Posts Tagged ‘power generation’

American Manufacturers Require Cheap Available Energy to be Competitive

Tuesday, February 9th, 2021

On his very first day in office, President Biden signed an Executive Order canceling the permit for the Keystone XL pipeline. Halting work on the “pipeline in South Dakota immediately eliminated 1,000 union jobs. TC Energy, the company that was developing the project, predicts that more than 10,000 jobs will be lost in 2021 due to the order.” Only a week later, he signed an Executive Order freezing new oil or natural gas leases and drilling permits on federal land. These orders put American energy independence at risk, which will hurt American manufacturers.

Most people don’t realize that there are already thousands of miles of Keystone pipelines that have been completed.  According to Wikipedia, Phase 1 started construction in 2008 and became operational in 2010.  Phase 1 goes from Hardisty, Alberta, Candada to Wood River and Patoka, Illinois, going through Saskatchewan and Nebraska.  Phase 2 goes from Steele City, Nebraska to Cushing, Oklahoma and was completed in 2011. Phase 3 goes from Cushing, Oklahoma to Nederland, Texas and was completed in 2014. A Phase 3b goes from Liberty County, Texas to Houston, Texas and become operational in 2017.  If completed, Phase 4 would go from Hardisty, Alberta, Canada to Steele City, Nebraska, passing through Montana.  It has been under construction since 2017 after President Trump approved the permit.

Rep. Daines (R-MT) introduced an amendment attached to a COVID-19 relief bill on February 4th to reverse the Executive Order canceling Phase 4 of the Keystone Pipeline.  Democratic Sen. Joe Manchin of West Virginia and Jon Tester of Montana initially voted in favor of the Republican amendment, so that it passed 52-48, but later reversed themselves and voted with other Democrats with to kill the amendment. V. P. Harris cast the deciding vote.

American manufacturing has flourished since it started in the 1790s partly because of the availability of cheap energy:  Water power was used by the first American industry, textiles. Large water wheels harnessed the flow of a river to provide the necessary power for mills to manufacture the textiles by means of a water-powered spinning frame. Stand-alone steam engines expanded the opportunities to manufacture other products at locations throughout the country in the early 1800s.  The discovery of oil in 1859 and the ability to process it into different forms of fuel for a variety of engines and motors accelerated the ability to manufacture a much wider variety of products.  These fuels were first used to power the trains and ships that transported goods all over the U.S., creating a mass domestic market for manufactured goods.  These fuels were used to power the cars, trucks, and airplanes after they were invented in the early 20th Century. These same fuels were used by companies to power the equipment and machines that manufactured vehicles and airplanes. Then, these new modes of transportation enabled American manufactures to expand their domestic markets and export products worldwide. 

With the invention of the Bunsen burner in 1885 by Robert Bunsen, vast new opportunities to use natural gas for energy were created. After “effective pipelines began to be built in the 20th century, the use of natural gas expanded to home heating and cooking, appliances such as water heaters and oven ranges, manufacturing and processing plants, and boilers to generate electricity…Because natural gas is the cleanest burning fossil fuel, it is playing an increasing role in helping to attain national goals of a cleaner environment, energy security and a more competitive economy.”

Prior to pipelines, oil was transported in barrels by wagons or flat boats, and then in wooden tank cars on trains.  There was a big problem with leakage of the oil in both barrels and wooden tank cars. A pipeline made out of wooden boards built in 1862 proved equally impractical, but the “first fully successful pipeline—which used wrought iron and highly reinforced joints to transport between 1,950 and 2,000 barrels of oil daily across five miles of land—came in 1865. By the early 1900s, Standard Oil owned 80% of the pipelines.

Regarding pipelines, Wikipedia says, “Oil pipelines are made from steel or plastic tubes which are usually buried. The oil is moved through the pipelines by pump stations along the pipeline. Natural gas (and similar gaseous fuels) is pressurized into liquids known as Natural Gas Liquids (NGLs).[3] Natural gas pipelines are constructed of carbon steel…Pipelines are one of the safest ways of transporting materials as compared to road or rail…”

For as long as the oil industry has tried to move its products through pipelines, they’ve been contested. At first, it was because private companies were building and controlling the pipelines creating monopolies.  Today, it is because environmentalists want to stop the production and transportation of oil and natural gas.

According to the U. S. Department of Transportation, “The biggest source of energy is petroleum, including oil and natural gas. Together, they supply 65 percent of the energy we use. According to the U.S. Energy Information Administration, oil furnishes 40 percent of our energy, natural gas 25 percent, coal 22 percent, nuclear 8 percent, and renewables make up 4 percent…The nation’s more than 2.6 million miles of pipelines safely deliver trillions of cubic feet of natural gas and hundreds of billions of ton/miles of liquid petroleum products each year. They are essential: the volumes of energy products they move are well beyond the capacity of other forms of transportation. It would take a constant line of tanker trucks, about 750 per day, loading up and moving out every two minutes, 24 hours a day, seven days a week, to move the volume of even a modest pipeline. The railroad-equivalent of this single pipeline would be a train of 225, 28,000-gallon tank cars.”

Notice that renewables, such as solar and wind power, only provide 4 percent of our energy.  It’s going to be a long time, if ever, before they can replace the energy provided by oil and gas.  Energy experts have estimated it would take 25 – 50 times the number of power plants to provide the energy to charge electric cars when, all new cars and passenger trucks sold in California be zero-emission vehicles by 2035.

Our modern way of life depends on energy.  It takes energy to produce the food we eat, the clothes and shoes we wear, to manufacture our household furnishings and appliances, as well as all of the variety of electronic systems and equipment we use.  It takes energy to provide transportation for ourselves, as well as to transport all of the products we use by means of cars, trucks, airplanes, and ships. It takes energy to manufacture the equipment and systems used by the military to protect our country. We need Phase 4 of the Keystone Pipeline to be completed and new oil and gas leases be permitted to ensure that our American manufacturers have the energy they need to be competitive in the global marketplace. Without sufficient affordable energy, life as we know it would end.

Cutting Edge Technologies Power Cincinnati Industries – Part 1

Sunday, December 11th, 2016

During the first day of my visit to Cincinnati, Ohio November 1st – 4th, I had the pleasure of meeting with key personnel from the Intelligent Maintenance System Center (IMS) at the University of Cincinnati:  Dr. Hossein Davari – IMS Center Post-Doctoral Fellow, Patrick Brown – IMS Center Program Director, Chao Jin – IMS Center Graduate Researcher, and Michael Lyons – IMS Center Program Coordinator.

Prior to my visit I had been provided with background information on how the University of Cincinnati evolved into what it is today:  “The Ohio Mechanics Institute (OMI), parent name of the College of Applied Science, was founded in 1828 as a private educational institution and the first school west of the Alleghenies dedicated to technical education.” This struck me because this was about the same time as the Lowell Machine Shop in Lowell, MA first started producing interchangeable parts for firearms sold to the Springfield Armory. I did not realize that Cincinnati was industrialized so early in the Industrial Revolution period.

“OMI operated exclusively as an evening college until 1901 when day courses on a pre-college level were added. In 1919 the day courses were revised into collegiate programs…In 1958 the college designated separate names for its day and evening operations, the day school became the Ohio College of Applied Science (OCAS) and the evening school was named the Ohio Mechanics Institute Evening College (OMIEC). The college merged with the University of Cincinnati in 1969 and offered programs in the engineering technologies and related areas with the aim of preparing individuals for careers as engineering technologists, engineering technicians, and managers in industry. The college began offering bachelor’s degrees in the early 70s. The name of the college was changed in 1978 to the OMI College of Applied Science and was shortened to the College of Applied Science in 2000.

In 2009, the UC Board of Trustees approved the creation of the College of Engineering and Applied Science (CEAS)… [to integrate] two predecessor colleges —The College of Engineering and The College of Applied Science… During the late 50s…advanced studies in engineering and research became the focus…to strengthen the college’s focus on graduate education. A joint project with the Engineer’s Council for Professional Development (ECPD), and local industry provided opportunities for young professional engineers to pursue graduate degrees without leaving their jobs. Both colleges and the City of Cincinnati have shared long and productive partnerships…through cooperative education assignments, research funding and graduate placement…”

Dr. Davari told me that the “IMS Center is a leading NSF Industry/University Cooperative Research Center (I/UCRC) that consists of the University of Cincinnati, the University of Michigan and Missouri University of Science & Technology.”

He said, “The Center has over twelve years of experience in developing and delivering Prognostics and Health Management (PHM) solutions for a wide-range of applications. The IMS Center’s mission is to enable products and systems to achieve and sustain near-zero breakdown performance, and transform maintenance data to useful information for improved productivity and asset life-cycle utilization. Since its inception in 2001, the Center has conducted over 100 successful industry and NSF supported projects, and has attracted over 80 members from all across the globe. The IMS Center was recently identified as the most economically impactful I/UCRC in NSF’s recent study titled Measuring the Economic Impacts of the NSF Industry/University Cooperative Research Centers Program: A Feasibility Study. According to this study, the Center delivered its members $846.7 million in combined benefits over the last ten years.”

Dr. Davari explained the work of their Masters in Science and PhD students, “Graduate students in the IMS Center focus on developing innovative technologies and tools for health assessment, degradation monitoring and prognostics of machinery. Graduate students work both towards conducting fundamental research along with developing specific tools to address the needs of the industry. Graduate students get the opportunity to work closely with industry members ranging from manufacturing to energy and transportation applications. With a unique set of skills and experience in the field of Prognostics and Health Management (PHM), they continue to develop innovative tools and technologies and bring value to both industry and academia. The IMS Center researchers have also won the PHM Society Data Challenge five times since 2008. It is an annual competition organized by the PHM society and is open to researchers in academia and industry worldwide.”

Dr. Davari stated, “In 2012, National Instruments awarded the Prognostics Innovation Award to IMS Center for the development of Watchdog Agent Prognostics toolkit. Watchdog Agent consists of a set of algorithms and tools developed for degradation assessment and failure prediction of machinery and processes. The toolbox has been implemented in various industrial applications and has been commercialized by National Instruments as an additional toolbox for the LabVIEW software package.

I told him I could see how important preventing failure is healthcare because a failure could result in serious harm to a patient and even be fatal. When I asked him to explain what a “Digital Twin is, he said, “It is a digital representation of the physical system, generated by data-driven and physics-based models. IMS Center has developed a Cyber-physical Interface, through which the data is being collected from a machine continuously. This data is then processed and converted to machine health information using tools in Watchdog Agent toolbox. This health information is used to make informed decisions for optimum maintenance and near-zero breakdowns. It also continuously seeks for possible variations in the machine performance and provides insight into the current performance of the machine compared to its past performance, or its peers doing the same job. Digital twin basically connects the physical world to cyber world for improved visibility and transparency in machine operation.” He later forwarded me a link to a video describing IMS technologies.

Next we visited the Ceramic Matrix Composite Laboratory at GE Aviation and met with Jon Blank, Composite Matrix & Advanced Composite Section Leader, and Perry Bradley, Communications Leader, GE Aviation, followed by a tour of the lab.

From the material I was provided in advance, I learned that advancing the use of ceramic matrix composites (CMCs) has challenged industry for decades. In my day job as a manufacturers’ sales rep for fabrication companies, I had represented a company doing ceramic injection molding and a company making pre-preg layup composite parts for airline interiors in the 1990s. I was aware of the ultra-lightweight and super-heat-resistant properties of CMCs and knew that companies were investing millions to try to win the race to mass-produce this engineered material.

We first toured the Leaning Center where all the engine models GE has produced were on display. It was inspiring to me to see that advancements in technology incorporated into these successive generations of engines. Since I have previously represented companies that produced forgings and investment castings, I understood how advances in metals technology, particularly the use of Titanium, had reduced weight and improved the efficiency of engines. Since Solar Turbines in San Diego was one of my customers, I was aware of their work in the development of using ceramic molded parts in small turbine engines. However, when I saw the complexity of shape and size of the CMC turbine blades that GE Aviation is now making, it was astonishing.

Mr. Blank told me that “For more than 20 years, GE scientists in the U.S. and worldwide have worked to develop CMCs as a differentiating technology in large gas turbines for power generation, and in jet engines for commercial and military jet planes. Now their big bet is paying off as GE leads the charge to industrialize CMCs for large engine applications. GE leads the world in introducing CMCs into the hot section of jet engines and gas turbines and is creating the vertically-integrated supply chain necessary to mass produce CMC components.”

He explained why CMCs are critical to advancing the jet propulsion and power generation industries. “Components made of CMCs allow gas turbines and jet engines to run hotter, and thus more efficient. Ultra-lightweight CMCs also reduce weight throughout the engine, leading to higher fuel efficiency. CMCs in gas turbines and jet engines contribute to lower emissions and improved environmental performance. They create a significant economic advantage. CMCs are made of silicon carbide ceramic fibers and ceramic resin, manufactured through a highly sophisticated process, and further enhanced with proprietary coatings. They are one-third the density of metal alloys and one-third the weight.”

He continued, “CMCs are more durable and heat resistant than metal alloys, allowing the diversion of less cooling air into the engine’s hot section, and thereby improving overall engine efficiency. By using the cooling air instead in the engine flow path, the engine can run more efficiently at higher thrust. The average rate of technology progress for turbine engine material temperature capability increased 50 degrees per decade. With the use of CMCs, GE will now increase the temperature by 150 degrees in this decade, 3x the traditional rate. The benefits of CMCs are a 10% thrust increase and increased temperature using 2400F CMCs.”

He said, “In 2009, GE Aviation ran the first CMCs in the hot section of the F136 military engine. The CMCs were structural shrouds that direct air in the high-pressure turbine section, the hottest area of the engine. The results encouraged us to pursue CMC components with its next-generation commercial jet engines. GE worked to expand its overall CMC production capability. In 2012, Nippon Carbon (NCK) of Japan, a producer of composite fibers, formed a joint venture with GE (25% ownership) and Snecma (25%) called NGS Advanced Fibers, which produces fibers for CMC components such as the CMC shrouds. The next year later, GE Aviation expanded CMC “lean lab” operations in Delaware to develop new CMC components and the plant in Asheville, North Carolina was selected as factory to mass produce CMC components. Their lab was established in 2014, and in 2015, the Huntsville, Alabama factory was selected to produce CMC building-block materials [fiber and tape.]”

As we toured the lab and watched a couple of parts being made, he said “We have now established a fully-integrated CMC supply chain in the U.S. involving CMC raw material production in Huntsville, research and low-volume production here in Cincinnati, the CMC Lean Lab in Delaware, and CMC mass production in Asheville.”

Mr. Bradley said, “The LEAP engine for narrow-body aircraft will enter airline service in 2016 with CMC shrouds [18 shrouds per engine] in the high-pressure turbine section. This is being developed by CFM International, which is a 50/50 joint company of GE and Snecma of France. By the end of the decade, GE will introduce the GE9X engine for the new Boeing 777X under development. This engine will also feature CMC components in both the combustor [inner and outer liner] and high-pressure turbine sections [stage 1 and 2 nozzles, and stage 1 shrouds]. ”

He also said, “GE Aviation continues to run an advanced military engine through the U.S. government-sponsored ADVENT program with CMCs in the combustor and turbine sections – demonstrating the highest core temperatures in jet propulsion history. In 2014, GE Aviation successfully ran CMC turbine blades – a high-speed rotating part – in a F414 military demonstrator. This is a huge breakthrough for GE in pursuing the use of CMC in rotating parts because up to now, CMCs have been limited to static parts in an engine.”

Mr. Blank concluded, “This is all part of GE Aviation’s continuing efforts to further mature CMC technology for future commercial and military engines. The demand for CMCs is expected to grow tenfold over the next decade.”

We ended day one with a meeting with the directors of several accelerators/incubators and a few entrepreneurs in these programs in the region, which I will cover in a future article. I already covered meetings I had with key leaders in my first article last week on “Cincinnati focuses on Re-industrialization to Create Prosperity. Part two of this article will cover the companies I visited on day two of my visit.