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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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Techno-economic-environmental impacts of industrial energy assessment: Sustainable industrial motor systems of small and medium-sized enterprises

Energy assessments can provide an effective way of identifying and implementing energy efficiency measures to save energy costs and avoid emissions throughout manufacturing facilities. Consequently, it generates significant economic and environmental benefits to localities, states, and the nation. Quantifying these benefits requires a systematic techno-economic-environmental framework for capturing the interactions. This article employs methodologies to improve the energy efficiency of small and medium-size industries through their sustainable industrial motor systems. Motor systems offer large opportunities to enhance energy efficiency through adopting advanced technologies and better-informed operations. Case studies presented illuminate the potential savings and impacts from implementing sustainable motor systems and the importance of energy assessments. Here, the integrated macro-economic analysis quantifies the regional sustainability impacts of implementing the industrial energy efficiency offered by an energy auditing program in Ohio over a ten-year period. Results show that implementing all the center’s motor recommendations have directly saved $\$702$ M in energy costs, avoided 2.7 million metric tons of carbon dioxide emissions, and created 3,445 jobs, resulting in a total annual economic impact of $\$788$ M stemming from direct, indirect, and induced regional economic impacts. It provides policy implications for encouraging sustainable industrial motor systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Leveraging inter-firm influence in the diffusion of energy efficiency technologies: An agent-based model

Energy efficiency technologies (EETs) are crucial for saving energy and reducing carbon dioxide emissions. However, the diffusion of EETs in small and medium-sized enterprises is rather slow. Literature shows the interactions between innovation adopters and potential adopters have significant impacts on innovation diffusion. Enterprises lack the motivation to share information, and EETs usually lack observability, which suppress the inter-firm influence. Thus, an information platform, together with proper policies encouraging or forcing enterprises to disclose EET-related information, should help harness inter-firm influence to accelerate EETs' diffusion. To explore whether and how such an information platform affects EETs' diffusion in small and medium-sized enterprises, this report builds an agent-based model to mimic EET diffusion processes. Based on a series of controlled numerical experiments, some counter-intuitive phenomena are discovered and explained. The results show that the information platform is a double-edged sword that notably accelerates EETs' diffusion by approximately 47% but may also boost negative information to diffuse even faster and delay massive adoption of EETs. Increasing network density and the intensity of inter-firm influence are effective to speed EET diffusion, but their impacts diminish drastically after reaching some critical values (0.05 and 0.15 respectively) and eventually harm the stability of the system. Ultimately, the findings implicate that EET suppliers should carefully launch their promising but immature products; policies that can reduce the perceived risk by enterprises and the effort to maintain an informative rather than judgmental information platform can prominently mitigate the negative side effects brought by high fluidity of information.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Industrial Assessment Center – integration of education and practice. Final progress report

The goal of the DOE’s Industrial Assessment Center (IAC) program is twofold: first, to help US manufacturing competitiveness by providing assessments and recommendations for small and medium-sized enterprises (SMEs) on energy efficiency, productivity, sustainability and competitiveness – including measuring the impacts of these recommendations on reducing greenhouse gas emissions; and second, to address a growing shortage of engineering professionals with applied energy and manufacturing-related skills by training a diverse cross-section of engineering students through hands-on involvement in these assessments. IUPUI has an IAC, which was established in 2011, in the Department of Mechanical and Energy Engineering, Purdue School of Engineering and Technology, IUPUI. The IAC has won the awards twice. We have built the center that has the expertise and infrastructure for quality energy assessments to manufactures and commercial building owners and aligned our current research and teaching activities to the DOE’ training mission with programs to train the next generation of industrial energy efficiency experts, with theory and hands-on experience in conducting energy assessment for small and median manufacturing enterprises. We have made recommendations that have the potential to save about $20M annually. We also initiated research projects to meet DOE priorities, specifically in the areas of smart manufacturing and cybersecurity. On the energy assessment side, the Center has provided energy assessments to 144 qualified companies, primarily located in Indiana. On the training side, the center has trained students in various programs, such as the department’s Bachelor of Science (BS) programs in Mechanical Engineering (ME) and BS in Energy Engineering (EEN), both are ABET accredited engineering programs, as well as a graduate level Energy Management and Assessment certificate program. At the present, the center has trained 95 students, 43 or them received the DOE issued certificates. Research projects were developed within the center to advance energy efficiency related technologies, which provided excellent opportunities for our trainees. The center has also been building a professional network with utilities, Manufacturing Extension Partnership (MEP), government agencies, and manufacturing companies, to increase our client base and promote collaborations. The center received the 2019 Center of Excellence of the Year Award and three students received the “Outstanding Achievement in Energy Engineering by an IAC Student” awards in the past five years.

42 ENGINEERING↗

Industrial Assessment Center for Energy Efficiency, Smart Manufacturing and Cyber Security of Illinois and Northwestern Indiana Small and Medium Sized Manufacturing Companies and Water Facilities (Final Technical Report)

The University of Illinois Chicago (UIC) established and implemented a U.S. Department of Energy (DOE) sponsored Industrial Assessment Center (IAC) from September 1, 2016 through December 31, 2021. The established UIC IAC focused on providing 1) technical assistance to small and medium-sized enterprises (SMEs) and water and wastewater facilities in Illinois and northwestern Indiana and 2) education and training university students developing the future energy workforce. The technical assessments incorporated energy efficiency, increasing productivity via smart manufacturing, energy management systems, enhancing on-site cyber security practices, and the promotion of DOE best practices and tools. The educational training enabled UIC faculty and staff to provide classroom education, exposure to industry research, multiple targeted training sessions, real world experience with industry professionals, and live training to implement professional grade audits and recommendations.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

A Collaborative Industrial Assessment Center (IAC) for Expanded Outreach within the Southeast

This GA-FL IAC had impacts on workforce development and economic impact for regional small- and medium-sized enterprises. Qualified faculty and campus staff educated and trained cohorts of students regarding state-of-the-art industrial assessments. Students gained hands-on experiences in learning about manufacturing processes, energy systems, developing assessment recommendations/calculations, and client interaction. These skills were complemented by the incorporation of IAC themes into some course curricula. As far as economic impact, the center conducted 66 assessments over 5 years primarily in Georgia and Florida. These represented hundreds of thousands of dollars in potential annual resource savings to the clients and region.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Future foundries: A convergent manufacturing platform

This article introduces the Future Foundries platform developed at Oak Ridge National Laboratory, a first-generation research system designed to demonstrate convergent manufacturing. Convergent manufacturing brings together additive, subtractive, and transformative processes in a digitally interconnected environment to enable end-to-end production workflows. By linking traditionally discrete steps, convergent platforms accelerate production, improve repeatability, and support high-mix, low-volume manufacturing. The Future Foundries platform exemplifies this vision in practice by combining four modular, vendor-agnostic process cells that include robotic WAAM, induction heating, optical metrology, and machining, coordinated through an automated pallet handler and a ROS 2-based digital thread. This architecture provides the flexibility and scalability needed for agile production in small and medium-sized manufacturing enterprises and for field deployable manufacturing. Two case studies illustrate the platform’s capabilities. The first presents an integrated workflow for fabricating, transforming, and repairing critical replacement components, showing how consolidated thermal, additive, inspection, and machining operations reduce manual part handling and streamline process flow. The second case study highlights coordinated multi-part production enabled by automated pallet logistics and multi-cell scheduling. Together, these examples showcase convergent manufacturing as a practical and scalable strategy for strengthening domestic casting and forging capacity, improving supply-chain resilience, and enabling rapid, adaptable production of mission-critical components.

Convergent manufacturing↗

Prototype Integrated Hydrogen Fuel Cell Powered Data Center (Cooperative Research and Development Final Report)

Data centers are the backbone of the modern economy-from the server rooms that power small- to medium-sized organizations, to the enterprise-class data centers that support American corporations, and the server farms that run cloud computing services. Rather than a traditional grid-centric data center approach, work under the CRADA will be directed towards implementing a proof-of-concept "hydrogen-based" data center utilizing hydrogen fuel cells, electrolyzers, and solar photovoltaics as key building blocks. This integrated proof-of-concept builds on preliminary work done by HPE and its partners Mercedes-Benz Research & Development North America, Inc. (MBRDNA) and Power Innovations, to dramatically simplify the electrical infrastructure in the data center, leverage the latest automotive-scale hydrogen fuel cell technologies, and tightly couple renewably generated DC power directly to the Information Technology (IT). While some limited aspects of this concept have been demonstrated previously the entire integrated proof of concept proposed here has not yet been realized.

08 HYDROGEN↗

UF Industrial Assessment Center - Budget Periods 2017-2021. Final Report

This report summarizes the work performed at the University of Florida’s Industrial Assessment Center (UF-IAC) during the five budget periods (BPs) in the years 2017 through 2021 under DOE Award No. DE-EE0007707. The objective of the work is to perform industrial assessments to small- and medium-sized manufacturing facilities in the State of Florida and to train students in industrial energy management and in performing industrial assessments. Specific details about the activities of the UF-IAC (referred to as the Center) during that time can be found in the 20 quarterly reports that were submitted throughout the duration of the contract. The project start and end dates are September 1, 2016 and August 31, 2021, respectively. The project was granted a six-month no-cost extension till February 28, 2022, to accommodate unexpected delays due to the COVID-19 pandemic. This project was performed by the University of Florida (PI: Dr. SA Sherif). The scope of work includes six milestone whose description and outcomes are listed in the Statement of Project Objectives (SOPO).

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