This document summarizes sustainable research and development activities at Oak Ridge National Laboratory (ORNL). It outlines ORNL's work in several areas including sustainable transportation (electric vehicles, batteries, biofuels), building technologies (energy efficient envelopes, equipment, systems), advanced manufacturing (carbon fiber, composites, additive manufacturing), and integrating basic research into clean energy applications. ORNL leverages its large budget, world-class facilities and expertise to collaborate with industry and provide solutions to energy and sustainability challenges.

1. Sustainable RD&D
at ORNL
ORNL’s 3rd Annual Southeast
Sustainability Summit
Martin Keller
Associate Laboratory Director
Energy and Environmental
Sciences Directorate
August 22, 2013
Knoxville, Tennessee

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ORNL is DOE’s largest science
and energy laboratory
$1.65B
budget
World’s
most intense
neutron
source
4,400
employees
World-class
research
reactor
3,000
research
guests
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

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Providing solutions to pressing
energy challenges
Sustainable
transportation
Energy efficiency
in buildings
Advanced
manufacturing

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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

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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 activities
in Tennessee

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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

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Wireless power transfer
Transformational technology for vehicle electrification
• Amenable to
existing highways
• PHEV/EV fast
charge on the fly

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Building technologies RD&D at ORNL:
Focus areas
Envelope Equipment System/building integration
Develop 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

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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

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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

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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

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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™

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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

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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 technology
in 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

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ORNL is helping grow an economic
development cluster around carbon fiber
ORNL
research
Commer-
cialization
strategy
Carbon
Fiber
Technology
Facility
Job
creation
Workforce
development
Industry
collaboration

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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

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