EPA FY2009 Annual Report EPA Implementation of Executive Order 13329 (Encouraging Innovation in Manufacturing) BACKGROUND: Executive Order 1 3329 was signed on February 26, 2004. The purpose of Executive Order 13329 is to help ensure that Federal agencies properly and effectively assist the private sectoi in its manufacturing innovation so as to sustain a strong manufacturing sector in the United States economy by advancing innovation, including innovation in manufacturing, through small business. HP A submitted its HO 13329 Action Plan to SB A on July 1, 2004 and our lirst report was submitted on March 14r 2005. HPA's "Y 2008 report was submitted in September 2009. Manulacturing-rclated R&l) encompasses improvements in existing methods or processes, or wholly new processes, machines or systems. Manufacturing innovation is fostered bv research and development of technologies that are aimed at increasing the competitive eapab.lity ol manufacturing concerns. Four main areas include: (1) I.nit process level technologies thai create or improve manufacturing processes; (2) Machine level technologies that create or improve manufacturinu equipment; (3) Systems level technologies tor innovation in the manufacturing enterprise; and (4) Environment or societa level technologies that improve workforce abilities and manufacturing competitiveness. This report covers: (1) Examples of Manufacturing-related SBIR Projects: (2) Procedures and Mechanisms Used to (live Priority to Manufacturing-Related SBIR Projects, and (-.¦>) 1 romotion and Outreach to promote F.xccutix c Order awareness. 1 EXAMPLES of Manufacturing-related SBIR Projects Manufacturing related SBIR Phase 1 and Phase II awards, LPA reeentK awarded 23 new- SBIR Phase I awards and 8 new Phase II awards. Six Phase I awards (S420.000) and 2 Phase II awards ($450,000) are manufacturing related awards under E.O. 1 3329. These awards valued at $870,000 are for unit process level technologies that create or improve manufacturing processes, machine level technologies that create or improve manufacturing equipment, systems level technologies for innovation in the manulaoturing enterprise or environmental or societal lex c 1 technologies that improve workforce abili.ies and manufacturing competitheness. I he IA -00) Phase 1 "Innovation in Manufacturing"" awards are summarized below: Award EPD-09-018 Jxovalive Design, LLC (1 roy. NTV ) Testinu the Viability of Agricultural By-products as a Replacement for Mineral Particles in a Novel. Low embodied Energy, Construction Material Award EPD-09-021 Faraday Technology. Inc. (Clavton, OH) Lnablina Commercialization of a Lead-Free Coating Manufacturing Process ------- Award EPD-09-23 Gevo. Inc. (Denver. CO) Second-Generation Isobutanol Producing Biocatalyst Award EPD-09-027 Inlegran Technologies USA, Inc. (Pittsburgh, PA) Amorphous Alloy Coatings tor Ha:d Chromium Replacement Award EPD-09-029 Eight Curable Coatings (Valley V cw, OH) Chromium-Free Corrosion-Resistant Hybrid EV Coatings Award EPD-09-031 Mountain Creek Enterprises (Monroe. GA) Feasibility Study to Produce Biodiesel from I ow Cost Oils and Hew Catalysts Derived from Agricultural & Forestry Residues The FY 2009 Phase II "Innovation in Manufacturing" awards are summarized below: Award EPD-09-044 Materials and Electrochemical Research (Tucson, AZ) A New Innovative Fow Cost Manufacturing Process to Produce Titanium. Award EPD-09-047 TDA Research. Inc. (Wheat Ridge, CO) Process-Intensified Low-Cost Biodiesel Using Meat Rendering, Greases and Food Waste Manufacturing-Related Success Stories, EPA developed a success stories publication that includes manulacturing related technologies and products. Five example success stories demonstrate the impact of the SB1R program on manufacturinc related innovation: (1) Solid Scrubber in the Semiconductor Industry (A 1 Ml, Inc.): (2) Replacement of Toxic Ilexavalent Chromium in the Plating Process (Faraday, Inc.); (3) New Coating Methods to Replace Waste and Hazards in Plating; (4) Environmentally Friendly Conversion Coating (Eynntech, Inc.): and (5) Electrochemical Production ot Potassium Ferrate (Lynntech. Inc.). 2. Procedures/Mechanisms Used to Give Priority to Manufacturing-Related SBIR Projects EPA has integrated manufacturing related priorities into Agency goals. EPA encouraged Agency managers to continue to include and possibly expand manufacturing related priorities in the EPA strategic goals and objectives that cover the SBIR Program, One mechanism used to give priority to manufacturing related projects is a specific topic in our solicitation tor manufacturing. Ihc EPA SBIR program solicitation includes the following topic: ------- TOPIC B. INNOVATION IN MANUFACTURING Executive Order 13329 directs EPA to properly and effectively assist the private sector in its manufacturing innovation in order to sustain a strong manufacturing sector in the US cconorm by advancing innovation. Manufacturing-related R&D encompasses improvements in existing methods or processes- or wholly new processes, machines or systems. Manufacturing innovation is fostered b\ technology R&D aimed at increasing the competitive capability of manufacturing concerns. Areas of interest include unit process level technologies that create or improve manufacturing processes, machine level technologies that create or improve manufacturing equipment, systems level technologies lot- innovation in the manufacturing enterprise, and environmental technologies that improve workforce abilities and manufacturing competitiveness. Companies seeking assistance with project development in this topic area are encouraged to contact their local National Institutes of Standards and Technology Manufacturing Extension Partnership office at http: w w w. me p. n i st. g o v. Specific areas ot interest include, but are not limited to: • Manufacturing process changes that utilize green technology to improve process efficiency and reduce pollution. These technologies may include non-traditional reactors, novel processing methods, new feedstocks, solvents or chemical systems that impro\e production efficiency and performance while eliminating or minimizing the use or generation ol harmful materials. • New filtration membranes for organic solvent recovery and similar applications, Also, development of technology for solvent free production of chemical products and new or improved catalyst products. • Prevention or reuse of paint sludges from captured overspray in painting operations and use of low volatile organic compounds (VOC) products for purging paint lines and painting guns, and alternate filter technologies, reusable filters or new technologies for collection of spray in dry paint booths. Other solicitation topics also cover manufacturing related needs. Topic C Nanotechnology includes new cleaner manufacturing processes, environmentally sound coatings, belter monitoring sensors and machine-level anc system level controls that improve manufacturing efficiency and effectiveness. Air. water and waste management programs cover new clean up technology and better manufacturing systems. Specific topics deal with automobile and chemical manufacturing, metal finishing trnd electronics manufacturing, green building products and water security and decontamination technologies and systems. I he EPA SBIR Solicitation emphasizes manufacturing related opportunities and needs, 3, Promotion and Outreach to promote Executive Order awareness Manufacturing has been integrated at EPA into manufacturing related priorities and Agency goals. EPA has encouraged Agency managers to continue to include and possibly expand manufacturing related priorities in the EPA strategic goals and objectives that cover the SBIR Program. EPA's SBIR program has emphasized manufacturing related topics and priorities at National, regional and state SBIR conferences. Emphasis has been placed on opportunities for businesses to submit new critical manufacturing technologies. ------- EPA has provided information on SBIR success stories including manufacturing related technologies and products. 1 .ynnteclTs "Hctcropolymolybdate Conversion Coatings is an example success story showing the impact of the SBIR program on manufacturing related innovation. Part of the success story is provided below. Problem: The use of chemical conversion coalings on aluminum alloys to achieve long-term corrosion resistance of painted spacecraft and aircralt structures has found widespread military and commercial applications. With increasing environmental concerns, the use of chemical conversion coatings that do 1101 contain harmful chemicals is of particular interest to the Department of Defense. National Aeronautics and Space Administration, and other federal agencies. At the core of the problem is the demonstration of human health effects associated with exposure to hexavalent chromium. Because hcxavaient chromium is a human carcinogen, concern exists not only about workplace exposure at high levels, but also about environmental exposure at much lower levels. SBIR Technology Solution: The new conversion coating is based on heteropolyrnolybdates, a class of compounds known as polyoxometalates. Ihese species are remarkable lor t:ieir molecular and electronic structural diversify. The heteropolymolyodate is a significant departure from the use of molybdate (Mo'r"().f~) as a conversion coating. Tests of coatings prepared from formulations consisting of hcteropolymolvbdates and several important additives demonstrate exceptional corrosion resistance. Some coatings outperformed the chromate-based conversion coatings in electrochemical corrosion-resistance tests and passed a standard 14-dav salt log test. The key to this technology is heteropolyrnolybdates. The primary effect of the hetero atom is an effective transformation of Mo (III) and Tvio (IV) to stable Mo (V) and Mo (VI). thereby enhancing the formulation oi conversion coatings on aluminum alloys, 1 his unique charactciistic provides an elusive self-healing capability. Surface spectroscopic studies indicate the presence of a stable reservoir of Mo(Vl) in the oxide layer that acts in an analogous way to Cr(VI). Com111creiatization: Lvnntech made significant headway towards commercialization ot this technology, Lvnnteeh's conversion coatings were designed to be environmentally Iriendly, which lowers cost because hazardous disposal fees are not required. Lvnntech established collaborations with otic of the leading aerospace contractors, as well as a leading supplier in the metal finishina industry. Through these collaborations, the company was invited to participate in a national study in search of chromium alternatives funded by the National Center for Manufacturing Sciences. In (his study. Lymtech demonstrated two lormulations that have the capabilities and potential to successfully replace chromium-based conversion coatings. Impact: Lvnntech dex eloped a new environmental^ friendly conversion coating based on heteropolyrnolybdates. The coatings demonstrate exceptional corrosion resistance; some outperformed chromate-based conversion coatings in electrochemical corrosion-resistance tests and passed a standard 14-day salt fog test. These coatings provide long-term corrosion resistance of painted surfaces and can be applied by painting, dipping, or spraying. 1 hese coatings are low-cost, require short treatment times, used at room temperatures, and compatible with existing cleaning and pretreatment processes. ------- |