Institutes for Sustainable Research Development & Deployment - Oak Ridge National Laboratory

Sustainable RD&D at ORNL

ORNL’s 3rd Annual Southeast Sustainability Summit

Martin KellerAssociate Laboratory DirectorEnergy and Environmental Sciences Directorate

August 22, 2013Knoxville, Tennessee

2 Sustainability Summit_1308

ORNL is DOE’s largest science and energy laboratory

$1.65B budget

World’s most intense

neutronsource

4,400employees

World-class research reactor

3,000researchguests annually

$500M modernization

investment

Nation’s largest

materials research portfolio

Most powerful open

scientific computing

facility

Nation’s most diverse

energy portfolio

Managing billion-dollar U.S. ITER

project

2 Green Economy 1302


Providing solutions to pressing energy challenges

Sustainable transportation

Energy efficiency in buildings

Advancedmanufacturing


New technologies and processes for:• Safe, secure, and

affordable vehicles for passengers and freight

• Domestic production of transportation fuel

• Reducing environmental impacts of transportation

• Predictable, reliable transport schedules

Electrification

• Wireless power transfer

• Advanced power electronics, fuel cell, and battery technologies

• Electric motors without permanent magnets

Efficiency

• Engine and aftertreatment technologies

• Hybrid powertrains

• Lightweight and propulsion materials

Alternative fuels

• Drop-in biofuels for legacy cars

• Renewable fuels for advanced engines

• Natural gas

Intelligent systems

• Managing congestion

• Efficient operations in commercial vehicles

• Data for decision-making

• Communications

Sustainable transportation: Developing a diversity of technologies


Scope Partners Impact at ORNL• Nationwide program

bringing >500 charging stations to Tennessee

• ORNL and partners have installed 144 solar and nonsolar EV charging stations

• City of Knoxville • University of Tennessee• State of Tennessee• Nissan• TVA• EPRI• Others

• 25 solar EV parking spaces

• 30 employees own EVs − 22 Nissan Leafs− 5 Chevy Volts− 1 Prius − 2 Ford C-Max

EV Project: ORNL is leading activitiesin Tennessee


Battery manufacturing R&D facility at ORNL

Nation’s largest open access facility

• Assisting industry in meeting demand for safe, affordable, extended-range hybrid and electric vehicles– Chemical and materials suppliers– Battery manufacturers and their customers– System integrators– Original equipment manufacturers

• Focus areas:– Manufacturability– Scale-up– Integration of new materials– Processes for higher production yield,

lower cost, and more efficient assembly

• Supported by DOE Vehicle Technologies Program and Advanced Manufacturing Office


Wireless power transferTransformational technology for vehicle electrification

• Amenable to existing highways

• PHEV/EV fast charge on the fly


Building technologies RD&D at ORNL: Focus areas

Envelope Equipment System/building integrationDevelop component

technologies that are more resistant to heat flow, airtight,

and moisture-durable than existing technologies

Develop component technologies that deliver the same amenities while using

significantly less energy than existing technologies

Verify that advanced component technologies

deliver what they promise and are durable and reliable

in real buildings


ZEBRAlliance Research Houses Collaboration with TVA and Schaad Companies

• 4 houses that demonstrate different strategies to achieve 50−60% energy savings

• Builder and industry partners invested ~ $2M for land, building materials, and labor

• After the project completion, Schaad Companies were able to reduce HERS indices of their average home by 30


Flexible Research Platforms(FRPs)

Maximum Building Energy Efficiency Research Laboratory (MAXLAB)

• 1 story metal building: Working with Metal Building Manufacturing Association to evaluate energy efficiency improvements for older buildings

• 2 story light commercial building: Working with HVAC manufacturers to evaluate multizone systems

• HVAC environmental chambers• Apparatus for testing air and moisture

of wall assemblies• ORNL’s 6th LEED Gold facility• Innovative energy saving techniques:

− Rainwater harvesting system− Daylight sensors, motion sensors,

lighting relay panels

Commercial buildings: Research tools


Product: GeoSpring™ Market transformation Consumer benefit• Realized 62% energy

savings compared to a conventional electric storage water heater

• Energy-efficient alternative with the same footprint and electrical connections as standard water heating technology

• An excellent retrofit candidate

• First hybrid electric Energy Star®–qualified water heater manufactured in the U.S.

• February 2012: Began production

• Currently being sold by major distributors

− Lowe’s− Sears− Ferguson

• Receive up to $300 in federal tax credit

• Realize annual energy savings up to $325

ORNL and General Electric: Heat pump water heater

11 Green Economy 1302


Product: GeoSpring™ Trilogy 40 Q-Mode Market transformation• First geothermal heat pump (GHP) certified

by Air-Conditioning, Heating, and Refrigeration Institute with Energy Efficiency Ratio (EER) >40 at ground-loop conditions

• Heating, cooling, 100% of water heating (not just a desuperheater)

− Energy savings: ~65% vs minimum efficiency (SEER 13) equipment

− Energy savings: ~33% vs state-of-the-art 2-stage GHP with desuperheater

• Outcome of a 4-year collaboration

• Currently in limited production

ORNL and ClimateMaster: Trilogy™ 40 Q-Mode™


Conducting manufacturing and materials R&D

Leveraging ORNL’s distinctive capabilities

Tackling 2 principal focus areas

• Reduce the energy intensity of U.S. industry

• Support development of new products

• Strengthen our nation’s vitality

• Neutron scattering• High-performance computing• Pilot-scale carbon fiber

production• Advanced characterization

• Carbon fiber and composites• Additive manufacturing

ORNL’s advanced manufacturing initiative

ORNL’s vision Provide industry with access to unique research facilities and expertise that reduce the risk and accelerate the development and deployment of next-generation materials and manufacturing technologies


Carbon fiber and composites

• Working with industry to develop and deploy technology with significant impacts on U.S. and global energy security

• Enabling deployment of low-cost technologyin high-volume applications– Low-cost raw materials– Low-cost fiber manufacturing processes– High-rate, robust composites

manufacturing processes

• Demonstrating scalability at the Carbon Fiber Technology Facility

14 ChattaRotary_1307


ORNL is helping grow an economic development cluster around carbon fiber

ORNL research

Commer-cialization strategy

CarbonFiber

TechnologyFacility

Jobcreation

Workforcedevelopment

Industrycollaboration


Integrating basic research and applied technology for clean energy

Lightweight materials

Cellulose

Lignin

Biofuels

High-value bioproducts for clean energy applications

Ultracapacitors

Chemical building blocks

Plastics, industrial additives, biomedical applications

Innovative processing

Hemicellulose


Discussion

http://www.ornl.gov/connect-with-ornl/for-industry/partnerships