New process technologies can rejuvenate U.S. manufacturing. Novel processing concepts can open pathways to double net energy productivity, enabling rapid manufacture of energy-efficient, high-quality products at competitive cost.
Four process technology areas are expected to generate large energy, carbon, and economic benefits across the manufacturing sector. Click the areas below to view our current projects in each.
Reactions and Separations
New technologies that provide high energy efficiency and process intensification can yield dramatic energy and cost savings in a range of industries, including oil refining, food processing, and chemical production. Example technologies include separation processes that rely on high-performance membranes and catalysts.
- Advanced Water Removal via Membrane Solvent-Extraction Technology
- New Design Methods and Algorithms for Multi-component Distillation Processes
- Process Intensification with Integrated Water-Gas-Shift Membrane Reactor
- Real-Time Remote Detection of HR-VOC Content in Flares - SBIR Phase II Recovery Act
- Ultra-High-Efficiency Aluminum Production Cells
- Grand Challenge Portfolio: Driving Innovation in Industrial Efficiency
- A New Method for Producing Titanium Dioxide Pigment and Eliminating CO2 Emissions (pg. 9)
- Advanced Nanostructured Molecular Sieves for Energy-Efficient Industrial Separations (pg. 8)
- Distributive Distillation Enabled by Microchannel Process Technology (pg. 9)
- Engineered Osmosis for Energy-Efficient Separations: Optimizing Waste Heat Utilization (pg.6)
- Reduction of Metal Oxide to Metal Using Ionic Liquids (pg. 5)
- SBIR Phase III Xlerator Program
- Launching A New Route To Styrene Monomer (pg.3)
- Reduction of Distillation Usage in the Manufacture of Ethanol By Reactive Water Separation (pg. 3)
High-Temperature Processing
Non-thermal or lower-energy alternatives to conventional, high-temperature processing technologies will enable more efficient production or recovery of critical materials (metallic and non-metallic). Such technologies could enable or enhance water-based, selective extraction of critical materials from low-grade ores; recovery of high-value materials in obsolete electronic equipment and waste; and low-temperature, high-efficiency chemical or electrochemical processes.
- Advanced Laser-Based Sensors for Industrial Process Control
- Energy Efficient Melting and Direct Delivery of High Quality Molten Aluminum
- Fuel-Flexible Combustion System for Refinery and Chemical Plant Process Heaters
- Fuel-Flexible, Low Emissions Catalytic Combustor for Opportunity Fuels
- Improved Heat Recovery in Biomass-Fired Boilers
- Low-Emissions Burner Technology using Biomass-Derived Liquid Fuels
- Minimization of Blast Furnace Fuel Rate by Optimizing Burden and Gas Distribution
- Paired Straight Hearth Furnace
- Energy-Intensive Processes Portfolio: Addressing Key Energy Challenges Across U.S. Industry
- Rapid Conditioning for Next-Generation Melting (pg. 9)
- Grand Challenge Portfolio: Driving Innovation in Industrial Efficiency
- Novel Steels for High-Temperature Carburizing (pg. 7)
Waste Heat Minimization and Recovery
Technology advances in ultra-efficient steam production, high-performance furnaces, and innovative waste-heat recovery will help to improve sustainability, reduce water usage, and decrease the energy footprint of U.S. manufacturing.
- Industrial Energy Efficiency Projects Improve Competitiveness and Protect Jobs
- Modifications and Optimization of the Organic Rankine Cycle to Improve the Recovery of Waste Heat
Sustainable Manufacturing
New manufacturing technologies that reduce process steps, materials usage, or part counts will reduce the energy embedded in the manufacturing value chain and decrease the use of raw materials in multiple markets. The same is true of technologies that enable the manufacture of materials or components that increase recycling and recyclability. Upon initial product conceptualization, new design and process tools could enable selection of a manufacturing process to meet specific cost, time, energy intensity, and life-cycle energy consumption requirements.
- Electrohydraulic Forming of Near-Net Shape Automotive Panels
- Energy Saving Melting and Revert Reduction Technology (E-SMARRT)
- Flexible Hybrid Friction Stir Joining Technology
- Hot Rolling Scrap Reduction through Edge Cracking and Surface Defects Control
- Ultra-Efficient and Power-Dense Motors
- Grand Challenge Portfolio: Driving Innovation in Industrial Efficiency
- Dry Kraft Pulping at Ambient Pressure for Cost-Effective Energy Savings and Pollution Deductions (pg. 3)
- New Manufacturing Method for Paper Filler and Fiber Materials (pg. 8)
Projects are also continuing under the former AMO R&D area: Combined Heat and Power.