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Efficiency

Ames National Laboratory

Novel High Energy Permanent Magnet Without Critical Elements

Ames Laboratory is developing a new class of permanent magnets based on the more commonly available element cerium for use in both EVs and renewable power generators. Cerium is 4 times more abundant and significantly less expensive than the rare earth element neodymium, which is frequently used in today's most powerful magnets. Ames Laboratory will combine other metal elements with cerium to create a new magnet that can remain stable at the high temperatures typically found in electric motors. This new magnetic material will ultimately be demonstrated in a prototype electric motor, representing a cost-effective and efficient alternative to neodymium-based motors.

Applied Research Associates, Inc. (ARA)

Active Cooling Thermally Induced Vapor-Polymerization Effect (ACTIVE)

Applied Research Associates (ARA) will design and fabricate a dry-cooling system that overcomes the inherent thermodynamic performance penalty of air-cooled systems, particularly under high ambient temperatures. ARA's ACTIVE cooling technology uses a polymerization thermochemical cycle to provide supplemental cooling and cool storage that can work as a standalone system or be synchronized with air-cooled units to cool power plant condenser water. The cool storage will be completed in two stages. During the day, the cool storage is maintained near the ambient temperature, and then at night the remainder of cooling can be done using the low temperature nighttime air. The cool storage unit is then ready for plant condenser reuse the next day. This technology will provide power plant condensers with return water at the necessary temperature levels to maintain power production at their optimum thermal efficiency.

Architectural Applications

Innovative Building-Integrated Enthalpy Recovery

Architectural Applications (A2) is developing a building moisture and heat exchange technology that leverages a new material and design to create healthy buildings with lower energy use. Commercial building owners/operators are demanding buildings with greater energy efficiency and healthier indoor environments. A2 is developing a membrane-based heat and moisture exchanger that controls humidity by transferring the water vapor in the incoming fresh air to the drier air leaving the building. Unlike conventional systems, A2 locates the heat and moisture exchanger within the depths of the building's wall to slow down the air flow and increase the surface area that captures humidity, but with less fan power. The system's integration into the wall reduces the size and demand on the air conditioning equipment and increases liable floor area flexibility.

Argonne National Laboratory

Nanocomposite Exchange-Spring Magnets for Motor and Generator Applications

Argonne National Laboratory (ANL) is developing a cost-effective exchange-spring magnet to use in the electric motors of wind generators and EVs that uses no rare earth materials. This ANL exchange-spring magnet combines a hard magnetic outer shell with a soft magnetic inner core--coupling these together increases the performance (energy density and operating temperature). The hard and soft magnet composite particles would be created at the molecular level, followed by consolidation in a magnetic field. This process allows the particles to be oriented to maximize the magnetic properties of low-cost and abundant metals, eliminating the need for expensive imported rare earths. The ultimate goal of this project is to demonstrate this new type of magnet in a prototype electric motor.

Argonne National Laboratory

Self-Assembled Nanocellular Composites with Super Thermal Insulation and Soundproof for Single-Pane Windows

Argonne National Laboratory (ANL) with its partners will develop a transparent nanofoam polymer that can be incorporated into a window film/coating for single-pane windows. The transparent polymer-nanoparticle composite will be applied to glass, and will improve the thermal insulation and the soundproofing of a window. Key to this technology is the generation of small and hollow nanometer-sized particles with thin shells. These will be embedded in a polymer with a carefully controlled structure and uniform dispersal of nanoshells in the polymer matrix. Competing approaches such as those used for silica aerogels have limited ability to fine tune the material's structure, resulting in materials with weaker mechanical strength, difficulties with transparency, and high processing costs. ANL will develop materials fabricated with self-assembly and a level of precision that allows careful prediction of how light and heat transmit through the material. The team also plans to introduce ultrasound-enhanced continuous processing techniques to manufacture the nanofoam at low cost and with high transparency without undesired haze and enhanced sound isolation capabilities. ANL predicts that the technology will enable an inexpensive window film that can be installed by the homeowner to upgrade a single-glazed window to double-glazed performance at about 25% of the cost.

Arizona State University

Diamond Power Transistors Enabled by Phosphorus Doped Diamond

Arizona State University (ASU) will develop a process to produce low-cost, vertical, diamond semiconductor devices for use in high-power electronics. Diamond is an excellent conductor of electricity when boron or phosphorus is added--or doped--into its crystal structures. In fact, diamond can withstand much higher temperatures with higher performance levels than silicon, which is used in the majority of today's semiconductor devices. However, growing uniformly doped diamond crystals is difficult and expensive. ASU's innovative diamond-growing process could create greater doping uniformity, helping to significantly lower the cost of diamond semiconductor devices.

Arizona State University

Effective Selective Area Doping for GaN Vertical Power Transistors Enabled by Innovative Materials Engineering

Arizona State University (ASU) proposes a comprehensive project to advance fundamental knowledge in the selective area doping of GaN using selective regrowth of gallium nitride (GaN) materials. This will lead to the development of high-performance GaN vertical power transistors. The ASU team aims to develop a better mechanistic understanding of these fundamental materials issues, by focusing on three broad areas. First, they will use powerful characterization methods to study fundamental materials properties such as defects, surface states, and investigate possible materials degradation mechanisms. Next, they will develop innovative epitaxial growth and fabrication processes such as Atomic Layer Etching and novel surface passivations, to tackle the materials engineering challenges related to selective area doping for GaN p-n junctions. Finally, they will apply their research to demonstrate randomly placed, reliable, contactable p-n junctions for GaN vertical power devices. If successful, this project will provide a path towards high efficiency, high power, small form factor, and high thermal performance GaN vertical power devices.

Arizona State University

Energy Efficient Electrochemical Capture and Release of Carbon Dioxide

Arizona State University (ASU) is developing an innovative electrochemical technology for capturing the CO2 released by coal-fired power plants. ASU's technology aims to cut both the energy requirements and cost of CO2 capture technology in half compared to today's best methods. Presently, the only proven commercially viable technology for capturing CO2 from coal plants uses a significant amount of energy, consuming roughly 40% of total power plant output. If installed today, this technology would increase the cost of electricity production by 85%. ASU is advancing a fundamentally new paradigm for CO2 capture using novel electrochemical reactants to separate and capture CO2. This process could be easily scaled and integrated in conventional fossil fuel power generation facilities.

Arizona State University

Single-Pane Windows with Insulating Sprayed Particulate Coatings

Arizona State University (ASU) and its partners will develop new windowpanes for single-pane windows to minimize heat losses and improve soundproofing without sacrificing durability or transparency. The team from ASU will produce a thermal barrier composed of silicon dioxide nanoparticles deposited on glass by supersonic aerosol spraying. The layer will minimize heat losses and be transparent at a substantially lower cost than can be done presently with silica aerogels, for example. A second layer deposited using the same method will reflect thermal radiation. The windowpanes will also incorporate layers of dense polymers to control condensation and adhesion, while improving strength. The coating is designed to last more than 20 years and be resistant to damage from scratching, peeling, or freezing of water vapor within the pores of the silica layer.

Arkansas Power Electronics International, Inc.

Low-Cost, Highly Integrated, Silicon Carbide Multi-Chip Power Modules for Plug-in Hybrid Electric Vehicles

Currently, charging the battery of an electric vehicle (EV) is a time-consuming process because chargers can only draw about as much power from the grid as a hair dryer. APEI is developing an EV charger that can draw as much power as a clothes dryer, which would drastically speed up charging time. APEI's charger uses silicon carbide (SiC)-based power transistors. These transistors control the electrical energy flowing through the charger's circuits more effectively and efficiently than traditional transistors made of straight silicon. The SiC-based transistors also require less cooling, enabling APEI to create EV chargers that are 10 times smaller than existing chargers.

Aspen Aerogels, Inc.

Aerogel Insulated Pane as a Replacement for Panes in Single Pane Windows

Aspen Aerogels and its partners will develop a cost-effective, silica aerogel-insulated windowpane to retrofit single-pane windows. Silica aerogels are well-known, highly porous materials that are strongly insulating, resisting the flow of heat. The team will advance their silica aerogels to have a combination of high visible light transmittance, low haze, and low thermal conductivity. The team's design consists of an aerogel sheet sandwiched between two glass panes to make a double glazed pane. This silica aerogel-insulated pane will be manufactured using an innovative supercritical drying method to significantly reduce the aerogel drying time, thereby increasing productivity and reducing cost. Aspen Aerogels' windowpane could be used to replace single panes in windows where thickness or weight preclude replacement with common double-pane units and at substantially lower cost.

Astronautics Corporation of America

An Efficient, Green Compact Cooling System Using Magnetic Refrigeration

Astronautics Corporation of America is developing an air conditioning system that relies on magnetic fields. Typical air conditioners use vapor compression to cool air. Vapor compression uses a liquid refrigerant to circulate within the air conditioner, absorb the heat, and pump the heat out into the external environment. Astronautics' design uses a novel property of certain materials, called "magnetocaloric materials", to achieve the same result as liquid refrigerants. These magnetocaloric materials essentially heat up when placed within a magnetic field and cool down when removed, effectively pumping heat out from a cooler to warmer environment. In addition, magnetic refrigeration uses no ozone-depleting gases and is safer to use than conventional air conditioners, which are prone to leaks.

ATK

A High Efficiency Inertial CO2 Extraction System

Researchers at Alliant Techsystems (ATK) and ACENT Laboratories are developing a device that relies on aerospace wind-tunnel technologies to turn CO2 into a condensed solid for collection and capture. ATK's design incorporates a special nozzle that converges and diverges to expand flue gas, thereby cooling it off and turning the CO2 into solid particles which are removed from the system by a cyclonic separator. This technology is mechanically simple, contains no moving parts and generates no chemical waste, making it inexpensive to construct and operate, readily scalable, and easily integrated into existing facilities. The increase in the cost to coal-fired power plants associated with introduction of this system would be 50% less than current technologies.

Avogy, Inc.

Vertical GaN Transistors on Bulk GaN Substrates

Avogy will develop a vertical transistor with a gallium nitride (GaN) semiconductor that is 30 times smaller than conventional silicon transistors but can conduct significantly more electricity. Avogy's GaN transistor will function effectively in high-power electronics because it can withstand higher electric fields and operate at higher temperatures than comparable silicon transistors. Avogy's vertical device architecture can also enable higher current devices. With such a small and efficient device, Avogy projects it will achieve functional cost parity with conventional silicon transistors within three years, while offering game-changing performance improvements.

Ayar Labs, Inc.

LytBit: An In-Rack Optical Communications System

Ayar Labs will develop new intra-rack configurations using silicon-based photonic (optical) transceivers, optical devices that transmit and receive information. The team will additionally develop methods to package their photonic transceiver with an electronic processor chip. Marrying these two components will reduce the size and cost of the chip system. Integrated packaging also moves the photonics closer to the chip, which increases energy efficiency by reducing the amount of "hops" between components. If successful, the project will prove that chip packages incorporating both optics and processors, or optics and switches, are possible. This will finally allow optics to penetrate deep into an electrical system and relieve chip interconnect bottlenecks, enabling system architecture improvements to achieve nearly double the energy efficiency with a structure more optimized for future data-use cases such as "big data" analytics and machine learning.

Baldor Electric Company

Rare-Earth-Free Traction Motor for Electric Vehicle Applications

Baldor Electric Company is developing a new type of traction motor with the potential to efficiently power future generations of EVs. Unlike today's large, bulky EV motors which use expensive, imported rare-earth-based magnets, Baldor's motor could be light, compact, contain no rare earth materials, and have the potential to deliver more torque at a substantially lower cost. Key innovations in this project include the use of a unique motor design, incorporation of an improved cooling system, and the development of advanced materials manufacturing techniques. These innovations could significantly reduce the cost of an electric motor.

Battelle Memorial Institute

Cascade Reverse Osmosis and the Absorption Osmosis Cycle

Battelle Memorial Institute is developing a new air conditioning system that uses a cascade reverse osmosis-based absorption cycle. Analyses show that this new cycle can be as much as 60% more efficient than vapor compression, which is used in 90% of air conditioners. Traditional vapor-compression systems use polluting liquids for a cooling effect. Absorption cycles use benign refrigerants such as water, which is absorbed in a salt solution and pumped as liquid--replacing compression of vapor. The refrigerant is subsequently separated from absorbing salt using heat for re-use in the cooling cycle. Battelle is replacing thermal separation of refrigerant with a more efficient reverse osmosis process. Research has shown that the cycle is possible, but further investment will be needed to reduce the number of cascade reverse osmosis stages and therefore cost.

BlazeTech Corp.

Hyperspectral Imaging for the Identification of Light Metals

BlazeTech is developing advanced sorting software that uses a specialized camera to distinguish multiple grades of light metal scrap by examining how they reflect different wavelengths of light. Existing identification technologies rely on manual sorting of light metals, which can be inaccurate and slow. BlazeTech's sorting technology would identify scrap metal content based on the way that each light metal appears under BlazeTech's sorting camera, automating the sorting process and enabling more comprehensive metal recycling. The software developed under this program will be used to dramatically improve existing metal sorting systems. This technology offers great potential to improve the efficiency of light metals recycling, as similar techniques have proven successful in other industries, including vegetation surveying and plastics identification.

Boston Electrometallurgical Corporation

Revolutionary Process for Low-Cost Titanium

Boston Electrometallurgical Corporation will develop and scale a one step molten oxide electrolysis process for producing Ti metal directly from the oxide. Titanium oxide is dissolved in a molten oxide, where it is directly and efficiently extracted as molten titanium metal. In this process, electrolysis is used to separate the product from the solution as a bottom layer that can then be removed from the reactor in its molten state. If successful, it could replace the multistep Kroll process with a one-step process that resembles today's aluminum production techniques. If successful, Ti ingots could be produced at cost parity with stainless steel, opening the doorway to industrial waste heat recovery applications and increasing its adoption in commercial aircraft.

Boston University

Scalable, Dual-Mode Occupancy Sensing for Commercial Venues

Boston University (BU) will develop an occupancy sensing system to estimate the number of people in commercial spaces and monitor how this number changes over time. Their Computational Occupancy Sensing SYstem (COSSY) will be designed to deliver robust performance by combining data from off-the-shelf sensors and cameras. Data streams will be interpreted by advanced detection algorithms to provide an occupancy estimate. All processing will be performed locally to mitigate security concerns. The system will be designed to accommodate various room sizes and geometries. Occupancy data will be sent to the building control system to manage the heating, cooling, and air flow in order to maximize building energy efficiency and provide optimal human comfort. Energy costs of heating and cooling can be reduced by up to 30% by training the building management system to deliver the right temperature air when and where it is needed. The system's use of components readily available in the market today promises low cost and fast commercialization.

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