Efficiency

SRI International is developing a reactor that is able to either convert titanium tetrachloride to titanium powder or convert multiple metal chlorides to titanium alloy powder in a single step. Conventional titanium extraction and conversion processes involve expensive and energy intensive melting steps. SRI is examining the reaction between hydrogen and metal chlorides, which could produce titanium alloys without multiple complicated steps. Using titanium powder for transportation applications has not been practical until now because of the high cost of producing powder from titanium ingots.

Research Triangle Institute (RTI) is developing a high-quality concentrating solar thermal energy transport and storage system for use in light metals manufacturing. A challenge with integrating renewable energy into light metals manufacturing has been the need for large quantities of very high temperature heat. RTI’s technology overcomes this challenge with a specialized heat transfer powder. This powder can be heated to temperatures of 1100 degrees Celsius with concentrating solar thermal energy, some 400 degrees Celsius higher than conventional solutions.

Pacific Northwest National Laboratory (PNNL) is developing a radically new process to produce magnesium from seawater. Today’s methods are energy intensive and expensive because the magnesium concentration in seawater is so low that significant energy is needed to evaporate off water and precipitate magnesium chloride salt. Further, conventional technologies involve heating the salt to 900°C and then using electric current to break the chemical bond between magnesium and chlorine to produce the metal.

Valparaiso University is developing a solar electro-thermal reactor that produces magnesium from magnesium oxide. Current magnesium production processes involve high-temperature steps that consume large amounts of energy. Valparaiso’s reactor would extract magnesium using concentrated solar power to supply its thermal energy, minimizing the need for electricity. The reactor would be surrounded by mirrors that track the sun and capture heat for high-temperature magnesium electrolysis.

Gas Technology Institute (GTI) is developing a continuously operating cell that produces low-cost aluminum powder using less energy than conventional methods. Conventional aluminum production is done by pumping huge electrical currents into a vat of molten aluminum dissolved in mineral salts at nearly 2000 degrees Fahrenheit. GTI’s technology occurs near room temperature using reusable solvents to dissolve the ore.

Titanium Metals Corporation (TIMET) is developing an electrochemical process for producing pure titanium powder. Incumbent titanium production processes require the importation of high-grade titanium ores. TIMET’s groundbreaking design will enable the use of abundant, low-cost, domestic ore to produce titanium powder electrolytically. By totally revolutionizing the electrolysis process, TIMET can fully optimize the process more effectively using a unique approach.

Energy Research Company (ERCo) is developing an automated Aluminum Integrated Minimill (AIM) that can produce finished components from mixed metal scrap. Unlike most current approaches, ERCo’s AIM can distinguish and accurately sort multiple grades of aluminum scrap for recycling. ERCo’s AIM reduces energy consumption in several ways. First, the technology would provide real-time feedback controls to improve the accuracy of the sorting process. The sorted scrap is then melted and cast.

The University of California, Berkeley (UC Berkeley) is developing a method for identifying the best metal organic frameworks for use in capturing CO2 from the flue gas of coal-fired power plants. Metal organic frameworks are porous, crystalline compounds that, based on their chemical structure, vary considerably in terms of their capacity to grab hold of passing CO2 molecules and their ability to withstand the harsh conditions found in the gas exhaust of coal-fired power plants.

Research Triangle Institute (RTI) is developing a solvent and process that could significantly reduce the temperature associated with regenerating solvent and CO2 captured from the exhaust gas of coal-fired power plants. Traditional CO2 removal processes using water-based solvents require significant amount of steam from power plants in order to regenerate the solvent so it can be reused after each reaction. RTI's solvents can be better at absorbing CO2 than many water-based solvents, and are regenerated at lower temperatures using less steam.

The team from Oak Ridge National Laboratory (ORNL) and Georgia Institute of Technology is developing a new technology that will act like a sponge, integrating a new, alcohol-based ionic liquid into hollow fibers to capture CO2 from the exhaust produced by coal-fired power plants. Ionic liquids—salts that exist in liquid form—are promising materials for carbon capture and storage, but their tendency to thicken when combined with CO2 limits their efficiency and poses a challenge for their development as a cost-effective alternative to current-generation solutions.