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NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the panel responsible for the report were chosen for their special competencies and with regard for appropriate balance.
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COMMITTEE ON INDUSTRIAL TECHNOLOGY ASSESSMENTS
R. RAY BEEBE (chair), Consultant,
Tucson, Arizona
GARY A. BAUM,
Institute of Paper and Science Technology, Atlanta, Georgia
JOHN V. BUSCH,
IBIS Associates, Wellesley, Massachusetts
NORMAN A. GJOSTEIN, Consultant,
Dearborn, Michigan
FRANCIS C. McMICHAEL,
Carnegie-Mellon University, Pittsburgh, Pennsylvania
MAXINE L. SAVITZ,
AlliedSignal Aerospace Corporation, Torrance, California
National Materials Advisory Board Staff
THOMAS E. MUNNS, Associate Director
AIDA C. NEEL, Senior Project Assistant
National Materials Advisory Board Liaison
KATHLEEN C. TAYLOR,
General Motors Corporation, Warren, Michigan
Government Liaisons
DENISE SWINK,
U.S. Department of Energy, Washington, D.C.
JAMES E. QUINN,
U.S. Department of Energy, Washington, D.C.
NATIONAL MATERIALS ADVISORY BOARD
EDGAR A. STARKE (chair),
University of Virginia, Charlottesville
JESSE L. BEAUCHAMP,
California Institute of Technology, Pasadena
EARL DOWELL,
Duke University, Durham, North Carolina
EDWARD C. DOWLING,
Cleveland Cliffs, Inc., Cleveland, Ohio
THOMAS EAGAR,
Massachusetts Institute of Technology, Cambridge
ALASTAIR GLASS,
Bell Laboratories, Lucent Technologies, Murray Hill, New Jersey
MARTIN E. GLICKSMAN,
Rensselaer Polytechnic Institute, Troy, New York
JOHN A.S. GREEN,
The Aluminum Association, Washington, D.C.
SIEGFRIED S. HECKER,
Los Alamos National Laboratory, Los Alamos, New Mexico
JOHN H. HOPPS,
Morehouse College, Atlanta, Georgia
MICHAEL JAFFE,
New Jersey Center for Biomaterials and Medical Devices, Piscataway
SYLVIA M. JOHNSON,
SRI International, Menlo Park, California
SHEILA F. KIA,
General Motors Research and Development, Warren, Michigan
LIAS KLEIN,
Rutgers, The State University of New Jersey, Piscataway
HARRY A. LIPSITT,
Wright State University, Dayton, Ohio
ALAN G. MILLER,
Boeing Commercial Airplane Group, Seattle, Washington
ROBERT C. PFAHL,
Motorola, Schaumberg, Illinois
JULIA PHILLIPS,
Sandia National Laboratories, Albuquerque, New Mexico
KENNETH L. REIFSNIDER,
Virginia Polytechnic Institute and State University, Blacksburg
JAMES WAGNER,
Case Western Reserve University, Cleveland, Ohio
JULIA WEERTMAN,
Northwestern University, Evanston, Illinois
BILL G.W. YEE,
Pratt and Whitney, West Palm Beach, Florida
RICHARD CHAIT, Director
BOARD ON MANUFACTURING AND ENGINEERING DESIGN
F. STAN SETTLES (chair),
University of Southern California, Los Angeles
ERNEST R. BLOOD,
Caterpillar, Inc., Mossville, Illinois
JOHN BOLLINGER,
University of Wisconsin, Madison
JOHN CHIPMAN,
University of Minnesota, Minneapolis
DOROTHY COMASSAR,
GE Aircraft Engines, Cincinnati, Ohio
ROBERT A. DAVIS,
The Boeing Company, Seattle, Washington
GARY L. DENMAN,
GRC International, Inc., Vienna, Virginia
ROBERT EAGAN,
Sandia National Laboratories, Albuquerque, New Mexico
MARGARET A. EASTWOOD,
Motorola, Inc., Schaumburg, Illinois
EDITH M. FLANIGEN, UOP (retired),
White Plains, New York
JOHN W. GILLESPIE,
University of Delaware, Newark
JAMIE C. HSU,
General Motors, Warren, Michigan
RICHARD L. KEGG,
Milacron, Inc., Cincinnati, Ohio
JAMES MATTICE,
Universal Technology Corporation, Dayton, Ohio
CAROLYN W. MEYERS,
North Carolina A&T State University, Greensboro
FRIEDRICH B. PRINZ,
Stanford University, Palo Alto, California
DALIBOR F. VRSALOVIC,
AT&T Laboratories, Menlo Park, California
JOSEPH WIRTH,
RayChem Corporation. (retired), Los Altos, California
JOEL S. YUDKEN,
AFL-CIO, Washington, D.C.
RICHARD CHAIT, Director
PANEL ON INTERMETALLIC ALLOY DEVELOPMENT
NORMAN A. GJOSTEIN (chair), Consultant,
Dearborn, Michigan
JOHN V. BUSCH,
IBIS Associates, Wellesley, Massachusetts
TIMOTHY HOWSON,
Wyman-Gordon Company, North Grafton, Massachusetts
LYMAN A. JOHNSON,
GE Aircraft Engines, Cincinnati, Ohio
HARRY A. LIPSITT,
Wright State University, Dayton, Ohio
ANATOLY NEMZER,
FMC Corporation, Princeton, New Jersey
MAXINE L. SAVITZ,
AlliedSignal Aerospace Corporation, Torrance, California
PANEL ON MANUFACTURING PROCESS CONTROLS
GARY A. BAUM (chair),
Institute of Paper Science and Technology, Atlanta, Georgia
THOMAS G. DEVILLE,
Bechtel Technology and Consulting, San Francisco, California
RICHARD J. EBERT,
Alcoa Technical Center, Alcoa Center, Pennsylvania
DENNIS K. KILLINGER,
University of South Florida, Tampa
STEVEN R. LECLAIR,
U.S. Air Force Research Laboratory, WPAFB, Ohio
JAY LEE,
United Technologies Research Center, East Hartford, Connecticut
FRANCIS C. MCMICHAEL,
Carnegie-Mellon University, Pittsburgh, Pennsylvania
JORGE L. VALDES,
Bell Laboratories, Lucent Technologies, Murray Hill, New Jersey
PANEL ON SEPARATION TECHNOLOGIES FOR INDUSTRIAL RECYCLING AND REUSE
GEORGE E. KELLER II (chair), Consultant,
South Charleston, West Virginia
R. RAY BEEBE, Consultant,
Tucson, Arizona
RICHARD J. FRUEHAN,
Carnegie-Mellon University, Pittsburgh, Pennsylvania
NORMAN N. LI,
NL Chemical Technology, Inc., Arlington Heights, Illinois
EVE L. MENGER,
Corning, Inc. (retired), Corning, New York
GUIDO P. PEZ,
Air Products and Chemicals, Inc., Allentown, Pennsylvania
PETER H. PFROMM,
Institute of Paper Science and Technology, Atlanta, Georgia
RONALD W. ROUSSEAU,
Georgia Institute of Technology, Atlanta
MICHAEL P. THOMAS,
Alcan Aluminum Corporation, Shelbyville, Tennessee
Acknowledgments
The Committee on Industrial Technology Assessments would like to thank all of the participants in the workshop panel studies, which were the principal data-gathering sessions for this study. The information and insight from these groups were invaluable to the committee.
In addition, the committee would like to thank those individuals who prepared presentations for committee meetings. Presenters included: Edward Dowling of Cyprus Amax; Joseph Wirth of RayChem; Gary Denman of GRC International; Paul Peercy of SEMI/SEMATECH; William Hanson of MIT Leaders in Manufacturing Program; Helena Chum of the National Renewable Energy Laboratory; Peter Angelini of Oak Ridge National Laboratory; Thomas Foust of the Idaho National Engineering Laboratory; Al Slywester of Sandia National Laboratories; and Thomas Foust, Doug Kaempf, Gideon Varga, Kurt Sisson, William Parks, and Marsha Quinn of the Department of Energy's Office of Industrial Technology. The committee is particularly grateful to Jim Quinn and Denise Swink and the staff of the Office of Industrial Technology for their technical assistance and support.
This report has been reviewed by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the NRC's Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the authors and the NRC in making the published report as sound as possible and to ensure that the report meets institutional standards for objectivity, evidence, and responsiveness to the study charge. The content of the review comments and draft manuscript remain confidential to protect the integrity of the deliberative process. We wish to thank the following individuals for their participation in the review of this report: James
J. Solberg, Purdue University; Edward Dowling, Cleveland Cliffs, Inc.; Gordon Forward, TXI Corporation; Michael Thomas, Alcan Aluminum Corporation; and Jay Lee, United Technologies Research Center.
While the individuals listed above have provided many constructive comments and suggestions, responsibility for the final content of the report rests solely with the authoring committee and the NRC.
Finally, the panel gratefully acknowledges the support of the staff of the National Materials Advisory Board and Board on Manufacturing and Engineering Design, including Thomas E. Munns, study director, and Aida C. Neel, senior project assistant.
Preface
In 1993, the U.S. Department of Energy (DOE) Office of Industrial Technology (OIT) established a group of seven industries designated as Industries of the Future (IOF). These industries were selected for their high energy use and large waste generation. The original IOF included the aluminum, chemicals, forest products, glass, metalcasting, petroleum refining, and steel industries. Each industry was asked to provide a future vision and a road map detailing the research required to realize its vision. In November 1994, the forest products industry was the first of the IOF industries to enter into an agreement with DOE.
OIT asked the National Research Council's National Materials Advisory Board (NMAB) to provide guidance for OIT's transition to the new IOF strategy. The Committee on Industrial Technology Assessment (CITA) was formed for this purpose with the specific tasks of reviewing and evaluating the overall OIT program, reviewing selected OIT-sponsored research projects, and identifying crosscutting technologies (i.e., technologies applicable to more than one industry). CITA was asked to focus on three specific areas: intermetallic alloys, manufacturing process controls, and separations. A separate panel was formed to study each area and publish the results in separate reports.
The committee was composed of experts with a wealth of knowledge in industrial processing, industrial energy utilization, and environmental issues and technologies. The committee members, in addition to serving on panels, held four meetings to develop the overall program assessment and to oversee the study panels. The committee meetings included briefing sessions on the organization and status of the OIT program; a review of project selection and management issues in industrial, academic, and government research programs; a review of specific IOF industry approaches to project selection and prioritization; and a
discussion of the role of the national laboratories in the IOF program. The conclusions and recommendations of the committee can be found in chapters 3 and 4. Chapter 3 includes general conclusions and lessons to be drawn from the panel studies of selected crosscutting technologies. Chapter 4 includes the committee's assessment of the overall program.
The chair wishes to thank the committee members for their enthusiasm, dedication, and service and the excellent OIT staff for their assistance, cooperation, and professionalism. The chair thanks all of the participants for their insights and stimulating discussions and the staff of the NMAB for their coordination and assistance throughout the entire process, including the publication of this report.
Comments and suggestions can be sent via electronic mail to nmab@nas.edu or by FAX to NMAB (202) 334-3718.
R. RAY BEEBE, chair
COMMITTEE ON INDUSTRIAL TECHNOLOGY ASSESSMENTS
Acronyms
AF&PA
American Forest and Paper Association
AIM
advanced industrial materials
AISI
American Iron and Steel Institute
API
American Petroleum Institute
ATS
advanced turbine systems
CEO
chief executive officer
CFCC
continuous-fiber ceramic composites
CITA
Committee on Industrial Technology Assessments
CMC
Cast Metals Coalition
CTO
chief technology officer
DARPA
Defense Advanced Research Projects Agency
DOD
Department of Defense
DOE
Department of Energy
ECUT
energy conversion and utilization
FY
fiscal year
I&I
Inventions and Innovations
IOF
Industries of the Future
LCC
Laboratory Coordinating Council
MEMS
microelectromechanical systems
NICE3
National Industrial Competitiveness through Energy, Environment, and Economics
NMA
National Mining Association
NRC
National Research Council
NSF
National Science Foundation
OIT
Office of Industrial Technology
ORNL
Oak Ridge National Laboratory
R&D
research and development
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