ranking officers of the member companies. These documents are then used by the industry to prepare technology road maps ( Table 1-2 ) and other
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
December 1996 December 1997
• Aluminum Industry: Industry/Government Partnerships for the Future
• Technology Vision 2020: The U.S. Chemical Industry
• Vision 2020 Catalysis Report
Aluminum
Chemicals
1998 February 1998
• Beyond 2000: A Vision of the American Metalcasting Industry
• The Future Begins with Mining: A Vision of the Mining Industry of the Future
• None
• Steel: A Natural Resource for the Future
• Forging Industry Vision of the Future
• Heat Treating Industry Vision 2020
Metalcasting
Mining
Petroleum Refining
Steel
Forging
Heat Treating
May 1995
September 1998
February 1996
January 1996
• Glass: A Clear Vision for a Brighter Future
Glass
November 1994
• Agenda 2020: A Technology Vision and Research Agenda for America’s Forest, Wood and Paper Industry
Forest Products
March 1996
January 1998
• Plant/Crop-Based Renewable Resources 2020: A Vision to Enhance U.S. Economic Security through Renewable Plant/Crop-Based Resource Use
Agriculture
Date Released
Documents
Industry Sector
TABLE 1-1 Status of IOF Vision Documents
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
INTRODUCTION 10
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
May 1998 May 1999 February 2000
• Inert Anode Roadmap: A Framework for Technology Development
• Aluminum Industry Roadmap for the Automotive Market: Enabling Technologies and Challenges for Body Structures and Closures
• Technology Roadmap for Bauxite Residue Treatment and Utilization
October 1997 November 1998 December 1998 September 1999
• Technology Roadmap for Computational Fluid Dynamics
• Vision 2020 Separations Roadmap
• Technology Roadmap for Materials of Construction and Maintenance in the Chemical Process Industries
• Technology Roadmap for Computational Chemistry (draft)
November 1997 April 1997
• Glass Technology Roadmap Workshop
• Metalcasting Industry Technology Roadmap
• Mining Industry Roadmap for Crosscutting Technologies
• None
• Steel Industry Technology Roadmap
• Forging Industry Technology Roadmap
• Report of the Heat Treating Technology Roadmap Workshop
Glass
Metalcasting
Mining
Petroleum Refining
Steel
Forging
Heat Treating
1997, revised February, 1998
1999
January 1998
September 1997
• Agenda 2020: The Path Forward — An Implementation Plan
1999
June 1997
• Catalysis Technology Roadmap
Forest Products
Chemicals
May 1997
• Aluminum Industry Technology Roadmap
Aluminum
February 1999
• The Technology Roadmap for Plant/Crop-Based Renewable Resources 2020: Research Priorities Fulfilling a Vision to Enhance U.S. Economic Security through Renewable Plant/Crop-Based Resource Use
Agriculture
Date Released
Road Maps
Industry Sector
TABLE 1-2 Status of IOF Technology Road Maps
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
INTRODUCTION 11
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
INTRODUCTION
12
implementation documents ( Table 1-3 ) in cooperation with industry associations and panels. The road maps serve as guides for OIT in selecting and funding R&D projects for each industry. Eight of the nine IOF industries have developed technology road maps. A critical element of the market-pull strategy has been a strong emphasis on team involvement in nearly all R&D projects. Team members may include national laboratories, universities, and industrial firms. Some OIT projects have also been extended beyond technology development to include product development and demonstration and early commercialization, in partnership with industry. However, the primary responsibility for commercialization lies with industry, and OIT plays a supporting role. CHARACTERISTICS OF THE INDUSTRIES OF THE FUTURE The successful development and commercialization of technologies for the nine IOF industries will require that OIT have a comprehensive understanding of the similarities and differences of the nine industries, as well as the business situations of individual companies operating in these sectors. All nine IOF industries are capital intensive, face global competition, are cyclical, produce commodity products (high product volumes, low prices, and low profit margins), and have mature markets and technologies. These business realities have profoundly limited the amount of capital available for industry investments in product development, the scale-up of new technologies, and facilities necessary for commercialization. Cost and profitability pressures also affect a company’s ability to accept and implement a new technology, as well as its willingness to take risks. Another intangible, but important, barrier to the acceptance of a new technology is organizational resistance to technological change in the industry. Mature businesses have long histories of working with well established technologies and entrenched attitudes that can sometimes be difficult to overcome. In selecting industrial partners, OIT must remain cognizant of how these factors may affect potential partners and outcomes. MATERIALS PROGRAMS AND CROSSCUTTING TECHNOLOGIES OIT’s materials programs, which are components of three separate programs (described in Chapter 3 ), were all begun prior to the changeover to the market-pull strategy. As carryovers from prior years, the AIM and CFCC programs have not been fully integrated into the IOF market-pull, road map strategy, although OIT continues to work on their full integration (NRC, 1999). The Advanced Industrial Materials (AIM) Program and the Continuous Fiber Ceramic Composites (CFCC) Program are focused on the development and commercialization of materials. The
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
• None
• Energy and Environmental Profile of the U.S. Petroleum Refining Industry
• None
• None
• None
Mining
Petroleum Refining
Steel
Forging
Heat Treating
December 1998
January 1998
• Opportunities for Advanced Ceramics to Meet the Needs of Industries of the Future
• None
January 1997
September 1998
• The Energy Performance Workshop for the Chemical and Pulp and Paper Industries, 2000–2020
• Advanced Ceramics in Glass Production: Needs and Opportunities
April 1996
• Paper Industry Research Needs
September 1998
• The Energy Performance Workshop for the Chemical, Pulp and Paper Industries, 2000–2020
Metalcasting
Glass/Ceramics
Forest Products
March 1998
• Report of the American Society of Mechanical Engineers’ Technical Working Group on Inert Anode Technologies
• Process Measurement and Control: Industry Needs
July 1999
• Life Cycle Inventory-Report of the North American Aluminum Industry
Aluminum
Chemicals
November 1998
• None
Agriculture
Date Released
Documents
Industry Sector
TABLE 1-3 Other IQF-Related Technology Documents
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
INTRODUCTION 13
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
INTRODUCTION
14
Industrial Power Generation program includes the development and testing of materials necessary to the development and commercialization of industrial power-generation equipment (e.g., advanced turbine systems [ATS] and microturbines). The Industrial Power Generation program has some areas of synergy with the AIM (intermetallics) and the CFCC programs (ceramics). Recently, the Industrial Power Generation Program has been transferred to the DOE Office of Power Technologies. OIT’s spending on materials R&D since 1996 is shown in Table 1-4 . As the table shows, the level of funding has been relatively constant during this period with trade-offs being made between individual programs. Total funding for materials R&D, however, is more than double the amounts shown, reflecting various contributions by industrial partners. Crosscutting technologies that benefit more than one industry are highly attractive because they increase the “return on investment” of taxpayer dollars. Although the resources required to solve the materials problems of a single industry may be great, the investment may make “business sense” for U.S. taxpayers if the results will benefit several industry sectors. However, materials needs cannot always be directly translated from one industry to another. The materials needs listed in the technology road maps are necessarily very broad and apparent overlaps may disappear when needs are defined in more detail. For example, nearly all of the technology road maps mention the need for improved refractories but do not define the term further. Because the operating environments and conditions differ greatly between industries (e.g., glass and steel), materials compositions, performance requirements, and fabrication techniques may also differ greatly. More specific descriptions are necessary to determine the similarities and differences among refractories for different industries. Nevertheless, crosscutting technologies offer significant benefits for public investment. TABLE 1-4 Trends in OIT Spending on Materials R&D (in $ millions) Program
1997
1998
1999
AIM
9.0
6.0
6.0
CFCC
8.4
8.4
8.4
ATS
4.9
4.8
6.0
Supporting Technologies (ORNL)
2.2
2.2
2.2
Microturbines
New program – no budget history
Total
24.5
21.4
22.6
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
INTRODUCTION
15
REPORT OBJECTIVES This report summarizes the committee’s overall evaluation of OIT’s materials programs. Chapter 2 provides an overview of the materials needs of the IOF industries, focusing on crosscutting technologies. Chapter 3 provides an overview of OIT’s materials programs. Chapter 4 presents the committee’s views on OIT’s management strategies, including program management, criteria for project selection, commercialization plans, and industry involvement. In Chapter 5 , the committee identifies opportunities for materials R&D for select IOF industries and crosscutting areas. Chapter 6 contains the committee’s overall recommendations for improving OIT’s materials programs.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
INTRODUCTION
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
16
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS NEEDS FOR THE INDUSTRIES OF THE FUTURE
17
2 Materials Needs for the Industries of the Future
The materials needs of the IOF industries are documented in detail in the technology road maps, and the reader is referred to these road maps for listings and discussions of IOF materials needs. Only a sampling of the most important materials needs of the industries, especially the needs that are common to many industries, are included in this report. Table 2-1 summarizes important materials needs of the IOF industries, shows the relative importance of each crosscutting problem to individual industries, and lists one or two of the major problems facing each industry. The importance of each crosscutting materials problem to each industry is based on the prevalence of the problem in that industry and how well it is being addressed. Oak Ridge National Laboratory (ORNL) has performed an independent analysis of the materials needs of the IOF industries based on the road maps, and the results of their analysis were presented to the committee and included in the committee’s deliberations (Angelini, 1999). Three things in Table 2-1 stand out immediately. First, many of the industries have some similar, if not identical, needs. Thus, selecting truly crosscutting R&D should not be difficult. Second, many of the important materials needs are in areas that are considered uninteresting, unexciting, or not on the cutting edge of technology. This fact must be considered as OIT project mangers establish the scope and extent of R&D programs. Third, a few areas of materials research are extremely important to ALL of the industries. Progress in these areas would, therefore, have the biggest impact on energy savings and waste reduction. These areas (corrosion, wear, high-temperature materials [including refractories], and materials modeling/database development) are emphasized in this report. CORROSION RESISTANCE Corrosion and oxidation are ubiquitous problems in industry, and there are no perfect solutions. Through research, they can be mitigated, however, by the development of materials, procedures, and coatings that can withstand specific process conditions.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
**
Abrasion of earthmoving parts
*
Wear
Examples
HighTemperature Materials (including refractories)
Examples
Modeling/ Database Development
*
Corrosion by agricultural chemicals
Examples
Examples
*
Corrosion
Agriculture
Long-term materials response to harsh environments
Modeling of castings, modeling of smelter cells
Corrosion modeling
**
Process modeling and refractory response
**
Refractories
Boilers
Containment vessels, refractories ***
***
Wear of refractories in tanks and on handling, molds, and process machinery
**
Molten glass attack on refractories
**
Glass
*
Wear of raw materials parts and abrasive wear during paper manufacture
***
Boilers, black liquor
***
Forest Products
**
Liquid/solid abrasion in pipes
**
Corrosion of reaction vessels and pipes
***
Chemicals
**
Refractories, anodes, cathodes
**
Wear of refractories
*
Liquid aluminum attack on refractories
**
Aluminum
TABLE 2-1 Importance of Selected Materials Needs to IOF Industries
Heat-flow modeling and design of gates and risers
**
Dies, refractories
**
Wear of dies
**
Molten metal attack on refractories
**
Metal Casting
Lifetime modeling of downhole materials
***
Tools and downhole equipment
**
Wear of drill bits
***
Drilling mud and effluent gases
***
Mining
Lifetime of materials used in handling
Thermomechanical response of dies, etc.
*
Dies
Better refractories
**
**
Wear and cracking of dies
*
N/A
*
Forging
***
Wear of refractories and equipment for handling hot metal
***
Corrosion of refractories and mill equipment
**
Steel
Thermal response of materials
*
Handling equipment
**
*
N/A
*
Heat Treating
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS NEEDS FOR THE INDUSTRIES OF THE FUTURE 18
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS NEEDS FOR THE INDUSTRIES OF THE FUTURE
19
The chemical process industry has long had serious corrosion problems that affect efficiency of production (necessary down time, achievable process rates), product purity (contamination), energy usage, and maintenance costs. The following excerpt from the chemical industry road map will give the reader an idea of the serious needs of this industry. Materials are needed to withstand high temperatures (1000°–3000°F) while retaining superior properties of strength, ductility, corrosion and wear resistance. One of the greatest causes of equipment failure in the chemical process industry is damage due to corrosion and high temperatures. Materials with enhanced resistance to organic acid environments could improve plant operations and maintenance requirements. Improved materials for chlorine based processes are another high opportunity area. Equipment that is more resistant to chlorine and other halogens would reduce the cost of many of the current corrosion problems encountered in dealing with these materials. Refractories and refractory coatings for high temperature furnaces are critical opportunity areas where new materials could have a significant impact on energy and maintenance costs. Development of high temperature nonstick surfaces could potentially improve maintenance of chemical process equipment. Most available non-stick coatings degrade or become volatile at high temperatures, limiting their usefulness in high temperature conditions (MTI, 1998).
The glass industry also has serious corrosion problems. In fact, molten glass has been referred to as a universal solvent. Note that materials that can function effectively in very aggressive environments are mentioned in several different connotations. The lack of cost-effective materials that perform adequately in glass furnace environments is another key barrier. In particular, there is a strong need for better refractory materials that can withstand very high temperatures, erosion, and corrosion, but not adversely affect the quality of the glass product. Another materials-related impediment is the performance limits of materials that contact the glass and are exposed to harsh operating environments. Advancement in these areas has been partly limited by a lack of good data on materials properties (Energetics, 1997a).
The lack of corrosion resistance has prohibited the use of glass fibers as the reinforcing agent in reinforced concrete. Although the market for this product is potentially large and very lucrative, alkali-resistant glass fibers are not available. Corrosion is also a serious problem in steel plants. Aqueous corrosion occurs wherever water is used for cooling; oxidation occurs whenever steel is exposed to high-temperature oxidizing gases (e.g., in reheat furnaces and caster runout tables). Because all of the IOF industries use or generate heat as part of their processes, refractories are crucial. Oxidation of refractories is mentioned in nine of the eleven IOF road maps listed in Table 1-2 , and the costs of replacing refractories (in terms of materials and down time) are high. Corrosion and oxidation of
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS NEEDS FOR THE INDUSTRIES OF THE FUTURE
20
refractories in the melts in which they are immersed has substantial financial costs and lowers productivity in the steel industry. However, the initial cost and lifetime costs of longer lasting refractories will have to be within the economic constraints of the IOF industries. Because of economic realities in the refractories industry, further improvements are likely to be incremental rather than radical (Freitag and Richerson, 1998). Ceramics, composites, and ceramic coatings are obvious materials for high-temperature applications, but the environmental degradation of these materials is a serious problem. Oxide ceramics are clearly preferable for use in oxidizing conditions but often do not have the necessary mechanical or temperature capability (within the cost restraints of the industry). Silicon carbide and silicon nitride have the high-temperature capability, and silicon carbide is particularly resistant to wear. However, both monolithic and composite materials oxidize and corrode in the severe conditions found in many industrial processes. Many different coatings are used to mitigate corrosion and oxidation problems, but they only delay the inevitable. No universal coating has been developed. The oxidation of coatings is mentioned as a problem in five of the eleven IOF road maps. Clearly, a fruitful area of R&D would be the design, production, and characterization of more effective coatings. WEAR RESISTANCE The wear of materials causes very serious problems in many industries. Equipment that comes in contact with even mildly abrasive substances is subject to wear and requires repair, or even replacement. In the forestry industry, dirt and sand on the incoming logs causes wear on the equipment. In agriculture, equipment that bites into the earth is subject to serious wear problems; the same is true for equipment used in the mining industry. In the most severe conditions, tools with diamond inserts or composite (e.g., tungsten carbide/cobalt) inserts are used to maximize lifetime. In surface mining, as in other industries, wear is a complex problem. Abrasion is the principal problem in the mining industry, but impact, erosion, galling, scuffing, fretting, and rolling contact are also problems. The forging industry would benefit greatly from new materials for dies and die making. The highest priority research for die making and materials is the development of a multi-attribute, heterogeneous die that eliminates the need for lubricants. This would be an engineered die that would have different material characteristics in various parts of the die to match the specific performance requirements of that area. This would provide greater wear resistance in areas that have a lot of material movement across them and would minimize friction and lubrication needs. Another research approach to extend die life is to develop coating and cladding of the die material (Energetics, 1997b).
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS NEEDS FOR THE INDUSTRIES OF THE FUTURE
21
HIGH-TEMPERATURE MATERIALS Because the rates and efficiencies of many processes increase with high temperature, there is always a demand for materials that can operate at higher temperatures. However, the cost of metallic materials increases as the operating temperature increases because the alloying elements necessary to increase temperature limits are themselves expensive. (Refractories are described in greater detail in Chapter 5 as an example of a crosscutting area for the IOF.) Gas turbines operate at the highest temperatures for metallic materials. Several technologies will have to be developed for low-emission, cost-competitive, small gas-turbine power systems for the distributed generation of electricity. The firing temperature will have to be increased substantially without exceeding the low life-cycle cost required by end users. Materials developments will include thermal-barrier coatings, advanced sealing techniques and high-thrust bearings, ceramic-matrix-composite combuster liners, ceramic turbine vanes, and other stationary components. Although the scale-up of single-crystal alloys has been accomplished, they cannot be produced at an acceptable cost for stationary turbines. In addition, users will require durable, long-life barrier coatings for oxidation resistance. An OIT program has developed one successful new material from an intermetallic compound, Ni3Al (NRC, 1997). Research on Ni3Al was begun at ORNL in 1981 and continues even today. A number of other laboratories and universities have also been working with the ORNL team. As this example shows, industries that request the development of new high-temperature materials must be aware of the long timeline for development. Between 1981 and 1996, ORNL spent about $27 million on this program. Trials of Ni3Al began in 1993, and Bethlehem Steel Corporation is now using the material in steel mill rolls and has placed a large order with Sandusky International for more. Other applications are now being evaluated, but the Bethlehem Steel order is the first substantial recognition of the usefulness of Ni3Al-based alloys. The cost for the steel mill rolls is now 50 percent of the cost in 1993. Because no failures have been experienced so far, lifetimes have not been determined. The heat-treatment industry could also benefit from higher temperature operations. This industry requires improved heating-source materials, alternatives to radiant-tube heating for more uniform temperatures, improved furnace-fan materials with increased creep strength, and advanced insulation materials to improve furnace efficiency, cost, and performance. The road map for the heat treating industry identifies a need for a number of new materials that could operate in higher processing temperatures and the development of compositions optimized for specific heat treatments (ASM Heat Treating Society, 1997). General Motors has been evaluating heat-treatment (carburization) fixtures made from the alloys developed at ORNL. Although Ni3Al-base alloys have been
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS NEEDS FOR THE INDUSTRIES OF THE FUTURE
22
shown to be much more resistant to carburization than the usual steels used in this application, as of 1996, no large orders had been placed because no component failures had been experienced so failure mechanisms were not known. Users have been reluctant to proceed until an economic incentive for their use has been demonstrated. MATERIALS MODELS AND DATABASES All of the IOF industries have noted the lack of materials modeling capability. In the metalcasting in/dustry road map, for example, two outstanding problems related to materials properties are cited: (1) a lack of fundamental knowledge of materials properties as a function of chemistry and casting route, and (2) a lack of operating data for the simulation and modeling of properties (CMC, 1998). The combined use of models and sensors would be a powerful tool for controlling processes, preventing failures, lowering costs, and increasing energy efficiency. Materials modeling, linked to materials databases, is important for designing improved materials. Rapid increases in computing power have made possible materials modeling and the design of materials from first principles. Materials modeling, whether for design or for determining the performance of existing materials under operating conditions, requires databases. Even the best materials models will not function properly if the necessary databases are not available. Therefore, the development of materials models must be done in coordination with the development of databases, which could be extremely expensive. Although the need for materials databases is widely recognized, the resources for generating and funding these databases have not been forthcoming. Databases and models are used by the designers, producers, and users of materials and are clearly outside the scope of any individual agency. Therefore, interdisciplinary R&D, with customization for specific industries, will be necessary. ISSUES THAT IMPACT CROSSCUTTING PROGRAMS A number of common issues and emerging technologies will impact crosscutting materials programs. These issues include digital product and process modeling capability; materials producibility and affordability; variation and quality control; pollution prevention technologies; and advanced maintenance technologies.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS NEEDS FOR THE INDUSTRIES OF THE FUTURE
23
Digital Product and Process Modeling As competitive pressures force shorter product development and realization cycles, every decision in product and process synthesis requires high-fidelity modeling and simulation to validate physics-based or behavior-based design attributes. The effective use of modeling tools for dynamics, thermal, mechanics, material, and behavioral systems are the prerequisites of tomorrow’s digital manufacturing. These models and the knowledge base will have to be shared in a networked and collaborative environment. The most recent work stations are capable of solving intensive engineering problems in hours, sometimes even minutes. For example, with ProCast finite element modeling and simulation tools, engineers can visualize possible cracks in casting parts caused by thermal variations in the manufacturing process. The manufacturer can then use these simulation models to assist suppliers in changing mold designs and delivering near-zero-defect casting parts that minimize reworking and defects. Materials Producibility and Affordability The affordable fabrication of materials is a challenge to all manufacturing sectors, especially the aerospace industry. As environmental regulations and performance requirements become more stringent (i.e., buy-and-fly ratio), companies are looking for better superalloy high-temperature materials and near-net-shape processing technologies to reduce the costs of raw materials and manufacturing operations. Currently, most research tools and process models in the research community are inadequate for predicting and validating material properties in manufacturing processes. For example, the casting of titanium-based aerospace parts requires labor-intensive, repetitive monitoring of material properties in the production process to ensure quality and reliability. Research focused on measuring on-line, residual stress in materials during the manufacturing process would help the industry. The research should expand the monitoring focus from dimensional accuracy to materials performance to provide a better understanding of the quality of processes, machines, and parts. This research could eventually lead to interdisciplinary research on integrated materials, manufacturing, physics, and computation, which would advance the fundamental understanding of manufacturing science and would benefit all industries. Variation and Quality Control Smart production systems could monitor process variations and lead to higher quality, less expensive operations. Research could focus on the development of
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS NEEDS FOR THE INDUSTRIES OF THE FUTURE
24
adaptable, reliable, intelligent process-control software that includes real-time, onboard models of machine, process, material, and environment. The objective would be to guarantee process and product quality globally through an integrated engineering regulating point system. To control process variations, process industries need reconfigurable, reusable, self-learning, and knowledge-transferable systems that can be added to sensors and process-control systems. Green Products and Processes Better integrated sensors and process-control technologies would improve energy efficiency and reduce waste generation, while lowering development and installation costs. A green manufacturing system (i.e., a green factory) would enable plants to monitor process parameters and would provide accurate information directly and quickly. Another pollution-prevention technology, alternative chemical-based coatings, would promote chemicalfree manufacturing processes. Innovative sensors could monitor and control chemically corrosive environments. Emerging technologies, such as microelectromechanical system (MEMS)-based process sensors and wireless communications, would help in the development of environmentally benign technologies. Advanced Maintenance Technologies for Product and Process Performance Service and maintenance are important to maintaining product and process quality and customer satisfaction. The recent rush to embrace computer-integrated technologies in manufacturing industries has increased the use of relatively unknown and untested technologies. The difficulty in identifying the causes of system failures that use these technologies has been attributed to several factors, including system complexity, uncertainties, and lack of troubleshooting tools. Currently, service and maintenance in many manufacturing industries are still reactive. The problem arises from an incomplete understanding of the day-by-day behavior of manufacturing machines and equipment. We simply do not know how to measure the performance degradation of components and machines, and we lack validated models and tools to predict what would happen when process parameters take on specified values. Research should be focused on determining the factors involved in product and machine breakdown and on developing smart, reconfigurable monitoring tools to reduce or eliminate production down time and reduce dimensional variations caused by process degradation. Achieving these goals will require intelligent reasoning agents in process controllers to provide proactive maintenance capabilities, such as measurements of performance degradation, fault recovery, self-maintenance, and remote diagnostics. Manufacturing and process
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS NEEDS FOR THE INDUSTRIES OF THE FUTURE
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
25
industries could then develop proactive maintenance strategies to guarantee the quality of process performance and ultimately minimize system breakdowns.
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS NEEDS FOR THE INDUSTRIES OF THE FUTURE
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
26
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS PROGRAMS
27
3 Materials Programs
The committee’s assessment focuses primarily on three programs: AIM (Advanced Industrial Materials Program), CFCC (Continuous Fiber Ceramic Composites Program), and the Industrial Power Generation Program (which was recently transferred to the DOE Office of Power Technologies). The Industrial Power Generation program has some areas of synergy with the other programs, especially intermetallics (AIM) and ceramics (CFCC). As carryovers from prior years, the AIM and CFCC programs are not yet fully integrated into the IOF market-pull strategy based on the industry technology road maps. However, OIT is working toward their full integration (NRC, 1999). Table 3-1 provides an overview of these three programs, including the status of technology development, demonstration, and commercialization for each. Materials development in the IOF industry programs are not evaluated in any detail in this report. ADVANCED INDUSTRIALS MATERIALS PROGRAM The mission of the AIM program is to develop and commercialize new and improved materials to increase productivity, improve product quality, and increase energy efficiency in major industries. In this program, DOE national laboratories, in cooperation with more than 100 companies, are working on a variety of material systems: metals, intermetallics, ceramics, polymers, and composites. Since the establishment of the IOF Program, AIM has redirected much of its research to involve and coordinate it with IOF programs, especially research related to the aluminum, chemicals, forest products, glass, metalcasting, refineries, and steel industries. Research on high-temperature materials, corrosion resistance, and wear resistance are the key needs of these industries. AIM interacts with industry by a variety of means, including cooperative research and development agreements (CRADAs), work-for-others agreements, user centers, and informal agreements (Sorrell, 1999).
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
Uniform-droplet process for monosized powder and near-net shape forming Participants: ORNL, Northeastern University, MIT, Industry Panel
ADVANCED INDUSTRIALS MATERIALS (AIM)
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Heat-treating furnace fan Participants: ORNL, AlliedSignal, General Electric, Engineered Composites, Solar Turbines
Radiant barrier screens Participants: ORNL, AlliedSignal Composites, Alzeta Vision Glass
Molten salt membranes for separatio n of hydrogen and carbon monoxide Participants: Los Alamos National Laboratory
Composition optimization, weldability and properties of thin-wall components cast by countergravity casting Participants: ORNL, Alloy Engineering and Casting, Caterpillar, General Motors Powertrain
Improved refractories for the glass industry Participants: ORNL, a consortium of 34 glass manufacturers
CVD for low-emissivity glass coatings Participants: Sandia National Laboratories, Pilkington, Libbey and Owens, Ford Motor Company
Evaluation of processing effects on fluidity of gray cast iron Participants: ORNL, Citation
Intermetallic alloys for the steel industry Participants: ORNL, Sandusky International, Bethlehem Steel, Alloy Engineering and Casting, United Defense, Caterpillar, Thermadyne, Timken, Ford Motor Company, Polymer, Alcon, FMC, Delphi
COMMERCIALIZATION PHASE
Refining pipe hangers Participants: ORNL, Engineered Composites
Advanced materials and processes (thermal cycling wear and corrosive environments) Participants: ORNL, A. Finkl and Sons, Inco Alloys, QC Forging, Necter Fab., Alcoa, FMC, PPG, Siebe, Norton
Thermal conducitvity of ceramic coatings for lost foam casting Participants: ORNL, University of Alabama
Electrochemical reactor for chloro-alkali process Participants: Los Alamos National Laboratory CRADA (being finalized)
Molybdenum disilicides for industrial applications Participants: Los Alamos National Laboratory, Shuller International, Inc.
Zeolite membranes for p-xylene separations Participants: Sandia National Laboratories, British Petroleum, Amoco
Microwave joining of silicon carbide ceramics Participants: ORNL, Argonne National Laboratory (ANL), FM Technology, Stone & Webster, INEX, Inc.
DEMONSTRATION PHASE
Conducting polymers Participants: Los Alamos National Laboratory
Chemically reactive thin films Participants: Sandia National Laboratories
Composites by reactive metal infiltration Participants: Sandia National Laboratories
Membrane systems for light gases Participants: Los Alamos National Laboratory, Amoco
Improved materials for kraft recovery boilers Participants: ORNL, a consortium of 18 pulp and paper companies
Advanced intermetallic alloys Participants: ORNL, Alloy Engineering and Casting, Duralloy Technology, Inco Alloys, Ford Moto r Company, Dow Chemical Company, Shenango, United Defense
TECHNOLOGY DEVELOPMENT PHASE
PROGRAM
TABLE 3-1 Overview of OIT Materials Programs (Note there is no continuity across each row)
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS PROGRAMS 28
Copyright © 2000. National Academies Press. All rights reserved.
Materials and processes -direct metal oxidation (AlliedSignal Composites) -chemical vapor infiltration (AlliedSignal Composites) -melt infiltration (General Electric) -polymer impregnation and pyrolysis (Dow) -sol-gel processing (McDermott Technologies) -reaction bonding (Textron Speciality Materials) -cold isostatic pressing and hot isostatic pressing (AlliedSignal) Advanced materials for gas turbines Participants: ORNL, Pratt and Whitney, Westinghouse, ANL, National Institute of Standards and Technology
CONTINUOUS FIBER CERAMIC COMPOSITES (CFCC )
INDUSTRIAL POWER GENERATION (Advanced Turbine Systems)
Plasma immersion hardening Participants: Los Alamos National Laboratory
Supporting technologies a -microstuctural characterization (ORNL) -standards and codes (University of Washington) -mechanical test methods (ORNL) -nondestructive characterization (ANL) -interfaces and seal coatings (ORNL) -mullite coatings development (Boston University) -environmental barrier coatings (ORNL) -oxide coatings and materials (Northwestern University) -time-dependent behavior (ORNL) -environmental effects in ceramic composites (ORNL)
Infrared burners Participants: ORNL, McDermott Technologies, Institute of Paper Science and Technology, Auburn University, Georgia Institute of Technology
Ceramics for gas turbines Participants: ORNL, Solar Turbines, AlliedSignal, B.F. Goodrich
Applications development -heat-treating furnace fan (Engineered Composites) -radiant burner screens (AlliedSignal, Alzeta, Vision Glass) -infrared burners (Institute of Paper Science and Technology, Auburn University, and Georgia Institute of Technology) -immersion tubes (Textron Systems) -hot-gas filters (McDermott Technologies, Siemens, Southern Companies Services) -refinery pipe hangers (Engineered Composites)
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS PROGRAMS 29
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS PROGRAMS
30
AIM has successfully developed an intermetallic alloy (Ni3Al )for the steel industry (NRC, 1997). In a presentation to the committee, a representative of ORNL noted that Ni3Al has excellent high-temperature strength and corrosion resistance (Angelini, 1999). Scientists at ORNL are also working on boron additions to this alloy to make it much less brittle. One of the most promising applications for this material is for rolls in steel heat-treating furnaces. In collaboration with Sandusky International and Bethlehem Steel, about 20 rolls of this material were tested and used without signs of blistering. The material is also being tested for radiant burner tubes and carburizing fixtures for heat-treating furnaces. In this long term R&D program, the material was developed from laboratory scale in 1980 to its current application. The new rollers are expected to save 32 trillion BTU by the year 2010 (Angelini, 1999). AIM has also successfully developed materials for use in kraft recovery boilers, which are used in the paper and pulp industry to concentrate waste fluids (Adams, 1997). Historically, cracks in the boiler tubes caused one or two explosions a year. DOE organized a work team of 27 scientists and engineers (18 from the paper and pulp industry, three from research laboratories, and six from tube suppliers) to solve this problem. An examination by the team of the boiler tubes in operation revealed that, because of corrosion, transient hot spots developed in the tubes, which significantly increased stress in the vicinity of the hot spot. Eventually, stress corrosion cracking occurred resulting in the rupture of the tubes. The tubes were 304 stainless-steel clad carbon-steel tubes. The problem was solved by changing the cladding from 304 stainless steel to alloy 825 or a modified alloy 625. This example shows how interaction with industry can lead directly to the improvement of an industrial process. Other successful projects by AIM include: refractories for glass production; composite zeolite/amorphous membranes for hydrocarbon separation; countergravity casting; uniform-droplet processing; membranes for gas separation; and low-e coatings for window glass. All of these projects are characterized by strong interactions between national laboratories, universities, and industrial recipients of the material improvements. In fact, collaborative interactions with industry have been the strength of the AIM program. As more OIT programs are integrated into the IOF market-pull strategy, the committee anticipates that there will be many more successful projects. CONTINUOUS FIBER CERAMIC COMPOSITES PROGRAM The CFCC program was initiated in 1992 to produce lightweight, strong, corrosion-resistant materials capable of performing in high-temperature environments. CFCC is carried out collaboratively by industry, national laboratories, and universities. The ultimate goal of the program is to improve processing methods
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS PROGRAMS
31
to produce reliable, cost-effective, ceramic materials that can be commercialized by industry. In contrast to the AIM program, the CFCC program is focused on a type of material rather than an industrial problem. Nevertheless, CFCC-developed materials are serious contenders (technologically) in some commercial markets, including radiant burners, immersion tubes, hot-gas filters, furnace fan blades, combuster liners for gas turbines, and other applications. If fiber costs can be reduced, some of these products may be commercialized in the next few years (M. Smith, 1999). The most widely publicized application of CFCC materials is combuster liners in gas turbines that could increase engine efficiency by reducing the required amount of cooling air. The simultaneous reduction in burning temperature for a given turbine inlet temperature could also decrease emissions of nitrogen oxides and carbon dioxide. With composite shrouds, large gas turbines would require no cooling and hence would have similar advantages. Because silicon carbide composites have sufficient strength and excellent strain tolerance, they avoid failure by thermal shock. Before silicon carbide composite combuster liners can be used commercially, however, their susceptibility to steam corrosion in the hot gas stream of the combuster will have to be overcome. Oxide coats of various compositions are currently being tried to obviate this problem. Costs will also have to be reduced before widespread industrial uses can be considered (Craig, 1999). INDUSTRIAL POWER GENERATION PROGRAM This goal of this program is to design and produce cleaner, more energy-efficient methods of generating electric power. A major part of the program is focused on improving gas turbines. R&D projects are focused on coating and process development, improved single-crystal airfoil manufacturing, materials characterization, ceramics development, and catalytic combuster materials. Most of these are collaborative projects involving industry, universities, and the national laboratories (Hoffman, 1999). One of the longest lived projects has been on the use of ceramics for hot-section components in gas turbines. Solar Turbines, Incorporated, which is studying advanced ceramics to improve the performance of gas turbines, has retrofitted the Centaur 50S engine with a CFCC silicon carbide combuster, a silicon nitride nozzle, and silicon nitride blades (Hoffman, 1999; Karnitz et al., 1999). In demonstrations, the engine ran at full power for extended periods (up to 1,000 hours) with higher engine efficiency, higher power output, and lower nitrogen oxide and carbon monoxide emissions. The major problem was the oxidation of the silicon nitride and silicon carbide in the turbine environment. Research is now under way to develop protective coatings to extend the lifetime of the ceramic components. Until this problem is solved, nonoxide ceramics cannot be used under the anticipated corrosive, high-temperature conditions of gas turbines.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MATERIALS PROGRAMS
32
A more traditional way of achieving higher turbine inlet temperatures is to coat air-cooled, single-crystal alloy blades with thermal-barrier coatings. Several turbine engine companies have programs in this area (Karnitz et al., 1999). The national laboratories are working with Pratt & Whitney Aircraft Company and Siemens Westinghouse Power Corporation to develop and test thermal-barrier coatings for use on critical hot-section components of gas turbines. This is a relatively new project, and no final results were available from either company. In 1999, they were in the materials selection and test development stage.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MANAGEMENT STRATEGIES
33
4 Management Strategies
This chapter provides the committee’s suggestions for improvements in program management, criteria for project selection, plans for commercialization, and industry involvement in OIT programs. Recommendations from this study (see Chapter 6 ), combined with the recommendations from an earlier NRC study (NRC, 1999), are applicable to crosscutting programs as OIT moves towards integrating its materials projects into the marketpull strategy. PROGRAM MANAGEMENT Based on presentations to the committee, it appears that the current OIT program management strategies are generally consistent with the objectives of the IOF Program. Nevertheless, program management could be improved in several ways. Crosscutting Approach Although R&D on crosscutting technologies is an effective way to leverage OIT research funding, finished products based on these technologies are not likely to be of equal value to multiple industries, largely because of the specific needs of each industry. To identify and develop a commercializable technology that would solve specific problems in several industries, OIT will first have to identify precompetitive research areas (towards the “basic” end of the research spectrum), the results of which could be a basis for OIT’s development of technologies for meeting the needs of a particular industry. OIT could also play a key role in the development of these technologies and in demonstrating the feasibility of revolutionary concepts.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MANAGEMENT STRATEGIES
34
Advisory Panels The U.S. Department of Defense uses advisory boards or panels to assist small and medium sized companies that perform federally funded work. Panels are set up by support contracts to avoid conflicts of interest. Each panel is composed of individuals with expertise in marketing, similar technologies/products, financial assistance (e.g., investment bankers or venture capitalists), patent licensing, and, in some cases, production specialists. Members of the panel are drawn from industry, universities, nongovernmental organizations, and government R&D agencies. Each individual is required to sign a nondisclosure agreement to prevent leaks of proprietary information. The purpose of the panels is to assist an industry in commercializing a new technology by providing advice on protecting intellectual property, finding financial aid, developing business plans, recommending contacts in similar technical areas, developing market surveys, and so on. One of the problems with DOE/OIT’s R&D is that, if a new technology is not used directly by the government or industry, it either remains on the shelf, is adopted and exploited by a foreign country, is reinvented years later with new funds, or reaches the market by accident. OIT’s market-pull approach is an attempt to change this situation. An advisory panel of industry experts might further increase the chances of commercial successes. Recommendation. The Office of Industrial Technologies (OIT) should establish a permanent advisory panel of industry experts to work in parallel with OIT’s industry teams. Members of the panel could be drawn from these teams and should include at least one representative of each Industries of the Future member industry. The advisory panel would provide expert knowledge and advice to OIT program managers and ensure that the ultimate goals are kept in focus throughout the development cycle of a technology. The panel should perform the following functions: • rank industry priorities and select programs • assist in developing program metrics (to measure progress) • review programs annually Specific Needs of Industries Government programs sometimes have unintended impacts on commercial investments in growing areas of the economy. Government planners must recognize that well meaning government research could inhibit commercial investment. For example, government-funded research, the results of which are open to the public, may reduce a new product to a commodity, eliminating any differential advantage or
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MANAGEMENT STRATEGIES
35
profitability. OIT program managers should study the business models in the IOF industries to determine their investment strategies. R&D will be most beneficial if an enthusiastic industry recipient plans to implement the new technology. In presentations to the committee, OIT representatives described the development of road maps by the IOF industries, the solicitation of proposals in specific R&D areas, and the awarding of contracts to teams (typically with industry, university, and national laboratory participation). OIT encourages these teams to transfer the results to commercial industries, through appropriate licensing agreements and other mechanisms, as early as possible. Although this is a logical progression, OIT has not fully addressed the following questions: 1. The road maps, in general, are shopping lists of many projects— ranging from projects that would require massive resources (e.g., “to develop a coal-based process that produces liquid iron directly from coal and ore fines or concentrate” [AISI, 1998]) to projects that would require modest resources (e.g., “to quantify the degree to which molten metal wets a ceramic substrate” [AISI, 1998]). How are projects prioritized? Who decides which proposals to solicit? 2. How are proposals reviewed? Is there a peer review to supplement OIT’s judgment, and who does it? 3. What criteria are used to measure progress? What criteria are used to determine if a project should be phased out and over what time scale? 4. What criteria does OIT use to ensure that the teams have the best available participants, as opposed to those most anxious for funding? Can OIT managers suggest that team members be changed to improve the overall composition of the team? 5. What is the economic impact of the research? How will this affect the technology transfer to industry? What are the economic incentives for implementing the new technology? CRITERIA FOR PROJECT SELECTION Currently, OIT’s project selection appears to be greatly influenced by the program manager heading the IOF department associated with a particular industry. Although this may ensure accountability, it may not result in the best selections. The committee recommends that OIT establish a panel of experts that includes industry leaders to select projects that are (1) of value to the industry and (2) consistent with OIT’s objectives of reducing energy consumption and waste generation. The panel should also assess the project’s potential economic payoff. OIT’s most critical
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MANAGEMENT STRATEGIES
36
function would be to fund and promote high-risk/high-payoff projects that would not be undertaken at the commercial level because of competitive pressures. Prioritization of Programs The industry road maps include many more needs than the OIT budget can possibly support. Thus, prioritization is essential. However, the committee was unable to clarify how OIT currently prioritizes projects. In the committee’s opinion, OIT should approach prioritization in the following way: • Industry should rank the needs listed in its own road map and then request proposals for its most critical needs. • OIT should establish a group of knowledgeable people, several from outside DOE, to assign qualitative rankings (e.g,. excellent, very good, good, fair and poor) for potential to meet industry needs and OIT goals of energy efficiency and waste reduction. • The OIT program manager should select from the best proposals available for the highest ranked projects. • OIT should ensure that the selected projects constitute a balanced program. Balanced Portfolio It was not clear to the committee how OIT selects and compares the low-risk/low-return projects with potentially high-risk/high-return projects. Very few projects appear to address the issues of risk or the probability of success. For some projects, potential energy savings was used as a measure of success, but economic impact was not considered. Surely, OIT must also consider economic impact when allocating its resources. Economic Impact as a Metric The successful transition of a product from R&D to the marketplace has been enthusiastically supported by the U.S. Congress as a means of improving the status of depressed industrial sectors that must compete in a global market. Several briefers identified potential energy savings as a goal but did not describe potential economic benefits or if their programs could compete successfully against foreign competition. OIT’s programs could contribute to the revitalization of economically depressed commodity industries. Measuring OIT’s success in terms of reduced energy
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MANAGEMENT STRATEGIES
37
consumption and reduced waste generation, as well as economic impact, would also be helpful to Congress in reviews of future agency budgets. In other words, OIT’s programs could be partly evaluated for their potential for improving U.S. industrial status. Visible success that can be measured in new competitive technologies, the creation of new jobs, and economic improvements in depressed areas will continue to be rewarded by Congress. OIT should develop metrics for reporting its achievements in these terms, in addition to metrics for reduced energy consumption and reduced waste generation. High Risk as a Criteria Many of the programs briefed to the committee were long term and did not have clear metrics for measuring their progress. Technology breakthroughs that could revolutionize entire industrial sectors or create new industries, such as the Internet, will require some high-risk R&D. Therefore, OIT should balance potential risks and benefits when evaluating proposals, and the portfolio should include some high-risk projects. Carefully chosen high-risk programs will challenge current technologies with innovative systems and procedures that might meet OIT’s goals and provide substantial economic benefits from investments Measures of Project Success OIT has not been able to declare a project successful because the criteria for a successful program were not specified at the outset. The “successes” presented to the committee were mostly interim successes based on technologies that may become commercialized over time. To avoid disappointments, OIT should establish a clear definition of a successful result (not necessarily commercial introduction, which can be a long process) at the proposal stage. During periodic reviews, if measurable progress has not been made, OIT may decide to reevaluate its support for the program and, perhaps, initiate a phased termination. This approach would relieve the pressure on contractors to solve problems that may not be soluble with current knowledge and would free funds for other uses. Considering how rapidly industrial needs are changing, annual reviews of ongoing projects can be used to judge whether or not to continue funding for a project. This process would require that OIT develop a definition of a successful project and establish criteria (metrics) for determining whether or not funding for a particular program should be continued.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MANAGEMENT STRATEGIES
38
COMMERCIALIZATION PLANS The committee found many areas for improvement in the commercialization of new technologies. Each national laboratory has an office of research and technology applications (ORTA) responsible for transferring potentially commercial technologies to the private sector. Every ORTA has at its disposal a network of potentially interested companies and can provide access to several databases and publications that could be used to advertise the availability of new technologies developed in the national laboratories and/or companies under contract to DOE. Companies in the ORTAs’ network could expedite the transfer of a technology to the market in several ways: facilitating license agreements to produce and market the technology; partnering with the developer; entering into a joint venture; or providing financial assistance in return for a portion of the royalties or rights to the technology. In addition to ORTAs, OIT could improve the commercialization process by taking advantage of SBIR and STTR programs, which focus on commercialization of technologies developed by small businesses. Barriers to Commercialization An understanding of, and sensitivity to, the financial hurdles and business-value concepts associated with project selection in a commercial environment are the most common barriers to the successful commercialization of technologies developed by OIT. During the evaluation stage of new projects, more attention should be paid to the economic impacts/benefits of the product on the commercial market. The willingness and ability of commercial firms to accept a new technology should also be considered. Many companies have low risk tolerance, especially companies operating in commodity markets, such as the IOF industries. Other commercial factors to consider during the project-value assessment are maturity of the market, the cyclical nature of some businesses, and sensitivity of the industry to capital-intensive projects. To ensure that projects are consistent with industry needs, cost/benefit analyses should be performed for each project. Characterization of projects in terms familiar to the industry would increase the likelihood of future commercialization. INDUSTRY INVOLVEMENT Truly effective research funded by OIT to develop and deliver advanced energy efficiency, renewable energy, and pollution prevention technologies should be closely coordinated with industry needs, in terms of timing and technology. The economic payoff may depend on meeting an industry need. If the research is not
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MANAGEMENT STRATEGIES
39
focused on meeting an industry need, OIT should carefully consider whether or not to support the project. In some cases, the research may be justified, but these should be the exception rather than the rule. OIT must also consider how its R&D programs will affect private investment in an industry. Government funding in a given area usually chases out private funds for a number of reasons. In general, government research, which must make its results available to the public, may undermine a product’s differential advantage and hence its profitability, thus reducing it to a commodity. To avoid this, OIT’s linkages with industry through IOF must remain strong. The industries in IOF are high-volume, slowly changing, commodity (i.e., with limited company control of pricing), capital-intensive, cyclical industries. Operating conditions frequently dictate that plants cannot risk experimental changes. In some cases, cash flow cannot support any changes. Opportunities do appear, however, although they cannot be predicted easily at the start of a program. Keeping operators and decision makers informed of new technologies may whet industry interest and encourage change. Ensuring that OIT R&D is consistent with industrial needs is paramount to ensuring the successful commercialization of technologies upon completion of the project. In the past, OIT has successfully used a teamreview approach to manage its programs, most, if not all, of which had buy-in by an industrial partner from the onset of the technology development process. Therefore, experience suggests that partnering with the end-user early in the project (ideally, beginning with project selection and scope development) is critical to successful commercialization. The establishment of industry-expert positions in DOE could help provide oversight of the project development process. Industry experts would bring an industrial perspective to the DOE programs and maximize the probability of their successful commercialization. Industrial end-users should include various levels of company management and employees, from CEOs to vice presidents to operation-level staff. A senior technical person in the company should be involved on a regular basis. Combined information from research universities and government agencies, and input from industry participants would ensure the selection of sound projects with high prospects for commercialization.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
MANAGEMENT STRATEGIES
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
40
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
41
5 Research and Development Opportunities
This chapter discusses the R&D opportunities for select IOF industries and for crosscutting R&D (using refractories as an example). After the materials needs of selected IOF industries are described, the R&D opportunities are discussed. In keeping with the crosscutting theme of this report, the committee focused on materials technologies that would enable or improve the understanding and processing of existing and new products used by more than one IOF industry rather than on the development of industry-specific products. ALUMINUM INDUSTRY Identified Needs Oxidation-Resistant and Corrosion-Resistant Materials In the Bayer process (used to convert bauxite to alumina), yields are relatively low; therefore, productivity (output and rate of production) is a key issue. Productivity could be improved if the process could be operated at high caustic concentrations, but this would require low-cost, high-temperature, abrasion-resistant, corrosionresistant materials or coatings. Materials Processing Smelting. The primary aluminum sector would benefit from an alternative to the prebaked carbon anodes now used in the smelting process. The new, nonconsumable anode material would have a longer life than carbon and, at the same time, would avoid carbon-dioxide emissions (an OIT project to develop this material
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
42
has already been funded). A related project is the development of wettable cathode materials to improve cell efficiency. The industry would benefit from a better understanding of the relationship between changes in raw materials used to make carbon anodes and their performance in the electrolytic cell. The object of this project would be to minimize dross and skim losses during melt/remelt operations through a better understanding of molten metal/oxygen reactions and the identification of new additives or procedures for preventing oxidation. Melting. Melting and casting of aluminum, in both the primary and secondary (remelt or recycling) sectors, requires durable materials, especially more durable refractories, for the containment and transfer of molten metal. Solidification. The aluminum industry would benefit from a better means of removing impurities, such as inclusions, from molten metal. Better filtration media and alternative filtration methods would be useful. Forming. The understanding of metal flow (e.g., modeling of metal flow in hollow extrusion dies) and the formability characteristics of wrought aluminum alloys (e.g., spring-back of sheet, distortion in joined components, such as laser welds), as well as test methods, could be greatly improved. R&D could focus on advanced forming processes (e.g., hydroforming, electromagnetic forming, superplastic forming) and advanced casting processes (e.g., semisolid casting and spray forming). Joining. The industry needs improved aluminum joining technologies, such as resistance spot welding, and improved materials to extend electrode tip life. Modeling Better modeling is a common need of the IOF industries and has crosscutting potential, although models are likely to have specific applications. Existing models could be improved for the solidification process, control of solidification during the casting process, and determining the relationship between composition, casting process, microstructure, surface properties, and stress/strain behavior at high temperatures. In the fabrication of wrought products, constituent models for alloys and the formability of automotive sheet could be improved, as well as modeling of the complex relationship between product behavior, structural properties, materials composition, and manufacturing processes (e.g., the relationship between mechanical properties and the formability of aluminum sheet, composition, microstructure, and thermomechanical history).
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
43
Other Needs Current tooling and die steels do not fully satisfy the industry’s needs. Better tool and die materials with improved heat-extraction capabilities would be useful. Scrap is an intrinsic by-product of aluminum fabrication, and the industry needs new, recycle-tolerant alloys with specifications that are better matched with scrap composition, thereby optimizing scrap utilization. The industry also needs robust, continuous-casting technology 5xxx and 6xxx alloys. The industry would benefit greatly from a searchable materials database that includes processing, microstructure, and properties to identify existing or tailored solutions to meet these challenges. Opportunities Current Programs 1 Three interrelated programs are focused on improving the energy and environmental efficiency of electrolysis cells used to smelt primary aluminum. The production of aluminum is extremely energy intensive, and the use of consumable carbon anodes gives rise to emissions of greenhouse gases. Inert anode and cathode technology for electrowinning of aluminum in primary electrolysis cells is the subject of extensive ongoing research. The market-pull for these technologies has increased with growing concerns about, and the need for, reductions of greenhouse gases. A parallel program is addressing the development of wettable ceramic-based materials for retrofitting existing cells to provide a stable, molten-aluminum, wetted cathode surface on top of the existing carbon cathode blocks, thereby improving efficiency. Another program is addressing the addition of compounds to the components of pot-cell linings to improve cell efficiency and cathode performance and improve the end-of-life disposal of spent potlining. Three programs are under way in the area of semifabricated products. One is addressing the development of improved grain refiners for reducing energy utilization and scrap generation and increasing furnace productivity. The other two are investigating the forming of aluminum: (1) spray forming for the direct production of (strip) products and (2) the semisolid forming of castings into near-net-shaped products.
1 Based on workshop presentation by Sara Dillich, U.S. Department of Energy Office of Industrial Technology, (Dillich, 1999) and John Green, The Aluminum Association (Green, 1999).
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
44
Future Opportunities Although many of the R&D needs identified in this report, such as the demand for chemically inert materials for electrolytic cells, are specific to the aluminum industry, a number of needs overlap with the needs of other IOF industries. Materials and materials process modeling was cited in all of the IOF road maps (see Table 1-2 ). Because IOF industries often face materials challenges unrelated to their fields of expertise, the development of tools to help identify materials solutions would be extremely useful. A comprehensive, internetaccessible, searchable database of material specifications and properties would be a valuable tool for determining the availability of existing solutions or highlighting the need for further development. The aluminum industry needs models for understanding the relationship between product materials characteristics (e.g., microstructure and properties) and processing (e.g., casting, rolling, and extrusion forming of sheet). Although these models are likely to be industry specific, the methodology used in their development may have wider applications. The Bayer process for the production of alumina from bauxite, a well established chemical process, could be improved with new materials. In the Bayer process, bauxite is crushed, ground, mixed with a solution of sodium hydroxide, and pumped into large autoclaves. In these vessels, under pressure and at temperatures in the range of 220°C to 350°C degrees, the caustic dissolves the alumina in the bauxite to form sodium aluminate. The yields from this process are relatively low, and the industry would like to increase output by operating at higher caustic concentrations. Research opportunities include the selection, adaptation, or development of corrosionresistant coatings (e.g, ceramic-based coatings) for the containment vessels. These coatings would also be useful for other IOF industries. The aluminum industry could use more durable refractory materials for melting, holding, and handling molten aluminum. Melting furnaces use salts to help break down the surface oxide during melting and chlorine for fluxing and magnesium control. Although the temperature requirements will differ for the aluminum industry and other industries, the chemical conditions are similar. A range of alkali-resistant and halogen-resistant coatings would be of interest to several IOF industries. CHEMICAL INDUSTRY Needs The chemical industry has three high-priority needs: new materials that would expand the limits of process operating conditions (e.g., higher temperatures and pressures); a better understanding of the operating limits within which existing and
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
45
new materials could be safely and reliably used; databases and models as tools for reliable, cost-effective predictions of the performance of materials under expected process conditions (e.g., aqueous and nonaqueous conditions and high-temperature processes). The technology road map developed by the Materials Technology Institute provides more details on the materials needs of this industry (MTI, 1998). .
Opportunities The committee identified several research opportunities to meet the needs of the chemical industry. The industry would benefit from improved materials capable of withstanding aggressive process environments (e.g., improved thermal spray coatings resistant to corrosive liquid environments; more cost-effective, reliable techniques of cladding exotic materials over a steel substrate; materials with improved resistance to hightemperature, high-dew point, and liquid halogen-containing environments; and materials resistant to metal dusting). Other opportunities for R&D are the fundamental understanding of process/materials interactions, predictive tools (e.g., computational process modeling; reliable tools for predicting material performance without costly testing; and modeling/predicting the performance of high-temperature materials), data acquisition (e.g., user-friendly databases on thermophysical, kinetic, and mechanical data), and monitoring and inspections (e.g., nonintrusive, nondestructive, on-line inspection methods and corrosion probes for high-temperature environments). FOREST PRODUCTS INDUSTRY Current Projects Composite Tubes in Kraft Recovery Boilers The recovery boiler is used in a kraft pulp mill to incinerate the unwanted organics (mainly lignin) that were removed from pulped wood. More than 50 million tons of kraft pulp are produced in the United States each year, and a roughly equivalent amount of organic material is incinerated in the recovery boilers of kraft mills. Therefore, this is a significant energy conversion process. The capital investment for a recovery boiler, the most costly unit in a kraft pulp mill, is about $200 million. The walls of the most recent units, especially at the floor of the recovery boiler (consisting of tubes through which cooling water circulates), have been made from stainlesssteel clad carbon-steel tubes instead of the older studded carbon-steel tubes. The walls of the lower portion of the furnace are covered with a
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
46
protective layer of frozen kraft smelt when the furnace is in operation. Without this protective layer, the tubes would quickly fail. One of the projects in the AIM Program is to elucidate the causes of composite tube cracking in the floor of recovery boilers. Cracking is happening more and more frequently and is of great concern to the industry in terms of safety and capital effectiveness. A multi-institutional team, including ORNL, the Institute of Paper Science and Technology, the Pulp and Paper Research Institute of Canada, and a large number of pulp and paper companies and suppliers is involved in this project. Computer modeling and experimentation has shown that the washing process of the recovery boiler is a significant source of corrosion and the subsequent failure of composite tubes (Adams, 1997). Identified Needs A study of the materials needs of the pulp and paper industry was issued in August 1995 (Angelini, 1995). Since then, other needs have been identified, especially in the area of low-effluent processing. An important factor for the pulp and paper industry is the extraordinary capital intensity of the process. Therefore, even though materials that could solve a given problem may be readily available in the marketplace, they may be prohibitively expensive. As a result, R&D to define the operating window for existing and installed materials may be more useful than R&D on new materials, which may be most useful for new processes, such as blackliquor gasification (i.e., high-temperature, gas-separation membranes to separate sulfurous gases, refractories, and erosion-resistant materials) (Harriz, 1999). Opportunities for new applications of existing materials (based on a database), unit operations, separations, and surface properties are described below. Wood Preparation Logs must be processed into chips that are then converted to pulp by chemical and/or mechanical means. Improving the erosion and abrasion resistance of cutting tools and surfaces of transport equipment would be a significant improvement. This could be achieved by surface treatments or the use of ceramics. Improvements in cutting and chipping tools and machinery for transporting logs would increase the effectiveness of existing capital equipment by reducing down time and maintenance requirements.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
47
Kraft Pulping Conventional corrosion problems occur throughout the recovery area. However, as mills strive to produce less effluent, process conditions and the chemical composition of liquors change. As a result, chloride and potassium build up in the recovery system of many mills. Problems include increased corrosion due to these changes in concentration. These problems could clearly be solved by switching to materials that are readily available in the marketplace, such as duplex steels. However, the capital costs of the changeover are usually prohibitive. Therefore, the industry would benefit from new applications that can be used safely with existing capital equipment. Problems with conventional recovery boilers include: corrosion at air ports, the lack of on-line monitoring to detect impending failures, and water-side corrosion cracking. Recycled Paper One of the pressing issues for the pulp and paper industry is sticky polymer residues in the recycled paper stream. These residues (from adhesives used on envelopes, labels, stamps, etc.) interfere with equipment by adhering to metal surfaces and can be very detrimental to the final product because they cause imperfections visible to the human eye. Separation is quite difficult because the density of these materials is close to the density of water. They also clog screens and filters. Opportunities for R&D include water-soluble adhesives and surface treatments that would reduce or eliminate the fouling of machinery by sticky adhesives. Bleaching The technologies of choice that meet current environmental regulations are substituting chlorine dioxide for chlorine and using oxygen delignification. An evaluation of using current materials with chlorine dioxide would be beneficial. Papermaking More wear-resistant materials and improved surface materials (mostly polymers) used to produce felts (for pressing) and wires (the continuous belt on which the paper slurry is sprayed in the first step of papermaking) would reduce down time. Other R&D areas of interest to the industry are: improved mechanical properties of the high-speed processes used in papermaking; improved surface
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
48
properties and durability of metallic surfaces (e.g., rolls and headbox); bearing materials, especially ceramic bearings, that do not require lubrication and can operate at higher speeds. Low-Effluent Processing in Pulp and Paper The buildup of chloride and potassium are problems in low-effluent kraft pulping. The buildup leads to plugging in the recovery boiler and may lead to corrosion. More rugged ultrafiltration and electrodialysis membranes and systems would be useful for separation processes to segregate the contents (both organic and inorganic) of bleach effluents before recycling the majority of the water. Membrane systems must be tolerant of small amounts of cellulose fibers to avoid the need for maintenance-intensive prefiltration. Current electrodialysis stacks are not fiber tolerant. The advantages of electrodialysis for recycling acidic bleach effluent have already been shown in DOE/OIT-sponsored research (Tsai and Pfromm, 1999). Inorganic elements in the pulping, bleaching, and papermaking operation can cause scaling and corrosion; the industry would benefit from a comprehensive simulation system for liquors and process conditions in pulping and papermaking, including the complex interactions of wood fibers with inorganic dissolved ions. Available databases are mostly tailored for other industries. Expanding these databases to include the thermodynamics of multicomponent, aqueous mixtures, including organics as they occur in papermaking, will require fundamental research. Lumber and Structural Wood More durable, resistant high-speed cutting tools used in lumber production would prevent catastrophic failures of equipment. Modifications of surface materials would help prevent the adhesives used in “engineered lumber” from disturbing processing operations. Research Opportunities The forest products industry offers several high-priority R&D opportunities. First, the industry would benefit from computer-searchable databases and simulations for modeling. Simulations of the behavior of multicomponent inorganic mixtures in pulping and papermaking will require fundamental research. Simulations would be useful for predicting the effects of low-effluent processing on the operation. Second, the industry needs better refractories that can withstand the conditions in new black-liquor gasification units. R&D in this area should focus on defining and assessing the
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
49
process conditions and determining desirable properties. Third, once fundamental data have been obtained, they must be integrated into existing databases and process simulation software. Fourth, the industry needs ways to increase the corrosion resistance and wear resistance of existing materials in the changing chemical and physical environment. Fifth, the industry would benefit from surface modification to prevent detrimental interactions with adhesives, improve wear resistance, and improve corrosion resistance. GLASS INDUSTRY Industry Needs The glass industry is dependent on materials technology for both products and manufacturing. Most of the industry’s products are melted in high-temperature furnaces fired by gas or petroleum or heated electrically. Process technology, which is primarily dependent on high-temperature material properties, then shapes, molds, pulls, stretches, grinds, polishes, or otherwise manipulates the product to give it its final form. Glass can also be produced by chemical synthesis, usually by sol-gel or chemical vapor deposition. As traditional “hot-melt” methods of producing glass have come under intense competitive pressure from competing materials and technologies, these methods are becoming economically significant. The industry as a whole is struggling to reduce costs because most glass products are commodities. To reduce the high capital and energy costs of “hot-melt” glass tanks, the industry has turned to more efficient processes, such as oxygen firing, which produces more heat and fewer pollutants per pound of fuel. However, these new techniques have revealed a need for better, lower cost refractory materials and melting processes. The industry is in need of any technology that can lower costs. Like most manufacturing industries, the glass industry as a whole has many technical needs because the business model for commodity businesses requires that costs be cut to the bone and overheads (including R&D) be ruthlessly slashed to underprice competition. Therefore, most glass companies do minimal research internally and depend on suppliers, consultants, and consortia to meet their research needs. The IOF Program has provided the industry with an excellent opportunity to make its needs known to the research community. At first glance, many of the industry’s needs appear to be common to other IOF industries, but there is usually a unique twist that makes the needs of this industry different. In cooperation with OIT, the entire industry working together for the common good has undertaken a refractories development program. Most glass products are manufactured using “hot-melting” processes, which entails putting a mix of sand, certain minerals, and fluxing agents together and melting them at very high
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
50
temperatures. The molten glass is then formed into shape, cooled, annealed, and sometimes ground and polished to produce the finished product. The industry produces a myriad of products, each with a unique composition and manufacturing process. All of them require high-temperature materials. Glass, which is loosely defined as any noncrystalline solid, can have an almost infinite number of compositions. Even if we limit our discussion to silica glasses, which includes most of the economically important glass products, nearly 100,000 different formulations are possible. These compositional differences, along with different melting temperatures and properties, have very different chemical reactivities resulting in different corrosion rates. The selection of refractory materials has always involved economic trade-offs between cost and lifetime, and even modest improvements in these materials will have a great impact on entire segments of the industry. Research Opportunities The glass industry has traditionally been very conservative in adopting new technologies because of the high capital costs of production and low profit margins of most glass products. Economic survival has dictated this approach, and the marketplace has ruthlessly enforced this discipline. Therefore, the industry has been very adverse to taking risks, which has slowed the pace of improvement. Nevertheless, many research areas would be beneficial for modernizing the industry’s aging infrastructure. Industry-wide data on high-temperature materials are not readily available. Research in this area could standardize high-temperature materials data and enable the industry to compile an industry-wide handbook. In this case (and others), the IOF Program can play an extremely important role for the glass industry. Research to develop technology to reduce energy costs, improve yield and/or quality, create new products, and improve product characteristics would all be very useful. Improvements might include smaller, more efficient glass tanks, faster flow through (more “pull” from) furnaces, better refractories, more efficient burners, cheaper oxygen technologies, better sensors, more useful modeling, better energy recovery from melting operations, faster product forming, lower cost raw materials, and better glass compositions. This list is certainly not all inclusive, and the reader is directed to the glass industry technology road map for more information (Energetics. 1997a ). Some crosscutting R&D areas are listed below: • refractory materials (compilation of properties and performance parameters) • high-temperature material (glass) properties • measurements of electroconductivity
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
• • • • • •
51
combustion research low-cost oxygen production modeling (including glass flow) sensor applications corrosion effects new product applications MINING INDUSTRY Needs
The mining industry (including the extraction processing of all metals but aluminum and steel) has been the subject of recent studies by the National Research Council (NRC, 2001) and others (e.g., RAND, in press). In 1992, the amount of energy used by the mining industry was: 77 trillion BTUs for the extractive processing of nonferrous metals and 582 trillion BTUs for excavating and hauling. The first mining industry road map on crosscutting technology deliberately excluded nonferrous metals in favor of technologies that would benefit both coal and hardrock mining (NMA, 1998). The next road map will address processing technologies for coal and extractive metallurgy. A future road map will cover specific mining technologies for coal and hard rock, which may address materials for wear and fatigue in more detail, as well as an energy and environment profile for mining, which will include more information on process technologies and materials needs. Research Opportunities Extractive industries for copper, nickel, cobalt, zinc, lead, gold, silver, and platinum group metals should be included in future mining industry road maps. These industries have limited funding for research but represent a broad segment of the mining industry, which is sorely in need of technical and financial support. STEEL INDUSTRY Needs The needs of the steel industry form a very long list (AISI, 1998). At the CEO level, the dominant problems for an integrated company are: the level of imports (routinely described as unfairly priced), which affects the whole price structure of this commodity material and thus the ability to remain competitive; and the supply of
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
52
new iron units to replace coke ovens and blast furnaces in the long run (one or two decades). Electric-melting carbon-steel companies have similar worries, with fewer concerns about imports because of their customer lists but equal concerns about finding high-quality melt stock (scrap or alternative iron units) at an affordable price to enable them to enter new markets. Specialty producers are also heavily impacted by imports. These factors explain why the industry is often characterized as not very forward looking. Limited cash flow has severely limited the implementation of new materials, and many important developments are the result of local initiatives by individual plants to reduce costs. Improved materials rarely result in higher prices in the market. Since about 1980, the actual average price of steel has not increased although quality and service have been vastly improved. In a “normal” environment, the profit on an average $500/ton steel might be $50. Normal environments are rare, however, and profits are often lower than this and may even be negative. It is generally accepted that replacing ingots by continuous casting was worth about $50/ton. A possible measure of an R&D program would be the potential of saving several dollars per ton (e.g., $10) and improving quality. Research Opportunities Corrosion Corrosion is an ubiquitous problem in steel plants. Aqueous corrosion occurs wherever water is used for cooling. Oxidation occurs whenever a product is exposed to high-temperature oxidizing gases (e.g., reheat furnaces and caster runout tables). If a scale is cracked in the roughing mill and washed away by high-pressure water, the result is lower yield. Conserving some of the heat in a slab by hot charging minimizes the chances of cracking a scale and also saves energy but requires careful scheduling when several different grades of steel are made in consecutive heats. Oxidation also occurs when hot gases are contained (e.g., in the off-take from a basic oxygen furnace). The melting of refractories into the oxide in which they are immersed also lowers productivity and increases costs. This problem has been mitigated in recent years but is still a serious concern. Currently, all of these problems must be solved locally, and incremental improvements continue to be made. Wear The machinery used in steel production, which is exposed to high loads and high temperatures (frequently nonuniform), takes a great deal of abuse. Hard coatings
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
53
of various types, preferably renewable coatings, would help greatly. Progress is made currently by incremental improvements. The combination of wear with chemical attack at high temperatures and thermal cracking makes testing new materials difficult. Refractories The industry uses enormous quantities of refractory materials as structural containers, protective coatings, and fluxes, especially in continuous casting. The recycling or disposal of refractories is a serious problem. Although incremental improvements could be made with new materials, reductions in costs are not likely to be revolutionary. Sensors Many automatic measurements of variables (e.g., dimension, temperature, composition, stress, and surface quality [including cracks and other imperfections]) are being pursued. The American Iron and Steel Institute has supported joint R&D on these difficult problems, sometimes with support from DOE, for many years. Much progress has been made, and further progress is expected. Improvements in sensors could also be useful for other metal producing industries. Monitoring transformations as they occur, either liquid-solid or solid-solid, is a primary goal, especially the simultaneous measurement of local stresses and/or strains. Numerous sensors to measure variables during casting are already available, but other apparently simple problems, such as exact location of the metal-slag interface, could be investigated. HEAT-TREATING INDUSTRY Needs The business environment for a heat-treating facility is quite different from that of a steel plant although the two industries employ an equal number of workers. A typical commercial plant is a job shop, frequently quite small and with limited technical staff. International competition is not often an issue but satisfying customers (who have a wide choice of suppliers) is. Input material may not be well characterized because heat treaters are primarily service providers. The sequence of operations can be described simply. Material is received, usually as machined parts. Each material has a temperature-time sequence for producing specific properties, which may or not be dependent on position. Chemical
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
54
changes in the surface can be part of the process, intentionally (e.g., carburizing or nitriding) or unintentionally (e.g., if control of the atmosphere in the furnace is inadequate). The parts are then cleaned, inspected, and shipped. Research Opportunities R&D opportunities include new equipment and hardware, such as design devices to ensure temperature uniformity and magnitude and to control heat losses and quenching devices to ensure uniform treatment of large volumes of material, reduce costs, improve disposal methods, and control cooling rates. Cooperative R&D in the industry could include the development of databases, sensors, and instrumentation and the creation of networks for the dissemination of nonproprietary information. Other opportunities are in new construction materials, the development of models to predict responses of parts throughout the production cycle (including efforts to shorten heat-treating times by increasing temperatures without adversely effecting material properties) and a better understanding of computational fluid dynamics. R&D to help the industry meet current pollution-prevention requirements is crucial. An economic analysis of issues likely to increase profits would help to set priorities for R&D projects. REFRACTORIES: AN ILLUSTRATIVE CROSSCUTTING AREA Refractories have been identified as a technology important to all nine IOF industries (see Table 2-1 ). The refractories industry itself, like many of the IOF industries, is undergoing a consolidation. Since 1990, several buyouts in this industry have resulted in the closing of R&D laboratories, greatly reducing the resources being devoted to research. In addition, the steel industry has greatly reduced its R&D and evaluation of refractories over the last several decades. Only a few U.S. universities have active programs in refractories research (J.D. Smith, 1999). The disproportion between the need for improved refractories by the IOF industries and the greatly reduced resources dedicated to R&D on refractories could limit improvements. All of the IOF industries use heat in at least one step in their manufacturing processes. The industries for which improved refractories would be most beneficial are aluminum, chemicals, glass, oil refining, and steel. Although refractories are not mentioned in every road map, often the need identified could only be met by improving the refractories or other materials involved in the process. The largest consumer of refractories is the iron and steel industry, which consumes approximately 50 percent of all of the refractories produced in the United States. The steel industry’s dependence on refractory materials has two key ramifications: (1)
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
55
research that improves the performance of refractory materials or reduces installation time will benefit the steel industry; and (2) R&D on steel making will be affected by the performance of refractory/containment materials. The development of new processes for the production of iron and steel has been limited by refractories that do not perform well in the proposed environments. The steel industry has identified the following specific needs: • • • • • • • •
prevention of the clogging of transfer nozzles improved monolithic products and installation methods (including dewatering) improvements in electric furnace delta sections and sidewalls better high-temperature data improved ladle, tundish, and mold refractories (including slide plates and shrouds) improved basic oxygen furnance taphole mixes improved stirring elements economical recycling methods for refractories
Some of the results of R&D in these areas could be transferred directly to other IOF industries. For example, the aluminum, metalcasting, and glass industries also use nozzles in their processes. The dewatering of monolithic refractories obviously applies to any industry that uses these materials. Knowledge of hightemperature properties would also be valuable to all of the IOF industries. Like the steel industry, the glass industry is highly dependent on refractories. In fact, molten glass is sometimes referred to as a universal solvent. Keeping refractory stones from getting into the glass bath is extremely important in the quality control of glass. In addition to the molten glass, the atmosphere above the glass bath is extremely corrosive to refractories. As a result of recent technological advances in the oxyfuel method of glass making, this atmosphere is even more corrosive to refractories than it had been. In general terms, the glass industry road map has identified a need for improved refractories for melting systems that use oxygen combustion. In fact, improved refractories for the crown and breast walls is one of the highest priorities in the glass technology roadmap (Energetics, 1997a). A fundamental understanding of the corrosion mechanisms of refractory compositions is another high priority need. It is safe to say that a better understanding of corrosion mechanisms will benefit more than one of the IOF industries. The Aluminum Industry Technology Roadmap also mentions refractories, for the reduction cell (Aluminum Association, 1997). For many years, the refractories industry, in conjunction with the aluminum industry, has been conducting research on various kinds of refractories specifically for the aluminum industry. Other areas of the aluminum process that require significant amounts of refractories are the anode baking pit furnaces, melting and holding furnaces, and troughs and runner systems.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
56
Recently, the aluminum industry has begun using stirring elements in the melting and holding furnaces. Improvements in stirring elements would also be valuable to the steel industry. The Technology Roadmap for Materials of Construction, Operation, and Maintenance in the Chemical Process Industries identifies refractories as a high-priority need with the potential to impact many chemical industries that use furnaces in the manufacturing process (MTI, 1998). The highest priority is for materials with high-temperature capabilities and corrosion resistance. Related needs include materials for halogen-based processes, high-temperature refractory coatings, high-temperature materials (> 3,000°F), and longer life, fieldrepairable refractories. The needs of the petrochemical industry and the plant/crop-based renewable resources industry are generally similar to those of the chemical process industry; and these industries would benefit directly from improved refractories. Although the mining industry does not have significant uses for refractories, the nonferrous metals industries do. The operating conditions of refractories in nonferrous metals processing are demanding. Nonferrous metals, such as copper, lead, zinc, and magnesium, are very hostile to refractories. A better understanding of chemical attack at high temperatures would be helpful to these industries. In other words, R&D on refractories for the steel, glass, and aluminum industries would also benefit the nonferrous metal industries. The forest products industry has identified a key need for refractories for the treatment of black liquor that can withstand high-temperature chemical attack. This industry is particularly interested in chromium-free refractories. Any advances in corrosion-resistant or erosion-resistant materials would benefit this industry. The forging and heat-treating industries use refractories but at lower temperatures and in less demanding environments than other metal industries. Neither the forging nor the heat-treating industry identified a need for improved refractories. Research Opportunities Although the committee identified many opportunities for crossscutting research from the IOF industry road maps, the one need common to all of the road maps is for a database on high-temperature materials. Very little reliable data are available for refractories. In recent years, government agencies have been reluctant to support R&D that generates data that may not lead to a new theory or scientific model, and industry has been unable to support this R&D. Nevertheless, the IOF representatives have clearly identified a need for a high-temperature database to advance their process efficiencies. The steel industry has identified a need for improved monolithic refractories, including installation methods; R&D in this area would benefit all of the IOF
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
57
industries. R&D could focus on the development of monolithic refractories that have properties equal to or better than brick, can be installed quickly and easily, and are cost effective. Significant progress in this area has been made in recent years with the introduction of low-cement/no-cement castables, self-flowing castables, and shotcreting of castables. A castable with a basic chemistry has not yet been developed. One example of the potential advantage of a castable refractory would be for the ladle. When a brick lining in a ladle is replaced, the bricks are removed and usually disposed of in a landfill. When a cast lining has worn too thin to be used it is cleaned, a mold is placed in the ladle, and the space between the worn lining and the mold is filled with a castable refractory. This method greatly reduces the environmental problem of disposing of the ladle lining. One concern associated with monolithic refractories, such as castables, is the removal of the mechanical and chemical water before it can be returned to service. This is a time-consuming process that increases the down time of the equipment and could potentially cause a catastrophic failure of the lining during the drying phase. Rapid drying castables are available, but, unfortunately, the ingredient that allows the rapid drying also degrades the properties of the castable. All of the IOF industries would benefit from R&D in this area. The steel industry road map indicated that refractories between the steel ladle and the continuous caster mold would yield major cost reductions. The industry greatly needs to reduce the cost of refractories for all equipment, from the well block and slide gate system at the ladle to the submersible entry nozzles to the tundish lining, the tundish slide plates, and the shrouds. These consumable items now represent a significant portion of the cost of producing steel. Several IOF road maps mention refractory coatings, an area in which considerable efforts have been mounted in recent years by the refractories industry and others. Although some applications have been successful, new coatings have seldom met expectations. This R&D area has a low probability of success but would have a high economic return. Another R&D area (although not specified in industry road maps) applicable to all of the IOF industries is insulating refractories, which would lead to energy savings, is one of OIT’s overall objectives. Refractory ceramic fiber is an extremely effective insulating material but is often not cost effective and has limited temperature capabilities. Health and safety concerns have also been raised about using this material. R&D in this area could focus on reducing costs, increasing service temperatures, finding a cost-effective substitute (e.g., foam), and developing a high-temperature ceramic fiber that is environmentally benign. More conventional insulating refractories (e.g., insulating firebrick) also have the potential to save energy, but very little work has been done in this area in recent years. Insulating castables could also have significant energy savings.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
RESEARCH AND DEVELOPMENT OPPORTUNITIES
58
OPPORTUNITIES FOR MATERIALS RESEARCH AND DEVELOPMENT In keeping with the crosscutting theme of this report, the committee has focused on materials technologies that would enable or improve the understanding and processing of existing and new products used by more than one IOF industry rather than on the development of industry-specific products. The R&D opportunities are summarized in the following recommendations. Recommendation. The Office of Industrial Technologies (OIT) should focus its materials technologies programs on a few high-priority areas that would meet the needs of several member industries of the Industries of the Future Program and, when warranted, develop crosscutting programs to address these areas. Areas to consider include: corrosion, wear, high-temperature materials (including refractories), and materials models and databases. OIT should use the panel of experts to identify materials-performance requirements and process parameters for each industry as a basis for selecting crosscutting technologies. OIT should then work with the panel to develop and select programs. Recommendation. Funding by industry, universities, and the national laboratories for the development of improved refractories has been reduced although most of the members of Industries of the Future have identified a need for them. The Office of Industrial Technologies should consider starting a refractories initiative to encourage cooperative research and development agreements and other mechanisms that would promote cooperation between industry and government agencies. OIT should consider supporting research and development in the following areas: reducing corrosion/erosion high-temperature reactions between molten metal, glass, and refractories; reducing the buildup of materials on the surface of the refractories; clarifying the fundamentals of monolithic refractories (including drying mechanisms and new binder systems); and developing data for finite element analysis design.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
OVERALL RECOMMENDATIONS
59
6 Overall Recommendations
With the IOF “market-pull” strategy in place, OIT has a solid basis for increasing the impact of its programs and projects. Although success in technology markets necessitates that some technology/product development plans remain proprietary, the IOF process of industry consensus is an excellent way to ensure the relevancy for OIT’s programs. LINKAGES BETWEEN INDUSTRY ROAD MAPS AND MATERIALS PROGRAMS The road maps are an excellent way of ensuring that OIT research is closely linked to meeting industry’s needs. One approach to setting priorities is first to ask the industry to rank its needs and then convene a group of knowledgeable experts (several from outside DOE) to assign qualitative rankings by class (e.g., excellent, very good, good, fair or poor). The program manager can select the best projects from the highest classes to create a balanced program. Proposal solicitations should be based on these priorities. Although R&D does not necessarily have to lead to an implementable solution quickly, progress toward that end should be demonstrated to warrant OIT support. To ensure that the list is current, industry road maps should be updated every two or three years, and unfinished road maps should be reviewed and either completed satisfactorily or the industry removed from the IOF Program. OIT must put mechanisms in place to maintain a precompetitive and crosscutting focus. This might be done by complementing industrial assessments of need with academic points of view and synthesizing decisions to structure requests for proposals and proposal rankings. Recommendation. The Office of Industrial Technologies should coordinate its materials technology programs with the technology road maps developed for the Industries of the Future (IOF) Program. Unfinished road maps should be completed, and all road maps should be updated every two to three years. Requests for research
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
OVERALL RECOMMENDATIONS
60
proposals should be linked specifically to the highest priority needs of the IOF industries. MATERIALS NEEDS IN INDUSTRY ROAD MAPS The committee identified improved corrosion resistance, wear resistance, high-temperature performance of materials (including refractories), and materials modeling/database development as important crosscutting needs for all of the IOF industries. However, differences in requirements for materials performance and operating environments must be specified to determine the best way to address these needs. This will also be necessary to determine if the results of R&D that meet the needs of one industry will be applicable to another, in other words, distinguishing between “real” and “apparent” crosscutting opportunities. Not all of the materials technology needs in the road maps can be addressed by OIT. It is, therefore, essential that OIT focus on the highest priority needs that are applicable to the most IOF industries. Recommendation. The Office of Industrial Technology should determine the highest priority needs in the technology road maps as a basis for identifying opportunities for crosscutting research. Industry experts should be engaged to define the materials-performance requirements and operating environments. This information could then be used to develop new programs and evaluate current programs. MARKET-PULL STRATEGY Some of OIT’s materials technology programs, specifically AIM and CFCC, predate OIT’s market-pull strategy by a number of years. It appears to the committee that these programs have been continued partly for historical reasons rather than because they are compatible with the market-pull strategy. This situation can be changed over time (1) by ensuring that new projects are strongly linked to the highest priority needs of several IOF industries, (2) by changing the emphasis of existing programs so that they will contribute to meeting the highest priority needs, and (3) by terminating programs that cannot be modified to fit with the market-pull strategy. These changes must be weighed against protecting the value of long-term investments in materials science and technology over a period of years and maintaining an appropriate balance of basic and applied research. Recommendation. Current and new materials technology programs should be fully integrated into the market-pull strategy. Proposals for new programs should be evaluated based on how they will meet the highest priority needs identified in the
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
OVERALL RECOMMENDATIONS
61
technology road maps. All programs should be reviewed annually. Those that support the highest priority needs should be strongly supported; those that do not should be refocused or discontinued. METRICS To avoid disappointments for both OIT and contractors, a clear definition of success (not necessarily commercialization, which can be a long process) should be agreed upon at the early proposal stage. If interim goals are not being met, reappraisals may be in order, or even a phased termination of the project to recoup scarce funds that could be used elsewhere. Nothing convinces an industry to invest in (or terminate) a project faster than an economic analysis of the results. Even rough estimates and an estimated time scale are helpful in this regard. These numbers will also help program managers identify what has worked best, thus serving as a guide for future decisions. Metrics should include energy efficiency, pollution prevention, and the use of renewable energy. Recommendation. A clear definition of “success” should be established at the beginning of all contracts, and progress should be measured annually by established metrics. A process should be developed for reevaluating projects that have not met their goals to determine if they should be continued.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
OVERALL RECOMMENDATIONS
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
62
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
REFERENCES
63
References
Adams, T.N. (ed.). 1997 . Kraft Recovery Boilers . Atlanta, Ga. : Technical Association of the Pulp and Paper Industry . AISI . 1998 . Steel Technology Road Map, Revised . Washington, D.C. : American Iron and Steel Institute . Also available on line at: http:// www.steel.org/mt/roadmap/roadmap.htm Angelini, P. (ed.). 1995 . Materials Needs and Opportunities in the Pulp and Paper Industry . ORNL/TM-12865 . Oak Ridge, Tenn. : Oak Ridge National Laboratory . Angelini, P. 1999 . Advanced Industrial Materials Program: Examples of an Approach to R&D . Presentation by P. Angelini, Oak Ridge National Laboratory, to the Committee on Materials Technologies for Process Industries , National Research Council , Washington, D.C. , September 16, 1999 . Aluminum Association . 1997 . Aluminum Industry Technology Roadmap . Washington, D.C. : Aluminum Association, Inc. ASM Heat Treating Society . 1997 . Report of the Heat Treating Technology Roadmap Workshop . Materials Park, Ohio : ASM Heat Treating Society . CMC (Cast Metals Coalition) . 1998 . Metalcasting Industry Roadmap . North Charleston, S.C. : Cast Metals Coalition . Also available on line at: http://www.oit.doe.gov/metalcast/roadmap.shtml Craig, P.A. 1999 . CFCC Materials for Industrial and Corrosive Applications . Presentation by P. Craig, AlliedSignal Composites, Inc., to the Committee on Materials Technologies for Process Industries , National Research Council , Washington, D.C. , September 16, 1999 . Dillich, S. 1999 . Aluminum, Metalcasting and Steel Industries of the Future . Presentation by S. Dillich, U.S. Department of Energy Office of Industrial Technology, to the Committee on Materials Technologies for Process Industries , National Research Council , Washington, D.C. , September 16, 1999 . Energetics . 1997a . Report of the Glass Technology Road Map Workshop . Columbia, Md. : Energetics, Inc. Also available on line at: http:// www.oit.doe.gov/IOF/glass/glass_roadmap.html Energetics . 1997b . Forging Industry Technology Roadmap . Columbia, Md. : Energetics, Inc.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
REFERENCES
64
Freitag, D.W. , and D.W. Richerson . 1998 . Opportunities for Advanced Ceramics to Meet the Needs of the Industries of the Future . Washington, D.C. : Office of Industrial Technologies, U.S. Department of Energy . Green, J. 1999 . The Aluminum “Industry of the Future” Partnership: Experience and Materials Needs . Presentation by J. Green, The Aluminum Association, to the Committee on Materials Technologies for Process Industries , National Research Council , Washington, D.C. , September 16, 1999 . Harriz, J.T. 1999 . Black-liquor gasification: a comprehensive update . TAPPI (Technical Association of the Pulp and Paper Industry) Journal 82(9) : 43–44 . Hoffman, P. 1999 . Industrial Power Program . Presentation by P. Hoffman, U.S. Department of Energy Office of Industrial Technology, to the Committee on Materials Technologies for Process Industries , National Research Council , Washington, D.C. , September 16, 1999 . Karnitz, M. , I. Wright , and M. Ferber . 1999 . Overview of Materials Accomplishments in the ATS Program . Presentation by M. Karnitz, Oak Ridge National Laboratory, to the Committee on Materials Technologies for Process Industries , National Research Council , Washington, D.C. , September 16, 1999 . MTI (Materials Technology Institute) . 1998 . Technology Road Map for Materials of Construction, Operation, and Maintenance in the Chemical Process Industries . St. Louis, Mo. : Materials Technology Institute . Also available on line at: http://www.mti-link.org NMA . 1998 . Mining Industry Roadmap for Crosscutting Technologies . Washington, D.C. : National Mining Association Technology Committee . Also available online at: http://www.oit.doe.gov/mining/ccroadmap.shtml NRC (National Research Council) . 1997 . Intermetallic Alloy Development: A Program Evaluation . Washington, D.C. : National Academy Press . NRC . 1999 . Industrial Technology Assessments: An Evaluation of the Research Program of the Office of Industrial Technologies . Washington, D.C. : National Academy Press . NRC . 2001 . Evolutionary and Revolutionary Technologies for the Mining Industries . Washington, D.C. : National Academy Press . RAND . In press. Critical Technologies for Mining. RAND Science and Technology Policy Institute . Santa Monica, Calif. : RAND . Smith, J.D. 1999 . Materials Issues in the Steel Industry . Presentation by J.D. Smith, University of Missouri-Rolla, to the Committee on Materials Technologies for Process Industries , National Research Council , Washington, D.C. , September 16, 1999 . Smith, M. 1999 . Continuous Fiber Ceramic Composites . Presentation by M. Smith, U.S. Department of Energy Office of Industrial Technology, to the Committee on Materials Technologies for Process Industries , National Research Council , Washington, D.C. , September 16, 1999 .
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
REFERENCES
65
Sorrell, C. 1999 . Advanced Industrial Materials . Presentation by C. Sorrell, U.S. Department of Energy Office of Industrial Technology, to the Committee on Materials Technologies for Process Industries , National Research Council , Washington, D.C. , September 16, 1999 . Tsai, S.P. , and P.H. Pfromm . 1999 . Electrodialysis for bleach effluent recycling in kraft pulp production . Canadian Journal of Chemical Engineering 77(10) : 1–8 .
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
REFERENCES
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
66
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
APPENDIX A
67
Appendix A Recommendations
PROGRAM MANAGEMENT Recommendation. The Office of Industrial Technologies (OIT) should establish a permanent advisory panel of industry experts to work in parallel with OIT’s industry teams. Members of the panel could be drawn from these teams and should include at least one representative of each Industries of the Future member industry. The advisory panel would provide expert knowledge and advice to OIT program managers and ensure that the ultimate goals are kept in focus throughout the development cycle of a technology. The panel should perform the following functions: • rank industry priorities and select programs • assist in developing program metrics (to measure progress) • review programs annually OPPORTUNITIES FOR MATERIALS RESEARCH AND DEVELOPMENT Recommendation. The Office of Industrial Technologies (OIT) should focus its materials technologies programs on a few high-priority areas that would meet the needs of several member industries of the Industries of the Future Program and, when warranted, develop crosscutting programs to address these areas. Areas to consider include: corrosion, wear, high-temperature materials (including refractories), and materials models and databases. OIT should use the panel of experts to identify materials-performance requirements and process parameters for each industry as a basis for selecting crosscutting technologies. OIT should then work with the panel to develop and select programs. Recommendation. Funding by industry, universities, and the national laboratories for the development of improved refractories has been reduced although most of the members of Industries of the Future have identified a need for them. The Office of Industrial Technologies should consider starting a refractories initiative to encourage
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
APPENDIX A
68
cooperative research and development agreements and other mechanisms that would promote cooperation between industry and government agencies. OIT should consider supporting research and development in the following areas: reducing corrosion/erosion high-temperature reactions between molten metal, glass, and refractories; reducing the buildup of materials on the surface of the refractories; clarifying the fundamentals of monolithic refractories (including drying mechanisms and new binder systems); and developing data for finite element analysis design. OVERALL RECOMMENDATIONS Recommendation. The Office of Industrial Technologies should coordinate its materials technology programs with the technology road maps developed for the Industries of the Future (IOF) Program. Unfinished road maps should be completed, and all road maps should be updated every two to three years. Requests for research proposals should be linked specifically to the highest priority needs of the IOF industries. Recommendation. The Office of Industrial Technology should determine the highest priority needs in the technology road maps as a basis for identifying opportunities for crosscutting research. Industry experts should be engaged to define the materials-performance requirements and operating environments. This information could then be used to develop new programs and evaluate current programs. Recommendation. Current and new materials technology programs should be fully integrated into the market-pull strategy. Proposals for new programs should be evaluated based on how they will meet the highest priority needs identified in the technology road maps. All programs should be reviewed annually. Those that support the highest priority needs should be strongly supported; those that do not should be refocused or discontinued. Recommendation. A clear definition of “success” should be established at the beginning of all contracts, and progress should be measured annually by established metrics. A process should be developed for reevaluating projects that have not met their goals to determine if they should be continued.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
APPENDIX B
69
Appendix B Biographical Sketches of Committee Members
Joseph G. Wirth, chair, was senior vice president and chief technical officer, Raychem Corporation (retired), and, prior to that, vice president, Plastics Technology Division, General Electric. While at General Electric, Dr. Wirth’s research interests were engineering plastics and silicones. He is the inventor of polyetherimides, a heat and fire-resistant plastic used in aircraft and automobiles. As manager of worldwide technology operations, corporate manufacturing, and new business development for Raychem, he was responsible for commercializing new materials. Corby G. Anderson is director of the Center for Advanced Mineral and Metallurgical Processing, Montana Technology Institute of the University of Montana. He has more than 20 years of experience in metallurgical engineering, including the mining industry, pyrometallurgy, hydrometallurgy, and mineral processing. Mr. Anderson is director of the International Precious Metals Institute (IPMI) and a trustee of the Northwest Mining Association. Orville Hunter, Jr., is retired vice president of technology at A.P. Green Industries, where he was responsible for refractories research and development, quality management, raw materials, environmental compliance, new product installation methods, applications engineering, and manufacturing process improvements. Sylvia M. Johnson is chief, Thermal Protection Systems Branch, NASA Ames Research Center. Previously, she was director of chemical and ceramic product development at SRI International. She has extensive research expertise in the properties and processing of ceramics and ceramic composites. Her research has focused on the synthesis of oxide and nonoxide ceramic powders; the processing, characterization, and evaluation of structural ceramics, especially silicon nitride; and methods of joining ceramics.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
APPENDIX B
70
Harry A. Lipsitt is professor emeritus in the Department of Mechanical and Materials Engineering at Wright State University. He spent 30 years at the Air Force Wright Laboratory working on the development and optimization of metallic and intermetallic materials for use in high-temperature applications. His earlier research included fracture toughness in ceramics; deformation mechanisms in two-phase alloys; and deformation mechanisms in ordered intermetallics. Nicholas Montanarelli was deputy director, Office of Technology Applications, Ballistic Missile Defense Organization (BMDO). His expertise is in materials technology transfer, as well as in evaluating the commercialization potential of technologies. Prior to BMDO, Mr. Montanarelli held a number of key technologytransfer positions in the federal government, including program director for East-West Trade in the Office of the Secretary of Defense at the Pentagon, special assistant in the Office of Science and Technology Policy at The White House, and program manager at the National Science Foundation. Anatoly Nemzer, manager of materials engineering at FMC Corporation, has expertise in materials needs and applications for the chemical process industry. He has been involved in process development chemistry and corrosion engineering in the chemical processing industry for more than 20 years. He has also been active in the development and evaluation of high-temperature, corrosion-resistant materials, including nickel aluminide, for application in chemical processing equipment. Harold W. Paxton (NAE), the U.S. Steel Professor of Metallurgy and Materials Science at CarnegieMellon University, has expertise in the properties and performance of metals as they are influenced by processing and steel industry applications. He is past chair of the General Research Committee of the American Iron and Steel Institute and was president of the American Institute of Mining, Metallurgical, and Petroleum Engineers. Peter H. Pfromm is associate professor of chemical engineering at the Institute of Paper Science and Technology. Dr. Pfromm’s industrial experience includes several years with Membrane Technology and Research, Inc., a company that specializes in membrane separations, and Pharmetrix, Inc., a company that develops controlled-release devices for drugs. His areas of expertise include polymer science, gaseous membrane separations, electrochemical separations, specialty separations, closed-cycle manufacturing, and paper recycling. Frederic J-Y Quan is manager of Technology Acquisition at Corning, Inc., where he is responsible for the company’s research contract business for a broad range of glass technologies and sponsors. Previous to this, he was in the Telecommunications Products Division, where he started the specialty fiber business for Corning. He also
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
APPENDIX B
71
worked in the Electronics Products Division, where he supported Corning’s resistor and capacitor business. Michael P. Thomas, director of technology and business development with Alcan Aluminum Corporation, has expertise in metallurgy and materials processing, with 15 years of industrial experience in new product research and development (R&D), R&D management, corporate strategy, and business management. His expertise is in the commercialization of separation technologies used in aluminum recycling and materials needs and applications to the aluminum industry. Sheldon M. Wiederhorn (NAE) is special assistant to the director of the Materials Science and Engineering Laboratory at the National Institute of Standards and Technology. His expertise is in the properties and processing of ceramics and ceramic composites. He has been cited for his work in the development and application of test methods and the basic understanding of the mechanical properties of ceramics.
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
APPENDIX B
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,
72
Copyright © 2000. National Academies Press. All rights reserved.
About this PDF file: This new digital representation of the original work has been recomposed from XML files created from the original paper book, not from the original typesetting files. Page breaks are true to the original; line lengths, word breaks, heading styles, and other typesetting-specific formatting, however, cannot be retained, and some typographic errors may have been accidentally inserted. Please use the print version of this publication as the authoritative version for attribution.
ACRONYMS
73
Acronyms
AIM AISI ATS CEO CFCC CRADA DOE IOF MEMS OIT ORNL ORTA R&D SBIR STTR
Advanced Industrial Materials Program American Iron and Steel Institute advanced turbine system chief executive officer Continuous-Fiber Ceramic Composites Program cooperative research and development agreements U.S. Department of Energy Industries of the Future Program microelectromechanical system Office of Industrial Technology Oak Ridge National Laboratory office of research and technologies applications research and development small business innovation research small business technology transfer
Materials Technologies for the Process Industries of the Future : Management Strategies and Research Opportunities, National Academies Press, 2000. ProQuest Ebook Central,